Sym Jet Sport X S50 User manual

SERVICE MANUAL
S50/R50/SR50
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How to use this manual
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Model illustration

Forward
This service manual contains the technical data of each component inspection and
repair for the SANYANG Jet Sport X S50 / R50 / SR50 series scooters.
The manual is shown with illustrations and focused on “Service Procedures”,
“Operation Key Points”, and “Inspection Adjustment” so that provides technician
with service guidelines.
If the style and construction of the scooters, Jet Sport X S50 / R50 / SR50 series,
are different from that of the photos, pictures shown in this manual, the actual
vehicle shall prevail. Specifications are subject to change without notice.
Service Department
Sanyang Industry Co., LTD.
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How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for SANYANG Jet Sport X S50 / R50 / SR50 series
scooters. In addition, please refer to the manual contents in detailed for the model
you serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information.
The 3rd to the 10th chapters covers engine and driving systems.
The 11th to the 14th chapters is contained the parts set of frame body.
The 15th chapter is electrical equipment.
The 16th chapter is wiring diagram.
Please see index of content for quick
having the special parts and system
information.
All information, illustration, directions and specifications included in this manual are
current as at the time of publication. SANYANG reserves the rights to make
changes at any time without prior notice and without incurring any obligation
whatever. Without written consent by SANYANG can not copy any part of this
manual.
There are 4 buttons, "Forward", "How to use this manual", "Mechanism
Illustrations", and "Contents" on the CD-R version, and can be access to these
items by click the mouse.
If user wants to look for the content of each chapter, selecting the words of each
chapter on the main contents can reach to each chapter. There are two buttons,
Back to homepage and Main contents, onto the top line of first page of the each
chapter. Thus, if the user needs to check other chapters, he can click the top
buttons to back the homepage or main contents. The content of each chapter
can be selected too. Therefore, when needs to checking the content inside of the
chapter, click the content words of the chapter so that can back to the initial
section of the content. In addition, there is a "This chapter contents" button at
the top line of each page so that clicking the button can back to the contents of
this chapter.
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Contents
Page Content Index
1-1 ~ 1-18
General Information
1
2-1 ~ 2-14
Service Maintenance Information
2
3-1 ~ 3-6
Lubrication System
3
4-1 ~ 4-10
Fuel System
4
5-1 ~ 5-6
Engine Removal
5
6-1 ~ 6-4
Cylinder Head / Cylinder / Piston
6
7-1 ~ 7-14
A.C. Generator
7
8-1 ~ 8-6
"V" Type Belt Driving System / Kick-Starter
8
9-1 ~ 9-6
Final Driving Mechanism
9
10-1 ~ 10-10
Crankcase / Crankshaft
10
11-1 ~ 11-12
Body Cover
11
12-1 ~ 12-12
Brake System
12
13-1 ~ 13-10
Steering / Front Wheel / Shock absorber
13
14-1 ~ 14-4
Rear Wheel / Shock absorber
14
15-1 ~ 15-22
Electrical Equipment
15
16-1 ~ 16-4
Electrical Diagram
16
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Model illustration
Jet Sport X S50 / R50 / SR50 Series
Headlight
Front brake lever
Rear brake lever
Taillight
Helmet hook
Fuel tank cap
Engine number
Luggage box
Muffler
Battery / Fuses / C.D.I. /
Eng. Oil tank cap
ENG. Stop / Starter switch
High & Low beam / Passing /
Turn signal / Horn switch
Air cleaner
Frame number
Front turn signal
Ignition switch
Rear turn signal
Seat lock
Rear turn signal
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1. General Information
1-1
Symbols and Marks·····················1-1
General Safety······························1-2
Service Precautions·····················1-3
Specifications·······························1-6
Torque values·······························1-7
Cables and Harness Routing······1-9
Troubleshooting···························1-13
Lubrication Points ·······················1-20
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are needed,
in case supplemental information is procedures needed for these symbols and marks, explanations will
be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are not
followed.
Caution Means that equipment damages may result if procedures are not
followed.
Engine oil Limits to use SAE 20 JASO FC class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: MAX-2 serial oils)
Grease King Mate G-3 is recommended.
Gear oil King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
OIL # 140)
Locking sealant
Apply sealant; medium strength sealant should be used unless otherwise
specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools Special tools.
O Correct Meaning correct installation.
X Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
1
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1. General Information
1-2
General Safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you
have to run your engine in a closed area, be sure
to use an extractor.
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verified.
We recommend that you wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system
can become extremely hot after engine
running. They remain very hot even after the
engine has been stopped for some time. When
performing service work on these parts, wear
insulated gloves and wait until cooling off.
Battery
Caution
• Battery emits explosive gases; flame is
strictly prohibited. Keeps the place well
ventilated when charging the battery.
• Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
do not be spray on your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery
acid in your eyes, flush it off immediately
with water and then go to hospital to see an
ophthalmologist.
• If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such
as castor oil or vegetable oil and then go to
see a doctor.
• Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Inhaling dust may cause disorders and cancer
of the breathing system.
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
This chapter Contents

1. General Information
1-3
Service Precautions
• Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts
for SANYANG scooter may damage the
scooter.
• Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
• When servicing this scooter, use only metric
tools. Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
• Clean the outside of the parts or the cover
before removing it from the scooter. Otherwise,
dirt and deposit accumulated on the part's
surface may fall into the engine, chassis, or
brake system to cause damage.
• Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals
because most cleaning agents have an
adverse effect on them.
• Never bend or twist a control cable to prevent
stiff control and premature worn out.
• Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
• When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
• Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
• Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
• Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.

