SYM Symply² 50 Service Manual PDF DOWNLOAD

Description

SYM Symply² 50 Service Manual SANYANG 50cc Scooter Repair Guide PDF DOWNLOAD

DESCRIPTION

SYM Symply² 50 Scooter Service Manual – Complete Workshop Documentation

This official SYM Symply 50 service manual provides comprehensive repair and maintenance procedures for the SYM (SANYANG) Symply² 50 scooter. Published by San Yang Industry Co., Ltd., this manual is the authoritative technical reference for motorcycle technicians servicing Symply2 scooter repair guide equipped vehicles with 4-stroke engines.

Model Overview – SYM Symply² 50

Model: Symply² 50 (also written as Symply2 50)
Engine: 49.5cc 4-stroke, forced air-cooled, single cylinder
Manufacturer: SANYANG (San Yang Industry Co., Ltd.)
Manual Pages: 176 pages
Manual Type: Complete Service Manual

Technical Specifications

Engine Specifications:

• Type: 4-stroke, forced air-cooled
• Displacement: 49.5cc
• Bore: 39.0mm
• Stroke: 41.5mm
• Compression Ratio: 11.8:1
• Max Power: 2.35 kW @ 8500 rpm
• Max Torque: 2.91 N·m @ 6500 rpm
• Cylinder: Single cylinder, horizontal arrangement
• Installation: Vertical, below center, incline 80°
• Ignition: C.D.I. (Capacitor Discharge Ignition)
• Starting System: Electric & kick starter
• Lubrication: Forced-circulation & splash system
• Air Filtration: Paper filter
• Fuel: Petrol (gasoline)

Transmission:

• Primary Reduction: Belt drive (CVT)
• Secondary Reduction: Gear
• Clutch: Centrifugal, dry type
• Transmission Type: C.V.T. (Continuously Variable Transmission)

Chassis and Dimensions:

• Overall Length: 1894mm
• Overall Width: 694mm
• Overall Height: 1138mm
• Wheelbase: 1327mm
• Dry Weight: 99kg (Front: 40kg, Rear: 59kg)
• Max Load: 209kg (Front: 84kg, Rear: 125kg)
• Passenger Capacity: Two persons / 150kg

Suspension:

• Front: Telescopic fork
• Rear: Single swing arm

Tires:

• Front: 120/70-12 (56J)
• Rear: 130/70-12 (56J)

Brakes:

• Front: Disc brake (Ø 190mm)
• Rear: Drum brake (Ø 110mm)

Performance:

• Max Speed: 45 km/h
• Climb Ability: 20° or below
• Speedometer Range: 0-80 km/h

Exhaust System:

• Muffler Type: Expansion & Pulse type
• Exhaust Position: Right side, backward
• Noise Emission: <70 dB

Electrical:

• Horn: 95-115 dB(A)

Complete Service Manual Contents

CHAPTER 1 – GENERAL INFORMATION/TROUBLE DIAGNOSIS

Symbols and Marks:

• Warning – Serious injury/death hazards
• Caution – Equipment damage prevention
• Engine oil – SAE 10W-30 API SH/CD class requirement
• Grease – King Mate G-3 recommended
• Locking sealant – Medium strength application
• Oil seal – Lubrication requirements
• Brake fluid – DOT3 or WELLRUN specification
• Special tools indication
• Correct/Wrong installation markers
• Component directions and assembly indicators

General Safety:

• Carbon monoxide – Ventilation requirements
• Gasoline handling – Fire and explosion hazards
• Battery safety:
  • Explosive gas warnings
  • Sulfuric acid handling
  • Eye and skin protection
  • Emergency procedures
• Used engine oil – Skin cancer prevention
• Brake shoe – Dust inhalation hazards
• Brake fluid – Paint damage prevention

Service Precautions:

