SYM Jet Euro 100 manuale d’uso

SER VICE MANU AL Forward Content s How T o Use This Manual Mechanism Illustrations 50/10 0 50/10 0[...]

FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG JET 50/100 and JET Euro 50/100 series motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guideli[...]

How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang JET 50/100 and JET Euro 50/100 series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. The first chapter covers general inf[...]

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 ~ 4-4 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/CRANKS[...]

MODEL ILLUSTRATION JET 50 / 100 Series 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 sw itch High & Low beam / T urn signal / Horn switch Air cleaner Frame number Front turn signal Ignition switch Rear turn signal [...]

MODEL ILLUSTRATION JET Euro Series 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 sw itch High & Low beam / T urn signal / Horn switch Air cleaner Frame number Front turn signal Ignition switch Rear turn signal Seat[...]

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1. GENERAL INFORMATION 1-1 Symbols and Marks···························1-1 General Sa fety ···································1-2 Service Pr ecautions ··························1-3 Specificati ons ································?[...]

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 consciousnes[...]

1. GENERAL INFORMATION 1-3 Service Precautions z Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. z 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. z When se[...]

1. GENERAL INFORMATION 1-4 z 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 f[...]

1. GENERAL INFORMATION 1-5 Specifications Make SANYANG MODEL JET 50 SERIES Overall Length 1785 mm Front TELESCOPIC Overall Width 630 mm Suspension System Rear UNlT SWING Overall Height 1115 mm Front 120 / 70 – 12 DIMENSION Wheel Base 1275 mm Tire Specifications Rear 130 / 70 – 12 Front 40 kg Rear 54 kg Front DlSK ( ψ 190mm) Curb Wei g ht Total[...]

1. GENERAL INFORMATION 1-6 Specifications Make SANYANG MODEL JET 100 SERIES Overall Length 1785 mm Front TELESCOPIC Overall Width 630 mm Suspension System Rear UNlT SWING Overall Height 1115 mm Front 120 / 70 – 12 DIMENSION Wheel Base 1275 mm Tire Specifications Rear 130 / 70 – 12 Front 40 kg Rear 54 kg Front DlSK ( ψ 190mm) Curb Wei g ht Tota[...]

1. GENERAL INFORMATION 1-7 Torque values Standard Torque Values for Reference Type Torque value Type Torque value 5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m 6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m 8 mm Bolt, nut 1.8 - 2.5 kg-m 6 mm Flange bolt, nut 1.0 - 1.4 kg-m 10 mm Bolt, nut 3.0 - 4.0 kg-m 8 mm Flange bolt, [...]

1. GENERAL INFORMATION 1-8 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[...]

1. GENERAL INFORMATION 1-9 Cables and Harness Routing Note the following w hen 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 respec[...]

1. GENERAL INFORMATION 1-10 High/low beam sw itch 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 This c[...]

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 This chapter Contents[...]

1. GENERAL INFORMATION 1-12 Fuel filter Battery C.D.I. UNIT Fuse Purge control valv e Oil control cable Fuel hose Fuel pump Vacuum hose Oil hose Rear brake cable Carburetor Oil lever switch This chapter Contents[...]

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, a[...]

1. GENERAL INFORMATION 1-14 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 compr[...]

1. GENERAL INFORMATION 1-15 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 [...]

1. GENERAL INFORMATION 1-16 E . CLUTCH, DRIVING AND DRIVING PULLEY 1. Clutch ling spring broken 2. Clutch outer cover stuck with clutch balance w eights 3. Connection parts in clutch and shaft worn out or burned Engine can be started but motorcycle can not be driv ing FAULT CONDITION PROBA BLE CAUSES 1. Driving belt worn out or deformation 2. Drivi[...]

1. GENERAL INFORMATION 1-17 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 piv ot This chapter Contents[...]

1. GENERAL INFORMATION 1-18 Note: This chapter Contents[...]

2. SERVICE MAINTENANCE INFORMATION 2-1 General Information ························· 2-1 Periodical Maintenance Schedule··· 2-2 Air Clean er ········································ 2-3 Fuel Lines ········································· 2-[...]

2. SERVICE MAINTENANCE INFORMATION 2-2 Periodical Maintenance Schedule Maintenance kilometer 300KM Every 1000KM Every 3000KM Every 6000KM Every 12000KM Check item Maintenance interval New 1 month 3 month 6 month 1 year Reference ☆ 1. Air cleaner I C R ☆ 2. Fuel filter C ☆ 3. Engine oil filter cleaning C C ☆ 4. Oil pump linkage operation che[...]

2. SERVICE MAINTENANCE INFORMATION 2-3 Air Cleaner • Remove the mounting screw from the air cleaner cover • Remove the air cleaner cover Remove the air cleaner element Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry. Caution Never use gasoline or acid organized solvent to clean the element. Soap the [...]

