SERVICE MANUAL

SERVICE MANUAL

SYM FORWARD

This service manual contains the technical data of each component inspection and repair for the SYM 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 guidelines.

If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

This manual that contains all data, illustration, indication and specifications is based on current production information. SYM reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this manual can be duplicated by any means without written permission of SYM.

SERVICE DEPARTMENT

SANYANG INDUSTRY CO., LTD.

HOW TO USE THIS MANUAL SYM

This service manual describes basic information of different system parts and system inspection & service for SYM 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 information and trouble diagnosis.

The second chapter covers service maintenance information.

The third to the eleventh chapters cover engine and driving systems.

The twelfth to fifteenth chapters are contained the parts set of assembly body.

The sixteenth chapter is electrical equipment.

The seventeenth chapter is for wiring diagram.

Please see index of content for quick having the special parts and system information.

SYM CONTENTS

CONTENTS

GENERAL INFORMATION/TROUBLE DIAGNOSIS ...................................1

MAINTENANCE INFORMATION .................................................................2

LUBRICATION SYSTEM..............................................................................3

FUEL SYSTEM .............................................................................................4

ENGINE REMOVAL......................................................................................5

CYLINDER HEAD/VALVE............................................................................6

CYLINDER/PISTON......................................................................................7

"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......................8

FINAL DRIVING MECHANISM.....................................................................9

A.C. GENERATOR/STARTING CLUTCH ....................................................10

CRANKCASE/CRANKSHAFT .....................................................................11

BODY COVER ..............................................................................................12

BRAKE SYSTEM..........................................................................................13

STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER ........................14

REAR WHEEL/SUSPENSION......................................................................15

ELECTRICAL EQUIPMENT .........................................................................16

WIRING DIAGRAM.......................................................................................17

SPECIAL TOOL............................................................................................18

MECHANISM ILLUSTRATIONS SYM

Front light/

Position light

Front turn signal light

High& Low beam/ Turn signal/Horn switch

Storage box

Tail light

Oil level

Front brake level

Rear brake level

Side stand

Frame number

Main stand

Gear oil filling bolt

Headlight switch/starter switch

Fuse &C.D.I Battery

Engine number/ Engine oil draining bolt

Fuel tank cap

Gear oil draining bolt

Air Cleaner

Kick starter pedal

Ignition switch

Rear turn signal light

Exhaust muffler

SYM

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYMBOLS AND MARKS ....................1-1

GENERAL SAFETY............................1-2

SERVICE PRECAUTIONS .................1-3

SPECIFICATIONS..............................1-9

SYMBOLS AND MARKS

TORQUE VALUES (ENGINE) .............. 1-10

TORQUE VALUES (FRAME) ............... 1-11

TROUBLES DIAGNOSIS ..................... 1-12

LUBRICATION POINTS ....................... 1-16

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 10W-30 API SH/CD class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil.

Gear oil

Limits to use SAE 85W-140 class oil. Warranty will not cover the damage that caused by not apply with the limited gear oil.

Grease

King Mate G-3 is recommended.

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 service 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).

1-1


SYM

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 verdict.

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 y Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. y Battery 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, then go to hospital to see an ophthalmologist. y If 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. y Keep electrolyte beyond reach of children.

Brake shoe

Do not use an compressed air or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid asbestos dust flying.

Caution

Inhaling asbestos 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 brake fluid beyond reach of children.

1-2

SYM


SERVICE PRECAUTIONS

y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG motorcycle may damage the motorcycle. y 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. y 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. y 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. y 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. y Never bend or twist a control cable to prevent stiff control and premature worn out. y 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. y 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. y Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later. y Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position). y Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

1-3


SYM

y 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. y Tighten assemblies with different dimension fasteners as follows: y 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. y 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.

Manufacturer's name y Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage. y 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 enlarged ends for tightening the clamps.

Groove

Clamp

Connector y Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.

Boots y 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.

1-4

SYM


y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y Check if positions and operation for installed parts is in correct and properly. y Make sure service safety each other when conducting by two persons. y Note that do not let parts fall down y 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 spark. y After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly.

And the two posts of battery have to be greased after connected the cables. y Make sure that the battery post caps are located in properly after the battery posts had been serviced. y If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse. capacity verification

1-5


SYM

y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not pull the wires as removing a connector or wires. Hold the connector body. y Make sure if the connector pins are bent, extruded or loosen. y 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. y Check if the connector is covered by the twin connector boot completely and secured properly. y Before terminal connection, check if the boot is crack or the terminal is loose. y Insert the terminal completely. Check if the terminal is covered by the boot. Do not let boot open facing up. y 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. y Wire band and wire harness have to be clamped secured properly. y Do not squeeze wires against the weld or its clamp.

1-6

SYM


y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Keep wire harnesses far away from the hot parts.

Do not touch it. y Route wire harness to avoid sharp edges or corners and also avoid the projected ends of bolts and screws. y Route harnesses so that they neither pull too tight nor have excessive slack.

Do not extend it too much. y 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. y Secure the rubber boot firmly as applying it on wire harness. y Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the damaged parts or replace them. y Never clamp or squeeze the wire harness as installing other components.

Please do not clip or squeeze the wire.

1-7


SYM

y Do not let the wire harness been twisted as installation. y 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. y Before operating a test instrument, operator should read the operation manual of the instrument. And then, conduct test in accordance with the instruction.

Do you know how to set the instrument to its measurement position and the insert locations of its two probes? y With sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later.

Clean rust.

1-8

SYM


SPECIFICATIONS

MAKER SANYANG MODEL AD05W1-6

Front TELESCOPIC FORK Overall Length

Overall Width

Overall Height

Wheel Base

1900 mm

665 mm

1040 mm

1330 mm

Front 120/60-13

Rear 130/70-12

Front DISK (ø 226 mm)

Total 113kg

Passengers/

Weight

Two men/188 kg

Front 76.5kg

Rear

Max. Speed

Climb Ability

DRUM (ø 130 mm)

45 km/hr Above

18° Below

Rear 186.5 kg

Total 263kg

Primary Reduction

Secondary

Reduction

Clutch Type

Installation and arrangement

Fuel Used

Cycle/Cooling

4-STROKE ENGINE

Vertical, below center, incline 80°

Unleaded (93/95)

4-stroke/forced air cooled

Transmission V-belt

Speedometer

C.V.T.

GEAR

Centrifugal, dry type

0 ~ 120 km/hr

Bore 37.0 mm Muffler

Exhaust Pipe Position mm and Direction

Expansion & Pulse Type

Right side, and

Backward

Cylinder Number/Arran gement

Single Cylinder Lubrication System

Compression

Ratio

Idle speed cc Exhaust

12.2±0.2 : 1

CO(g/km)

Emission

(IDLE) HC(g/km)

2100±100 rpm

Fuel tank capacity

Max. HP

Max. Torque

2.3KW/ 7500 rpm

3.2N.m /6500 rpm

Ignition C.D.I.

Starting System Electrical & Kick starter

Air Filtration

Noise Emission

Separated-lubrication

1.057

0.149

5.20L

Paper filter

< 84dB(A)

1-9


SYM

TORQUE VALUES (ENGINE)

Cylinder head bolts

Cylinder head left side cover bolts

Cylinder head nuts

Tappet adjust hole cap

Cylinder/cylinder head two-ends bolts 4

Camshaft sprocket bolt 1

Right crank case cover bolts

Pulse generator bolts

Valve adjustment fixing nuts

10

2

2

2

2

4

2

Spark plug

Engine oil filter screen cap

Engine oil drain plug bolt

Gear oil draining plug

Gear oil filling bolt

Oil pump flat screw

Left crankcase cover bolts

Camshaft chain tensioner pivot

Camshaft chain adjuster bolts

1

2

10

1

2

1

1

1

1

Cooling fan bolts

Cooling fan cover bolt

RR. brake shoe anchor fixing nut

RR. brake arm bolt

Shroud A/B

Start clutch lock nut

Flywheel nut

Transmission(Gear box) bolts

Movable drive face nut

Drive pulley nut

A.C. generator flange bolt

Start motor bolts

Crankcase bolts

Air/C connect bracket bolts

Kick starter arm bolt

Carburetor nut

Exhaust pipe bolts

Exhaust pipe connecting nuts

2

1

2

1

2

7

1

1

2

2

2

2

1

1

4

2

1

1

THREAD DIA

(mm)

6

6

6

6

6

8

12

10

6

8

6

6

20

10

6

6

8

6

8

6

6

6

6

10

30

12

8

6

8

6

5

5

6

6

8

30

TORQUE

VALUE(Kg-m)

REMARKS

0.8~1.2

0.7~1.1

1.5~2.0

0.7~1.1

0.8~1.2

9.0~10

3.5~4.5

2.6~3.0

5.0~6.0

3.5~4.5

0.8~1.2

0.8~1.2

0.8~1.2

0.8~1.2

0.8~1.2

0.8~1.2

3.0~3.6

1.0~1.4

0.8~1.2

0.7~1.1

0.8~1.2 Apply oil to thread

1.0~2.0

0.7~1.1 Tighten to crankcase

2.0~2.4

0.8~1.2

0.35~0.5

0.7~1.1 Apply oil to thread

1.0~1.4

1.0~2.0

3.5~4.5

1.0~1.5

1.0~1.5

0.8~1.2

0.8~1.2

0.8~1.2 Hex socket bolt

1.0~1.4

1-10

SYM


TORQUE VALUES (FRAME)

THREAD DIA

ITEM Q'TY

(mm)

Mounting Hex socket bolt for steering handlebar

TORQUE

VALUE(Kg-m)

REMARKS

4 10 4.0~5.0

Mounting nut for steering rod 1 25.4 1.0~2.0

Cone seat for steering rod

Front wheel shaft nut

1

1

1

25.4

12

16

0.2~0.3

5.0~7.0

11.0~13.0 Rear wheel shaft nut

Wheel hub/rim mounting nuts

Speedometer cable locking screw

Front shock absorber mounting bolts

Rear shock absorber upper connection bolt

Rear shock absorber lower connection bolt

Brake lever bolts

Front brake hose bolts

Front brake air-bleeding valve

Front brake disc mounting bolts

Front brake clipper mounting bolts

Drum brake arm bolts

(front/rear)

Engine suspension bracket bolts

Engine connection bolt

Main standard nut

8 8 2.8~3.2

1 5 0.15~0.3

4 8 2.4~3.0

1 10 3.5~4.5

1 8 2.4~3.0

2

2

6

10

0.8~1.2

3.3~3.7

1 6 0.8~1.0

4 10 4.0~4.5

2 10 3.1~3.5

2 6 0.8~1.2

2 10 4.5~5.5 On frame side

Foot-starting lever bolt

Air cleaner bolts

1

1

1

2

10

10

6

6

4.5~5.5

3.5~4.5

1.6~1.8

1.0~1.4

On engine side

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

5mm bolt、nut

6mm bolt、nut

8mm bolt、nut

10mm bolt、nut

12mm bolt、nut

TIGHTEN TORQUE

0.45~0.60kgf-m

3.00~4.00kgf-m

5.00~6.00kgf-m

TYPE

3mm screw

6mm screw、SH nut

6mm bolt、nut

8mm bolt、nut

10mm bolt、nut

TIGHTEN TORQUE

0.05~0.08kgf-m

0.70~1.10kgf-m

1.00~1.40kgf-m

2.40~3.00kgf-m

3.50~4.50kgf-m

1-11


SYM

TROUBLES DIAGNOSIS

A. Engine hard to start or can not be started

Check and adjustment Fault condition

Loosen carburetor drain bolt to check if there is gasoline inside the carburetor

Fuel supplied tom carburetor sufficient

Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.

Check if sparks perform cylinder compression pressure test. cylinder compression pressure normal

Re-start by following the starting procedures

No ignition

No fuel is supplied to carburetor

Weak sparks, no spark at all

Low compression pressure or no pressure

There are some signs of ignition, nut engine can not be started

Remove the spark plug again and check it.

Dry spark plug

Wet spark plug

Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air

Probable causes

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

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

Blowing in normal

Blowing clogged 1. Malfunction of automatic by- starter

1-12

SYM


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.

Check ignition timing

(Using ignition lamp)

Engine speed can not be increased.

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

5. Fuel level too low in carburetor

6. Fuel nozzle clogged in carburetor.

Ignition timing correct

Incorrect ignition timing

1. Malfunction of CDI

2. Malfunction of AC alternator

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if carburetor jet is clogged

No clogged

Remove spark plug

No foul or discoloration

Check if engine over heat

Normal

Continually drive in acceleration or high speed

No compression

Clogged

Fouled and discoloration

Engine overheat

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

1. Remove foreign

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

6. Poor circuit on the cooling system

No knock

Knock

1. Too much carbon deposited in combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

1-13


SYM

C. Engine runs sluggish (especially in low speed and idling)



(using ignition lamp)

Normal Abnormal

Probable causes

1. Incorrect ignition timing (malfunction of CDI or AC alternator)

Adjust the air screw of carburetor

Good Poor

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

Air sucked through carburetor gasket

No air sucked Air sucked

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

5. Vacuum hose crack

Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground

Good spark Poor

1. Spark plug fouled


3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

D. Engine runs sluggish (High speed)



Normal Abnormal

Check for fuel supplying system in automatic fuel cup

Good Poor

Probable causes


2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Check if carburetor clogged

No clogged Clogged

1. Cleaning

1-14

SYM


E. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITIONS

Engine can be started but motorcycle can not be moved.

Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)

Poor initial driving ( Poor climbing performance)

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 damaged

1. Clutch ling spring broken

2. Clutch outer stick with clutch balance weights

3. Connection parts in clutch and shaft worn out or burned

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.

1-15


SYM

LUBRICATION POINTS

Acceleration cable/ Front & rear brake lever pivot

Seat lock

Steering shaft bearing

Speedometer gear /

Front wheel bearing

Side stand shaft

Main stand shaft

Rear wheel bearing

1-16

SYM 2. MAINTENANCE INFORMATION

PRECAUTIONS IN OPERATION .......2-1

PERIODICAL MAINTENANCE

SCHEDULE ........................................2-2

LUBRICATION SYSTEM....................2-3

FUEL SYSTEM...................................2-4

AIR CLEANER....................................2-5

THROTTLE VALVE OPERATION ......2-5

CRANKCASE BLOW-BY SYSTEM ....2-6

VALVE CLEARANCE INSPECTION &

ADJUSTMENT....................................2-6

CARBURETOR IDLING SPEED

ADJUSTMENT ..................................2-7

IGNITION SYSTEM/SPARK PLUG .. 2-8

CYLINDER COMPRESSION

PRESSURE........................................ 2-9

DRIVING SYSTEM............................. 2-9

STEERING SYSTEM ......................... 2-10

SUSPENSION SYSTEM ....................2-10

FRONT DISK BRAKE SYSTEM ......... 2-11

DRUM BRAKE SYSTEM.................... 2-13

WHEEL/TIRE...................................... 2-14

BATTERY........................................... 2-15

HEADLIGHT ADJUSTMENT .............. 2-15

NUTS、BOLTS TIGHTEN.................. 2-15

PRECAUTIONS IN OPERATION

Specification

Fuel Tank Capacity 5.2L

Engine Oil

Transmission Gear oil

Clearance of throttle valve

Spark plug

“F” Mark in idling speed

Full timing advanced

Idling speed

2~6 mm

A7RC Gap: 0.6~0.7 mm

Before TDC 13±1º / 1700 rpm

Before TDC 27º / 8000 rpm

2100±100 rpm

Cylinder compression pressure

Valve clearance: IN/EX

Tire dimension

12.6±0.2 kg/cm²

0.05±0.02 mm/0.05±0.02 mm front / rear 120/60-13 130/70-12

Tire pressure (cold) single Front: 2.00 kg/cm² rear: 2.00 kg/cm²

Two persons Front: 2.00 kg/cm² rear: 2.25 kg/cm² battery 12V6Ah (closed type, maintenance-free battery)

Play of drum brake lever 10~20 mm

2-1

2. MAINTENANCE INFORMATION SYM

PERIODICAL MAINTENANCE SCHEDULE

Mainte nance

Code

1 Month

Item Initial

Every1000KM

3 month

Every3000KM

6 month

Every6000KM

1 year

Every12000K

M

I C C R

1

☆

Air cleaner

2

☆

Fuel filter

3 ☆

Oil filter

4

☆

Engine oil change

5 Tire pressure

6 Battery inspection

7 Brake & free play check

8 Steering handle check

9 Cushion operation check

10 Every screw tightening check

11 Gear oil check for leaking

12 ☆Spark plug check or change

13 ☆Gear oil change

14 Frame lubrication

15 Exhaust pipe

16 ☆Ignition timing

17 ☆Emission check in Idling

18 ☆Throttle operation

19 ☆Engine bolt tightening

20 ☆CVT driving device (belt﹞

21 ☆CVT driving device (roller)

22 Lights/electrical equipment/mutli-meters

23 Main/side stands & springs

24 Fuel pipes

25 Cam chain

26 ☆Valve clearance

27 ☆Crankcase blow-by over-flow pipe

I I R

C C C

R

Replacement for every 1000km

I I

I

I

I

I

I

I

R

I

I

I

I

I

I

I

I I R


L

I

I I

A I

I I

I I

C

I I

I I

I I

I I

I A

I


Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication

Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

Remarks:

1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items

must be perform normally periodical maintenance following the use r manual instructions. They are prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the

Heavily- polluted environment.