• SANYANG genuine parts requirement
• Special tools usage (7 specialized tools listed)
• Metric tools requirement
• Component cleaning procedures
• Electrical connector handling:
  • Terminal insertion techniques
  • Boot covering requirements
  • Pin inspection procedures
  • Proper disconnection methods
  • Wire harness routing
  • Heat protection
  • Sharp edge protection
  • Handlebar clearance
  • Twist prevention
  • Connector rust cleaning
• Test instrument operation

Specifications:

• Complete technical data (detailed above)
• Dimensional specifications
• Weight distribution

Torque Values:

• Engine torque specifications
• Frame torque specifications
• Critical fastener torque settings

Trouble Diagnosis:

• Comprehensive troubleshooting charts
• Symptom-based diagnosis
• Electrical system troubleshooting
• Engine performance issues

Lubrication Points:

• Complete lubrication diagram
• Service interval specifications
• Recommended lubricants

CHAPTER 2 – MAINTENANCE INFORMATION

Maintenance Schedule:

• Periodic service intervals
• Component inspection checklists
• Replacement schedules
• Adjustment procedures

Special Tools:

• SYM-6204010 – Outer bearing puller
• SYM-3110A00 – ACG flywheel puller
• SYM-9020100 – Lock nut puller
• SYM-2210100 – Universal holder (MDF/clutch outer)
• SYM-2301000 – Clutch spring compressor
• SYM-9020200 – Clutch nut wrench
• SYM-2822100-GY6 – GY6 starter gear puller

CHAPTER 3 – LUBRICATION SYSTEM

Oil System:

• Engine oil circulation
• Oil pump operation
• Oil filter service
• Oil change procedures
• Oil capacity specifications
• Oil level checking

CHAPTER 4 – FUEL SYSTEM

Fuel Components:

• Fuel tank removal and installation
• Fuel unit service
• Carburetor service:
  • Disassembly procedures
  • Jet sizing
  • Float level adjustment
  • Mixture adjustment
• Air cleaner maintenance
• Fuel line routing
• Throttle cable adjustment

CHAPTER 5 – ENGINE REMOVAL

Complete Engine Removal:

• Pre-removal preparation
• Exhaust system disconnection
• Electrical disconnections
• CVT cover removal
• Engine mounting bolt removal
• Extraction procedures
• Installation procedures

CHAPTER 6 – CYLINDER HEAD/VALVE

Valve Train Service:

• Cylinder head removal
• Valve clearance adjustment
• Valve inspection
• Valve guide service
• Valve seat reconditioning
• Head gasket replacement
• Torque specifications

CHAPTER 7 – CYLINDER/PISTON

Cylinder Assembly:

• Cylinder removal
• Piston removal
• Piston ring service:
  • Ring gap measurement
  • Ring installation
• Piston pin service
• Cylinder bore measurement
• Honing procedures

CHAPTER 8 – “V” TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

CVT Transmission:

• V-belt drive system operation
• Drive pulley (variator) service:
  • Roller weights
  • Ramp plate
  • Movable face
• Driven pulley (clutch) service:
  • Clutch spring
  • Clutch shoes
  • Engagement RPM
• V-belt inspection and replacement
• Kick starter arm mechanism
• Starter clutch service

CHAPTER 9 – FINAL DRIVING MECHANISM

Final Drive:

• Reduction gear service
• Output shaft service
• Bearing replacement
• Oil seal service
• Gear backlash adjustment

CHAPTER 10 – A.C. GENERATOR/STARTING CLUTCH

Charging System:

• A.C. Generator (alternator) testing
• Stator coil inspection
• Rotor removal (flywheel puller required)
• Starting clutch service
• Voltage output testing

CHAPTER 11 – CRANKCASE/CRANKSHAFT

Crankshaft Assembly:

• Crankcase splitting
• Crankshaft inspection
• Big end bearing service
• Main bearing replacement
• Crankcase reassembly
• Sealant application

CHAPTER 12 – BODY COVER

Body Panel Service:

• Front cover removal
• Side panel removal
• Floor panel removal
• Seat removal
• Panel fastener locations

CHAPTER 13 – BRAKE SYSTEM

Brake Service:

• Front disc brake:
  • Brake lever adjustment
  • Brake pad inspection
  • Caliper service
  • Rotor measurement
  • Brake fluid service
• Rear drum brake:
  • Brake lever adjustment
  • Brake shoe inspection
  • Drum measurement
  • Adjustment procedures

CHAPTER 14 – STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

Front End Service:

• Steering head bearing service
• Front fork (telescopic):
  • Disassembly
  • Oil change
  • Spring inspection
  • Seal replacement
• Front wheel service
• Bearing replacement
• Alignment procedures

CHAPTER 15 – REAR WHEEL/SUSPENSION

Rear Suspension:

• Rear wheel removal
• Single swing arm service
• Rear shock absorber service
• Wheel bearing replacement
• Axle inspection

CHAPTER 16 – ELECTRICAL EQUIPMENT

Complete Electrical System:

• Battery service
• Fuse locations
• CDI unit (C.D.I.)
• Ignition coil testing
• REG.REC (Regulator/Rectifier)
• Head light and position light
• Tail light service
• Turn signal lights (front and rear)
• Horn testing
• Meter (instrument cluster)
• Switches:
  • Ignition switch
  • Light/starter switch
  • Engine control switch
  • High/low beam switch
  • Seat open switch
  • Turn signal switch
  • Horn switch
• Winker relay
• Start magnetic switch
• Wiring harness routing
• Connector service

CHAPTER 17 – ELECTRICAL DIAGRAM

Wiring Schematics:

• Complete wiring diagram
• Color-coded wire identification
• Component locations
• Circuit descriptions

Component Locations (Mechanism Illustrations)

Left Side View:

• Meter (instrument cluster)
• Front turn signal light
• Head light/Position light
• Front disc brake
• Engine number location
• Light/starter switch
• Engine control switch
• Battery/Fuse/CDI location
• Engine oil draining bolt
• Winker relay
• Front brake lever
• Ignition switch

Right Side View:

• High & low beam/Seat open/Turn signal/Horn switches
• Rear brake lever
• Start magnetic switch
• Fuel tank/Fuel unit
• Horn/REG.REC
• Frame number location
• Tail light
• Rear turn signal light
• Air cleaner
• Gear oil filling bolt
• Gear oil draining bolt
• Exhaust muffler
• Ignition coil
• Oil level gauge
• A.C. Generator

Manufacturer Information

San Yang Industry Co., Ltd.

• Service Department
• SANYANG (SYM Brand)

Recommended Products:

• Engine Oil: SAE 10W-30 API SH/CD class
• Grease: King Mate G-3
• Brake Fluid: DOT3 or WELLRUN

Why This Manual is Essential

This 50cc scooter troubleshooting guide provides:

✓ Factory-authorized procedures – Official SANYANG documentation
✓ Complete system coverage – All mechanical and electrical systems
✓ CVT transmission service – V-belt drive detailed procedures
✓ 4-stroke engine overhaul – Complete disassembly/assembly
✓ Electrical system diagnosis – Full wiring diagrams
✓ GY6-style engine – Common 50cc platform service
✓ Special tools – 7 specialized tools illustrated
✓ Safety protocols – Comprehensive warnings and precautions

Perfect For

• Motorcycle mechanics specializing in scooter repair
• Scooter service shops maintaining SYM vehicles
• DIY scooter owners performing their own maintenance
• Technical training schools teaching small engine repair
• Motor scooter enthusiasts restoring Symply² scooters
• Parts departments identifying replacement components
• Fleet maintenance with SYM scooters
• GY6 engine specialists servicing 50cc scooters

Applications and Usage

SYM Symply² 50 scooters are popular for:

• Urban commuting and city transportation
• Campus and short-distance travel
• Economical personal transportation
• Entry-level motorcycling
• Asian and international markets
• Light delivery applications

Important Notes

• Specifications subject to change without notice
• Actual vehicle prevails if different from manual
• SANYANG genuine parts required for warranty
• Metric tools only – No English system
• Copyright protected – No unauthorized duplication

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