2. SERVICE MAINTENANCE INFORMATION 2-4 Fuel Filter Remove the luggage box. Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking. Engine Oil Line Remove the body cover. Check the engine oil line and replace damaged par[...]

2. SERVICE MAINTENANCE INFORMATION 2-5 Oil Pump Control Cable Caution To adjust the oil pump control cable after adjusted the throttle grip play. Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body. Loosen the adjustment nut of the oil pump control cable. Tu[...]

2. SERVICE MAINTENANCE INFORMATION 2-6 Tire Caution Tire pressure should be checked when cold. Check tire for cracks, damage, nail, or other object stuck in tread. Recommended tire and tire pressure Tire size Front: 120 / 90 - 10 Rear: 130 / 90 - 10 Tire pressure (cold) kg/cm 2 1.75 2.0 Check if the tire tread and wall rubber for crack or damage, a[...]

2. SERVICE MAINTENANCE INFORMATION 2-7 Rear Brake Free Play: (Drum Brake Type) Measure the free play of the rear brake lever at the end of the lever. Free play: 10-20 mm (3/8-3/4 in) Adjust the free play by turning the front brake adjustment nut if necessary. Brake Confirmation Caution After brake adjustment, it has to check the brake operation to [...]

2. SERVICE MAINTENANCE INFORMATION 2-8 Brake System Hose: (Front Disc Brake Type) Make sure that the brake hose is corrosion or damage, and also check the system for leaking. Brake Fluid: Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit. Also check brake system fo[...]

2. SERVICE MAINTENANCE INFORMATION 2-9 z Remove the pin bolt cap. z Loosen the bolt. z Remove the front wheel shaft bolt. z Take out the front wheel. Remove brake caliper mounting bolt and then remove the brake caliper. Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining. Pry out the brake lining with[...]

2. SERVICE MAINTENANCE INFORMATION 2-10 Steering System Caution The control cables can not interfere with the rotation of steering handle. Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the hand[...]

2. SERVICE MAINTENANCE INFORMATION 2-11 Transmission Oil Leak Check if the transmission is leak. Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt. Replacement Remove the oil level check bolt. Remove the oil draining bolt, and then drain[...]

2. SERVICE MAINTENANCE INFORMATION 2-12 Control Cable Lubrication Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the cables thoroughly. Driver Belt z Remove left crankcase cover. z Check if the belt is crack or worn out. Replace the belt if necessary. z Measure the driving belt width Allowable limit[...]

2. SERVICE MAINTENANCE INFORMATION 2-13 Carburetor Idle Speed Adjustment Caution z Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. z Idle speed check and adjustment have to be done after engine is being warn up. It around operates engine from stop to running for 10 minute[...]

2. SERVICE MAINTENANCE INFORMATION 2-14 Headlight Adjustment Loosen headlight mounting bolt. Move the headlight for adjustment its light beam. Tighten the headlight mounting bolt after adjusted. Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance. Headlight mounting bolt Headlig[...]

3. LUBRICATION SYSTEM 3-1 Lubrication System Diagram ············ 3-1 Precautions In Operation ·················· 3-2 Lubricant ············································ 3-2 Trouble Shoot ing······························· 3-2 Oil Pump Re mov[...]

3. LUBRICATION SYSTEM 3-2 Precautions In Operation z Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump. z If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation. z It should bleed the oil output tube (from oil pump to c[...]

3. LUBRICATION SYSTEM 3-3 Oil Pump Removal Caution Before removing the oil pump, clean the oil pump and crankcase. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control cable, and remove the control cable. Remove the oil tube, and clip its end side to prevent oil from flowing out. Remove the oil output tube form intake ma[...]

3. LUBRICATION SYSTEM 3-4 Oil Pump/Oil Tube Air Bleeding Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage. Caution After disconnect the oil tube, air enters oil tube due to oil leak out without added oil. There is why the oil tube and oil pump h[...]

3. LUBRICATION SYSTEM 3-5 Oil Tank Removal/Installation Remove the luggage box and seat. Remove the battery and battery box. Remove the R/L. side cover, rear center cover, rear carrier and body cover. Remove the rear fender. Remove the oil input tube from oil pump, and then drain oil to a clean container. Remove the oil switch wire of the oil indic[...]

3. LUBRICATION SYSTEM 3-6 NOTES: This chapter Contents[...]

4. ENGINE REMOVAL 4-1 Maintenance In formation ················ 4-1 Engine re moval ································ 4-2 Engine insta llation ···························· 4-4 Maintenance Information There are parts that require removal of engine for maintenance. z Crankcase[...]

4. ENGINE REMOVAL 4-2 Engine removal Remove body cover. Remove the spark plug cap from the spark plug section. Remove the fuel output and the vacuum tubes from fuel pump. Remove the oil control cable from oil pump. Remove the oil tube from oil pump and then clip the tube. Remove the wire connectors of auto by starter and ACG. Remove the upper part [...]