3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage.

4. Preventive maintenance a. Ignition system - Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur. b. Carbon deposit removal - Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious lower than ever. c. Replace worn out pistons, cylinder head.

2-2


LUBRICATION SYSTEM

Engine Oil Capacity

Caution y

The vehicle must be parked on a level ground when checking oil capacity. y

Run the engine for 2-3 minutes then stop, wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.

Remove dipstick to check the oil level. If oil level is below the lower limit mark, add oil to the specified upper limit mark.

Oil change

Shut off the engine and remove dipstick.

Remove the oil drain plug on the bottom-left of crankcase to drain oil.

After draining out oil, clean oil plug and its gasket and reinstall. Replace the gasket if it is damaged.

Torque value: 3.5~4.5 kgf-m

Caution

Warm up the engine. This will make the oil flow out easily.

Add oil to the specified capacity.

Oil Viscosity: SAE 10W-30, recommended using King-Mate serial oil.

Engine oil capacity:

Disassembly: 800cc

Change: 650cc

When checking for oil leak, run the engine at idle speed for a few minutes, then check oil capacity with dipstick.

Cleaning the oil strainer

Drain oil from engine, remove the strainer cover, spring and strainer.

If there is an accumulation on the screen, wash it off with suitable solvent

(recommended using compressed air).

Check O-ring for damage, replace if necessary.

Reinstall strainer, spring, O-ring and strainer cover.


Dipstick strainer cover oil strainer spring

Oil drain plug

2-3


Gear Oil

Inspection

Check gear oil if leaking.

Park the motorcycle with main stand on flat level place.

Turn off engine and remove the gear oil draining plug.

Place a measurement cup under the draining hole.

Remove the oil drain plug and drain gear oil into a measurement cup.

Check gear oil if enough.

Replacement

At first, remove the gear oil refilling bolt, and then remove the draining plug.

Install the draining plug after drained oil out.


Caution

Inspect if washer is in good condition.

Replace it with new one if it was deformed or damaged.

Fill out gear oil to specified quantity from the engine oil filling hole.

Install the oil filling bolt.


Transmission oil capacity: 110 c.c.(100 c.c. for change)

Recommended: genuine SYM HYPOID gear oil (SAE 85W-140).

Fuel System

Fuel Pipe

Remove luggage box, rear center cover, body cover, and rear fender, as well as front inner box.

Check all pipes, and replace it when they are deterioration, damage or leaking.

Warning

Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

Fuel filter

Remove the side cover.

Remove fuel pipe from the fuel filter.

Replace the fuel filter with new one.

Install the fuel filter.

Caution

The arrow on the fuel filter means the flow direction of fuel and check it if leaking after installation.


Fuel filter

2-4


AIR CLEANER

Element

Remove 7 screws from the air cleaner cover.

Remove element of air cleaner (2 screws).

Check the element if dirt or damaged.

Replace it with new one if dirt or damaged.

Caution y Air cleaner element contains a paper made filter so do not try to clean it. y Make sure that the air cleaner cover had been installed properly after installation.

THROTTLE VALVE OPERATION

Have a wide open of throttle valve as handle bar in any position and release it to let back original (full closed) position.

Check handle bar if its operation is smooth.

Check throttle valve cable and replace it if deteriorated, twisted or damaged.

Lubricate the cable if operation is not smooth.

Measure handle bar free play in its flange part.

Free play：2~6 mm

Adjustment can be done in either ends.

Secondary adjustment is conducted from top side.

Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment nut.

Rubber boot screws×7

Air cleaner element

2~6 mm

Fixing nut

Adjustment nut

2-5


Primary adjustment is conducted from button side.

Loosen fixing nut, and adjust by turning the adjustment nut.

Tighten the fixing nut, and check acceleration operation condition.

Adjustment nut

Fixing nut

Caution

When always riding in rainy area or full throttle position, maintenance period must be shorted. The deposits can be seen in the transparent section of draining hose.

VALVE CLEARANCE ADJUSTMENT

TDC mark

Caution

Checks and adjustment must be performed when engine is cold (below 35℃).

Remove luggage box and front center cover.

Remove the left body cover & left side cover.

Remove cylinder head cap.

Remove the ignition timing check hole on the cooling fan cover.

With “T” type wrench, turn crankshaft in clockwise motion so that mark (“T”) on the generator flywheel aligns with the mark on the crankshaft, and camshaft is at TDC position also as same as level of cylinder head top-end. A single hole on camshaft sprocket is forward to up. (Piston is at TDC position in the compression stroke.)

Caution

The crankshaft can not be rotated in counter-clockwise to prevent from damage so that valve clearance can not be measured.

Ignition timing mark

2-6


VALVE CLEARANCE INSPECTION

AND ADJUSTMENT

Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX):

0.05±0.02

mm/0.05±0.02 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

It has to make sure that valve-rocker arm is be adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.

CARBURETOR IDLE SPEED

ADJUSTMENT

Caution

y Inspection & adjustment for idle speed have to be performed after all other parts in engine that needed adjustment have been adjusted. y Idle speed check and adjustment have to be done after engine is being warm up

(around 10 minutes).

Park the motorcycle with main stand and warn up engine.

Open the carburetor cover from the luggage box.

Turn the throttle valve stopper screw to specified idle speed.

Specified idle speed: 2100±100 rpm

Emission adjustment in Idle speed

Warm up the engine for around 10 minutes and then conduct this adjustment.

1. Connect the tachometer onto engine.

2. Adjust the idle speed adjustment screw and let engine runs in 2100±100 rpm.

3. Insert the exhaust sampling muffler of exhaust analyzer into the front section of exhaust pipe. Adjust the air adjustment screw so that emission value in idle speed is within standard.

4. Slightly accelerate the throttle valve and release it immediately. Repeat this for 2~3 times.

5. Read engine RPM and value on the exhaust analyzer. Repeat step 2 to step 4 procedures until measured value within standard.

Exhaust Emission: CO:＜1.057g/km

HC: ＜0.149g/km

Ignition coil cable

Valve clearance adjustment

Throttle valve stopper screw

Air adjustment screw

2-7


IGNITION SYSTEM

Ignition timing

Caution

C.D.I ignition system is set by manufacturer so it can not be adjusted.

Ignition timing check procedure is for checking whether C.D.I. function is in normal or not.

Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap.

Check ignition timing with ignition light.

Start engine and set engine idle speed in

2100±100 rpm, and if the mark aligns with the “F”, then it means that ignition timing is correct.

Increase engine speed to 8000 rpm to check ignition timing advance. If the detent aligns with advance mark “װ”, then it means ignition timing advance is in functional. If not, check CDI set, pulse flywheel, and pulse generator. Replace these components if malfunction of these parts are found.

SPARK PLUG

Appointed spark plug: TORCH A7RC

Remove luggage box.

Remove center cover.

Remove spark plug cap.

Clean dirt around the spark plug hole.

Remove spark plug.

Measure spark plug gap.

Spark plug gap: 0.6~0.7 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary.

Screw the park plug into the plug hole with hands, then tighten the plug with a wrench to prevent from damaging the spark plug's thread.


Connect spark plug cap.

Ignition light

Spark plug cap

Side electrode

0.6~0.7mm

F mark

Center electrode

2-8


CYLINDER COPMRESSION PRESSURE

Warn up engine and then turnoff the engine.

Remove the luggage box and the center cover.

Remove spark plug cap and spark plug.

Install compression gauge.

Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.

Caution

Rotate the engine until the reading in the gauge no more increasing.

Usually, the highest pressure reading will be obtained in 4~7 seconds.

Compression pressure: 12.2

±0.2:1 kg/cm².

Check following items if the pressure is too low: z Incorrect valve clearance z

Valve leaking z Cylinder head leaking, piston, piston ring and cylinder worn out

If the pressure is too high, it means carbon deposits in combustion chamber or piston head.

Spark plug cap

Gear teeth

DRIVING SYSTEM

DRIVING BELT

Remove left side cover.

Remove mounting bolt located under air cleaner.

Remove 9 bolts of the engine left crankcase.

Remove the left crankcase cover.

Check if the belt is crack or worn out.

Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.

Width limit: above 18.5 mm

Clutch pad

Start the motorcycle and gradually increase throttle valve openness to check clutch pad operation.

If the motorcycle moves with shaking, then check its clutch pad for wearing. Replace it if necessary.

Clutch pad

Cylinder pressure gauge

Width

Clutch

2-9


STEERING SYSTEM

Caution

Check all wires and cables if they are interfered with the rotation of steering handle bar.

Lift the front wheel out of ground.

Turn handle from right to left and check if turning is smoothly.

If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing.

SUSPENSION SYSTEM

Warning

y Do not ride the motorcycle with poor shock absorber. y

Looseness, wear or damage shock absorber will make poor stability and drive ability.

Front shock absorber

Hold front brake lever and press down the front shock absorber for several times to check its operation.

Hold front brake lever and push forward the front shock absorber for several times to check its locking status.

Check if it is scratched or leaking.

Replace damaged and non-repairable components.

Tighten all nuts and bolts.

Rear Shock absorber

Press down the rear shock absorber for several times to check its operation.

Check if it is scratched or leaking.

Replace damaged and non-repairable components.

Park the motorcycle with main standard.

Start engine and let the rear wheel rotate after increased engine rpm. Check engine for any parts loose or shaking. Also check the engine suspension bushing for wear out.

Replace the bushing if worn out.

Tighten all nuts and bolts.

Rear Shock absorber

2-10


FRONT DISC BRAKE SYSTEM

BRAKE SYSTEM HOSE

Make sure the brake hoses for corrosion or leaking oil, and also check brake 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 to UPPER limit.

Also check brake system for leaking if low brake level found.

Caution

y In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop. y Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. y Do not mix non-compatible brake fluid together.

FILLING OUT BRAKE FLUID

Tighten the drain valve, and add brake fluid.

Place the diaphragm in.

Operate the brake lever so that brake fluid contents inside the brake system hoses.

AIR BLEED OPERATION

Connect a transparent hose to draining valve.

Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.

Caution

Before closing the air bleed valve, do not release the brake lever.

Brake fluid cap

Low brake level bubble

Brake hose

Lower limit drain valve transparent draining hose

2-11


Brake fluid cap

ADDED BRAKE FLUID

Add brake fluid to UPPER limit lever.

Recommended brake fluid: DOT3 or DOT4

WELL RUN brake fluid.

Caution

Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

BRAKE LINING WEAR

The indent mark on brake lining is the wear limitation.

Replace the brake lining if the wear limit mark closed to the edge of brake disc.

Caution

It is not necessary to remove brake hose when replacing the brake lining.

Remove the brake clipper bolt, and take out the clipper.

Caution

Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining be clipped.

Remove brake lining bolt.

Take out the lining.

Caution

In order to maintain brake power balance, the brake lining must be replaced with one set.

Low limit

Brake clipper Brake disc

Brake clipper bolts x 2 bolts x 2

Brake ling wear limit

2-12


DRUM BRAKE SYSTEM

Front Brake Free Play: (Drum brake)

Measure free play of rear brake level at the end of the lever.

Free play: 10-20 mm

Adjust the free play by turning the front brake adjustment nut if necessary.

REAR BRAKE FREE PLAY: (DRUM

BRAKE TYPE)

Measure the free play of the front brake lever at the end of the lever.

Free play: 10-20 mm

Adjust the free play by turning the front brake adjustment nut if necessary.

BRAKE CONFIRAMTION

Caution y After brake adjustment, it has to check the brake operation to make sure the front and rear wheel can be braked. y Pull the brake lever, and make sure that the wear limit marks of brake ling on the both front & rear brake arm are closer and touch to the “

△”

marks. If so, replace the brake ling with new one.

10∼20mm

“△” mark

Increasing free play

Decreasing free play

Adjustment nut

Adjustment nut

Decreasing free play

Increasing free play

“△” marks

2-13


BRAKE LIGHT SWITCH

The brake light switch is to lit up brake light as brake applied.

Make sure that electrical starter can be operated only under brake applying.

WHEEL/TIRE

Check if both front and rear tire pressure are within specification.

Caution

Tire pressure check should be done as cold tire.

Appointed tire pressure

Tire size Front tire Rear tire

Tire pressure as cold tire

(Kg/cm²)

Load for single

Load for two persons

1.75 2.00

1.75

2.25

Appointed Tire

Front/Rear wheel: 120/70-12 / 130/70-12

Check if tire surface is ticked with nails, stones or other materials.

Check if tire surface or wall for crack or damaged, and replace it if necessary.

The tire tread depth can be checked by visual inspection or depth gauge. y Replace the tire if tire tread dent or unusual wearing out. y The tire should be replaced if the wear limit mark (△) is in visible.

Measure tire thread depth from tire center surface.

Replace the tire if the depth is not come with following specification:

Front tire: 1.5 mm

Rear tire: 2.0 mm

Caution

The wear limit marks (△) are located around the tire wall even for inspection.

Brake light switch

Wear limit indictor 〝△〞mark

2-14


BATTERY

Battery Removal

Remove the 4 screws on the floor panel.

Remove battery cap. (4 screws)

Battery cables removal:

1. At first, remove the negative “-” cable.

2. Then, remove the positive “+” cable.

3. Remove the battery.

If there is some rust on battery posts, clean it with steel brush.

Install the battery in the reverse procedures of removal.

Caution y If there is rust on the posts very serious, spray some hot water on the posts.

Then, clean it with steel brush so that can remove rust for more easily. y Apply some grease on the posts after rust removed to prevent from rust again.

HEADLIGHT ADJUSTMENT

Remove the front cover.

Turn on the main switch.

Turn the headlight adjustment screw. And adjust the headlight beam height.

Then, tighten the adjustment screw after the beam height in proper position.

Caution

y To adjust the headlight beam follows related regulations. y

Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.

NUTS, BOLTS TIGHTENESS

Perform periodical maintenance in accord with the Periodical Maintenance Schedule.

Check if all bolts and nuts on the frame are tightened securely.

Check all fixing pins, snap rings, hose (pipe) clamps, and wire holders for security.

Battery cover screws

Headlight adjustment screw

2-15

SYM 3. LUBRICATION SYSTEM

MECHANISM DIAGRAM ....................3-1

OPERATIONAL PRECAUTIONS .......3-2

TROUBLE DIAGNOSIS......................3-2

ENGINE OIL .......................................3-3

MECHANISM DIAGRAM

Valve rocker arm

Scoop lubrication

Connecting rod

Forcedly lubrication

Crankshaft

CLEANING ENGINE OIL STRAINER... 3-3

OIL PUMP ............................................ 3-4

GEAR OIL ............................................ 3-7

Forcedly lubrication

Camshaft

Inner passage

Oil strainer

Oil pump

3-1

3. LUBRICATION SYSTEM SYM

OPERATIONAL PRECAUTIONS

General Information

z

This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.

Oil viscosity

Specifications

Engine oil quantity Disassembly 800 c.c.

Replacement 650 c.c.

Oil viscosity SAE 10W-30 or equivalent

Use SAE 5W-40 when outside temperature is below 0℃.

Gear Oil quantity Disassembly 110 c.c.

Replacement 100 c.c.

Oil viscosity of gear oil SAE 85W-140 unit : mm

Inner rotor clearance

- 0.12

Oil pump

Clearance between outer rotor and body

Clearance between rotor side and body

- 0.12

0.05~0.10 0.20

Torque value

Engine oil drain plug 3.5~4.5kgf-m

Engine oil filter screen cap 1.0~2.0kgf-m

Gear oil drain bolt 1.0~1.5kgf-m

Gear oil filling bolt 1.0~1.5kgf-m

Oil pump fixing screws 0.8~1.2kgf-m

TROUBLE DIAGNOSIS

Low engine oil level

z

Oil leaking z z

Valve guide or seat worn out

Piston ring worn out

Low Oil Pressure

z

Low engine oil level z z

Clogged in oil strainer, circuits or pipes

Oil pump damage

Dirty oil

z

No oil change in periodical z z

Cylinder head gasket damage

Piston ring worn out

3-2


ENGINE OIL

Turn off engine, and park the motorcycle in flat ground with main stand.

Check oil level with oil dipstick after 3-5 minutes.

Do not rotate the dipstick into engine as checking.

If oil level is nearly low level, fill out recommended oil to upper level.

Oil Replacement

Caution

Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely.

Place an oil pan under the motorcycle, and remove oil strainer cap.

Make sure if the aluminum washer of the draining bolt is damaged. If so, replace it with new one.

Install the drain plug and tighten it.


CLEANING ENGINE OIL STRAINER

Remove the oil strainer cap.

Remove oil strainer and spring.

Clean oil strainer (recommended using compressed air to clean dirty foreign).

Check if the strainer and O-ring of the oil strainer are broken. Replace with new one if found.

Install the oil strainer and spring.

Install the oil strainer cap and tighten it.


Fill out oil to the oil filler (Oil viscosity SAE

10W-30)

Use SAE 5W-40 when outside temperature is below 0℃.

Engine oil quantity: Replacement 650 c.c.

Dipstick

Oil strainer cap oil strainer

Oil drain plug spring

3-3


OIL PUMP

Oil Pump Removal

Remove the alternator (refer to chapter10).

