Sym Fiddle II 50 SYM Series User manual

SERVICE MANUAL
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MECHANISM ILLUSTRATIONS

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This service manual contains the technical data of each component inspection
and repair for the SANYANG Fiddle 50 series scooter. 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 scooter, Fiddle 50 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 Fiddle 50 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.
Th third to the tenth nine chapters covers engine and driving systems.
The tenth to the fourteenth is contained the parts set of assembly body.
The fifteenth chapter is electrical equipment.
The sixteenth 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 ~ 1-16 GENERAL INFORMATION
1
2-1 ~ 2-12 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-6 LUBRICATION SYSTEM 3
4-1 ~ 4-6 ENGINE REMOVAL 4
5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON 5
6-1 ~ 6-4 ALTERNATOR 6
7-1 ~ 7-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 7
8-1 ~ 8-6 FINAL DRIVING MECHANISM 8
9-1 ~ 9-6 CRANKCASE/CRANKSHAFT 9
10-1 ~ 10-10
FUEL SYSTEM
10
11-1 ~ 11-6 BRAKE SYSTEM 11
12-1 ~ 12-12
BODY COVER
12
13-1 ~ 13-12
STEERING/FRONT WHEEL/SUSPENSION
13
14-1 ~ 14-4 REAR WHEEL/SUSPENSION 14
15-1 ~ 15-20
ELECTRICAL EQUIPMENT
15
16-1 ~ 16-2 ELECTRICAL DIAGRAM 16
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MODEL ILLUSTRATION
FA05U
Head light
Front brake lever Rear brake lever
Tail light
Helmet hook
Fuel tank cap
Engine number
Storage box
Muffler
Battery / Fuses /
C.D.I. /
Eng. Oil tank cap
Light / Starter switch
High & Low beam /
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 ···································1-5
Torque values···································1-6
Cables and Harness Routing ··········1-8
Troubleshooting·······························1-11
Lubrication Points····························1-15
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.
OCorrect Meaning correct installation.
XWrong 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).
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1