4. ENGINE REMOVAL 4-3 Remove rear brake cable from engine rear-lower side. Remove air cleaner mounting bolts. (2 bolts) Support the engine and then remove shock absorber lower mounting bolt. Remove two exhaust pipe connection nuts. Remove two bolts beside fan cover and exhaust pipe. Mounting bolt Shock absorber lower mounting bolt Brake cable Exhau[...]

4. ENGINE REMOVAL 4-4 Remove engine mounting nut and bolt. Engine installation Install in the reverse order of removal procedures. Tighten the engine mounting and rear shock absorber upper/lower bolts. Torque value: Engine hanger bolt: Rear shock absorber upper mounting bolts: Rear shock absorber lower mounting bolts: Exhaust pipe connection nut: M[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-1 Maintenance In formation ·················· 5-2 Troubleshootin g ································ 5-2 Cylinder H ead ····································· 5-3 Cylinder/Pi ston ·························[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-2 Maintenance Information Precautions In Operation z The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. z It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. z Remove all washes from the interfaces [...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-3 Cylinder Head Cylinder Removal Removal body covers. Remove spark plug cap. Remove fan cover. Remove engine shield. Remove two connection nuts of the exhaust pipe. Remove exhaust muffle mounting bolt, and then remove the exhaust pipe. Cylinder Head Removal Remove the 4 cylinder head bolts and then remove the cyli[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-4 Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 0.10 mm Cylinder Head Installation Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder. Tighten the 4 bolts with diagonal direction and by 2-3 sequences. Tigh[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-5 Cylinder/Piston Cylinder Removal Be careful to pull the cylinder up and prevent piston from damage. Caution Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously. Piston Removal Place a clean rag onto crankshaft to cover the piston. Remove piston pin clip (one pi[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-6 Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 0.10 mm In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure. With the max. value to decide cylinder wear out condition. Service limit JET 50 : 39.050mm JET 100 : 51[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-7 Piston Ring Inspection Measure the end gap of each piston ring. Service limit: 0.40 mm Caution With the piston, push each piston ring into cylinder correctly. Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end, and then check its clearance. Measure the ID of connecting rod sma[...]

5. CYLINDER HEAD/CYLINDER/PISTON 5-8 Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase. Apply with two-stroke engine oil onto needle bearing and piston pin, and then install the piston pin onto connecting rod. Install piston, and place “EX” mark of the piston toward to exhaust [...]

6. ALTERNATOR 6-1 Maintenance In formation ················ 6-2 Alternator Removal ·························· 6-3 Alternator Inst allation······················· 6-4 6 3.8 kg f -m Home page Contents[...]

6. ALTERNATOR 6-2 Maintenance Information Precautions in Operation z The maintenance service of A.C. alternator can be carried out directly on the motorcycle. z Please refer to Chapter 15 for the relative alternator inspection. Torque value: Flywheel 3.8 kgf-m Tool General tool Rotor puller Universal holder Coil resistance value for the A.C. altern[...]

6. ALTERNATOR 6-3 Alternator Removal Remove the body cover. Remove two bolts and then take out cooling fan cover. Remove four bolts, and then take out the cooling fan. Hold flywheel with universal holder. Support the flywheel and the remove the 10 mm nut on the flywheel. Remove the flywheel with rotor puller. Cooling fan cover Universal holder Roto[...]