Remove the engine right crankcase cover.

Make sure that the pump axle can be rotated freely.

Remove the oil pump driving gear nut.

Remove the oil pump .

Oil Pump Inspection

Check the clearance between oil pump body and outer rotor.

Limit: below 0.12 mm

Check clearance between inner and outer rotors.


3-4

Pump driving gear

Screws×2


Check clearance between rotor side face and pump body.


Oil Pump Re-assembly

Install inner and outer rotors into the pump body.

Align the indent on driving shaft with that of inner rotor. Install the driving shaft.

Install the oil pump cover and fixing pin properly and then tighten screw. (1 screw)

Oil pump body Drive shaft

Fixing pin outer rotor inner rotor

Oil pump cover

Pump driving gear

Oil Pump Installation

Install according to the reverse procedure of removal.

Screws×2

3-5



Filling bolt

GEAR OIL

Oil Level Inspection

Park the motorcycle on flat ground with main stand.

Turn off engine and remove both gear oil filling bolt and gear oil draining plug.

Remove gear oil filling bolt and place a measurement cup under the draining plug.

Remove the oil draining plug and the pour gear oil into the measurement cup.

Measure the gear oil quantity if within standard value.

Add specified gear oil if the oil level too low.

Standard quantity: 110 cc.

Replacement: 100 cc.

Gear Oil Replacement

Remove the gear oil filling bolt and its draining plug and then drain oil completely.

Install the draining plug and tighten it. (Make sure if the plug washer is damaged. If so, replace it with new one.)

Torque Value：1.0~1.5 kgf-m

Add new gear oil (100 c.c.) from the gear oil filling hole and then install the gear oil filling hole bolt after added oil. And then, tighten the bolt.

Torque Value: 1.0~1.5 kgf-m

※Recommended to apply with SAE

85W-140.

Start engine and run it for 2~3 minutes.

Turn off engine and check if oil leaking.

3-6

SYM 4. FUEL SYSTEM

MECHANISM ILLUSTRATION ............. 4-1

PRECAUTIONS IN OPERATION ......... 4-2

TROUBLE DIAGNOSIS........................ 4-3

CARBURETOR REMOVAL .................. 4-4

VACUUM CHAMBER ........................... 4-4

ACCELERATE PUMP ..........................4-6

MECHANISM ILLUSTRATION

Fuel strainer

Fuel unit

AUTO BY-STARTER .......................... 4-7

FLOAT CHAMBER ............................. 4-8

INSTALLATION OF CARBURETOR .. 4-9

IDLE SPEED ADJUSTMENT ............. 4-9

FUEL TANK ........................................ 4-10

AIR CLEANER.................................... 4-11

Carburetor

Fuel tank cap

4-1

4. FUEL SYSTEM SYM



Warning

Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline.

Cautions

z Do not bend or twist throttle valve cable. Damaged cable will make unstable driveability.

z When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly z There is a drain screw in the float chamber for draining residual gasoline. z Do not disassemble automatic by-starter and air cut-off valve arbitrarily.

Specification

Item Specification

Main jet

Speed limited:45km/h



Slow jet

Idle speed

Needle Jet

Mass of float

Float needle

Fuel quantity adjustment screw

Level in float chamber

Jet needle

Throttle handle free play

Torque value

Fuel valve tightening nut: 1.5~2.0 Kgf-m

Tool

Special service tools

Vacuum/air pressure pump

General service tools

Fuel level gauge

82#

85#

85#

35#

2100±100 rpm

￠2.6 mm

7.2g±0.4 g

￠2.0 mm

1 1/2±3/4 turns

7.0±0.5 mm

DA8CD

2~6 mm

4-2



Power insufficiency and fuel consuming

Poor engine start

z No fuel in fuel tank z Clogged fuel tube z Too much fuel in cylinder z No spark from spark plug (malfunction of ignition system) z Clogged air cleaner z

Malfunction of throttle valve operation

Stall after started

z

Malfunction of ignition system z Incorrect ignition timing carburetor z Dirty engine oil z Air existing in intake system z

Incorrect idle speed

Rough idle

z Malfunction of ignition system z Incorrect idle speed

Mixture too lean

z Clogged fuel injector z Vacuum piston stick and closed z Malfunction of float valve z Fuel level too low in float chamber z Clogged fuel tank cap vent z Clogged fuel filter z Obstructed fuel pipe z Clogged air vent hose z

Air existing in intake system

Mixture too rich

z Clogged air injector z Malfunction of float valve z Fuel level too high in float chamber z

Dirty fuel

Intermittently misfire as acceleration

z

Malfunction of ignition system

Late ignition timing

z Malfunction of ignition system z

Malfunction of carburetor z

Dirty air cleaner

4-3


CARBURETOR REMOVAL

Remove the luggage box.

Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor.

Remove fuel pipe, vacuum hose.

Disconnect auto by-starter connectors.

Release the clamp strip of air cleaner.

Release the clamp strip of carburetor isolator.

Take the carburetor out.

VACUUM CHAMBER

Removal

Loosen drain screw, and drain out residual fuel in float chamber.

Remove screws (2 screws) of vacuum chamber cover and the cover.

Remove compress spring and vacuum piston. throttle valve cable vacuum hose

Vacuum Chamber cover

Vacuum piston clamp strip of isolator vacuum hose auto by-starter

Screws×2 compress spring

4-4


Remove fuel needle seat, spring, and injector needle.

Check if the vacuum piston for wear out, crack or other damage.

Check if the diaphragm for damage or crack.

Cautions

Do not damage vacuum diaphragm.

Installation

Install injector needle, spring and fuel needle seat to vacuum piston.

Cautions

z Note direction as installing the piston set because wrong direction of the piston cab not be installed. z Align the indent of vacuum diaphragm with the carburetor body.

Install vacuum piston to carburetor body.

Install compress spring.

Install vacuum chamber cover and tighten 2 screws. fuel needle seat fuel needle spring injector needle piston piston diaphragm lock position

Piston spring

Screws×2

Vacuum Chamber cover

4-5


ACCELERATE PUMP

Removal

Loosen the fixing screws from carburetor.

Remove the accelerate pump drive arm from the carburetor.

Remove 3 mounting screws and remove the float chamber cover.


Installation

Install the valve as reverse order of removal.

Cautions

Do not damage the vacuum diaphragm or in opposite installation direction.

Screws ×2

Accelerate pump drive arm

4-6


AUTO BY-STARTER

Inspection

Turn off engine and waiting for over 10 minutes for cooling.

Check resistance across the two terminals of the auto by-starter

Resistance value: Max. 10Ω (Measured

after engine stopped for more than 10

minutes)

Replace the auto by-starter with a new one if resistance value exceeds standard.

Remove the carburetor, allow it to cool off for

30 minutes.

Connect a hose to fuel richment circuit.

Pump compressed air to the circuit.

Replace the auto by-starter if the circuit clogged.

Connect battery posts (12V) to starter’s connectors. After 5 minutes, test the rich circuit with compressed air. If air flow through the circuit, then replace the starter.

Removal

Remove fixing plate screw, and then remove the plate and auto by-starter from carburetor.

Valve inspection

Check if auto by-starter and valve needle for damage or wear out.

Installation

Install auto by-starter to the carburetor body.

Install fixing plate to the upper groove of auto by-starter, and install its flat surface to carburetor. Install screw and tighten it.

Cautions

Align the round point of the starter with the screw hole of air intake side.

Screw fixing plate

Screw auto by-starter round point fixing plate valve needle

4-7


FLOAT CHAMBER

Disassembly


Remove the float pin and float valve.

Checking

Check float needle valve and valve seat for drop difference damage, wear out, dirty or clogged.

Cautions

In case of worn out or dirt, the float needle valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float needle valve must be replaced with a new one.

Remove main jet,slow jet, fuel amount adjustment screw.

Cautions

z Take care not to damage jets and adjust screw. z Before removing adjustment screw, turn it all the way down and note the number of turns. z Do not turn adjustment screw forcefully to avoid damaging valve seat face.

Clean jets with cleaning fluid.

Then use compressed air to blow dirt off.

Blow carburetor body passages with compressed air. float float pin float pin float slow jet fuel am ount adjustmen t screw main jet screws× 3 float needle valve float pin main jet slow jet

4-8


Installation

Install main jet, slow jet and fuel amount adjustment screw.

Cautions

Set the adjustment screw in according to number of turns noted before it was removed.

Install the float needle valve, float and float pin.

Checking Fuel Level

Cautions

z Check again to ensure float valve, float for proper installation. z

To ensure correct measurement, position the float meter in such a way so that float chamber face is vertical to the main jet.

Fuel level: 3.5±1 mm

INSTALLATION OF CARBURETOR

Install carburetor in the reverse order of removal.

Following adjustments must be made after installation.

z Throttle valve cable clearance adjustment

z

Idle speed adjustment

IDLE SPEED ADJUSTMENT

Caution

z Fuel amount adjust screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. z Never screw in forcedly to avoid damaging the screw seat. z

The main stand must be used to support the motorcycle to perform the adjustments.

Use a tachometer when adjusting engine RPM.

Screw in adjustment screw gently, then back up to standard turns.

Standard turns: 1 1/2±3/4 turns

Warm up engine, adjust throttle valve stopper screw to standard RPM.

Idle speed rpm: 2100±100 rpm

Connect the sampling hose of exhaust analyzer to exhaust front end. Press test key on the analyzer.

Adjust the air volume adjustment screw and read

CO reading on the analyzer.

CO standard value: 1.0~1.5 %

Accelerate in gradual increments, make sure both rpm and CO value are in standard values after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above for adjusting to standard value.

float meter

Throttle valve cable adjustment nut fuel amount adjustment screw throttle valve stopper screw air volume adjustment screw

4-9


FUEL TANK

Fuel unit removal

Remove the seat.

Remove the rear carrier. (3 bolts)

Remove the luggage box and the double seat(4 bolts).

Disconnect fuel unit connector.

Remove fuel unit.

Cautions

z Do not bend the float arm of fuel unit.

z Do not fill out too much gasoline to fuel tank.

Fuel unit inspection. (Refer to chapter 16 - electrical equipment).

Fuel unit installation

Install the gauge in the reverse order of removal.

Cautions

Do not forget to install the gasket of fuel unit or damage it.

FUEL TANK REMOVAL

Open the seat.


Remove the luggage box and the double seat(4 bolts).

Remove the left & right body cover.

Disconnect the fuel unit connector.

Remove the fuel pipe, fuel filter.

Remove the fuel tank (2 bolts).

Fuel Tank Installation

Install the tank in the reverse order of removal. fuel unit gasket fuel unit connector

4-10


AIR CLEANER

Removal

Remove the seat .

Remove the luggage box assembly (4 bolts).

Loosen the clamp strip of air cleaner.

Remove evaporative return hose.

Remove the air cleaner body bolts (2 bolts).

Remove the air cleaner.

Installation

Install the air cleaner in the reverse order of removal.

Air Cleaner Element Cleaning

Remove the air cleaner cover (7 screws).

Remove the air cleaner element (2 screws).

With compressed air to clean dirty around the element. Replace it if it is too dirty to clean.

Cautions

The air cleaner element is made of paper so do not soap it into water or wash it with water. air filter strap bolts×2 screws×7

Air cleaner element

4-11

SYM 5. REMOVAL OF ENGINE

MECHANISM DIAGRAM ...................... 5-1

OPERATIONAL PRECAUTIONS ......... 5-2

ENGINE REMOVAL ............................. 5-3


4.5~5.5kgf-m

REMOVAL OF ENGINE SUSPENSION

BUSHING ............................................. 5-6

ENGINE SUSPENSION FRAME.......... 5-7

INSTALLATION OF ENGINE ............... 5-8

2.4~3.0kgf-m

3.5~4.5kgf-m

4.5~5.5kgf-m

4.5~5.5 kgf-m

5-1

5. REMOVAL OF ENGINE SYM



y Engine must be supported by a bracket or adjustable tool in height. y The following parts can be serviced with the engine installed on the frame.

1. Carburetor

2. Driving disk, driving belt, clutch, and transporting disk

3. Final reduction gear mechanism

Specification

Engine Oil Capacity

Gear Oil Capacity

Torque Values

Engine suspension bolt (frame side)

Engine suspension nut (engine side)

Bolt of rear shock absorber upper connection

Bolt of rear shock absorber lower connection

Specification

4.5~5.5kgf-m

4.5~5.5kgf-m

3.5~4.5kgf-m

2.4~3.0kgf-m

5-2


ENGINE REMOVAL

Open the seat.

Remove the luggage box assembly (4 bolts ).

Remove the body cover .

Remove the power connector of auto by- start.

Remove the generator connector and pulse generator connector.

Remove the starter motor wire on the Starter magnetic switch.

Remove the spark plug cap.

Generator connector pulse generator connector

Auto by-start connector

Starter magnetic switch

Spark plug cap

5-3


Remove the fuel pipe, vacuum hose, and throttle valve cable from the carburetor.

Loose the strap screw of the air cleaner guide, and remove the air cleaner guide.

Remove the exhaust muffler (Bolts ×

2, Nuts × 2).

Remove the rear wheel (Nut × 1).

Remove the air cleaner connection bolts (2 bolts).

Bolts×2

Nut ×1

2 bolts

5-4


Remove the rear brake cable nut.

Remove the rear brake cable.

Remove the rear shock absorber lower bolt.

Loose the strap screw of engine left guide, and then remove the engine left guide.

Remove the engine suspension nut and bolt

(engine side), and then remove the engine.

Caution

y With a bracket to support the engine to prevent from it damage by falling down as removing the engine.

Check if the engine suspension, rear shock absorber bushing, and cushion rubber for damage. Replace them with new ones if so.

Rear shock absorber bolt

Strap screw of guide

Engine suspension bolt/nut

Brake cable nut

Bushing

5-5


REMOVAL OF ENGINE

SUSPENSION BUSHING

If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / presser, Φ28mm &Φ20mm, to press the bushing out, and replace it with new one.

Engine suspension bushing: Φ28mm

Rear shock absorber bushing: Φ20mm

Pressing out

Place the detent section of the bushing remover toward the bushing, and drive both the pressing ring and bolt in to press the bushing out.

Pressing In

Place the flat section of the remover toward the bushing, and then drive the bushing, pressing ring, and bolt in to install the bushing.

5-6


ENGINE SUSPENSION FRAME

Removal

Remove the right side bolt of engine suspension frame.

Remove the left side bolt of engine suspension frame.

Check if the engine suspension frame bushing and cushion rubber for damage. If so, replace with new ones.

Installation

Tighten the bolts and nuts of engine suspension frame.

Engine suspension frame nut:

Torque Value: 4.5~5.5 kgf-m

Bolt of engine suspension frame (left side)

5-7


INSTALLATION OF ENGINE

Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones.

Install the engine according to the reversing order of removal.

Engine suspension nut×1

Caution

y Notice both feet and hands safety for squeezing as engine installation. y Do not bent or squeeze each wires or hose. y Route all cables and wires in accordance with the routine layout.

Engine suspension nut:

Torque Value: 4.5~5.5kgf-m

Rear shock absorber bolt:

Torque Value: Top: 3.5~4.5kgf-m lower: 2.4~3.0kgf-m

Rear wheel axle nut:

Torque Value: 11.0~13.0kgf-m

Rear shock absorber lower bolt

Brake cable nut

Rear wheel axle nut×1

5-8

SYM 6. CYLINDER HEAD/VALVE



TROUBLE SHOOTING.......................6-3

CAMSHAFT REMOVAL .....................6-4

CYLINDER HEAD REMOVAL ............6-6

CYLINDER HEAD INSPECTION.......... 6-8

VALVE SEAT INSPECTION AND SERVICE

6-10

CYLINDER HEAD REASSEMBLY ....... 6-12

CYLINDER HEAD INSTALLATION ...... 6-13

CAMSHAFT INSTALLATION ............... 6-13

CYLINDER HEAD DISASSEMBLY ....6-7


0.7~1.1 kgf-m

1.0~1.4 kgf-m

0.8~1.2 kgf-m

0.8~1.2 kgf-m

VALVE CLEARANCE ADJUSTMENT .. 6-14

0.8~1.2 kgf-m

6-1

6. CYLINDER HEAD/VALVE SYM



y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm. y Cylinder head service cannot be carried out when engine is in frame.

Compression pressure

12.2±0.2:1 kg/cm²

-

Intake 25.686~25.786 25.29

Camshaft Height of cam lobe

Exhaust 25.50~25.60 25.12

ID of valve rocker arm 10.000~10.015 10.10

Rocker arm

OD of valve rocker arm shaft 9.972~9.987 9.910

OD of valve stem

Intake 4.975~4.99 4.90

Exhaust 4.955~4.97 4.90

Valve

Free length of valve spring

ID of Guide

Clearance between valve stem and guide

5.000~5.015 5.030

Intake 0.010~0.037 0.080

Exhaust 0.030~0.057 0.100

Outer 35.25

-

Inner 32.26~32.56

-

Torque Value

Cylinder head cover bolt

Cylinder head bolt (LH)

Bolt of timing chain auto-adjuster

Spark plug

Cylinder head nut

Valve adjustment fixing nuts

TOOLS


Valve reamer: 5.0mm

Valve guide driver: 5.0mm

Valve spring compressor

0.8~1.2kgf-m

0.8~1.2kgf-m

0.8~1.2kgf-m

1.0~1.4kgf-m

0.8~1.2kgf-m

0.7~1.1kgf-m

6-2


TROUBLE SHOOTING

Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated.

