Sym Citycom.300i User manual

DK Version 1.0 2009
Citycom.300i
SERVICE MANUAL
FOREWORD
HOW TO USE THIS MANUAL
CONTENTS
SERIAL NUMBER

Foreword
This service manual contains the technical data of each component inspection and
repairment for the SANYANG LH30W series scooter. The manual is shown with
illustrations and focused on €Service Procedures•, €Operation Key Points•, and
€Inspection Adjustment•, providing technicianswith service guidelines.
If the style or the mechanical structures of the scooter, LH30W series scooter, are
different from those of the photos or pictures shown in this manual, the actual
vehicle shall prevail. Specifications are subject to changeswithout notice.
Service Department
SANYANG INDUSTRY CO., LTD.
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How To Use This Manual
This service manual describes the basic information of different system parts and
system inspection & service for SANYANG LH30W series scooter. In addition,
please refer to the manual contents in detail for the model you serviced in inspection
and adjustment.
The first chapter covers the general information and the trouble diagnosis.
The second chapter covers the periodic maintenance information and the special
tool models.
Thethird to the 11th chapters cover the engine and the driving systems.
The 12th chapter is the cooling system.
The 13th to the 16th chapter contain the relative parts of the body frame assembly.
The 17th chapter is the electrical system.
The 18th chapter is the emission control system.
The 19th chapter is the wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, €Foreword•, €Contents•, €How to use this manual•and
€Mechanism Illustrations•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 contents can reach to each chapter. There are two buttons,
€Homepage and 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 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 €To this chapter contents•button at the second page of each
contentsso that clicking the button can back to the contents of this chapter.
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Contents
Page Content Index
1-1 ~ 1-16 General Information 1
2-1 ~ 2-17 Maintenance Information 2
3-1 ~ 3-8 Lubrication System 3
4-1 ~ 4-60 Fuel Injection System 4
5-1 ~ 5-11 Engine Removal 5
6-1 ~ 6-16 Cylinder Head/ Valve 6
7-1 ~ 7-8 Cylinder/ Piston 7
8-1 ~ 8-14 “V” Type Belt Driving System/ Kick-Starter 8
9-1 ~ 9-8 Final DriveMechanism 9
10-1 ~ 10-10 Alternator 10
11-1 ~ 11-8 Crankshaft/ Crankcase 11
12-1 ~ 12-14 Cooling System 12
13-1 ~ 13-16 Body Cover 13
14-1 ~ 14-12 Brake System 14
15-1 ~ 15-10 Steering/ Front Wheel/ Front Cushion 15
16-1 ~ 16-6 Rear Wheel/ Rear Fork/ Rear Cushion 16
17-1 ~ 17-23 Electrical Equipment 17
18-1 ~ 18-7 Emission Control System 18
19-1 Electrical Diagram 19
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Serial Number
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1. GENERAL INFORMATION
1-1
Symbols and Marks............................ 1-1
General Safty……………………………1-2
Service Precautions........................... 1-3
Specifications..................................... 1-9
Torque Values .................................... 1-10
Troubles Diagnosis............................ 1-12
Parts to Be Greased........................... 1-16
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 needed for these symbols and marks, explanations will be added to
the text instead of using the symbols or marks only.
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 10W-40 API SL class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: LIQUI MOLY Racing 4T 10W-40 oil)
Grease LIQUI MOLY LM50is recommended.
Gear oil
LIQUI MOLY gear oil serials are recommended. (GL4/5 GEAR OIL
SAE 75W-90)
Locking sealant
Apply sealant, medium strength sealant should be used unless otherwise
specified. Recommended LIQUI MOLY
Oil seal Apply with lubricant. .
Renew Replace with a new part before installation.
Brake fluid Use LIQUI MOLY brake fluid DOT3.
Special tools Special tools
Correct Meaning correct installation.
