SY-250-F Chassis

SY-250-F Chassis
Manuel de l’
Chassis
Chassis
1
Manuel de l’
Chassis
SUMMARY
1
GLOSSARY..................................................................................................................................................... 4
2
PLASTICS : ..................................................................................................................................................... 5
2.1 SIDE COVERS REMOVAL : .............................................................................................................................................. 5
2.2 SIDE COVERS INSTALLATIONS :..................................................................................................................................... 5
3
FUEL TANK : .................................................................................................................................................. 6
3.1 FUEL TANK AND SIDE COVERS REMOVAL : .................................................................................................................... 6
3.2 FUEL TANK AND SIDE COVERS INSTALLATION :............................................................................................................. 6
4
AIR CLEANER CASE : ................................................................................................................................... 7
4.1 AIR CLEANER CASE REMOVAL : .................................................................................................................................... 7
4.2 AIR CLEANER CASE INSTALLATION : ............................................................................................................................. 7
5
EXHAUST PIPE : ............................................................................................................................................ 8
5.1 EXHAUST PIPE REMOVAL : ............................................................................................................................................ 8
5.2 EXHAUST PIPE INSTALLATION :..................................................................................................................................... 8
6
MUFFLER :...................................................................................................................................................... 9
6.1 MUFFLER REMOVAL : ................................................................................................................................................... 9
6.2 MUFFLER INSTALLATION : ............................................................................................................................................ 9
7
FRONT WHEEL : .......................................................................................................................................... 10
7.1 FRONT WHEEL REMOVAL : .......................................................................................................................................... 10
7.2 FRONT WHEEL INSTALLATION :................................................................................................................................... 10
8
REAR WHEEL :............................................................................................................................................. 11
8.1 REAR WHEEL REMOVAL :............................................................................................................................................ 11
8.2 REAR WHEEL INSTALLATION : .................................................................................................................................... 11
9
FRONT BRAKE.............................................................................................................................................. 12
9.1 FRONT BRAKE CONTROL REMOVAL :........................................................................................................................... 13
9.2 FRONT BRAKE CONTROL INSTALLATION : ................................................................................................................... 13
10
REAR BRAKE :............................................................................................................................................. 14
10.1
10.2
11
STEERING : .................................................................................................................................................. 16
11.1
11.2
12
FORK REMOVAL :.................................................................................................................................................... 17
FORK INSTALLATION : ............................................................................................................................................ 17
OIL CHANGE, FORK OF LEFT SIDE ............................................................................................................................. 18
OIL CHANGE, FORK OF RIGHT SIDE ........................................................................................................................... 19
SWING ARM : ............................................................................................................................................... 20
13.1
13.2
14
HANDLE CROWNS REMOVAL : ................................................................................................................................ 16
HANDLE CROWNS INSTALLATION : ......................................................................................................................... 16
FORK :........................................................................................................................................................... 17
12.1
12.2
12.3
12.4
13
REAR BRAKE CONTROL REMOVAL : ........................................................................................................................ 15
REAR BRAKE CONTROL INSTALLATION :................................................................................................................. 15
SWING ARM REMOVAL :.......................................................................................................................................... 20
SWING ARM INSTALLATION : .................................................................................................................................. 20
SHOCK ABSORBER : .................................................................................................................................. 21
14.1
14.2
REAR SHOCK ABSORBER REMOVAL : ...................................................................................................................... 21
REAR SHOCK ABSORBER INSTALLATION : ............................................................................................................... 21
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Manuel de l’
15
CLUTCH CONTROL ..................................................................................................................................... 22
15.1
15.2
16
CLUTCH CONTROL REMOVAL : ............................................................................................................................... 22
CLUTCH CONTROL INSTALLATION : ........................................................................................................................ 22
SIDE STAND AND FOOTREST : ................................................................................................................. 23
16.1
16.2
17
Chassis
SIDE STAND AND FOOTRESTS REMOVAL : ............................................................................................................... 23
SIDE STAND AND FOOTRESTS INSTALLATION : ........................................................................................................ 23
FRAME : ........................................................................................................................................................ 24
17.1
17.2
ENGINE REMOVAL : ................................................................................................................................................ 25
ENGINE INSTALLATION :......................................................................................................................................... 25
3
Manuel de l’
Chassis
1 Glossary
Lubricate with grease.