Rough Idle

Low compression pressure.

Low compression pressure

1. Valve

y Improper valve adjustment. y Burnt or bended valve. y Improper valve timing. y Valve spring damaged. y Valve carbon. y Poor sealing on valve seat. y Improper spark plug installation.

2. Cylinder head

y Cylinder head gasket leaking or damage. y Tilt or crack cylinder surface.

3. Piston

y Piston ring worn out.

High compression pressure

y Too much carbon deposit on combustion chamber or piston head.

Noise

y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Cam chain wear out or looseness y Auto-adjuster wear out or damage of cam chain y Camshaft sprocket wear out y Rocker arm or rocker arm shaft wear out

White smoke

y Valve guide or valve stem wear out y Valve stem seal wear out

6-3


CYLINDER HEAD REMOVAL

Remove the engine from the vehicle (Refer to chapter 5).

Remove the shroud of the engine.

Remove the crankcase blow-by system hose from the cylinder head.

Remove the cylinder head cover 4 bolts and then remove the cylinder head cover.

Loosen the bolt of camshaft chain adjuster in

. a counter-clockwise motion for release adjuster.

Removed cam chain adjustment bolt. And then removed the chain adjuster (bolts × 2)

Removed cylinder head side cover.

4 bolts bolts

Chain adjuster

Cylinder head side cover

6-4


Turn the flywheel in counter-clockwise motion with T type wrench until the “T” mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position.

Remove camshaft sprocket bolt(bolt × 2).

Remove the cam sprocket and cam chain.

Removed the bolts of the left side of the cylinder head between cylinder head and cylinder(bolt × 2).

Removed cylinder head fixed nut (nuts × 4).

Bolts × 2

Bolts × 2

TDC mark

Nuts × 4

6-5


Remove cylinder head.

Caution

Loosen the nuts diagonally by 2-3 sequences.

DISASSEMBLY CYLINDER HEAD

Remove the fixed (bolt × 1), then remove the camshaft.

Remove the valve rocker arm shaft.

Remove the valve rocker arm.

Camshaft

6-6


Use the special tool of compress valve springs. Remove valve spring removed location pin.

Caution

Do not over-compressed valve springs.

Avoiding weaken the spring flexibility.

Put out the spring stopper, spring and valve.

Remove the valve cotter,valve spring retainer,valve oil seal .

Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder head matching surface.

Caution

Do not damage the matching surface of cylinder head.

CAMSHAFT INSPECTION

Inspect cam lobe height for damaged.

Service Limit

IN: Replacement when less than 25.57 mm

EX: Replacement when less than 25.41 mm

Inspect the camshaft bearing for looseness or wear out. If any, replace whole set of camshaft and bearing.

Camshaft bearing

6-7


VALVE ROCKER ARM/ SHAFT

INSPECTION

Measure the valve rocker arm I.D.

Service Limit: Replace when it is above

10.100 mm

Measure the active O.D. of the valve rocker arm shaft.


9.910 mm

Calculate the clearance between the rocker arm shaft and the rocker arm.


0.10 mm

CYLINDER HEAD INSPECTION

Check if spark plug and valve holes are crack.

Measure cylinder head flat with a straightedge and flat feeler gauge.

Service limit: below 0.05mm

Valve spring free length

Measure the free length of intake and exhaust valve springs.

Standard:

35.250 mm

The narrow pitch of the spring shall face to the combustion chamber.

6-8


Valve stem

Check if valve stems are bend, crack or burn.

Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter.

Service Limit: IN→ 4.900mm

EX→ 4.900mm

Valve guide

Caution

Before measuring the valve guide, clean carbon deposits with reamer.

Special Service Tool: 5.0mm valve guide reamer

Measure and record each valve guide inner diameters.

Service limit: 5.300mm

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: IN→ 0.08mm

EX→ 0.10mm

5.0mm 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. If so, replace valve guide.

Correct it with reamer after replacement.

If clearance still exceeds service limit after replaced valve guide, replace valve stem too.

Caution

It must correct valve seat when replacing valve guide.

Valve guide replacement

Heat up cylinder head to 100~150 ℃ with heated plate or toaster.

Caution

y Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed as heating it. y Wear on a pair of glove to protect your hands when operating.

Valve guide driver

5.0mm

6-9


Hold the cylinder head, and then press out old valve guide from combustion chamber side.

Tool: Valve guide driver 5 mm

13 mm

(0.15in)

Valve guide driver

5.0mm

Caution

y Check if new valve guide is deformation after pressed it in. y When pressing in the new valve guide, cylinder head still must be kept in 100~150

℃.

Adjust the valve guide driver and let valve guide height is in 13mm.

Press in new valve guide from rocker arm side.

Tool: Valve guide driver 5 mm

Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.

Caution

y Using cutting oil when correcting valve guide with a reamer. y Turn the reamer in same direction when it be inserted or rotated.

Correct valve seat, and clean up all metal residues from cylinder head.

Special tool: Valve guide reamer 5 mm

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.

Valve guide reamer 5.0mm

Caution

y Do not let emery enter into between valve stem and valve guide. y Clean up the emery after corrected, and apply with red paint onto contact faces of valve and valve seat.

Remove the valve and check its contact face.

Caution

Replace the valve with new one if valve seat is roughness, wear out, or incomplete contacted with valve seat.

If the valve and the valve seat still can not be matched sealing after grinded, replace it with new one.

6-10

Valve seat valve seat width


Valve seat inspection

If the valve seat is too width, narrow or rough, correct it.

Valve seat width


Check the contact condition of valve seat.

Valve seat grinding

The worn valve seat has to be grinded with valve seat chamfer cutter.

Use 45° valve seat chamfer cutter to cut any rough or uneven surface from valve seat.

Caution

After valve guide had been replaced, it has to be grinded with 45° valve seal chamfer cutter to correct its seat face.

Use 32° cutter to cut a quarter upper part out.

Roughness

45°

Old valve seat width

32°

Use 60° cutter to cut a quarter lower part out.

Remove the cutter and check new valve seat.

Use 45° cutter to grind the valve seat to specified width.

Caution

Make sure that all roughness and uneven faces had been grinded.

Grind valve seat again if necessary.


1.0mm

60°

45°

6-11


Coat the valve seat surface with red paint.

Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a seal track will be created on contact surface.

Contact surface too high


32°

Caution

The contact surfaces of valve and valve seat are very important to the valve sealing capacity.

If the contact surface too high, grind the valve seat with 32° cutter.

Then, grind the valve seat with 45° cutter to specified width.

If the contact surface too low, grind the valve seat with 60° cutter.

Then, grind the valve seat with 45° cutter to specified width.

Contact surface too low


60°

After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface.

Clean up all emery coated onto cylinder and valve after grinded.

CYLINDER HEAD REASSEMBLY

Lubricate valve stem with engine oil, and then insert the valve into valve guide.

Install new valve stem oil seal.

Install valve springs and retainers.

Caution

The closed coils of valve spring should face down to combustion chamber.

6-12

Valve cotters

Valve spring retainer

Valve spring

Valve stem oil seal

Valve


Use valve spring compressor to press valve spring.

Install valve split locks and release the valve compressor.

Caution

In order to avoid to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch.

Special tool: valve spring compressor

Tap valve stem to make valve retainer and valve stem sealing properly.

Caution

Place and hold cylinder head on to working table so that can prevent from valve damaged.

CYLINDER HEAD INSTALLATION

Install the lock pins and new cylinder head gasket onto the cylinder head.

Install the camshaft chain plate.

At first, tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.

With T type wrench to turn crankshaft in a clockwise motion so that the “T” mark on the flywheel aligns with the mark on crankcase.

(piston is at TDC position).

Install the cylinder head nuts and tighten it.


Install the cylinder head left side bolt and tighten it.


Install the spark plug and tighten it.


Lock pins

Nuts ×4

Cylinder head gasket

Bolts ×2

6-13


y Apply with oil onto the thread of cylinder head bolts and tighten the bolts in diagonally for 2-3 sequences. y Do not over tightening the bolts to avoid the cylinder head deformation, noise created or leaking so that effects motorcycle’s performance.

Install the cam shaft. Place the TDC marks of the cam sprocket at same level of the top-end of cylinder head. The other single hole of the cam sprocket is in upward. Then, install the cam chain onto the cam sprocket.

Tighten the 2 bolts of the cam sprocket.

Install the cylinder head side cover.

Turn the cam chain adjuster in clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly. Tighten the bolt cap of the adjuster adjustment hole.

“T” mark

Bolts ×2

Caution

The O-ring must be installed into glove.

chain adjuster

VALVE CLEARANCE ADJUSTMENT

Loosen valve clearance adjustment nuts and bolts located on valve rocker arm.

Measure and adjust valve clearance with feeler gauge.

After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the adjustment nut.

Standard Value: IN/EX 0.05±0.02mm

Especial tool

6-14

SYM 7. CYLINDER/PISTON




CYLINDER REMOVAL .......................7-3


0.8~1.2kgf-m

PISTON REMOVAL............................7-5

PISTON RING INSTALLATION..........7-7

PISTON INSTALLATION....................7-8

CYLINDER INSTALLATION .............. 7-8

7-1

7. CYLINDER/PISTON SYM



y Both cylinder and piston service cannot be carried out when engine mounted on frame.

Cylinder

Bend/wrap age

－

0.050

Piston/

Piston ring

Clearance between piston and rings

Ring-end gap

OD of piston

Clearance between piston and cylinder

ID of piston pin hole

OD of piston pin

Clearance between piston and piston pin

Top ring

2 nd

ring

Top ring

2 nd

ring

Oil ring

0.025~0.060

0.015~0.050

0.200~0.400

0.090

0.090

0.500

0.250~0.400 0.650

0.200~0.700 -

37.005~36.985 -

0.025~0.040 0.100

13.002~13.008

12.994~13.000

0.002~0.014

13.040

12.980

0.018


Low Or Unstable Compression Pressure

z

Cylinder or piston ring worn out. z

Compress pressure to high. z

Too much carbon deposited in combustion chamber and piston.

Knock or Noise

z z

Cylinder or piston ring worn out.

Carbon deposits on cylinder head z top-side.

Piston pin hole and piston pin wear out.

Smoking in Exhaust Pipe

z

Piston or piston ring worn out. z z

Piston ring installation improperly.

Cylinder or piston damage.

Engine Overheat

z

Carbon deposits on cylinder head top side.

7-2


CYLINDER REMOVAL

Remove cylinder head. (refer to chapter 6)

Remove 2 bolts and then take out the cam chain auto-adjuster.

Remove cam chain plate.

Remove cylinder.

Remove cylinder gasket and lock pins

Clean the residues attached onto the matching surfaces of cylinder and crankcase.

Cylinder camshaft chain adjuster

2 bolts

7-3


Cover the holes of crankcase and cam chain with a piece of cleaning cloth.

Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.

Caution

To soap the residues into solvent so that the residues can be removed more easily.

INSPECTION

Check if the inner diameter of cylinder is worn out or damaged.

In the 3 positions (top, center and bottom) of cylinder, measure the X and Y direction values respective in the cylinder.

Service limit:39.047mm

Calculate both the real roundness (the difference between X and Y motion values) and the cylindrical roundness (the difference in the top, center or bottom positions of X or Y motion values.). Then, determinate by the max. value.

Service limit

Real roundness: correct or replace as over 0.05 mm

Cylindrical roundness: correct or replace

as over 0.05 mm

Check Cylinder flat.

Service limit: correct or replace as over

0.05 mm

Exhaust side

Top

Center

Bottom

Intake side

7-4


PISTON REMOVAL

Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling.

Hold another snap ring with pliers.

Push out the piston pin from the side that not removed the snap ring.

Remove piston rings.

Caution

Pay attention to remove piston rings because they are fragile.

Disassemble the piston rings.

Check if the piston rings are damaged or its grooves are worn.

Cleaning the carbon in piston ring grooves.

Install the piston rings and then measure clearance between piston ring and its grooves.

Service Limit: Top ring: replace if over

0.09mm

2nd ring: replace if over

0.09mm

Take out the piston rings and place them respective into cylinder below 20mm of cylinder top. Measure each piston ring gaps.

Caution

Push the piston rings into cylinder with piston top-end in parallel motion.

Service Limit: Top ring: replace if over

0.50mm

2nd ring: replace if over

0.650mm

Piston piston ring

Piston ring

Push in

Feeler gauge

Feeler gauge

7-5


Measure the outer diameter of piston pin.

Service Limit: 12.980mm

Measure the inner diameter of connecting rod small end.


Measure the inner diameter of piston pin hole.


Calculate clearance between piston pin and its hole.


Measure piston outer diameter.

Caution

The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin.


Compare measured value with service limit to calculate the clearance between piston and cylinder.

7-6


PISTON RING INSTALLATION

Clean up piston top, ring groove, and piston skirt.

Install the piston ring onto piston carefully.

Place the openings of piston ring as diagram shown.

Caution

y Do not damage piston and piston rings as installation. y All marks on the piston rings must be forwarded to up side. y Make sure that all piston rings can be rotated freely after installed.

Top ring

2nd ring

Side ring

Spacer

Side ring

Over 20 mm

120°

Top groove

Oil ring

2nd groove

Oil groove

7-7


PISTON INSTALLATION

Install piston and piston pin, and place the IN mark on the piston top side forward to intake valve.

Install new piston pin snap ring.

Caution

y Do not let the opening of piston pin snap ring align with the opening piston ring. y Place a piece of cleaning cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation.

CYLINDER INSTALLATION

Clean up all residues and foreign materials on the matching surface of crankcase.

Pay attention to not let these residues and foreign materials fall into crankcase.

Caution

To soap the residues into solvent so that the residues can be removed more easily.

Install 2 lock pins and new cylinder gasket.

Coat engine oil to inside of cylinder, piston and piston rings.

Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.

Caution

Do not push piston into cylinder forcefully because this will cause the piston and the piston rings to be damaged.

Install the cam chain plate, the cylinder head gasket and lock pins.

Install cylinder head. (refer to Chapter 6)

Install the cam chain auto-adjuster. (2 bolts)

Piston pin

IN mark

Piston

7-8

SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH


MAINTENANCE DESCRIPTION ........8-2

TROUBLE DIAGNOSIS ......................8-2

LEFT CRANKCASE COVER ..............8-3

KICK STARTER ARM ........................ 8-3

DRIVING BELT................................... 8-4

SLIDING PULLEY .............................. 8-6

CLUTCH/DRIVEN PULLEY............... 8-9


5.0~6.0kgf-m

3.5~4.5kgf-m

5.0~6.0kgf-m

0.8~1.2kgf-m

8-1

8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

MAINTENANCE DESCRIPTION

Precautions in operation

General information

• Driving pulley, clutch, and driven pulley can be serviced on the motorcycle.

• Driving belt and driving pulley surface must be free of grease.

Specification

Unit: mm

Driving belt width

ID of sliding pulley bush

OD of roller

ID of clutch outer

Thickness of clutch pad

Free length of drive pulley spring

OD of driven pulley

ID of sliding pulley

ID: Inner Diameter

OD: Outer diameter

Torque value

Sliding pulley nut: 5.0~6.0kgf-m

Clutch outer nut: 5.0~6.0kgf-m driving pulley nut: 3.5~4.5kgf-m


Engine can be started but motorcycle can not be moved

z z z z

Worn driving Belt

Worn tilt plate

Worn or damaged clutch pad

Broken driven pulley

Shudder or misfire when driving

z z

Broken clutch pad

Worn clutch pad

17.50

20.035~20.085

16.8

20.150

15.920~16.080 15.570

107.00~107.20 107.50

4.000 2.0

97.20 96.5

33.965~33.985 33.940

34.000~34.025 34.060

Special Service Tools

Clutch spring compressor

Bearing puller (inner type)

Clutch mounting nut wrench

Universal fixture

Insufficient horsepower or poor high speed performance

z

Worn driving belt z

Insufficient spring capacity of driven z z pulley

Worn roller

Driven pulley operation un-smoothly

8-2


air cleaner lock bolts

LEFT CRANKCASE COVER

Left crankcase cover removal

Remove air cleaner. (2 bolts)

Remove kick starter arm. (1 bolt)

Loosen vent strap on the front-left side of cover, and then remove the vent.

Remove engine left-side cover (8 bolts). kick starter arm

Screws×6

KICK STARTER ARM

Disassembly

Remove left side cover plate on the left crankcase cover(screws×6).

Remove left side cover plate gasket.

First put kick starter pedal into the starter shaft. After a little rotation, remove the drive gear and washer.

Removed kick starter pedal, starter shaft, return spring and the thrust washer.

Check if starter shaft, drive gear, bushing, for wear or damage. Replace it with new one if necessary.

Check the return spring for spring force or damaged. Replace it with new one if poor parts found.

Friction spring drive gear

Starter shaft return spring

8-3


Reassembly

Apply with some specified grease on the gear, shaft.

Install the friction spring of driving gear onto convex part of the case cover.