6. ALTERNATOR 6-4 Disconnect alternator wire connector and pulse generator connector. Remove the pulse generator and alternator four (4) bolts, and then take out the alternator assembly. Caution Care to be taken for not damaging the alternator coil. Alternator Installation Install the alternator assembly. Connect the alternator connector. Caution C[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-1 Maintenance In formation ················ 7-2 Trouble Shoot ing ····························· 7-2 Left Crankcase Cover ······················ 7-3 Reassembly Of Kick Starter ············ 7-4 Installation Of The Left Crank[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-2 Maintenance Information Precautions In Operation The surfaces of drive belt and driven pulley must be free of grease. Specification Item Standard value(mm) Limit(mm) Drive belt width 18.0 16.5 ID of movable drive face 20.035~20.085 20.120 OD of movable drive face boss 23.964~23.985 23.918 OD of wei[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-3 Left Crankcase Cover Left crankcase cover removal Remove left body side cover. Remove air cleaner. Remove kick start arm. Remove left crankcase cover. Disassembly of Kick Starter Remove snap clip and thrust washer from left crankcase cover. Install kick start arm, rotate the lever slightly and then[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-4 Reassembly Of Kick Starter Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle. Install the fric[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-5 Drive Belt Removal Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer. Caution y Using special tools for tightening or loosening the nut. y Fixed rear wheel or rear brake will damage reduction gear system. Push the drive belt into belt groove as di[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-6 Install the driven pulley that has installed the belt onto drive shaft. Install the clutch with universal holder, and then tighten nut to specified torque value. Torque value: 3.8 kgf-m Movable Drive Face Removal Remove left crankcase cover. Hold generator flywheel with universal holder, and then r[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-7 Removal Remove movable drive face set and drive belt from crankshaft. Remove ramp plate. Remove weight rollers from movable face. Inspection The weight roller is to press movable driven face by means of centrifuge force. Thus, if weight rollers are worn out or damage, the centrifuge force will be a[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-8 Check if movable drive face boss is worn or damage and replace it if necessary. Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit. Service limit: 20.12[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-9 Install movable drive face assembly onto crankshaft. Drive Face Installation Press drive belt into pulley groove, and then pull the belt on to crank shaft. Install drive face, washer and nut. Caution y Make sure that two sides of drive face have to be free of grease. Clean it with cleaning solvent.[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-10 Clutch/Driven Pulley Disassembly Remove drive belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution y Do not press the compressor too much. Hold the clutch spring compressor onto bench vise,[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-11 Clutch weight Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 82.5 mm Driven pulley Check following items: y If both surfaces are da[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-12 Clutch Block Replacement Remove clip and washer, and then remove clutch weight and spring from drive plate. Caution y Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity. Check if shock absorption rubber is damage or def[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-13 Install snap clip and mounting plate onto lock pin. Replacement of Driven Pulley Bearing Remove inner bearing. Caution y If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. y If the pulley equipped with ball bearing, it has to remove snap cli[...]

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER 7-14 Installation of Clutch/Driven Pulley Assembly Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Install sliding pulley onto driven pulley. Install guide pin and guide pin roller. Install socket. Install driven pulley, spring[...]

8. FINAL DRIVING MECHANISM 8-1 Maintenance In formation ················· 8-2 Troubleshootin g ······························· 8-2 Disassembly of Final Driving Mechanis m ········································ 8-3 Inspection of Final Driving Mechanism ····[...]

8. FINAL DRIVING MECHANISM 8-2 Maintenance Information Limited usage of gear oil ： gear oil #140 Recommended oil ： Bramax serial oil. Oil quantity ： 120 c.c. (110 c.c. as replacement) Special tools: Inner type bearing puller (SYM-6204020) Outer type bearing puller (SYM-6204010) Final shaft oil seal installer (SYM-9125500) Drive shaft oil seal[...]

8. FINAL DRIVING MECHANISM 8-3 Disassembly of Final Driving Mechanism Remove driven pulley Drain gear oil out from gearbox. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side. Remove final gear, final shaft and counter gear, counter shaft. Remove the drive shaft from left c[...]

8. FINAL DRIVING MECHANISM 8-4 Inspection Of Final Driving Mechanism Check if the drive shaft, counter shaft and final gear shaft are worn or damage. Check if the gear box cover bearing, oil seal and the inner diameter of counter shaft are worn or damage. Check if the left crankcase cover bearing, oil seal and the inner diameter of countershaft are[...]

8. FINAL DRIVING MECHANISM 8-5 Install countershaft, final driven gear and thrust washer. Install new gasket and lock pin. Install gearbox cover. Install clutch/driven pulley assembly. Install driven pulley, drive belt, and left crankcase side cover. Install body cover. Install rear wheel. Fill out specified oil quantity into gearbox. Counter gear [...]

8. FINAL DRIVING MECHANISM 8-6 Notes: This chapter Contents[...]

9. CRANKCASE/CRANKSHAFT 9-1 Maintenance In formation ····················9-2 Troubleshootin g ··································9-2 Crankcase Disassem bly ····················· 9-3 Crankshaft Re moval ···························· 9-3 Crankshaft In[...]

9. CRANKCASE/CRANKSHAFT 9-2 Maintenance Information z This chapter concerns disassembly of the crankcase for repair purpose. z Before disassembling crankcase, except removing engine firstly, following components must be removed too. • Carburetor (chapter 10) • Oil pump (chapter 3) • Reed valve (chapter 10) • Driving belt (chapter 7) • Alt[...]

9. CRANKCASE/CRANKSHAFT 9-3 Crankcase Disassembly Remove the crankcase bolts. Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase. Crankshaft Removal As the diagram show with 3 special bolts to install the specified service tool onto the left crankcase. Remove the cran[...]

9. CRANKCASE/CRANKSHAFT 9-4 Crankshaft Inspection Measure the clearance of connecting rod big end. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge. Service limit:[...]

9. CRANKCASE/CRANKSHAFT 9-5 Crankcase Installation Clean the crankshaft with solvent and blow it with compressed air. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase. Caution y All rotation and sliding surfaces have to be applied with clean engine oil. y Remove all gaskets onto the crankcase inte[...]