Lubricate with copper grease.
Use hard locking agent.
Use soft locking agent.
6 N.m
Tightening torque.
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Manuel de l’
Chassis
2 Plastics :
2.1 Side covers removal :
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Unscrew the fuel tank cover upper bolt.
Remove the cover.
Unscrew the air cleaner case cover bolt.
Remove the cover.
Unscrew the 3 rear fender bolts.
Remove the rear fender.
Unplug the electric cables.
For each side, unscrew the 2 silencer side
covers bolts.
Remove the silencers side covers.
Unscrew the 4 license plate support bolts and
remove it.
2.2 Side covers installations :
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Install the silencer side covers.
For each side, screw the 2 silencer side covers
bolts.
Install the rear fender.
Plug the electric cables.
Screw the 3 rear fender bolts, putting the
heat-protecting washers.
Install the air cleaner case cover.
Screw the air cleaner case cover bolt.
Install the license plate support and screw the
4 fixing bolts.
Install the tank cover.
Screw the fuel tank cover upper bolt.
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Manuel de l’
Chassis
3 Fuel tank :
3.1 Fuel tank and side covers removal : 3.2 Fuel tank and side covers
installation :
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Remove the fuel tank cover (see “side cover
removal”)
Remove the fuel tank, dismounting the fuel
hose clip and disconnecting the hose (warning,
the cock position must be on “OFF”)
Remove the side covers.
Drain the fuel tank on the position “RES”
(never throw out the fuel in the nature).
Unscrew the cover bolts.
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Install the cock with a new seal.
Screw the 2 cock bolts.
Install the side covers.
Install the fuel tank, connecting the fuel hose
with the clip.
Install the tank cover (see “side covers
installation”).
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Manuel de l’
Chassis
4 Air cleaner case :
4.1 Air cleaner case removal :
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Remove the fuel tank cover, the air cleaner
case, the side covers and the rear fender (see
“side cover removal”).
Remove
the
silencer
(see
« silencer
removal »).
Unscrew the air cleaner sleeve collar.
Remove the air cleaner case.
Remove the air cleaner cap by pulling it.
Remove the air cleaner filter.
4.2 Air cleaner case installation :
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Install the air cleaner filter.
Install the air cleaner cap.
joint the air cleaner sleeve to the carburettor.
Screw the collar.
Install the silencer (see “silencer installation”).
Install the rear fender, the air cleaner case, the
side covers and the fuel tank cover (see “side
cover removal”).
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Manuel de l’
Chassis
5 Exhaust pipe :
5.1 Exhaust pipe removal :
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Remove the air cleaner case (see « air cleaner
case removal »).
Remove the carburettor (see « carburettor
removal »)
Unscrew the exhaust pipe fixing nut and bolt.
Remove the exhaust pipe.
5.2 Exhaust pipe installation :
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Place the exhaust pipe (put a new seal).
Screw the exhaust pipe fixing nut and bolt.
Install the carburettor (see “carburettor
installation”).
Install the air cleaner case (see “air cleaner
case installation”).
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Manuel de l’
Chassis
6 Muffler :
6.1 Muffler removal :
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Remove the fuel tank cover, the air cleaner
case cover, the side covers and the rear fender
(see “side cover removal”).
Unscrew the 4 bolts fixing the silencer to the
frame.
Remove the silencer of the exhaust pipe.
6.2 Muffler installation :
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Lubricate the graphite seals.
Joint the silencer to the exhaust pipe.
Screw the 4 bolts fixing the silencer to the
frame.
Install the rear fender, the air cleaner case
cover, the side covers and the fuel tank cover.
(see “side cover installation”).
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Manuel de l’
Chassis
7 Front wheel :
7.1 Front wheel removal :
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Unscrew the 3 bottom fork axle bolts.
Unscrew the axle with hexagonal tool.