Install, return spring and starter shaft as diagram shown.

Install kick starter arm temporary.

Rotate the lever and then align driving gear with width-tooth on the starter shaft.

Install thrust washer and socket onto starter shaft.

Installation of the left crankcase cover

Install the left crankcase cover. (8 bolts)

Install front vent tube of left cover and tighten the strap.

Install kick starter arm. (1 bolt)

Tighten the air cleaner. (2 bolts) starter shaft gear

Strap driving gear

Bolts

Kick starter arm shaft

8-4


DRIVING BELT

Removal

Remove left crankcase cover.

Hold the sliding pulley with a universal fixture, and then remove the nut and sliding pulley.

Hold driving pulley with universal fixture, and remove nut and clutch outer.

Caution

Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake only will damage reduction gear system.

Push the driving belt into belt groove as diagram shown so that the belt can be loosened, and then remove driven belt and clutch at same time.

Inspection

Check the driving belt for crack or wear.

Replace it if necessary.

Measure the width of driving belt as diagram shown. Replace the driving belt if it exceed maintenance limited specification.


Caution y Using the genuine parts for replacement.

y The surfaces of driving belt or pulley must be free of grease. y Clean up all grease or dirt before installation.

sliding pulley driving pulley

Driving belt

Tooth

Universal fixer

Nut

Universal fixer

Width

8-5


Installation

Pull out driving pulley and then insert the driving belt into the driven belt.

Caution

Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.

Install the starter clutch.

Install the clutch set with driving belt onto the driving shaft.

Install the sliding pulley on the other end of belt.

Install clutch outer.

Install the clutch with universal fixture, and then tighten nut to specified torque value.


Caution

When install the driving belt, if there is a arrow mark, then the arrow mark must point to rotation motion. If not, the letters on the belt must be forwarded to assembly direction.

sliding pulley

Nut

Universal fixer

Driven pulley clutch outer

Clutch outer

8-6


SLIDING PULLEY

REMOVAL

Remove left crankcase cover.

Hold driving pulley with universal fixture, and then remove driving pulley nut.

Remove driving pulley.

Remove the sliding pulley fixing nut and remove the driving belt from the sliding pulley.

Remove the driving belt from the sliding pulley.

Remove the limited speed bush.

Remove the bush and remove the sliding pulley from the crankshaft.

Remove tilt plate.

Remove weight rollers from sliding pulley.

Crankshaft

Tilt plate

Sliding pulley

Special tool

Sliding pulley

Bush

Limited speed bush

Roller

8-7


Inspection

The operation of sliding pulley is means of the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.

Check if rollers are wear out or damage.


Measure each rollers’ outer diameter.

Replace it if exceed the service limit.

Service limit: 15.57 mm

Measure the inner diameter of the sliding pulley.


Measure the inner diameter of the pulley bush.

Replace it if exceed the service limit.


Assembly/Installation

Install the weight rollers.

Install the title plate guide boot onto the title plate.

Install the title plate.

Weight roller

Weight roller

Guide boot

Sliding pulley

Pulley bush

Tilt plate

8-8


Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub.

Caution

The pulley surface has to be free of grease. Clean it with cleaning solvent.

Install siding pulley assembly onto crankshaft.

Driving pulley install

Press driving belt into pulley groove, and then press down the up & down sides of the driving belt to separate it away from the driving pulley hub.

Caution

To press down the up & down sides of the driving belt can avoid to pressing and damaging the belt when installing the driving pulley, and also can make sure that the driving pulley can be tighten.

Install driving pulley, washer and nut.

Caution

Make sure that two sides of pulley surfaces have to be free of grease.

Clean it with cleaning solvent.

Hold driving pulley with universal fixture.

Tighten nut to specified torque.


Install left crankcase cover.

Crankshaft

Press down

Driving belt

Pulley bush

Pulley surface

Sliding pulley

Pulley bush

Limited speed bush

8-9


CLUTCH/DRIVEN PULLEY

Disassembly

Remove driving 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

Do not press the compressor too much.

Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special nut wrench.

Release the clutch spring compressor and remove clutch and spring from driven pulley.

Remove socket from driven pulley.

Remove oil seal from driven pulley.

Remove guide pin, guide pin roller, and sliding pulley, and then remove O-ring & oil seal seat from sliding pulley.

Inspection

Clutch outer

Measure the inner diameter of clutch outer friction face. Replace the clutch outer if exceed service limit.


Special nut wrench

Clutch spring compressor

Sliding pulley

O-ring

Inner diameter

Oil seal

Guide pin

Socket

Guide pin

Guide pin roller

Clutch outer

8-10


Clutch pad

Measure each clutch pad thickness.

Replace it if exceeds service limit.


Driven pulley spring

Measure the length of driven pulley spring.

Replace it if exceeds service limit.


Driven pulley

Check following items;

• If both surfaces are damage or wear.

• If guide pin groove is damage or wear.

Replace damaged or worn components.

Measure the outer diameter of driven face and the inner diameter of movable driven face. Replace it if exceeds service limit.

Service limit: Outer diameter 33.94mm

Inner diameter 34.06mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.


Check if needle bearing is damage or too big clearance. Replace it if necessary.

Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent.

Clutch pad

Outer diameter

Driven face

Inner diameter

Driven surface

Free length

Clutch

Movable driven face

Guide pin groove

Needle bearing

Outer ball bearing

8-11


Clutch Block Replacement

Remove snap and washer, and the remove clutch block and spring from driving plate.

Check if spring is damage or insufficient elasticity.

Check if shock absorption rubber is damage or deformation. Replace it if necessary.

Apply with grease onto setting pins.

Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.

Install new clutch block onto setting pin and then push to specified location.

Caution y Grease or lubricant will damage the clutch block and effect the block’s connection capacity.

Install the spring snap into groove with pliers.

Spring

Clutch block

Shock absorption rubber

Shock absorption rubber

Clutch block

Spring

Driving plate

Snap ring

Setting pin

8-12


Install snap ring and mounting plate onto setting pin.

Replacement of driven pulley bearing

Remove inner bearing.

Caution

y If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly. y If the pulley equipped with ball bearing, it has to remove snap ring and then the bearing.

Remove snap ring and then push bearing forward to other side of inner bearing.

Place new bearing onto proper position and its sealing end should be forwarded to outside.

Apply with specified grease.

Recommended to use G-3.

Install the snap ring and hold the bearing.

Install a new inner bearing.

Caution

y Its sealing end should be forwarded to outside as bearing installation. y Install needle bearing with hydraulic presser. Install ball bearing by means of hydraulic presser.

Align oil seal lip with bearing, and then install the new oil seal (if necessary).

Outer bearing

Snap ring

Snap ring bearing

Specified grease

Inner needle

Outer bearing

Sealing end

Inner bearing

Oil seal

Snap ring

Sealing end

8-13


Installation of clutch/driven pulley

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 oil socket.

Install driven pulley, spring and clutch into clutch spring compressor, and press down the assembly by turning manual lever until mounting nut that can be installed.

Hold the compressor by bench vise and tighten the mounting nut to specified torque with special nut wrench.

Remove the clutch spring compressor.

Torque value: 5.0~6.0 kg-m

Install clutch/driven pulley and driving belt onto driving shaft.

Oil seal

O-ring

Sliding pulley

O-ring

Oil socket

Oil seal

Guide pin

Guide pin roller

Special nut wrench

Specified grease

Guide pin

Clutch spring compressor

8-14

SYM 9. FINAL DRIVING MECHANISM


OPERATIONAL PRECAUTIONS .......9-2


DISASSEMBLY OF FINAL DRIVING

MECHANISM......................................9-3

INSPECTION OF FINAL DRIVING

MECHANISM ..................................... 9-3

BEARING REPLACEMENT ............... 9-4

RE-ASSEMBLY OF FINAL DRIVING

MECHANISM .....................................9-6


2.6~3.0 kgf-m

9-1

9. FINAL DRIVING MECHANISM SYM


Specification

Application gear oil: 4-stroke lubricant

Recommended gear oil: 85W-140

Oil quantity: 110 c.c. (100 c.c. when replacing)

Tools


Inner type bearing puller

Outer type bearing puller

Gear box oil seal installer

Gear box bearing installer


Engine can be started but motorcycle can not be moved

• Damaged driving gear

• Burnt out driving gear

• Broken driving belt

Noise

• Worn or burnt gear

• Worn gear

Torque value

Gear box cover

Gear oil drain plug

Gear oil filling bolt

Gear oil leaks

• Excessive gear oil

• Worn or damage oil seal

2.6~3.0 kgf-m

1.0~1.5 kgf-m

1.0~1.5 kgf-m

9-2


DISASSEMBLY OF FINAL DRIVING

MECHANISM

Remove the rear wheel. (refer to chapter 15)

Remove the clutch.

Drain gear oil out from gear box.

Remove gear box cover bolts (7bolts) and then remove the gear box cover and the final driving shaft.

Remove gasket and setting pin.

Remove countershaft and gear.

Remove final driving gear and shaft.

INSPECTION OF FINAL DRIVING

MECHANISM

Check if the countershaft and the gear are wear or damage.

Check if the final driving shaft and gear are burn, wear or damage. countershaft gear driving shaft

7 bolts final driving shaft countershaft final driving gear final driving shaft final driving gear

9-3


Check bearings on the gear box cover.

Rotate each bearing’s inner ring with fingers.

Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box & cover tightly.

If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.

Check oil seal for wear or damage, and replace it if necessary.

Check driving shaft and gear for wear or damage.

BEARING REPLACEMENT

Caution

Never install used bearings. Once bearing removed, it has to be replaced with new one.

Remove driving shaft bearing from left crankcase using following tools;


Install new driving shaft bearing into left crankcase.

Tool:

Press the bearing into cover with C type hydraulic presser or bearing installer. bearing countershaft gear final driving shaft countershaft final driving gear driving shaft

Special tool

9-4


Press out the driving shaft from the crankcase.

Remove oil seal from the crankcase.

Remove the driving shaft bearing from the gear box cover with the inner type bearing puller.

Caution

Using the bearing protector as pressing out the driving shaft from the left crankcase.

Specified tool:

Inner type bearing puller.

If the driving shaft is pulled out with its bearing, then remove the bearing with bearing puller and bearing protector.

Tool:

Multi-functional bearing puller

Bearing protector

Install a new driving shaft bearing onto crankcase.

Then, install the driving shaft.

Specified tool:

Press the bearing in with C type hydraulic presser or bearing installer.

Install a new final driving shaft bearing onto crankcase.

Specified tool:

Press the bearing in with C type hydraulic presser or the bearing installer.

Apply with some grease onto the lip section of oil seal and then install the seal.

Driving shaft driving shaft final driving shaft bearing

Bearing protector

Multi-functional bearing puller

9-5


RE-ASSEMBLY OF FINAL DRIVING

MECHANISM

Install final driving shaft and final driving gear, countershaft, and countershaft gear.

Install the setting pins(2 pins) and new gasket.

Apply with grease onto the oil seal lip of final driving shaft.

Install the gear box cover and 7 bolts.

(tighten the bolts)

Torque: 2.6~3.0 kgf-m

Install the clutch/sliding driving pulley.

Install the driving pulley, belt and left crankshaft cover.

Install the rear wheel.

Add gear oil.

Recommended usage gear oil :SAE

85W-140

(110 cc: standard capacity)

(100 cc: when replacement) countershaft dowel pins final driving shaft final shaft gear

7 bolts

Filling bolt

Draining bolt

9-6

SYM 10. A.C. GENERATOR


A.C.GENERATOR REMOVAL ...........10-2

RIGHT CRANKCASE COVER

REMOVAL .......................................... 10-3

RIGHT CRANKCASE COVER

INSTALLATION .................................. 10-4

MOUNTED COIL SET

INSTALLATION .................................. 10-4

FLY WHEEL INSTALLATION............. 10-4


General information

y Refer to chapter 5: Engine removal and installation y Refer to chapter 1: The troubleshooting and inspection of A.C. generator

Torque value:

Flywheel nut

Exhaust muffler bolt 8 mm

Oil screen cover

3.5~4.5kgf-m

3.0~3.6kgf-m

1.0~2.0kgf-m


Flywheel puller

Universal fixture

10-1

10. A.C. GENERATOR/STARTING CLUTCH SYM

A.C. GENERATOR REMOVAL

Pulse generator

Coil

Drain out the engine oil.

Remove the exhaust muffler. (2 bolts, 2 nuts)

Remove the fan shroud. (4 bolts)

Flywheel

Cooling fan

Cable guide

Cooling fan shroud


Exhaust muffler

Remove the fan. (4 bolts)

Hold the flywheel with the universal fixture.

Remove the 10mm nut on the flywheel.

Special Service Tools:

Universal Fixture

Cooling fan

Universal fixture

10-2


Remove the flywheel with the flywheel puller.

Special service tools:

Flywheel puller

Shaft protector

Caution

Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller.

Flywheel puller

Pulse generator connector

Remove the connectors of the A.C. generator and pulse generator.

Remove the 6 bolts for the pulse generator, the A.C. generator coil and cable guide.

Then, remove the A.C. generator assembly.

Caution

Do not damage the alternator coil.

RIGHT CRANKCASE COVER

REMOVAL

Remove the right crankcase cover. (8 bolts)

Remove setting pin and gasket.

Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase.

Caution

Do not damage the connection surfaces.

Pulse generator

Coil

8 bolts

generator connector

Cable guide

10-3

10. A.C. GENERATOR/STARTING CLUTCH SYM

RIGHT CRANKCASE COVER

INSTALLATION

Install setting pin and new gasket on the crankcase.

Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip.

Install right crankcase cover onto the right crankcase. (8 bolts)

Torque value: 1.5~2.0kgf-m

8 bolts

Pulse generator

MOUNTED COIL SET

INSTALLATION

Install the coil set onto right crankcase cover. (2 bolts)

Install pulse generator. (2 bolts)

Torque: 0.8~1.2kgf-m

Tie the wire harness hose onto the indent of crankcase.

Install A.C. generator connector and pulse generator connector.

Coil

generator connector


Auto by-start connector

FLYWHEEL INSTALLATION

Make sure that there is no magnetic powder.

If so, clean up it.

Align insert on crankshaft with the flywheel groove, and then install the flywheel.

Hold the flywheel with flywheel holder, and tighten its nut.


Special service tool:



10-4


Install the cooling fan. (4 bolts)

4 bolts

Cooling fan

Install the cooling fan shroud. (4 bolts)

Install the exhaust muffler. (2 bolts, 2 nuts)

Add some engine oil according the specified quantity.


Exhaust muffler

10-5

SYM 11. CRANKCASE/CRANKSHAFT


.............. 11-1


... 11-2


................ 11-2


0.8~1.2 kgf-m

DISASSEMBLY OF CRANKCASE

11-3

CRANKSHAFT INSPECTION

....... 11-5

ASSEMBLY OF CRANKCASE

..... 11-6

0.7~1.1 kgf-m

11-1

11. CRANKCASE/CRANKSHAFT SYM



z This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. z Complete following operations before disassembling crankcase.

Cylinder head

Cylinder and piston

V-belt Drive pulley

AC generator/ Starting Clutch

Chapter 6

Chapter 7

Chapter 8

Chapter 10

If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have to replaced.

Left, right clearance of the big end of the connecting rod 0.100~0.350 0.550

Radial clearance of the big end of the connecting rod

Run-out

Torque value

Bolts for crankcase

Bolts for cylinder/cylinder head

Engine oil draining plug

Bolts for cam chain tensioner

Special Service Tools

Crankcase remover/set

Crankshaft installation puller


Outer type bearing puller

Bearing pressing tools

Oil seal pressing tools


Engine noise

• Loose crankshaft bearing

• Loose crankshaft pin bearing

• Wear piston pin or piston pin hole

0.000~0.008 0.050

Below 0.030

0.8~1.2 kgf-m

0.7~1.1 kgf-m

3.5~4.5 kgf-m

0.8~1.2 kgf-m

0.10

11-2


DISASSEMBLY OF CRANKCASE

Remove the 2 bolt from the right crankcase.

Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase.

Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.

Drive the screw of the crankcase remover/set into the crankcase, and then separate the left and the right crankcases.

Remove the cam chain.

2 bolt

1 hex socket bolt

Caution z Never pry out the connection surfaces of crankcases as separating. Otherwise, the connection surfaces could be damaged and cause oil leaking. z It have to separate the cam chain and the drive gear before pressing out the both left and right crankcases.

Special Service Tools:

Crankcase remover/set

11-3


Remove the crankshaft from the right crankcase.

Caution z The left and right bearings of crankshaft is to press-fit onto the crankshaft.

Remove gasket and dowel pins (2).

Scrape gasket residues off the crankcase contact surface.

Caution z Do not damage contact surface of the crankcase. z Soap the gasket residues into solvent and the residues will be removed easily.

Remove oil seal from the left crankcase.

11-4


CRANKSHAFT INSPECTION

Measure left and right clearance of connecting rod big end.

Service limit: Replace when it is more

than 0.55 mm

Measure the radical clearance of the big end at the vertical directions.

Service limit : 0.05 mm

Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.


Bearing Inspection

Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly.

Check if the inner ring is connected onto the crankshaft tightly.

Replace crankshaft as a set when noise or looseness is detected.