9. CRANKCASE/CRANKSHAFT 9-6 Assemble the right crankcase with assembly tools. Install right crankcase onto the crankshaft. Install right crankshaft puller and install bush onto crankshaft. Screw the right crankshaft puller onto crankshaft. Turn the puller in C.W. direction and then completely screw the puller to bottom. Lubricate crankshaft bearing[...]

10. FUEL SYSTEM 10-1 Maintenance In formation ················· 10-2 Troubleshootin g ······························· 10-2 Throttle Va lve ···································· 10-3 Carburetor Remove ·························· 10-4 Auto By-S[...]

10. FUEL SYSTEM 10-2 Maintenance Information Precautions in Operations Warning Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. y Care must be taken when dealing with gasoline, and always work in a well-ventilated place [...]

10. FUEL SYSTEM 10-3 Throttle Valve Removal Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Inspection Installation Place the fuel needle onto the throttle valve and clip it with needle clamp. Install the seal[...]

10. FUEL SYSTEM 10-4 Carburetor Remove Remove the body cover. Disconnect the auto by-starter connector. Loosen draining screw and then drain out fuel inside the carburetor. Loosen carburetor upper part and remove carburetor upper part. Remove fuel and oil hoses from carburetor. Remove carburetor mounting bolt and carburetor. Auto By-Starter Inspect[...]

10. FUEL SYSTEM 10-5 Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes. Pump compressed air into the f[...]

10. FUEL SYSTEM 10-6 Float/Float Valve/Jet Removal Remove the float from carburetor body. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to[...]

10. FUEL SYSTEM 10-7 Flaot Level Inspection Measure float fuel level to have the upper end of float just contact with the float. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Installation Caution Do not let foreign materials into the carburetor. Install the carburetor [...]

10. FUEL SYSTEM 10-8 Inspection Check the reed valve for damage and its reed strength. Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper. Otherwise, it will cause its strength insufficient and rough engine running. If the reed val[...]

10. FUEL SYSTEM 10-9 Air Cleaner Removal/Installation Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner. Install in the reverse order of removal procedures. Bolts This chapter Contents Hose clamp[...]

10. FUEL SYSTEM 10-10 Notes: This chapter Contents[...]

11. BRAKE SYSTEM 11-1 Front Disc Brake System ··············· 11-1 Rear Drum Br ake System ·············· 11-2 Maintenance In formation ··············· 11-3 Troubleshootin g ····························· 11-4 Hydraulic Di sc Brake ······················ 1[...]

11. BRAKE SYSTEM 11-2 Rear Drum Brake System 2.5 kgf-m 11.0 kgf-m 0.55 kgf-m This chapter Contents[...]

11. BRAKE SYSTEM 11-3 Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. y The brake caliper can be removed without removing the hydraulic system. y After [...]

11. BRAKE SYSTEM 11-4 Troubleshooting Disc Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disc 7. Low brake fluid 8. Blocked brake pipe 9. Warp/bent brake disc 10. Bent brake lever Hard operation of brake lever 1. Blocked brake [...]

11. BRAKE SYSTEM 11-5 Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, then remove the brake fluid reservoir. Cover the painted surfaces, plastic or rubber components with a rag when serv[...]

11. BRAKE SYSTEM 11-6 Disc Brake -Air Bleed 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. Caution y Do not release the brake lever before the drain valve is closed. y Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system. 2. Slowly re[...]

11. BRAKE SYSTEM 11-7 Brake Disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Remove the brake disc from wheel. Check the disc for deformation and bend. Allowable limit: 0.30 mm Disc Brake - Master Cylin[...]

11. BRAKE SYSTEM 11-8 Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Allowable limit: 12.550 mm Measure the outer diameter of the piston. Repla[...]

11. BRAKE SYSTEM 11-9 Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake lamp switch. Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified torque value. Make sure the hose is installed correctly. Instal[...]

11. BRAKE SYSTEM 11-10 Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution y Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts. y Brake performance will be reduced by grease on brake lining. Remove wheel and [...]

11. BRAKE SYSTEM 11-11 Installation Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin. Caution Brake efficiency will be reduced if brake linings is contaminated by oil or grease. Insta[...]

11. BRAKE SYSTEM 11-12 Notes: This chapter Contents[...]

12. BODY COVER 12-1 Body Overview ······························· 12-1 Maintenance Information ··············· 12-2 Side Cove rs····································· 12-3 Luggage Bo x ··································· 12-3 Body Co[...]

12. BODY COVER 12-2 Maintenance Information Body covers disassemble sequence: y Be careful not to damage various covers in disassembly or re-assembly operation. y Never injure hooks molded on the body covers in disassembly or re-assembly operation. y Align the buckles on the guards with slot on the covers. y Make sure that each hook is properly ins[...]