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
Homepage Contents

1. GENERAL INFORMATION
1-2
General safety
Carbon monoxide
If you have to run your engine, make sure
that 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 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. Keep the places well ventilated
when charging the battery.
‧Battery fluid
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 fluid on your skin, flush it off
immediately with water. If you get battery fluid
in your eyes, flush it off immediately with
water and then go to ahospital.
‧If you swallow the battery fluid 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 the battery fluid beyond the reach of
children.
Brake pad
Do not use compressed air or a cleaning brush to
clean the brake system; use a vacuum cleaner to
prevent the brake fibersfrom drifting in the air.
Caution
Inhaling brake fiber may result in lung disease or
cancer.
Brake fluid
Caution
Brake fluid may cause damage to the surface of
the painted parts, or even the structure of the
plastic or rubber parts. Place a clean cloth for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
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1. GENERAL INFORMATION
1-3
Service Precautions
Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts for
Sanyang motorcycle may damage the motorcycle.
Special tools are designed for remove and install
of components without damaging the parts being
work ed on. Using wrong tools may result in parts
damaged.
When servicing this motorcycle, 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 motorcycle.
Otherwise, dirt and deposit accumulated on the
part's surface may fall into the engine, chassis,
or brake system to cause a 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
unsmooth 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 wil l 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.
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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
unles s 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 en larged 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.
Manufacturer's name
Groove
Clamp
Connector
Boots
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1. GENERAL INFORMATION
1-5
Lubricate the rotation face with specified lubricant
on the lubrication points before assembling.
Check if positions and operation for installed parts
is in correct and properly.
Make sure service safety each other when
conducting by two persons.
Note that do not let parts fall down.
Before battery removal operation, it has to
remove the battery negative (-) cable firstly. Notre
tools like open-end wrench do not contact with
body to prevent from circuit short and create sp
ark.

After service completed, make sure all
connection points is secured. Battery positive
(+) cable should be connected firstly.
And the two battery terminals have to be greased
after connected the cables.
Recommended LIQUI MOLY battery terminal
grease
Make sure that the battery post caps are located
in properly after the battery posts had been
service d.
If fuse burned, it has to find out the cause and
solved it. And then replace with specified capacity
fuse.
Capacity
verification
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1. GENERAL INFORMATION
1-6
When separating a connector, it locker has to be
unlocked firstly. Then, conduct the service
operation.
Do not pull the wires as removing a connector or
wires. Hold the connector body.
Make sure if the connector pins are bent,
extruded or loosen.
Insert the connector completely. If there are
two lockers on two connector sides, make sure
the lockers are locked in properly.
Check if any wire loose.
Check if the connector is covered by the twin
connector boot completely and secured
properly.
Before terminal connection, check if the boot is
crack or the terminal is loose.
Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
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.
Wire band and wire harness have to be
clamped secured properly.
Do not squeeze wires against the weld or its
clamp.
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1. GENERAL INFORMATION
1-7
Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
Keep wire harnesses far away from the hot
parts.
Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
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. Thoroughly clean the surface where
tape is to be applied.
Secure the rubber boot firmly as applying it on
wire harness.
Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
Never clamp or squeeze the wire harness as
installing other components.
Never Touch
Never too tight
Never clamp or
squeeze the wire
harness
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1. GENERAL INFORMATION
1-8
Do not let the wire harness been twisted as
installation.
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.
Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Do you know how to set the
instrument to its measurement
position and the insert locations
of its two probes?
Clean rust
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1. GENERAL INFORMATION
1-9
Specifications
MAKER SANYANG MODEL LH30W-6
Overall Length 2210 mm Front Telescopic Fork
Overall Width 785 mm
Suspension
System Rear Unit Swing
Overall Height 1445 mm Front 110 /70-16 52P
Dimension
Wheel Base 1500 mm Tire Specifications Rear 140 /70-16 65P
Front 77 kg Front Disk (φ260 mm)
Rear 107 kg
Curb Weight
Total 184 kg
Brake System Rear Disk (φ260 mm)
Passengers/Weight Two /150 kg Max. Speed Above 128 km/hr
Front 104 kg Performance Climb Ability Below 27‚
Rear 230 kg Primary
Reduction Belt
Weight
Total Weight
Total 334 kg Secondary
Reduction Gear
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline 80‚
Reduction
Transmission C.V.T.