60 mm clearance

90 mm clearance

11-5


ASSEMBLY OF CRANKCASE

Install cam chain into the chain hole of the left crankcase, and then split out the cam chain.

Caution

z Do not damage the cam chain as installing the crankshaft.

Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.

Install the right crankcase and tighten the crankcase bolts (1 bolts).


Install the cam chain tensioner.

Install a new O-ring onto the mounting bolt of the chain tensioner.

Apply some oil on the O-ring and tighten the bolt.


Caution

z The O-ring must be installed into the bolt’s groove.

2 bolt hex socket bolt dowel pins

11-6


Apply with some grease onto the oil seal lip and then install it onto the left crankcase.

Press-fit the oil seal to specified position with the oil seal installer (25x37x6).

Special service tools: the oil seal installer (25x37x6)

11-7

SYM 12. BODY COVER

MAINTENANCE INFORMATION........12-2

HANDLE COVER ...............................12-3

FRONT COVER..................................12-4

FRONT INNER BOX...........................12-5

BODY COVER/REAR CENTER

COVER/REAR FENDER .................... 12-6

FRONT CENTER COVER.................. 12-8

LUGGAGE BOX ................................. 12-8

FLOOR PANEL .................................. 12-8

SIDE COVER ..................................... 12-9

UNDER COVER ................................. 12-10

Right body cover

Inner fender

Right side cover

Tail light lens

RR. mudguard

Handle visor

Rear handle cover

Luggage box

Double Seat

RR. fender

Front handle cover

Front cover il

Top cover

Center cover

Floor panel

Under cover

RR. fender

mudguard

Rear carrier

FR. Inner box lid

Under spoiler

FR. Inner

box

Left body cover

Left side cover

Front fender

12-1

12. BODY COVER SYM

MAINTENANCE INFORMATION

Body covers disassemble sequence:

Front Handle cover

Rear handle cover

Front fender

Front wheel

Top cover

Front cover

Under cover

Under spoiler

Luggage box & Seat

Rear carrier

Left/right side cover

Front center cover

Rear fender

Floor panel

Tail light

Front inner box 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 installed during the assembly. y Never compact forcefully or hammer the guard and the covers during assembly.

12-2


HANDLE COVER

Removal:

Remove 1 lower mounting screw of the handle front cover.

Remove the mounting screws (4 screws) between the front handle cover and the rear handle cover.

Removed the head light wire connectors.

Removed the left/right turn signal light connectors.

Remove the front handle cover.

Remove the speedometer cable.

Remove the rear handlebar cover. (3 screws)

Removed the rear handle cover.

Installation:

Install according to the reverse procedure of removal.

Caution

With the clipper to fix the end-section of the handlebar cover. Do not pull it forcedly to avoid to breaking the hooks. screw ×1 screws ×4

screws×3

turn signal light connectors

12-3


FRONT COVER

Removal

Remove the top cover.

Remove the 1 mounting bolt of front cover from the frame.

Remove the front under cover 4 mounting screws between the front under cover and the frame .

Remove the 2 mounting screws between the front cover and the left/right side cover.

Screws1 × 2

Top cover

bolt×1 screws2 × 2

12-4


Remove the 8 mounting screws between the front cover and the front inner box.

Remove the front cover from the frame.

Installation

Install according to the reverse procedure of removal. screws 4 × 2

Front cover

FRONT INNER BOX

Removal

Remove the 8 mounting screws of front cover from the inner box A.

Remove the hook screw bolt from the front inner box. screws 4 × 2

1 bolt

12-5


Remove the main switch cover.

Remove the front cover and front under cover.

Remove the 2 screws between the inner box and the floor panel.

Remove the front inner box

Installation

Install the inner box A and the front inner box

B according to the reverse procedure of removal.

2 screws

Main switch cover

4 bolts

BODY COVER/REAR CENTER

COVER/REAR FENDER

Removal

Open the seat.

Remove 4 bolts in the front of the luggage box.

Remove 2 bolts in the rear of the luggage box.



2 bolts

3 bolts

12-6


Remove the 2 mounting bolts of the rear fender.

Remove the 4 mounting screws between the body cover and the frame.

Remove the left/right side 2 mounting bolts under rear of the body cover between the body cover and the frame.

Remove the rear fender.

Remove the left/right body cover.

Installation

Install the body cover and rear fender according to the reverse procedure of removal.

4 screws

1 bolt

Bolts1 × 2

12-7


FRONT CENTER COVER

Removal

Remove the 4 screws bolt in the battery cover.

Remove the 1 screw in the front center cover.

Remove the front center cover.

Installation

Install the front center cover according to the reverse procedure of removal.

LUGGAGE BOX

Removal

Open the seat.

Remove the 4 bolts in front of the luggage box.

Remove the 2 bolts in the rear of the luggage box.

Remove the luggage box and the double seat.

Installation

Install the luggage box according to the reverse procedure of removal.


2 bolts

screws×4 screws×1

4 bolts

12-8


screws×4

FLOOR PANEL

Removal

Remove the 4 screws in the battery cover.

Remove the 1 screw in the front center cover.

Remove the front center cover.

Remove the 4 bolts in the floor panel.

Remove the luggage box and the double seat.

Remove the 2 bolts between the floor panel and the frame.


Bolts1×2 screw×1 screws×4

12-9


Remove the front cover and front under cover.

Remove the 2 mounting screws between the floor panel and the front inner box.

Remove the floor panel.

Installation

Install the floor panel according to the reverse procedure of removal.

2 screws

SIDE COVER

Removal

Remove the left/right side 2 mounting screws in the front of the side cover.

Remove the left/right side 2 mounting bolts in the rear of the side cover.

Remove the left/right side cover.

Installation

Install the side cover according to the reverse procedure of removal.

UNDER COVER

Removal

Remove the floor panel.

Remove the left/right side cover.

Remove the left/right side 4 mounting bolts between the under cover and frame.

Remove the under cover.

Installation

Install the under cover according to the reverse procedure of removal.

Screws1 × 2

Bolts2 × 2

Screws1 × 2

12-10

SYM 13. BRAKE

MECHANISM DIAGRAM-FRONT

DISC BRAKE SYSTEM...................... 13-1

MECHANISM DIAGRAM-REAR

DRUM BRAKE SYSTEM.................... 13-2

MAINTENANCE INFORMATION ....... 13-3

TROUBLE DIAGNOSIS ..................... 13-4

HYDRAULIC BRAKE SYSTEM

INSPECTION...................................... 13-5

BRAKE FLUID

REPLACEMENT/AIR-BLEED............ 13-6

BRAKE CALIPER .............................. 13-7

BRAKE DISC ..................................... 13-8

BRAKE MASTER CYLINDER ........... 13-8

DRUM BRAKE-DRUM ....................... 13-11

BRAKE LING ..................................... 13-11

BRAKE PANEL.................................. 13-12


Front Disc Brake System

0.8~1.0 kgf-m

2.8~3.2 kgf-m

3.3~3.7 kgf-m

4.0~4.5 kgf-m

5.0~7.0 kgf-m

13-1

13. BRAKE SYM


Rear Drum Brake System

0.8~1.2 kgf-m

0.8~1.2 kgf-m

13-2

SYM 13. BRAKE

MAINTENANCE INFORMATION

Precautions in Operation

Caution

Installing lining dusts may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. z z z z z

The brake caliper can be removed without removing the hydraulic system.

After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.

While refilling brake fluid, care should be taken not to let the foreign material entering into the brake system.

Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.

Check the operation of the brake system before you go.

Item Standard Limit

The thickness of front brake

3.50 2.00

Front brake disc eccentricity

Master cylinder inner diameter

0.15 0.30

25.40

─

ID of front & rear brake drums

OD of front brake disc

Thickness of front disc brake

Thickness of front drum brake

130.00 131.00

─

226.00

─

As brake ling mark

─

2mm or As brake ling mark

─

2mm or As brake ling mark Thickness of rear brake lining

Torque values

Bolt for front brake arm

Bolt for rear brake arm

Brake hose bolt

Bolt for brake caliper

Air-bleed valve

0.8~1.2kgf-m

0.8~1.2kgf-m

3.3~3.7kgf-m

3.1~3.5kgf-m

0.8~1.0kgf-m

13-3

13. BRAKE SYM

TROUBLE DIOGNOSIS

DISC BRAKE

Soft brake lever

z Air inside the hydraulic system z Hydraulic system leaking z Worn master piston z Worn brake pad z Poor brake caliper z Worn brake lining/disc z Low brake fluid z Blocked brake pipe z Warp/bent brake disc z Bent brake lever

Uneven brake

z Dirty brake lining/disc z Poor wheel alignment z Clogged brake hose z Deformed or warped brake disc z Restricted brake hose and fittings

Tight brake

z Dirty brake lining/disc z Poor wheel alignment z Deformed or warped brake disc

Hard operation of brake lever

z Blocked brake system z Poor brake caliper z Blocked brake pipe z Seized/worn master cylinder piston z Bent brake lever

Brake noise

lining z Deformed brake disc z Poor brake caliper installation z Imbalance brake disc or wheel

13-4

SYM 13. BRAKE

HYDRAULIC BRAKE SYSTEM

INSPECTION

Inspection

Visual inspect for brake fluid leaking or damage. Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components.

Hose connection

Operate the brake system and check the brake lining. Check the front brake from front side, and replace the brake lining with new one when the brake lining wear limitation groove reaches to the brake disc.

Park the motorcycle on a flat ground and check its brake fluid level.

Recommended brake fluid: WELLRUN DOT 3 brake fluid

CAUTION z The fluid level will not be correct if parking the motorcycle in title or just parking. It has to waiting for around 3~5 minutes. z Never use faked brake fluid to prevent from chemical reaction. z It has to apply with same brand brake fluid to sure the brake performance.

Brake Fluid Add

Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap.

Place a rag onto painting, plastic or rubber components when conduct brake system maintenance.

CAUTION z Do not over the upper level when adding brake fluid and avoid to spilling brake fluid on painted surfaces, plastic or rubber components to result in their damages. brake caliper

Brake disc brake lining wear limitation groove lower level

Master cylinder cap

13-5

13. BRAKE SYM

Remove the master cylinder cap and diaphragm.

master

Add good quality brake fluid and it has to add cylinder same brand brake fluid into the master cylinder.

Clean dirty brake disc. diaphragm

CAUTION

The dirty brake lining or disc will reduce the brake performance. The mixed non-compatible brake fluid will reduce brake performance. Foreign materials will block the system causing brake performance to be reduced or totally lost.

BRAKE FLUID REPLACEMENT/

AIR-BLEED

Connect drain hose to drain valve.

Open the drain valve on the caliper and hold and release the brake lever alternatively until the old brake fluid is entirely drained out.

Close the drain valve and add specified brake fluid into the brake master cylinder.

CAUTION

To reuse the spent brake fluid will effect brake performance.

Connect one end of transparent hose to the drain valve, and put the other end into a container.

Open the drain valve around 1/4 turns, and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever.

Close the drain valve when finishing the brake system refilling fluid procedure, and operate the brake lever to check whether air bubble is in brake system or not. If brake is still soft, please bleed the system as described below.

1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve.

CAUTION z Do not release the brake lever before the drain valve is closed. z Always check the brake fluid level when carrying out the air bleeding procedure to avoid air entering into the system.

2. Slowly release the brake lever, and wait for a few seconds until it reaches its top position.

3. Repeat the steps 1 and 2 until there is no air bubble at the end of the hose. Tightly close the drain valve.

4. Make sure the brake fluid is in the UPPER level of the master cylinder, and refill the fluid if necessary.

5. Cover the cap.

Bubbles drain valve

Draining valve

Transparent hose

13-6

SYM 13. BRAKE

BRAKE CALIPER

Removal

Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses. hose bolt

CAUTION z Do not spill brake fluid on painted surfaces.

Remove two caliper bolts and the caliper.

Make sure the brake lining condition. Replace the lining if the brake lining wear limitation groove close to the brake disc.

Brake Lining Replacement

Compress the caliper and let the brake lining out of the caliper mounting plate. Compress the brake lining locking spring. Remove the inner brake lining firstly and then remove the outer brake lining.

Compress the brake caliper at first as installation. Install the inner brake lining firstly, and then install the outer brake lining.

INSTALLATION

Install the brake caliper and tighten the attaching bolts securely.

Torque: 3.3 kgf-m

CAUTION z Use M8 x 35 mm flange bolt only. z Long bolt will impair the operation of brake disc.

Tighten the lining guide bolt.


Use two seal washers and hose bolts to lock the hose and brake caliper in place.


Refill up the brake fluid to the reservoir and make necessary air bleeding. brake lining brake pad wear limitation groove brake pad brake mounting plate piston locking spring brake caliper

13-7

13. BRAKE SYM

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.


CAUTION z Do not let grease touch to the brake disc that will cause brake performance. z Do not clean the brake lining with air gun.

Operator should wear mask & glove and use vacuum cleaner to clean the brake lining.

BRAKE MASTER CYLINDER

Removal brake disc micrometer brake hose

CAUTION

Do not let foreign materials enter into the cylinder. bolts x2

CAUTION

The whole set of master cylinder, piston, spring, diaphragm and circlip should be replaced after removal.

Remove the front and rear handlebar guards.

Remove the leads of brake lamp switch.

Drain out the brake fluid.

Remove the brake lever from the brake master cylinder.

Remove the brake hose.

Remove the master cylinder seat and the master cylinder.

Remove the rubber pad.

Remove the circlip.

Remove the piston and the spring.

Clean the master cylinder with recommended brake fluid. rubber boot circlip rubber washer piston spring brake lamp switch master cylinder

13-8

SYM 13. BRAKE

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.


master cylinder

Dial gauge

Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds allowable limit.


Assembly

Piston

Micrometer circlip

CAUTION z It is necessary to replace the whole set comprising piston, spring, piston cup, and circlip. z Make sure there is no dust on all components before assembling.

Apply clean brake fluid to the piston cup, and then install the cup onto the piston.

Install the larger end of the spring onto the master cylinder.

The master cup’s cavity should be face inside of master cylinder when installing the master cup.

Install the circlip. rubber boot rubber washer piston spring brake lamp switch master cylinder

CAUTION z Never install cup lip in the opposite direction. z Make sure the circlip is seated securely in the groove.

Install the rubber pad into groove properly.

13-9

13. BRAKE SYM

INSTALLATION

Place the master cylinder onto handlebar, and install the split ring and bolts. The

“UP” mark on the split ring should face upward.

Align the split ring on the master cylinder seat with the alignment point on the handlebar.

Tighten the upper bolt of the seat to specified torque value, and then tighten lower bolt to the same specified torque value. master cylinder split ring

“UP” mark mounting seat bolts x 2

Install the brake lever, and connect leads to brake lamp switch.

Connect brake hoses with 2 new washes.

Tighten the brake hose bolt to the specified torque value.

Torque value: 3.5 kgf-m

Make sure the hose is installed correctly. sealing washer hose bolt

CAUTION

Improper routing may damage leads, hoses or pipes.

CAUTION

Kink of brake leads, hose or pipe may reduce brake performance.

Add specified brake fluid and bleed the system and conduct the air-bleeding job for the system. brake hose

13-10

SYM 13. BRAKE

DRUM BRAKE-DRUM

Brake Drum

Removal

Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the dust.

Caution

•Inhaling dust may cause respiration system disorder even cancer. Never use an air hose or a dry brush as to clean the brake parts.

•Grease on brake lining will reduce braking efficiency.

Remove wheel. Remove brake drum from wheel hub.

Inspection

Check the brake drum for wear and damage, replace wheel hub if necessary

Measure the ID of hub at several points and record the largest value.

Service limit : 131.0 mm

Caution

•Remove the rust by using #120 sand paper.

•An inside micrometer must be used when measuring ID of brake drum because the brake drum has a friction back plate.

BRAKE LINING

Inspection

Measure the thickness of the brake lining at three points (both ends and center).

If the thickness is less than specified, or if it is contaminated by oil or grease, replace as a set.

Service limit : Front 2.0 mm

Rear 2.0mm

Rear brake drum

Brake lining

13-11

13. BRAKE SYM

Removal

Caution

Brake linings must be replaced as a set.

Remove brake shoes from the brake panel by pulling out the brake linings with two hands.

Installation

Apply a thin coat of grease to the brake cam and the anchor pin.

Hook the brake spring onto the brake cam.

Pull out the brake linings and install them onto the brake panel. Wipe off the excessive grease from the brake cam and the anchor pin after installation.

Slightly grind the brake lining surfaces with sand-paper to clean the surfaces. front brake cam

後 rear anchor pin

Caution

Braking efficiency will be reduced if brake lining is contaminated by oil or grease.

BRAKE PANEL

Removal

Remove the brake arm bolt and then remove the brake arm, wear indicator, brake return spring and brake cam as well as the oil seal from the brake panel. brake spring

Front brake spring brake shoes brake cam anchor pin brake shoes

Brake cam

Brake arm

Return spring

Wear indicator

Bolt

Rear Wear indicator

Return spring

13-12

SYM 13. BRAKE

Installation

FRONT BRAKE PANEL

Apply a thin cost of grease onto the brake cam shaft.

Install the brake cam.

Apply a thin cost of grease onto the oil seal lip and then install the oil seal onto the brake cam shaft. Finally, install it on the brake panel.