12. BODY COVER 12-3 Side Covers 1. Removal: y Remove 3 screw (front/middle) from two side covers. y Slide the side cover backward so that their hooks are out of slots. y Take out the side cover end part and then remove the cover. 2. Installation: y Install in reverse order of removal procedures. Caution The tail of each cover is held with buckles a[...]

12. BODY COVER 12-4 Body Cover 1. Removal: y Remove 4 bolts from rear carrier, and then remove rear carrier. y Remove 1 screw and 2 nuts and 1bolt from luggage box, and then remove luggage box. z Remove 3 screws from the tail cover,.and then remove the tail cover. Remove 2 screws astern of the body cover Bolts Screws This chapter Contents[...]

12. BODY COVER 12-5 Remove 2 screw form of the body cover Remove the body cover. 2. Installation: y Install in reverse order of removal procedures. Bolts This chapter Contents[...]

12. BODY COVER 12-6 Front Cover 1. Removal: y Remove 2 bolts from the front side reflector, and then remove front side reflector. y Remove 2 screws from the front inner box and front cover. y Remove 1 screw from the front cover. y Remove electric cord coupler from the head light. y Remove the front cover. 2. Installation y Install in reverse order [...]

12. BODY COVER 12-7 Front Under Spoiler 1. Removal: y Remove right and left side cover. (6 screws) y Remove 4 screws from the front inner box. y Remove 2 screws from the front upper part of the front spoiler and the front inner box. y Remove the front spoiler. 2. Installation: y Install in reverse order of removal procedures. Screws Screws Screw Th[...]

12. BODY COVER 12-8 Front Inner Box 1. Removal: y Remove the front cover. y Remove the front under spoiler. y Remove hook and 1 screw. y Remove key set cover. y Remove 2 bolts from the floor panel. y Remove the front inner box. 2. Installation: y Install in reverse order of removal procedures. Bolts Hook & 1 screw Ke y set co ver This chapter C[...]

12. BODY COVER 12-9 Floor Panel 1. Removal: y Remove 6 screws and the side cover. y Remove 6 screws and the body cover. y Remove the floor panel. (4 bolts) 2. Installation: y Install in reverse order of removal procedures. Front Fender Removal: y Ramoval 1 bolt and fr brake hose clamp. y Ramoval 2 screws form front fender right and left side. y Ram[...]

12. BODY COVER 12-10 Steering Handle Cover 1. Removal: y Remove 6 screws from the handle rear cover. y Remove handle front cover. y Remove front winker electric cord coupler y Remove 1 screw from rear side by handle rear cover. y Remove 2 inner screws. y Disconnect each switch connectors. y Remove speedometer cable. y Remove handle rear cover. 2. I[...]

12. BODY COVER 12-11 Under Cover 1. Removal: y Remove 2 bolts from the under cover. y Remove under cover. 2. Installation: y Install in reverse order of removal procedures. 2 bolts 2 nuts This chapter Contents[...]

12. BODY COVER 12-12 Note: This chapter Contents[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-1 Maintenance In formation ················· 13-2 Troubleshootin g ······························· 13-2 Steering Ha ndle ································ 13-3 Front Wh eel ·····························?[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-2 Maintenance Information Specification Item Standard value (mm) Limit (mm) Shaft bending ─ 0.2 (0.01 in) Radial ─ 2.0 (0.08 in) Rim wobbling Axial ─ 2.0 (0.08 in) Torque Value Steering handle nut 4.5 kgf-m Front brake caliper bolt 3.3 kgf-m Front wheel axle 6.0 kgf-m Steering stem mounting nut 1.5 kgf-m[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-3 Steering Handle Removal Remove handle cover, front cover and inner box. Remove throttle grip after mounting screw removed. Remove master cylinder (disc brake) after 2 bolts removed. Remove rear brake lever bracket after mounting bolt removed. Remove handle mounting bolt and nut, and then remove the handle. I[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-4 Place master cylinder onto handle and align its connection surface with bolt hole on the handle (disc brake). Install the mounting seat. Tighten the upper part bolt, and then tighten lower bolt. Install all components in reverse order of removal procedures. Conduct following adjustment: y Oil pump control ca[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-5 Inspection Place the axle onto a V-block to measure its run-out with a dial gauge. The dial gauge indicated 1/2 run-out. Service limit: 0.20 mm Place the wheel on to a rotation seat, and turn the wheel to check its bearing free play. If the bearing is noisy or its free play is too much, replace it. Place the[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-6 Remove dust seal, bearing and side collar. Special tools Inner bearing puller (SYM-6204020) Installation Fill out the block of bearing by grease. Drive the left bearing and install the dist. collar. Install the right bearing. Caution y Carefully install the bearing in correct and evenly. y Bearing outer face[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-7 Lubricate the speedometer gear with grease and install the gear into the wheel hub. Align the flange part on the speedometer gear with the slot of wheel hub. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease. Apply with grease onto[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-8 Front Shock Absorber Removal y Front cover y Front under spoiler y Front fender y Front wheel Disc Brake Remove the caliper mounting bolt and the caliper. Take out the hose from hose clamp. Remove the front shock absorber upper bolt and the shock absorber. Installation Align the cover flange with upper level[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-9 Front Fork Removal y Handle y Front wheel y Front shock absorber Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing. Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seat[...]