Remove the axle.
Remove the front wheel.
Warning : don’t use the brake without the
wheel (put a key between the pads).
7.2 Front wheel installation :
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Lubricate the front wheel axle and lubricate
the threading with copper grease.
Place the front wheel (with the disc between
the pad kit) and install the axle, with the
spacer (at the calliper side).
Screw the axle.
Unscrew (partly) the 2 bolts at the right side of
the front fender bracket.
Lock the front brake and push down on the
handlebar several times.
Screw the bottom fork bolts.
Screw the fender bracket bolts.
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Manuel de l’
Chassis
8 Rear wheel :
8.1 Rear wheel removal :
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Unscrew the rear wheel nut.
Remove the right eccentric.
Remove the rear wheel axle.
Remove the rear wheel.
Warning : don’t operate the brake without the
wheel (put a key between the pads).
8.2
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Rear wheel installation :
Place the rear wheel (and the chain).
Install the left eccentric on the axle.
Lubricate the axle.
Install the axle.
Install the right eccentric.
Lubricate the axle nut threading with copper
grease.
Adjust the drive chain slack.
Screw the rear wheel nut.
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Manuel de l’
Chassis
9 Front brake :
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Manuel de l’
9.1 Front brake control removal :
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Unscrew the two front brake calliper.
To take out the disc : remove the front wheel
(see “front wheel removal”) then unscrew the
4 disc fixing bolts.
To remove the pad kit : unscrew the bolt and
remove the lock pin.
To remove the master cylinder cover : unscrew
the 2 cover bolts (warning : this task must be
done the master cylinder fixed to the
handlebar, and the bike stable and straight).
To remove the master cylinder from the
handlebar : unscrew the 2 master cylinder
bracket bolts.
To remove the lever : unscrew the nut then
unscrew the bolt and finally remove the lever
(be careful to the spacers).
To remove the hose, unscrew the pipe portion
bolt, near the slave cylinder then near the
master cylinder (warning : the liquid is
corrosive for the painting and dangerous for
the body).
Chassis
9.2
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Front brake control installation :
To install the hose : screw the pipe portion bolt
to the master cylinder after changing the
washer seals, then screw the pipe portion bolt
the slave cylinder after changing the washer
seals.
To install the lever : put the 2 spacers then
screw the bold after positioning the lever and
finally, screw the nut.
To install the master cylinder cover : screw the
2 cover bolts.
To install the master cylinder on the handlebar
: install the bracket and screw the 2 fixing
bolts.
To install the disc : put the 4 washers and the
4 spacers then screw the 4 bolts with hard
locking agent, and finally install the front
wheel (see “front wheel installation”).
Install the calliper and the front disc protective
plate then screw the 2 calliper fixing bolts.
Warning : if the hose has been removed, you
must air bleed the front brake control.
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Manuel de l’
Chassis
10 Rear brake :
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Manuel de l’
10.1 Rear brake control removal :
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Remove the rear wheel (see “rear wheel
removal”).
Remove the rear brake calliper.
Unscrew the rear brake pedal bolt.
Take out the bolt and remove the pedal.
Unscrew the liquid container screw.
Warning : the liquid container must be kept
with the cap upwards to avoid the air bleed.
Unscrew the 2 rear brake master cylinder
fixing bolts and remove it.
To remove the brake hose : unscrew the
master cylinder fixing hose fixing bolt then
unscrew the slave cylinder hose fixing bolt
(Warning : the liquid is corrosive for the
painting and dangerous for the body).
Chassis
10.2 Rear brake control installation :
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To install the hose : screw the pipe portion bolt
to the master cylinder after changing the
washer seals, then screw the pipe portion bolt
the slave cylinder after changing the washer
seals.
Install the rear master cylinder and the 2 fixing
bolts.
Install the liquid container then screw the two
fixing bolts.
Lubricate the brake pedal spacer.
Install the brake pedal and install the fixing
bolt.
Screw the pedal axle nut.
Install the rear brake calliper.
Install the rear wheel (see “rear wheel
installation”).
Warning : if the hose has been removed, you
must air bleed the front brake control.