Align the end-part of the brake return spring with the hole of brake panel.

Align both the inner gear of wear indicator and the mark on the brake arm with the indent gear of brake cam, and then install it.

Tighten the bolts and nuts to specified torque.


Front

Oil seal

Rear

Brake cam

Brake arm

Return spring

Wear indicator

Wear indicator

REAR BRAKE PANEL

Apply a thin cost of grease between the oil seals on the brake cam shaft.

Install the brake cam.

Align the mark on the brake arm with the inner gear of the brake cam.

Tighten the bolts and nuts to specified torque.

Hook on the return spring.


Return spring

Brake arm

13-13

SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER




STEERING HANDLE.......................... 14-3


FRONT WHEEL ................................. 14-4

FRONT SHOCK ABSORBER ............ 14-9

FRONT FORK/STEERING COLUMN 14-9

2.4~3.0kgf-m

4.0~5.0kgf-m

1.0~2.0kgf-m

0.2~0.3kgf-m

3.1~3.5kgf-m

5.0~7.0kgf-m

5.0~7.0kgf-m

14-1

14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM


General Information y Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. y Be careful not to allow oil or grease get on brake drum or linings.

Torque values

Front wheel axle 5.0~7.0kgf-m

Steering handlebar nut 4.0~5.0kgf-m

Steering column top cone sliding ring

Steering column lock nut

0.2~0.3kgf-m

1.0~2.0kgf-m

Speedometer cable nut

Front shock absorber: Upper nut

Tools


Steering column wrench

0.15~0.3kgf-m

2.4~3.0kgf-m

Bearing remover

Inner type bearing remover

Attachment, 32×35 mm

Attachment, 42×47 mm

Steering column nut wrench

Steering column top cone ring nut wrench


Hard steering stem

y Over tightening of steering stem lock nut y Broken steering stem steel ball and cone bearing seat y Insufficient tire pressure

Steering stem off center

y Uneven left/right cushion y Bend fork y Bent front wheel/tire offset

Front wheel wobbling

y Deformed rim y Front wheel bearing loose y Faulty tire y Wheel axle nut tightened improperly

Soft front suspension

y Weak fork springs y Oil leakage of the shock absorber seal

Front suspension noise

y Cushion cover friction noise y Cushion bolts loose

14-2


STEERING HANDLE

REMOVAL

Remove handle front & rear covers and the front cover (refer to chapter 12).

Disc Brake

Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring.

Split ring

Master cylinder

Seat

Caution

Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder.

Remove acceleration handlebar screw and then remove the handlebar, acceleration cable, and handlebar cover & seat.

Remove the rear brake lever nut and screw, then take out the rear brake cable.

Remove the brake lever seat bolt, and then remove the seat.

Screw

Brake lever nut

Bolts x 2

Brake lever seat bolt

Brake lever screw

Brake cable

14-3


With a wrench to hold the handlebar bolt and then remove the nut.

Take out the handlebar after removed the bolt.

Installation

Install the handlebar according to the reverse procedure of removal.

Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat, acceleration handlebar, and acceleration cable.

FRONT WHEEL

Removal

Disc Brake type

Support body bottom and lift front wheel free of ground.

Remove the bolts, and disconnect speedometer cable from the gear box.

Remove the wheel axle nut and pull out the axle. Then, remove the front wheel.

Caution

Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder.

Bolt

Speedometer cable

Nut

Wheel axle nut

14-4


Inspection

Wheel axle

Set the axle in V-blocks and measure the run-out.

Service limit: 0.2 mm.

Wheel Rim

Place the wheel onto a rotated bracket.

Turn the wheel with hand and measure its wobble value with a dial gauge.

Service limit:

Radial : 2.0 mm

Axial : 2.0 mm

Disassembly (Disc type)

Remove 3 hex socket bolts and brake disc.

Wheel axle

14-5


Remove the left axle ring and dust seal.

Remove the dust seal on the right side of speedometer gear.

Remove the bearing with the inner type bearing remover.

Take out the bearing spacer and then remove the other bearing.

Tool:

Inner type bearing remover

Bearing Inspection

Turn the inner race of bearing with fingers.

The bearing should be turn smoothly. Also check if the outer collar is tightly connected to the wheel hub.

If the bearing do not turn smoothly, or if they are too loose in the races, or damaged, then, remove and replace the bearings with new ones.

Caution

The bearing must be replaced in pair.

Installation

Install the bearing according to the reverse procedure of removal.

Apply some grease into the bearing seat of the wheel hub.

Install the left bearing onto the seat.

Install the bearing spacer and then install the right bearing onto the seat.

Speedometer gear dust seal

Bearing

Bearing

Dust seal

Wheel side collar

DISC BRAKE

Bearing spacer

Bearing

Dust seal

Clearance

DRUM BRAKE

Bearing spacer

Bearing

Clearance

Clearance

Clearance

14-6


Caution

y Do not install used bearing and replace the bearing once it has been removed. y Do not the bearing in tile motion when installing.

Tool:

C-type compressor or bearing compressor.

Disc Brake

Apply with some grease inside of the dust bearing.

Install the dust seal and the front wheel side collar.

Apply with some grease on both side of the speedometer gear oil seal, and then install the seal.

This two example will to louse the bearing.

Speedometer gear dust seal

Bearing

Bearing spacer

Bearing

Dust seal

Wheel side collar

DISC BRAKE

14-7


Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc (drum brake) or speedometer gear box.

Caution

Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease.

Place the front wheel between the front shock absorbers.

Disc Brake

Align the flange part on the speedometer gear with the slot of shock absorber stopper.

Disc Brake

Install the front wheel axle from right shock absorber side.

Install the wheel axle nut, and tighten it to specified torque value.


Connect the speedometer cable to the speedometer gear box.

Gear box flange part

Stopper

Brake panel slot

Wheel axle nut Speedometer cable

14-8


FRONT SHOCK ABSORBER

Removal

Remove the front fender, front lower spoiler, front guard, and front wheel as well as front brake components.

Remove the brake fluid hose clipper or cable guide on the left shock absorber. (bolt x 1)

As for disc brake, remove the cable guide on the right shock absorber. (bolt x 1)

Remove the top connection bolt of the right shock absorber. (bolt x 4)

Remove the shock absorber from the front fork.

Installation

Install the shock absorbers according to the reverse procedure of removal.

Align the shock absorber top-edge with the top-end level of the front fork when installing the front shock absorber onto the front fork.

Then, tighten the nut.


FRONT FORK/STEERING COLUMN

Removal

Firstly, remove the handlebar, front wheel, front brake set, and front shock absorbers.

Remove the steering column nut.

Remove the top cone ring, and then remove the steering column.

Caution

Place the steering column bearing balls into a parts container to avoid to missing or shortage.

Steering column nut

Bolts

Shock absorbers

Brake fluid hose clipper

Top cone race

14-9


With a plastic hammer to tap the steering column slightly, and then remove the top ball bearing seat.

Remove the lower-end cone bearing seat on the frame with a punch.

Caution

Do not damage the frame and the steering column.

Installation

Install a new top-cone bearing seat onto the top of steering column.

And then, push the lower-cone bearing seat from bottom until to locking position.

Caution

Do not let the ball bearing in title motion as installation.

Apply with some grease onto the top & bottom bearing balls, and then install the balls into bearing seat.

Press in a new lower cone-race onto the steering column, and lubricate it with grease.

Install the steering column.

Lubricate the top-cone race with grease.

Drive the cone-race into the steering column until contact with the top bearing seat no clearance. Note, return 1/2 turn and then tighten the top cone race to specified torque.

(tighten the race around 1/4~3/8 turn more.)


Caution

Do not tighten the top cone race too tight to prevent from damage the ball bearing seat when tightening the top cone race.

Install the steering column nut and lock the top cone race. Then, tighten the nut.


Install the bearing seat according to the reverse procedure of removal.

Caution

Lower all bearing seat

Balls

Lower cone-race


Top cone-race



Top cone-race

Balls

Top ball bearing seat.

Return 1/2 turn

Locking to

1/4~3/8 turn

Check the steering column if it can be turned freely and no clearance in vertical motion.

Top cone-race

14-10

SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

MECHANISM DIAGRAM.................... 15-1

PRECAUTIONS IN OPERATION....... 15-2

TROUBLE DIAGNOSIS ..................... 15-2


2.4~3.0kgf-m

0.8~1.2kgf-m

EXHAUST MUFFLER......................... 15-3

REAR WHEEL.................................... 15-3

REAR SHOCK ABSORBER ............... 15-4

3.5~4.5kgf-m

1.0~1.4kgf-m

11.0~13.0kgf-m

3.0~3.6kgf-m

15-1

15. REAR WHEEL/REAR SHOCK ABSORBER SYM



As for the wheel removal, service, and installation procedures, please refer to the service manual of high speed tire.

Wheel wobbling

Radial - 2.0

Axial - 2.0

Thickness of rear brake lining 4.0 2.0

Torque values:

Rear axle nut

Rear shock absorber upper mount bolt

Rear shock absorber lower mount bolt

Exhaust muffler connection nut

Exhaust muffler connection bolt


Rear wheel wobbling

z bend wheel rim z poor tire z loosen wheel shaft

Shock absorber too soft

z insufficient shock absorber spring force

Braking Noise

z worn brake lining z brake drum deformation z improperly brake panel installation z unparalleled brake drum or wheel unparallel.

11.0~13.0kgf-m

3.5~4.5kgf-m

2.4~3.0kgf-m

1.0~1.4kgf-m

3.0~3.6kgf-m

Poor brake performance

z Poor brake adjustment z contaminated brake lining z worn brake lining z greased brake drum z contaminated and seized brake cable z improperly installation of brake cable

15-2

SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

EXHAUST MUFFLER

Removal

Remove the front-end nut of the exhaust muffler. (nuts x 2)

Remove the bolts. (bolts x 2)

Remove the exhaust muffler.

Installation

Install the exhaust muffler according to the reverse procedure of removal.

Exhaust muffler

Caution

Replace the exhaust muffler gasket if it is broken or deformed.

Torque value:

Exhaust muffler connection bolt:

3.0~3.6kgf-m

Exhaust muffler connection nut:

1.0~1.4kgf-m

REAR WHEEL

Inspection

Measure wheel rim wobbling.

Service limit:

Radial: 2.0mm

Axial: 2.0mm

If the wheel rim wobbling out of the specification, except resulted from the wheel rim deformation, it might be loosen or worn final driving shaft bearing or bend, deformed driving shaft.

Removal

Remove the exhaust muffler . (bolts x 3)

Remove the rear wheel. (wheel axle nut x1)

Nuts x 2

Bolts×2

15-3

15. REAR WHEEL/REAR SHOCK ABSORBER SYM

REAR SHOCK ABSORBER

Removal

Remove the luggage box. (bolts x 6)

Remove the rear carrier. (bolts x 3)

Remove the left & right body covers. (screws x 4, bolts x 3)

Remove the air cleaner bolts (bolts x2)

Remove the lower nut of the rear shock absorber (bolt x 1)

Remove the upper nut of the rear shock absorber (bolt x 1)

Remove the rear shock absorber.

rear shock absorber

Installation

Install the rear shock absorber according to the reverse procedure of removal.

Caution

The rear shock absorber has to be replaced with one set and can not be replaced by unauthorized persons. Otherwise, it might damage the rubber bushing and construction.

Torque values

Rear shock absorber lower mount bolt:

2.4~3.0 kgf-m

Rear shock absorber upper mount bolt:

3.5~4.5 kgf-m upper mount bolt

15-4

SYM 16. ELECTRICAL EQUIPMENT




CHARGING SYSTEM.........................16-5

IGNITION SYSTEM ............................16-11

MECHANISM DIAGRAM

Winker relay

Rear stop switch

REG.REC

Horn

Light/starter switch


Fuel unit

Auto by-star

Spark plug

Ignition coil

STARTING SYSTEM..........................16-14

METER ...............................................16-15

LIGHTS/BULBS ..................................16-17

SWITCH .............................................16-19

FUEL UNIT .........................................16-22

Horn/turn signal light/high & low beam

Front stop switch

Main switch

C.D.I/ Battery/ fuse box

16-1

16. ELECTRICAL EQUIPMENT SYM


Charging System

z When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.

(First disconnect the negative cable terminal, next, the positive cable terminal.) z MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water. z

Battery must be taken out from scooter when charging the battery. But do not open the battery caps. z Do not quick charge the battery unless in emergency. z

A voltmeter must be used when checking battery charging condition. z Battery can be charged or discharged alternately. To set a discharged battery idle for a prolonged period will shorten its service life and reduce its capacity. Usually, battery’s capacity will reduce after

1~2 years. After low capacity battery was charged, its voltage will increase. If it connects to an additional load, the voltage will reduce suddenly, and then go up again. z Over-charged battery. Usually, the over-charged battery can be seen externally. If a short circuit occurred inside the battery, there will be no voltage on the terminals of battery if voltage regulator does not operate. Then, the battery’s voltage will be too high that may reduce battery’s life. z The battery will be self-discharged if it was set idle for a long time. An idle battery must be charged about every 2months. z A new battery filled with electrolyte will generate a voltage after filled out electrolyte. The voltage should be in 12.5V or more after 10 minutes. When electrolyte is not enough, the battery must be filled with electrolyte and then charged to prolong the battery’s life-span. z Please check electrical device according to the procedure of diagnosis chart. z Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage-current regulator will be damaged. The ignition switch must be turned OFF before performing any work. z

Please do not replace with traditional type battery as replacement. z

Please refer to the removal instruction when removing the alternator and the pulse generator.

Ignition System

z

Please follow the procedure of trouble diagnosis chart to check ignition system. z

The ignition system equipped with a auto-advanced timing device in CDI unit. Thus, ignition timing need not to be adjusted. In case of incorrect ignition timing occurred, check the CDI unit or alternator system. It has to check the ignition timing with the ignition timing light if replaced these components. z

Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by impact. Therefore, take care when disassembling. z

Most of ignition system problems were resulted from poor connecting connector. Please check the connectors first when servicing. z

Make sure that the heat range of spark plug is suitable. Improper spark plug is the main cause of poor engine operation or combustion. z

Inspection procedures in this manual are based on Max. voltage. This manual also contains methods of how to check ignition coil resistance and component operation. z

Please follow the continuity chart to check ignition switch.

Starting System

z Starting motor can be removed directly from engine. z

Please refer to chapter 10 for starting clutch removal procedures.

16-2


Specification

Charging System

Items Specification

Charging rate

Battery

Voltage

(20℃)

Full charged

Under charged

Capacity

Lighting coil resistance (20℃)

Alternator

Charging coil resistance (20℃)

Leaking current

RPM for starting charging

STD:0.6A/5~10hrs, emergency charging:

6A/0.5hrs

13.1V

12.3V

12V / 6.2A

Between yellow-green: 0.8±0.1Ω

Between white-green: 0.6±0.1Ω

Less 1mA

2000rpm(headlight ON)

Resistance (20℃) 5W5Ω

Resistor

Resistance (20℃) 30W7.5Ω

Ignition System

4.5~5.5Ω

7.0~8.0Ω

Item Specification

Spark plug

Ignition coil resistance

(20℃)

Standard

TORCH A7RC (Recommended usage)

Hot type

Cold type

TORCH A8RC

TORCH A6RC

Spark plug gap 0.6~0.7 mm

Primary

0.21±10%Ω

Secondary

With plug cap : 7.6±10%KΩ

Without plug cap : 3.1±10%KΩ

Ignition timing

“F” Mark

Timing advanced character

Before TDC 13° / 1700 rpm



Pulse generator resistance (20℃)

Ignition coil-primary max. voltage

Pulse generator voltage

Starting System

50~200Ω

95~400 V

1.7 V above

Item Specification

Starting motor

16-3



Charging System

No power supply

z Dead battery z Disconnect battery cable z Fuse burned out z

Faulty ignition switch

Low voltage

z

Weak battery z

Loose battery connection z

Charging system failure z

Voltage-current regulator failure

Intermittent power supply

z Loosen wire connector in charging system z Loose battery cables z Loose charging system connection z Loose connection in lighting system

Charging system failure

z burn Fuse z Loose, broken or shorted wire or wire connection z Faulty voltage-current regulator z

Faulty alternator

Starting System

Starter motor does not work

z The fuse is blown z The battery is not fully charge z Poor main switch z Poor starter switch z The front and rear brake switches do not operate correctly z Starter magnetic switch is out of work z The ignition coil is poorly connected, open or short-circuited z

The starter motor is out of work

Ignition

System

No spark produced by spark plug

z The spark plug is out of work z The cable is poorly connected, open or short-circuited

- Between alternator and C.D.I.

- Between CDI and ignition coil.

- Between CDI and main switch z Poor main switch z Poor C.D.I. z alternator is out of work

Engine does not crank smoothly

z Primary coil circuit

- Poor ignition coil

- Poor connection of cable and connectors

- Poor main switch z Secondary coil circuit

- Poor ignition coil

- Poor spark plug

- Poor high-tension cable

- Current leakage in the spark plug cap z Incorrect ignition timing

- Poor alternator

- Improper installation of the pulse sensor

-

Poor C.D.I.