13. STEERING/FRONT WHEEL/SUSPENSION 13-10 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.5 kgf-m Install in reverse order of removal procedures. Steering stem mounting nut Top cone race This chapter Contents[...]

14. REAR WHEEL/SUSPENSION 14-1 Maintenance In formation ················· 14-2 Troubleshootin g ······························· 14-2 Rear Wh eel ······································· 14-3 Rear Shock Ab sorber ······················ 14-4 14[...]

14. REAR WHEEL/SUSPENSION 14-2 Maintenance Information Specification Item Standard value (mm) Limit (mm) Rear wheel rim run out - 2.0 (0.08 in) Torque Value Rear shock absorber upper mounting bolt: 4.0 kgf-m Rear shock absorber lower mounting bolt: 2.7 kgf-m Rear wheel nut: 11.0 kgf-m Rear wheel hub: 2.5 kgf-m Exhaust muffler nut: 1.2kgf-m Exhaust [...]

14. REAR WHEEL/SUSPENSION 14-3 Rear Wheel Remove Remove exhaust pipe nut. (2 connection nuts) Remove exhaust muffler bolt (3 bolts), then remove the muffler. Remove rear wheel shaft nut and then remove the rear wheel. Inspection As the diagram shown, measure wheel rim wobbling with a dial gauge. Service limit: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm[...]

14. REAR WHEEL/SUSPENSION 14-4 Brake Hub Replacement Remove 4 nuts of cover and wheel rim, and then remove the wheel hub. Install the wheel hub and tighten the nuts. Tighten torque: 2.5 kgf-m Installation Install the rear wheel and tighten the nut. Tighten torque: 11.0 kgf-m Install exhaust pipe & muffler. Tighten torque (bolt): 3.3 kgf-m Tight[...]

15. ELECTRICAL EQUIPMENT 15-1 Maintenance Information ··············· 15-2 Troubleshootin g ····························· 15-3 Battery ············································· 15-4 Charging Sy stem ···························· 1[...]

15. ELECTRICAL EQUIPMENT 15-2 Maintenance Information Precautions in Operation y When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positiv e cable terminal.) y The model of the spark plug and the tightening torque. y The ignition timing. y Adju[...]

15. ELECTRICAL EQUIPMENT 15-3 Troubleshooting No voltage y Battery discharged y The cable disconnected y The fuse is blown y Improper operation of the main switch Low voltage y The battery is not fully charged y Poor contact y Poor charging system y Poor voltage regulator No spark produced by spark plug y The spark plug is out of work y The cable i[...]

15. ELECTRICAL EQUIPMENT 15-4 Battery Battery Removal/Installation Turn off main switch. Open seat. Remove screw and the open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal. Voltage Check Open seat and battery cover. [...]

15. ELECTRICAL EQUIPMENT 15-5 Charging System JET 50 / JET 100 JET EURO 50 / JET EURO 100 AC. Gen era tor Auto by - starter Regulator rectifier Main Switch Fuse 15A Battery Green Red Black Yellow Yellow Yellow Yellow White Yellow Green Red Resistor 10.2 Ω 5W Resistor 5.9 Ω 30W Green/ Black Pink Green/ Black Resistor 8 Ω 5W Auto by- starter AC[...]

15. ELECTRICAL EQUIPMENT 15-6 Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal. Caution y In the current leakage test, set the current range at larger scale, then gradually decrease to[...]

15. ELECTRICAL EQUIPMENT 15-7 Caution To replace the old battery, use a new battery with the same current and voltage. The following problems are related to the charging system, follow the instructions provided in the checking list to correct it if any one of the problems takes place. (1) The charging voltage can not exceed the voltage between two [...]

15. ELECTRICAL EQUIPMENT 15-8 Voltage Regulator Inspection – JET 50/100 Check the each pins of connector on the voltage regulator. Inspection Probable cause Check voltage between battery terminal (red) and ground (green). Blown fuse or poor main switch contact Check continuity between ground and frame. Open-circuit wire Check charging coil (white[...]

15. ELECTRICAL EQUIPMENT 15-9 Inspection on SCR – JET EURO 50/100 Remove the front cover. Disconnect 4P connectors to remove the SCR. Item Check Points Standard Value Main switch connection R – B Battery voltage (ON) Battery connection R – G Battery voltage Charging coil Y – Y 0.4~0.8 Ω If the readings measured are not normal, check parts [...]