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
yBattery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
yBattery 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.
yIf 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.
yKeep 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.
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1. GENERAL INFORMATION
1-3
Service Precautions
zAlways use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
zSpecial tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
zWhen 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.
zClean 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.
zWash 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.
zNever bend or twist a control cable to prevent
stiff control and premature worn out.
zRubber 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.
zWhen 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.
zStore complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
zNote the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
zComponents 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.
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1. GENERAL INFORMATION
1-4
zThe 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.
zTighten 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.
zWhen 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.
zRemove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
zThe 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.
zRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
zThe 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.
zLubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.
Boots
Manufacturer's name
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1. GENERAL INFORMATION
1-5
Specifications
Make SANYANG MODEL FA05 Series
Overall Length 1680 mm Front TELESCOPIC
Overall Width 750 mm Suspension
System Rear UNlT SWING
Overall Height 1070 mm Front 3.00 - 10 42J(T/L)
DIMENSION
Wheel Base 1170 mm Tire
Specifications Rear 3.00 - 10 42J(T/L)
Front 33 kg
Rear 50 kg Front DRUM (ψ110mm)
Curb
Wei
g
ht
Total 83 kg
Brake
System Rear DRUM (ψ95mm)
Passengers/
Weight Two /110 kg Max. Speed 48 km/hr Below
Front 55 kg Climb Ability 20° Below
Rear 138 kg Primary Reduction BELT
WEIGHT
Total Weight
Total 193 kg Secondary
Reduction GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement Vertical, below center, incline
PERFORMANCE
Transmission C.V.T.
Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr
Cycle/Cooling 2-stroke/forced air
cooled Horn 93 ~ 112 dB/A
Bore 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 7.1 : 1 CO Below 1.2 g/km
Max. HP 2.1 kw / 6750 rpm
Exhaust
Concentration
HC+Nox Below 1.0 g/km
Max. Torque 3.5 Nm / 5500 rpm E.E.C. X
Ignition C.D.I. P.C.V. X
ENGINE
Starting System Electrical & kick Catalytic reaction control
system ○
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1. GENERAL INFORMATION
1-6
Torque values
Standard Torque Values for Reference
Type Torque value Type Torque value
5 mm Bolt, nut 0.45 - 0.6kgf-m 5 mm Bolt 0.35 - 0.5kgf-m
6 mm Bolt, nut 0.8 - 1.2kgf-m 6 mm Bolt, SH nut 0.7 - 1.1kgf-m
8 mm Bolt, nut 1.8 - 2.5kgf-m 6 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 6 1.0 When engine
cooled
Spark plug 1 14 1.4
Flywheel nut 1 10 3.8
Sliding driving disc nut 1 10 3.8
Sliding driving disc nut 1 28 5.5
Clutch outer cover nut 1 10 3.8
Drain bolts 1 8 1.3
Crankcase bolts 6 6 1.0
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1. GENERAL INFORMATION
1-7
Frame
Item Q’ty
Thread Dia.
(mm) Torque Value (Kgf-m) Remarks
Bolt for engine suspension 1 10 5.0
Bolt for engine suspension bracket 1 12 6.0
Upper bolt for rear shock absorber 1 10 4.0
Lower bolt for rear shock absorber 1 8 2.7
Mounting screws for exhaust pipe
connection 2 6 1.2
Nut for exhaust 2 8 3.3
Brake hose bolts 2 10 3.5
Brake caliper mounting bolts 2 8 3.1
Brake cushion guide bolts 2 6 1.8
Brake cushion guide bolts cap 2 6 1.0
Brake drain valve 1 6 0.6
Rear brake arm bolts 1 5 0.55
Tightening nut for steering rod 1 25.4 7.0
Front shaft nut 1 12 6.0
Mounting bolt for handle 1 10 5.0
Mounting nut for front hub 4 8 2.5
Mounting bolt for front brake disc 3 8 4.5
Rear shaft nut 1 14 11.0
Nut for rear hub 4 8 2.5
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1. GENERAL INFORMATION
1-8
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
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1. GENERAL INFORMATION
1-9
c: Throttle cable
d: Front brake cable
e: Rear brake cable
f: Speedometer cable
Right handle switch
Throttle cable
Speedometer cable
f
Regulator
Resistor
Horn
Front brake cable
Front brake cable
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Right handle switch
Rear brake cable
d
f
d
cedf

1. GENERAL INFORMATION
1-10
ACG. & Start relay connector
Ignition coil
Thermo switch
CDI unit
Power filter unit ASS’Y
Air injection cut valve
Thermo switch unit
Thermo switch connector
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1. GENERAL INFORMATION
1-11
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
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1. GENERAL INFORMATION
1-12
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
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
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1. GENERAL INFORMATION
1-13
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)
Check for fuel supplying
system in automatic fuel cup
Check if carburetor clogged
1. Incorrect ignition timing (malfunction
of CDI or AC generator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good Poor
Good spark Poor
No air sucked Air sucked
Good Poor
Normal Abnormal
Air sucked through
carburetor gasket
Adjust the air screw of
carburetor
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
CHECK AND ADJUSTMENT FAULT CONDITION PROBABLE CAUSES
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC generator
Normal Abnormal
Normal Clogged 1. Cleaning
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1. GENERAL INFORMATION
1-14
E. CLUTCH, DRIVING AND DRIVING PULLEY
1. Clutch ling spring broken
2. Clutch outer cover stuck with clutch balance weights
3. Connection parts in clutch and shaft worn out or
burned
Engine can be started but
motorcycle can not be driving
FAULT CONDITION PROBABLE CAUSES
1. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damage
7. 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)
1. Driving belt worn out or deformation
2. Balance weight roller worn out
3. Driving sliding gear shaft worn out
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.
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1. GENERAL INFORMATION
1-15
Lubrication Points
Engine suspension bushing
Seat lock
Rear wheel bearing
Steering shaft bearing
Speedometer gear/ front
wheel bearing
Side stand shaft
Main stand shaft
Throttle cable/
Front & rear brake lever pivot
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