Weak starter motor

z Poor charging system z The battery is not fully charged z Poor connection in the windings z

The motor gear is jammed by foreign material

Starter motor is working, but engine does not crank

z

Poor starter motor pinion z

Poor starter clutch z

The starter motor run in reverse direction z

Poor battery

16-4


CHARGING SYSTEM

Charging wire diagram yellow alternator white

Auto by-starter

REG.REC. green/black

5

5

W

Ω

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 (as shown on left diagram). red green fuse(10A

) red battery green green

Battery(-) terminal

Caution z In the current leakage test, set the current range at larger scale, then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse. z Do not turn the main switch to “ON” position during test.

If the leaked current exceeds the specified value, it may indicate a short circuit.

Allowable current leakage: Less than 1 mA.

Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit. ground wire

16-5


Battery

Removal

Remove the battery cover.

Battery cover

CAUTION z z

Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, and then send to hospital.

When clothes is spread by electrolyte, it will contact with skin. So, it must flush with great quantity water to take off the clothes.


Disconnect the negative (-) cable from the battery first, then the positive (+) cable.

Remove the battery.

Install the battery in reverse order of removal.

CAUTION

z

To prevent form circuit short, connect positive(+) terminal at first, and next negative (-) terminal.

Positive cable (+) positive (+)

Negative cable (-)

Fuse box negative (-)

16-6


Voltage Check

With a digital voltage meter or multi-meter to measure battery voltage.

Voltage:

Fully charged: 13.0 – 13.2V (at 20℃)

Undercharged: Below 12.3 V (at 20℃)

CHARGING

Connect the Charger positive (+) to the battery positive (+) terminal.

Connect the Charger negative (-) to the battery negative (-) terminal.

Standard Max.

Charging current

Charging time

0.6A 6.0A

5~10H 1H

Warning

z Strictly keep flames away from a charging battery. z The charging “ON”/ “OFF” is controlled by the charger’s switch. Do not control the charging by battery jump wires. z Turn the charger’s switch “OFF” at first before or after charging to prevent from sparks created on the connectors and explosion. z To charge a battery must be based on the battery’s ampere-hour showed on label.

CAUTION

z Quick charge a battery should be used only in an emergency. z

Make sure the current and charging time of above description. z The battery will be damaged by too much current or too rush charging. z When finishing charge, it is necessary to measure voltage after 30 minutes.

After installing the battery, coat the terminals with clean grease.

16-7


Charging Voltage/Current

Inspection

Caution z Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.1 V. If undercharged, the current changes dramatically. z

While starting the engine, the starter motor draws large amount of current from the battery. Thus, do not start the engine with battery.

After the engine is warmed up, replace original battery with a fully charged battery.

Connect a digital voltmeter to the battery terminals.

Connect an ammeter between both ends of the main fuse.

Caution

When the probe is reversibly connected, use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero, ammeter at one direction only.

Caution z Do not use short-circuit cable. z It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal, however, while the starter motor is activated, the surge current of the motor draws from the battery may damage the ammeter. Use the kick lever to start the engine. z The main switch shall be turned to OFF position during the process of inspection.

Never tamper with the ammeter and the cable while there is current flowing through. It may damage the ammeter. digital voltmeter ammeter

Fuse ends

Connect a tachometer.

Turn on the headlight to high beam and start the engine.

Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage/current.

Specified Charging Current:

(headlight OFF) 0.6 A or more/2500rpm

1.2 A or more / 6000 rpm

(headlight ON) 0.4 A or more/2500rpm

1.0 A or more / 6000 rpm

Control Charging Voltage:

14.0+/0.5 V / 2000 rpm

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 battery terminals and the charging current is in the discharging direction.

(2) The charging voltage and current are too much higher than the standard values.

The following problems are not related to the charging system; correct it if any by following steps indicate in the checking list.

(1) The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rpm. z

Bulbs used exceed their rate and consume too much power. z The replacement battery is aged and does not have enough capacity.

(2) The charging voltage is normal, but the current is not. z The replacement battery is aged and does not have enough capacity. z Battery used do not have enough electricity or is over charged. z The fuse of the ammeter is blown. z The ammeter is improperly connected.

(3) The charging current is normal, but the voltage is not. z

The fuse of the voltmeter is blown.

16-8


VOLTAGE REGULATOR INSPECTION

Remove the front cover. (screws 4 x 2).

Remove the front cover mounting bolt(bolt x

1)and remove the left/right turnlight wiring connector.

Disconnect the 4P connector on the diode, and check the continuity between main wire terminals according to following method.

Horn

Main wire circuit inspection

Item (wire color)

Check voltage between battery terminal (red) and ground (green).

Check continuity between ground(green) and frame.

Judgment

Battery voltage

Continuity

Check illumination wire

(yellow) to ground.

(disconnect the connector of the resistor’s pin and automatic by-starter pin.

Illumination switch is in OFF)

Continuity & resistance

Check charging coil (white) to ground)

Continuity & resistance

If the measured value is abnormal, check the abnormal wire circuit. If components are good, it could be a poor wire circuit.

If all items are in good condition, then replace the voltage regulator.

If main wire circuit check is in normal and there is no loose in the pins of voltage regulator connector, then measure the resistance between the connector of voltage regulator.

Voltage Regulator Check

Unit: Ω

Multi-meter(+)

Multi-meter

Red

(R)

White

(W)

Yellow

(Y)

Green

(G)

Red (R)

∞ ∞ ∞

REG.REC

Winker relay

Headlight wiring connector

White (W)

∞

0.04~0.06

160~180

Yellow (Y)

∞

0.04~0.06

160~180

Green (G)

∞

160~180 160~180

If the resistance values are abnormal among the pins, replace the voltage regulator.

REG.REC

Caution z Do not touch the probe of multi-meter by fingers, then the resistance values will be incorrect because there is some resistance existence in human body. z To use the multi-meter recommended by

SYM. Otherwise, the measured resistance might be different.

White

Green

RED

Yellow

16-9


Alternator charging coil

Charging coil connector

Auto by-star light coil connector

Caution

The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine.

Check

Remove the 3P connector of the alternator.

Measure the resistance between the white wire on the alternator and frame ground with a multi-meter.

Standard: 0.6±0.1Ω (20℃)

Replace the alternator charging coil if the measured value exceeds standard.

Alternator lighting coil

Check

Remove the 3P connector of the alternator.

Measure the resistance between the yellow wire on the alternator and frame ground by multi-meter.


Standard: 0.8±0.1Ω (20℃)

Replace the alternator lighting coil if the measured value exceeds standard.

Resistor check


Measure the resistance between the resistor wire (green/black) and frame ground.

Standard: 5Ω/5W: 4.5~5.5(green/black)

Standard: 7.5Ω/30W: 7.0~8.0(pink) resistors

16-10


IGNITION SYSTEM

Ignition System Circuit

Pluser

Blue/yellow green green

Black

Engine start control switch

Black

Blue/yellow

CDI UNIT

Removal

green

C.D.I. unit

Blue /yellow

Black/ yellow black/yellow

Ignition coil green green spark plug

Remove the right body cover, then the C.D.I. unit can be removed from the frame.

CDI UNIT

Check

Disconnect the connector from the CDI unit.

Make the following inspection at each terminal of the harness side connector.

ITEM Measure at: Standard (at 20C)

Pulse Generator

Ignition

Coil

Primary Black/yellow-green

Secondary

Green-high voltage cable -w/o cap

Green-high voltage cable - w/ cap

0.21Ω±10%

3~5KΩ

7~12KΩ

16-11


Ignition coil

Removal

Remove the luggage box, center cover.

Remove spark plug cap.

Remove the primary coil wire of ignition coil.

Remove the fix bolts for the ignition coil, and remove the ignition coil.

Install the ignition coil in reverse order of removal.

Ignition coil

Caution

Install primary coil with black/yellow lead connected to black connector and green lead connected to green connector.

Spark plug confirmation

Remove the spark plug and install a good plug into plug cap, and then ground it to engine ground.

Make sure its spark condition. If it is in not good or burnt spark plug, replace the spark plug with new one.

Caution z Make sure each wire connection is correct, and test as required. Even the wire connection is in correct, sometimes, it might not be tested occurred.

Connect the high voltage shunt with a multi-meter or input a resistor in the 10MΩ

100V of voltage meter.

Connect ignition coil wires, and connect a shunt between primary terminal (black/yellow and green) and frame ground.

Press the starting motor button, or starting lever to test the max. primary voltage of ignition coil.

Connection: connect (+) terminal to green side, and (-) to black/yellow side.

Min. voltage: Above 95 V.

Caution

Do not touch metal parts on the test probe with fingers to avoid electric shock.

Primary coil check

Disconnect the primary coil connector and check the resistance between primary coil terminals.

Standard: 0.21Ω±10%Ω(at 20℃)

Primary coil is good if resistance within standard.

Primary coil is broken if resistance is infinite.

Replace the coil. high voltage shunt black/yellow green

16-12


Secondary coil

Attached the spark plug cap, measure the resistance between plug cap side and green terminal.

Standard value: 7-12 kΩ(20℃)

Remove the spark plug cap, measure the resistance between plug cap side and green terminal.

Standard value: 3-5 kΩ(20℃)

Secondary coil is good if resistance within standard.

Secondary coil is broken if resistance is infinite. If the spark plug cap attached and the measured value is exceed standard value, it means the spark plug cap is in not good.

Replacement

Remove the ignition coil bolt to replace the ignition coil if necessary.

Pulse generator

Ignition coil

Caution

Checking pulse generator can be done on engine. But, the spark plug must be installed onto the cylinder head, and cylinder compression pressure must be in normal condition.

Check

Remove body cover.

Remove the pulse generator connector.

Measure the resistance between blue/yellow terminal on engine side and frame ground.

Standard: 140±20Ω(20℃)

Replace the alternator if the measured value exceeds standard value.

16-13


STARTING SYSTEM

Starting Circuit

Starter magnetic switch inspection

Turn main switch to "on", and operate the brake lever. Then press starting button to check if there a click sound. It is normal if there is a click sound.


Disconnect the battery negative (-) terminal.

Remove the battery positive (+) connection and starting motor wires from the starter magnetic switch large pin.

Remove the power control connector of the

Starter magnetic switch.

Connect a Ohmmeter between the Starter magnetic switch large pins.

Connect the green/yellow wire to battery positive (+) terminal, and yellow/red to battery negative (-) terminal.

Check the continuity between the Starter magnetic switch large pins. If it is not continuity, then replace the starter magnetic switch.



16-14


Starting Motor Removal


Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal.


Remove the starting motor power wire.

Remove the starting motor mounting bolts and motor.

Starting Motor Installation

Install the motor in reverse order of removal.

Bolts x2

METER

Removal


Remove the speedometer cable.


Remove the power connector of the meter.

Meter

Meter connector speedometer cable

16-15


Remove the rear handle cover.

Remove the meter mounting screws.

Take out the meter.

Speedometer

Turn Left Signal

Indicator

Fuel meter

High Beam Indicator

Time meter

Turn Right

Signal

Odometer/Trip kilometer

Caution

Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components.

Installation

Install the meter in reverse order of removal.

16-16


LIGHT/BULBS

Headlight Bulb Replacement

Rear the front handle cover.

Disconnect the headlight wire connector.

Press down the bulb spring locker and then remove the locker with turning it left motion.

Remove the bulb.

Replace the bulb with new one if necessary.

(12V 35W/35W)

Caution z Do not touch the bulb surface with fingers because the bulb will create hot-spot so that let it be burnt. It has to be package with cloth or wear glove as installing. z Wipe the bulb with cloth to prevent from damaged if the bulb be touched by hands.

Install the bulb in reverse order of removal.

Turn the main switch ON/OFF to check if the bulb has been installed properly after installation.

Please conduct the headlight beam adjustment job if replace the headlight bulb.

The headlight beam adjustment

Loosen the adjustment bolt located under the headlight. headlight beam adjustment screw

Caution z This outer cover of headlight is a fixed type so that the light seat will be moved only when adjusting.

16-17


Front Turn Signal Lamp Bulb

Replacement


Remove the wire connector of the turn signal light.

Pull out the bulb and replace it with new one.

(12V 10W)

Installation

Install the bulb in reverse order of removal.

Bulbs Replacement of tail light/brake light/rear turn signal light.

Remove the 2 screws of the taillight

&left/right turn light lens.

Remove the tail light assembly.

Replace the bulbs of the tail light, brake light

(12V 5W/21W)

Replace the bulbs of the turn signal light

(12V/10W).

Installation

Install the bulb in reverse order of removal. the wire connector of the turn signal light

Screw x 2

Front turn signal light turn signal light tail light & brake light

16-18


MAIN SWITCH/HORN

Main Switch

Check

Remove the headlight connector and the front cover.

Disconnect main switch leads connector.

Check connector terminals for continuity. color

Location

Black Red green green

LOCK

●

● main switch connector terminals

OFF

●

● main switch bolts x 2

ON

● ●

Replacement

Remove the main switch connector and fixing bolts (bolts x 2)

Remove the main switch.

Install a new main switch and tighten the bolts. (bolts x2)

16-19


Handle switch


Disconnect the connector of the handle switch.

Check the continuity of follow pins listed below columns.

Headlight switch

headlight switch color

Brown Yellow Pink

Location

Brown

/White

Yellow

●

●

●

●

● starting switch

● ● brown /white yellow headlight switch ●

Starting switch

●

Location color

Yellow/red green brown yellow pink

FREE

● ●

High/Low beam switch/ passing

color blue white brown/ white

Location

●

●

White/ green

●

● yellow/red turn signal switch green

Starting switch passing

Horn switch color

Location

●

Black Light green

● horn switch

Blue

Black

High/Low beam switch/ passing

FREE

●

● orange

Sky blue

High/Low beam switch/ seat open white brown/white turn signal switch gray

Light green

Black

Horn switch

16-20


Turn signal light switch

Location

color Sky blue

Gray orange

● ●

FROM R

● ● orange turn signal light switch

N

FROM L

● ●

Sky blue gray

● ●

Brake light switch

The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever.

If the switch damaged, replace it with new one.

Horn


Connect the light blue wire on the horn to the battery positive (+) terminal, and the green wire to the battery negative (-) terminal.

Then, the horn should sound.


16-21


FUEL UNIT

Open the seat.

Remove the luggage box(bolts x 4) .

Remove the R.R. carrier(bolts x 3) .

Remove the body cover.

Disconnect the fuel unit wire connector.

Fuel unit

Caution

Do not damage or bend the float arm as removing.

The resistance values are listed below when the float arm in “F” and “E” positions.

Float arm position Resistance value

E(empty)

97.5~107.5Ω

4~10Ω

F(full)

DOWN(empty)Connect the fuel unit to the main harness.

Turn the main switch “ON” position.

Move the float arm in “UP” & “DOWN”, and then check if the fuel unit indication needle is in correct position.

Caution

Turn on the turn signal light to make sure battery is in good condition before this test.

Float arm position

Indicator needle

UP(full) E(empty)

DOWN(empty) F(full)

Installation

Install the fuel unit in reverse order of removal.

UP

(full)

DOWN

(empty)

16-22

SPECIAL TOOL SYM

ITEM: ACG FLYWHEEL PULLER ITEM:

ONE-WAY CLUTCH & STARTING GEAR

NO：SYM-3111000

PURPOSE:

REMOVE ACG FLY WHEEL

LOCK NUT PULLER

NO：SYM-9020100

PURPOSE:

REMOVE ONE-WAY CLUTCH FIX NUT

ITEM: BEARING DISASSEMBLER

NO：SYM- 6202Z / 6204

PURPOSE: REMOVE THE BEARING

ITEM: UNIVERSAL HOLDER

NO：SYM-2210100

PURPOSE:HOLD THE MDF/CLUTCH OUTER

ITEM: CLUTCHSPRING COMPRESSOR

NO：SYM-2301000

PURPOSE:DISASSEMBLE THE CLUTCH

ITEM: CLUTCH NUT WRENCH

NO：SYM-9020200

PURPOSE:LOOSE THE CLUTCH NUT

1

SERVICE MANUAL

SERVICE MANUAL

This service manual contains the technical data of each component inspection and repair for the SYM 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 guidelines.

If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

This service manual describes basic information of different system parts and system inspection & service for SYM 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 information and trouble diagnosis.

The second chapter covers service maintenance information.

The third to the eleventh chapters cover engine and driving systems.

The twelfth to fifteenth chapters are contained the parts set of assembly body.

The sixteenth chapter is electrical equipment.

The seventeenth chapter is for wiring diagram.

Please see index of content for quick having the special parts and system information.

CYLINDER COPMRESSION PRESSURE

z

Unit: mm

Charging System

System

Related manuals

Table of contents

SERVICE MANUAL

SERVICE MANUAL

This service manual contains the technical data of each component inspection and repair for the SYM 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 guidelines.

If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

This service manual describes basic information of different system parts and system inspection & service for SYM 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 information and trouble diagnosis.

The second chapter covers service maintenance information.

The third to the eleventh chapters cover engine and driving systems.

The twelfth to fifteenth chapters are contained the parts set of assembly body.

The sixteenth chapter is electrical equipment.

The seventeenth chapter is for wiring diagram.

Please see index of content for quick having the special parts and system information.

CYLINDER COPMRESSION PRESSURE

z

Unit: mm

Charging System

System

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Table of contents