15. ELECTRICAL EQUIPMENT 15-10 Ignition System JET 50/100 series JET EURO 50/100 series Black/Red Blue/Yellow Black/White Black/Yellow Green Blue/Yellow Green Black/Yellow Black/Blue Black Red This chapter Contents[...]

15. ELECTRICAL EQUIPMENT 15-11 Ignition Coil Inspection y Remove body cover. Measure the primary coil resistance Resistance :0.19~0.23K Ω (A) → (B) Measure the secondary coil resistance Resistance : 8.2~9.3K Ω (A) → (C) Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance. Resistance : 3.1~[...]

15. ELECTRICAL EQUIPMENT 15-12 Electrical System Circuit Inspection Pulse Generator/Exciting Coil Remove body cover. Disconnect alternator connector. Resistance Measurement: (20 ℃ ) Pulse generator coil (blue/yellow - ground): 50~200 Ω Exciting (yellow - ground): 400~800 Ω CDI Electrical System Circuit Inspection Remove body cover. Disconnect t[...]

15. ELECTRICAL EQUIPMENT 15-13 Starting System Starter Relay Inspection Remove luggage box. Connect both the green/yellow (-) and the yellow/red (+) pins to battery posts directly. If the red and red/white pins are also in continuity, it means it is in normal. Starter Motor Pinion Removal/Installation Remove left crankcase cover. Remove starter mot[...]

15. ELECTRICAL EQUIPMENT 15-14 Starter Motor Removal/Disassembly Remove body cover. Remove bolt and oil pump control cable. Disconnect starter motor harness connector. Remove 2 bolts for separation starter motor and gasket. Remove 2 bolts for disassembly the starter motor. Armature Inspection Check the armature for discoloration or other damage. It[...]

15. ELECTRICAL EQUIPMENT 15-15 Oil Level Switch Troubleshooting y If the oil level in oil tank is in specified level, but the oil level indicator still goes on . 1. Remo ve body cover. 2. Disconnect oil gauge wire, and turn the main switch to ON position. y If there is no oil in oil tank or low oil l evel, but the oil level indicator still not goes[...]

15. ELECTRICAL EQUIPMENT 15-16 Fuel Unit Removal/Installation Remove 4 bolts and floor panel. Disconnect fuel unit connector. Remove the fuel unit plastic cap. Turn the snap ring in CCW direction and then remove the fuel unit. Caution Do not bend the float arm. Install in reverse order of removal procedures. Remark: Aligning the slot of fuel unit w[...]

15. ELECTRICAL EQUIPMENT 15-17 Switch / Horn Remove handle covers and front cover. Remove front inner box. Check continuity on each switch. The connected circles with a line are that they should be in continuity. Main Switch Wire color Black Black / White Green Red Mark BAT2 IG E BAT1 LOCK ● ● OFF ● ● ON ● ● Turn signal light switch Wir[...]

15. ELECTRICAL EQUIPMENT 15-18 Light Switch Wire color Brown Yellow Pink Mark HL CI RE OFF ● ● ON ● ● Start Switch Wire color Yellow / Red Green Mark ST E FREE PUSH ● ● Front / Rear Brake Light Switch If the switch is in continuity as braking, it is in normal. The switch is non-adjustable. Horn If the horn give out sound as connecting t[...]

15. ELECTRICAL EQUIPMENT 15-19 Bulb Replacement Headlight/position light JET EURO 50/100 Remove front cover. Remove bulb seat and replace the bulb. Install the all removed parts. JET 50/100 Remove front cover. Loosen the headlight bulb stop plate and replace the bulb. Remove the position light bulb seat and replace the bulb. Install the all removed[...]

15. ELECTRICAL EQUIPMENT 15-20 Rear winker light Remove rear winker lens. Replace winker light bulb. Front winker light Remove 6 screws and then remove handle front cover Replace winker light bulb 6 Screws 1 Screw This chapter Contents[...]

15. ELECTRICAL EQUIPMENT 15-21 Clock unit – JET EURO 50/100 Remove 6 screws and then remove handle front cover Remove 2 screws and then remove clock unit. Meter Remove handlebar front cover. Take out the bulb seat from the bottom of instrument panel. Install the all removed parts. Clock Handle rear cover This chapter Contents[...]

15. ELECTRICAL EQUIPMENT 15-22 Notes: This chapter Contents[...]

16. ELECTRICAL DIAGRAM 16-1 JET 50 ELECTRICAL DIAGRAM 16 Home page Contents[...]

16. ELECTRICAL DIAGRAM 16-2 JET 50 EURO ELECTRICAL DIAGRAM Home page Contents[...]

16. ELECTRICAL DIAGRAM 16-3 JET 100 ELECTRICAL DIAGRAM Home page Contents[...]

16. ELECTRICAL DIAGRAM 16-4 Notes: Home page Contents[...]