User manual SYM CITYCOM 300I SERVICE MANUAL

[. . . ] FOREWORD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER Citycom. 300i SERVICE MANUAL Homepage Contents 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 technicians with 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 changes without notice. Service Department SANYANG INDUSTRY CO. , LTD. Homepage Contents 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. [. . . ] Service Limit: IN: 4. 90 mm EX: 4. 90 mm Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5. 0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5. 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide. Service Limit: IN0. 08 mm EX0. 10 mm 5. 0 mm valve guide reamer Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too. Caution It has to correct valve seat when replacing valve guide. 6-9 To this chapter contents 6. Cylinder Head / Valve Valve Stem Replacement Heat up cylinder head to 100~150 with heated plate or toaster. Valve guide driver 5. 0mm Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. Wear on a pair of glove to protect your hands when operating. Hold the cylinder head, and then press out old valve guide from combustion chamber side. Tool: Valve guide driver: 5. 0 mm Caution Check if new valve guide is deformation after pressed it in. When pressing in the new valve guide, cylinder head still have to be kept in 100~150. Adjust the valve guide driver and let valve guide height is in 13 mm. Press in new valve guide from rocker arm side. Tool: Valve guide driver: 5. 0 mm Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer. Valve guide driver 5. 0 mm Caution Using cutting oil when correcting valve guide with a reamer. Turn the reamer in same direction when it be inserted or rotated. Correct valve seat, and clean up all metal residues from cylinder head. Tool: Valve guide reamer: 5. 0 mm Valve guide reamer 5. 0 mm 6-10 To this chapter contents 6. Cylinder Head / Valve Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide. Clean up the emery after corrected, and apply with engine oil onto contact faces of valve and valve seat. [. . . ] PCV Function Test 1) Disconnect the hose of connection to the activated-carbon canister, and then connect a T-type hose connector to pressure source as shown below: Pressure gauge Engine vacuum To air filter Pressure source Purge Control Valve 2) Apply 100mmAq into pressure source inlet as engine stopped then plug it. The pressure at the gauge should not drop to below 10mmAq within 10 seconds. 18-3 To this chapter contents 18. Emission Control System Catalytic Converter (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. [. . . ]