1. General Information
1-4
• The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length out side the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
• Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
• When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, check the shaft
on which the oil seal is to be installed for
smoothness and for burrs that may damage
the oil seal.
• Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
• The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can
go to their connections so that there is enough
room below the enlarged ends for tightening
the clamps.
• Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
• The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Both of these examples can result in bearing
damage.
• Lubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.
Boots
Manufacturer's name

1. General Information
1-5

1. General Information
1-6
Specifications
Make SANYANG MODEL Jet Sport X 50 series
Overall Length 1840 mm Front Telescopic Fork
Overall Width 690 mm Suspension
System Rear Unit Swing
Overall Height 1120 mm Front 120 / 70 – 12
Dimension
Wheel Base 1275 mm Tire
Specifications
Rear 130 / 70 – 12
Front 42 kg Front Disk (Ø190mm)
Rear 56 kg Disk (Ø160mm)
Curb
Weight
Total 98 kg
Brake System
Rear DRUM (Ø110mm)
Passengers /
Weight
One / 75 kg Max. Speed 48 km/hr Below
Front 64 kg Climb Ability 22°Below
Rear 109 kg Primary Reduction BELT
Weight
Total Weight
Total 173 kg Secondary Reduction
GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement Horizontal, below center, incline
Forman Perce
Transmission C.V.T.
Fuel Used Unleaded (92/95) Speedometer 0 ~ 80 km/hr
Cycle/Cooling 2-stroke/forced air cooled
Horn 93 ~ 112 dB/A
Bore Ø 39 mm Muffler Expansion & Pulse
Type
Stroke 41.4 mm Exhaust Pipe Position and
Direction Right side, and Backward
Cylinder
Number/Arrang
ement Single Cylinder Lubrication System Separated-lubrication
Displacement 49.4 cc
Compression Ratio
7.2 : 1 CO 1.0 g/km ↓
Max. HP 2.6 kw / 6000 rpm
Exhaust
Concentration
HC+Nox 1.2 g/km ↓
Max. Torque 4.2 Nm / 5500 rpm E.E.C. X
Ignition C.D.I. P.C.V. X
Engine
Starting System Electrical & kick Catalytic reaction control
system ○

1. General Information
1-7
Torque values
Standard Torque Values for Reference
Type Torque value Type Torque value
5 mm Bolt, nut 0.45 ~ 0.6kgf-m 5 mm Screw 0.35 ~ 0.5kgf-m
6 mm Bolt, nut 0.8 ~ 1.2kgf-m 6 mm Screw, flange bolt
(SH Type) 0.7 ~ 1.1kgf-m
8 mm Bolt, nut 1.8 ~ 2.5kgf-m 8 mm Flange bolt, nut 1.0 ~ 1.4kgf-m
10 mm Bolt, nut 3.0 ~ 4.0kgf-m 8 mm Flange bolt, nut 2.4 ` 3.0kgf-m
12 mm Bolt, nut 5.0 ~ 6.0kgf-m 10 mm Flange bolt, nut 3.5 ~ 4.5kgf-m
The torque values listed in below table are for more important tighten torque values. Please see above
standard values for not listed in the table.
Engine
Item Q’ty Thread Dia.
(mm) Torque Value (kgf-m) Remarks
Cylinder head bolt 4 7 1.6~2.0 When engine cooled
Spark plug 1 14 1.1~1.7
Inlet pipe nut 2 6 0.8~1.2
Flywheel nut 1 10 3.5~4.5
Movable drive face nut 1 12 5.5~6.5
Drive plate nut 1 28 5.0~6.0
Clutch outer nut 1 10 3.5~4.5
Mission oil check bolt 1 10 1.0~1.5
Mission oil drain bolt 1 8 1.0~1.5
Mission cover bolt 7 8 2.4~3.0
Crankcase bolts 6 6 1.0~1.5
Cooling fan bolts 4 6 0.6~1.0
Brake shoe anchor pin 1 8 1.5~2.0
Nuts for exhaust pipe 2 6 1.0~1.4
Mounting bolts for exhaust 2 8 3.0~3.6
Others - 6 0.8~1.2