Fuel Used Unleaded gasoline Speedometer 0 ~ 160 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore 73 mm Muffler Expansion & Pulse
Type
Stroke 62.8 mm Exhaust Pipe Position and
Direction
Right side, and
Backward
Cylinder
Number/Arrange
ment Single Cylinder Lubrication System Forced circulation & splashing
Displacement 262.8 cc Solid Particulate
Compression Ratio 10.0 : 1CO Below 2.0 g/ km
Max. HP 15.4 kw / 7000 rpm
Exhaust
Concentrat
ion
HC Below 0.3g/ km
Max. Torque 23.5 Nm / 5500 rpm EECˇ
Ignition Full transistor
Ignition(ECU) PCV ˇ
Engine
Starting System electrical starter Catalytic Converter ˇ
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1. GENERAL INFORMATION
1-10
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
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、SH nut 0.7~ 1.1kgf-m
8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m
10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m
12 mm bolt、nut 5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder head nut 4 8 2.0~2.4
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.1
Cylinder head stud bolt (EX. pipe) 2 7 0.5~1.0
Tappet adjustment hole cap bolt 6 6 1.0~1.4
Tappet adjustment screw nut 4 5 0.7~1.1
Apply oil to
thread
Spark plug 110 1.0~1.2
Carburetor insulator bolt 2 6 0.7~1.1
Cylinder stud bolt 4 8 0.7~1.1
Engine left cover bolt 7 6 1.1~1.5
Engine oil draining bolt 112 1.1~1.5
Engine oil strainer cap 130 1.3~1.7
Mission draining bolt 1 8 0.8~1.2
Mission filling bolt 110 0.8~1.2
Clutch driving plate nut 128 5.0~6.0
Clutch outer nut 1 12 5.0~6.0
Driveface nut 112 5.0~6.0
Flywheel nut 1 12 5.0~6.0
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.0~2.4
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1. GENERAL INFORMATION
1-11
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Stopper nut for engine hanger
rubber 1 8 1.8~2.2
Engine hanger nut 2 12 4.0~5.0
Engine hanger bolt 1 12 4.0~5.0
Engine connection bolt 110 3.5~4.5
Front wheel axle nut 112 5.0~7.0
Rear wheel shaft nut 114 10.0~12.0
Rear fork 2 8 4.0~5.0
Rear cushion upper bolt 210 3.5~4.5
Rear cushion under bolt 2 8 2.4~3.0
Nut for steering post 110 4.0~5.0
Front cushion 4 8 2.4~3.0
Brake lever nut 2 6 0.8~1.2
Nut for the rear brake arm 1 6 0.5~0.6
Front brake hose bolt 410 3.0~4.0
Front brake caliper bolt 4 6 3.0~3.5
Front brake diskmounting bolt 7 8 4.0~4.5
Air-bleed valve 1 5 0.5~0.6
Speedometer cable locking screw 1 5 0.15~0.3
Exhaust muffler bolt 3 8 3.2~3.8
Exhaust muffler connection nut 2 7 1.0~1.2
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1. GENERAL INFORMATION
1-12
Troubles Diagnosis (Electronic Fuel Injection System)
A. Engine cannot be started or difficult to be started
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Check and adjustment Fault condition Probable causes
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.
Dry spark plug Wet spark plug
1. Fuel injector Defile or blocked
2. Malfunction of throttle valve operation
3. Malfunction of a
djust and press the valve
Press the fuel sprayer feed pipe and
confirm whether there is petrol in the
feed pipe
The petrol amount of the fuel
injector is supplied with
sufficiently
Have not supplied with the
fuel
for
fuel injector
1. Check the fuel amount in the fuel tank
2. Check the supply of the fuel,gasoline
hose and the vacuum tube are blocked or
not.
