SERVICE MANUAL

SYM 5. REMOVAL OF ENGINE

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

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

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

MECHANISM DIAGRAM

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

OPERATIONAL PRECAUTIONS

General Information

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

SYM 5. REMOVAL OF ENGINE

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

5. REMOVAL OF ENGINE SYM

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

SYM 5. REMOVAL OF ENGINE

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

5. REMOVAL OF ENGINE SYM

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

SYM 5. REMOVAL OF ENGINE

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

5. REMOVAL OF ENGINE SYM

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