1. General Information
1-8
Frame
Item Q’ty Thread Dia.
(mm) Torque Value (kgf-m) Remarks
Mounting nut for handle 1 10 4.0~5.0
Steering stem lock nut 1 25.4 1.0~2.0
Steering top cone race 1 25.4 0.2~0.3
Front cushion bolts 4 8 2.4~3.0
Front wheel axle nut 1 12 5.0~7.0
Air cleaner bolts 2 6 1.0~1.4
Brake master cylinder mounting bolts
4 6 1.0~1.4
Brake hose bolts 2 10 3.3~3.7
Brake caliper mounting bolts 2 10 3.1~3.5
Brake shoe guide bolts 2 6 1.5~2.0
Brake shoe guide bolts cap 2 6 0.8~1.2
Brake drain valve 1 6 0.8~1.0
Mounting bolt for brake disc 7 8 4.0~4.5
Rear brake arm bolts 1 5 0.8~1.2
Rear brake lever nuts 2 5 0.8~1.2
Bolt for engine hanger 4 12 5.5~6.5
Bolt for engine hanger bracket 1 10 4.5~5.5
Upper bolt for rear cushion 1 10 3.5~4.5
Lower bolt for rear cushion 1 8 2.4~3.0
Rear wheel nut 1 16 10.0~12.0

1. General Information
1-9
Cables and Harness Routing
Note the following when routing cables
and wire harnesses:
• A loose wire, cable or harness may cause
safety hazard. After clamping, check each
wire to make sure it is secured.
• Do not squeeze wires against the weld or its
clamp.
• Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
• Route harnesses so that they neither pull too
tight nor have excessive slack.
• Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
• Route wire harnesses to avoid sharp edges or
corners.
• Avoid the projected ends of bolts and screws.
• Keep wire harnesses far away from the
exhaust pipes and other hot parts.
• Be sure grommets are seated in their groves
properly.
• After clamping, check each harness to be
certain that it is not interfered with any moving
or sliding parts.
• After routing, check that the wire harnesses
are not twisted or kink.
• Wire harnesses routed along the handlebar
should not be pulled too tight or have
excessive slack, be rubbed against or interfere
with adjacent or surrounding parts in all
steering positions.
• Thoroughly clean the surface where tape is to
be applied.
• Wrap electrical tape around the damaged parts
or replace them.
O ：Correct X ：Wrong

1. General Information
1-10
High/low beam switch
Horn switch
Rear brake lamp
switch
Winker switch
Speedometer
Headlight
switch
Starter switch
Throttle cable
Headlight
Rear brake cable
Speedometer
cable
Throttle cable
Main switch
Regulator
Resistor
Horn
Front brake
hose
Speedometer cable
Front brake cable
Winker relay
Front brake
lamp switch

1. General Information
1-11
Throttle cable
Rear brake cable
Fuel unit cord
Fuel filter
Speedometer cable
Rear brake cable
Front brake
hose
Throttle cable
Fuel unit
Winker relay
Front brake hose
Rear brake cable
Speedometer cable
Throttle cable
Front brake hose
Fuel pump

1. General Information
1-12
Fuel filter
Battery
C.D.I. UNIT
Fuse
Purge control valve
Oil control cable
Fuel hose
Fuel pump
Vacuum hose
Oil hose Rear brake cable
Carburetor
Oil lever switch

1. General Information
1-13
Troubleshooting
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to
check if there is gasoline
inside the carburetor
Fuel supplied tom
carburetor sufficient No fuel is supplied to carburetor
Remove spark plug, install it
into spark plug cap, and
perform a spark test against
engine ground.
Perform cylinder compression
pressure test.
Check if sparks Week sparks or no
spark at all
Cylinder compression
pressure normal Low compression pressure or no pressure
Re-start by following the
starting procedures
No ignition There are some signs of
ignition, but engine can
not be started
Remove the spark plug again
and check it.
Remove carburetor after 30
minutes and connect a hose
onto fuel supplement circuit.
Then blow the hose with air.
Dry spark plug Wet spark plug
Blowing in normal Blowing clogged
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to
carburetor and intake vacuum, are
clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum
hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
7. Malfunction of main switch
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
6. Crankcase leakage for pre-compression
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
1. Malfunction of auto-starter

1. General Information
1-14

1. General Information
1-15
B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration and
check engine speed
Engine speed can be
increased. Engine speed can not be increased.
Check ignition timing (Using
ignition lamp)
Check cylinder compression
pressure (using compression
pressure gauge)
Ignition timing correct Incorrect ignition timing
Compression pressure
correct No compression pressure
Check if carburetor is clogged
Normal Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration
Fouled and discoloration
No knock Knock
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
1. Malfunction of CDI
2. Malfunction of AC generator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Crankcase leakage for pre-compression
1. Remove dirt
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
Normal Engine
overheat
Continually drive in
acceleration or high speed 1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Lean mixture
Check and adjustment Fault condition Probable causes