3. Malfunction of fuel pump relay or wiring
badly
4. Relay damage of the fuel pump or wiring
badly
5. E.E.C system tube are blocked
6.
Malfunction of
fuel pump
Piston ring seized
Malfunction of cylinder valves
Worn cylinder and piston ring
Cylinder gasket leak
Sand hole in compression parts
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
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
1. Malfunction of spark plug.
2. Defile of spark plug
3. Malfunction of ECU.
4. Malfunction of the 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. GENERAL INFORMATION
1-13
B. Engine run sluggish (Speed does not pick up, lackof power)
Check and adjustment Fault condition Probable causes
Try gradual acceleration
and check engine speed
Engine speed can not be
increased.
1. change the fuel injector
Engine speed can be
increased.
Air cleaner clogged
Poor fuel supply
Lines in fuel tank evaporation system clogged
Exhaust pipe clogged
Fuel injector clogged.
Check ignition timing
(Using ignition lamp)
Ignition timing correct Incorrect ignition timing Malfunction of ECU
Malfunction of AC generator
Check cylinder compression
pressure (using compression
pressure gauge)
Compression pressure correct No compression pressure
Cylinder & piston ring worn out
Cylinder gasket leaked
Sand hole in compression parts
Valve deterioration
piston can not be moved.
Check fuel injector clogged
or not
No foul or discoloration Fouled and discoloration
Remove spark plug
foul and discoloration
No foul or discoloration Remove dirt
Incorrect spark plug heat range
Piston and cylinder worn out
Lean mixture
Poor fuel quality
Too much carbon deposited in combustion
chamber
Ignition timing too advanced
Normal Engine overheat
Check if engine over heat
Continually drive in
acceleration or high speed
No knock Knock
Too much carbon deposited in combustion
Malfunction of fuel injector.
Poor fuel quality
Ignition timing too advanced
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1. GENERAL INFORMATION
1-14
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes
Check ignition timing
(using ignition lamp)
Normal Abnormal
1. damage the insulator gasket.
2. Throttle body wrongly attached
3. Inlet pipe gasket abnormal
4. ABV pipe cracked
Have not sucked the air Suck the air
The gasket of the throttle
body has air to suck or not
Good spark Poor
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
Check the fuel pump
supply
situation
good poor
Normal Clogged 1. change the fuel injector
Incorrect ignition timing (malfunction of ECU or
AC generator)
Spark plug fouled
Malfunction of E.C.U.
Malfunction of AC generator
Malfunction of ignition coil
Open or short circuit in spark plug leads
Malfunction of main switch
Check ignition timing
Check and adjustment Fault condition Probable causes
Normal Abnormal Malfunction of ECU.
Malfunction of AC generator
Insufficient fuel in fuel tank
Fuel filter clogged
Restricted fuel tank vent
Check if fuel injector clogged
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1. GENERAL INFORMATION
1-15
E. CLUTCH AND DRIVING PULLEY
Clutch lining spring broken
Clutch outer stuck with clutch balance weights
Connection parts in clutch and shaft worn out or burned
Engine can be started but
motorcycle can not run
FAULT CONDITION PROBABLE CAUSES
Driving belt worn out or deformation
Driving disk damaged
Driving pulley spring broken
Clutch lining broken
Driving shaft groove broken
Transmission gear damage
Transmission gear worn out or burned
Engine running and misfire as
motorcycle initial forward moving
or jumping sudden (rear wheel
rotating as engine in running)
Poor initial driving (Poor climbing
performance)
Driving belt worn out or deformation
Balance weight roller worn out
Driving sliding gear shaft worn out
Driving disk spring deformation
Driving sliding gear shaft worn out
Greased in driving belt and sliding gear.
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