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Manuel de l’
Chassis
11 Steering :
11.1 Handle crowns removal :
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Remove the fork (see « fork removal »).
Unscrew the 4 handle upper holders fixing
bolts and remove the holders.
Remove the handlebar.
Unscrew the 2 handle lower holders fixing
bolts and remove the holders.
Unscrew the front fork cap nut.
Remove the upper handle crown.
Unscrew the upper bearing support nut.
Remove the washer, the o’ring and the
bearing.
Remove the lower handle crown.
11.2 Handle crowns installation :
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Lubricate the lower steering bearing.
Install the upper handle crown in the steering.
Lubricate and install the upper steering
bearing.
Install the o’ring.
Install the washer then screw the upper
bearing support nut with the steering nut
wrench (screw to eliminate the play, make
sure there are no hard points in the steering).
Install the upper handle crown and screw the
front fork cap nut.
Install the lower handle holders and screw the
2 fixing bolts.
Install the handle bar.
Install the upper handle holders and screw the
4 fixing bolts.
Install the fork (see “fork installation”).
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Manuel de l’
Chassis
12 Fork :
12.1 Fork removal :
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Remove the front wheel (see « front wheel
removal »).
Unscrew the 2 front calliper fixing bolts and
remove the calliper.
Unscrew the 2 front fender fixing bolts and
remove the fender.
Unscrew the 4 front fender bracket fixing bolts
and remove the bracket.
Unscrew the 2 upper crown bolts.
Unscrew the 3 lower crown bolts (warning :
the inner tube will fall).
Repeat this work for the second inner tube.
12.2 Fork installation :
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Install correctly the inner tube (the upper line
should be just visible at the top of the upper
crown).
Screw temporarily the lower crown bolts.
Screw the upper crown bolts (lubricated with
copper grease).
Screw the lower crown bolts (lubricated with
copper grease).
Repeat the work for the other inner tube.
Install the front fender bracket and screw the
4 fixing bolts.
Install the front fender and screw the 2 fixing
bolts (don’t forget the plastic washers).
Install the front brake calliper and the holder,
then screw the 2 fixing bolts.
Install the front wheel (see “front wheel
installation”).
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Manuel de l’
Chassis
12.3 Oil change, fork of left side
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Remove the front fork cap bolt
Leave spacer and spring
Return the fork to empty oil.
For completely empty oil of the fork,
move several time inner tube and
damper rod
When oil is completely evacuate,
return the fork and add some ml of
new oil for rinse the interior of fork .
Repeat operation 3 and 4
Return fork in the good feel and fill it
with oil, MOTUL Fork Oil Light 5W.
Pump several time to distribute oil
fork.
The oil quantity is good then the level
of oil is 110 mm (4.33 in) with inner
tube and damper rod in lower position.
Pump several time (inner tube and
damper rod) and check the level. If the
level isn’t constant, supplement .
Install the spring and the spacer
(metal ring in contact with spring)
Remove Front fork cap bolt and tighten it
Open fork
Front fork cap bolt
Spacer
Spring
Inner tube
Recover oil and deposit it in the places envisaged
for this purposes (dechetery,..).
(20Nm ; 15Ibf.ft)
Oil level
Oil level measure
Steel rule
Inner tube in
lower position
Inner tube in lower position
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Manuel de l’
Chassis
12.4 Oil change, fork of right side
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Remove the front fork cap bolt
Loosen the locknut and remove the
front fork cap bolt.
Return the fork to empty oil.
For completely empty oil of the fork,
move several time inner tube and
damper rod
When oil is completely evacuate,
return the fork and add some ml of
new oil for rinse the interior of fork .
Repeat operation 3 and 4
Return fork in the good feel and fill it
with oil, MOTUL Fork Oil Light 5W.
Pump several time to distribute oil
fork.
The oil quantity is good then the level
of oil is 60 mm (2.36in) with inner tube
and damper rod in lower position.
Pump several time (inner tube and
damper rod) and check the level. If the
level isn’t constant, supplement .
Install the front fork cap bolt, the
locknut doesn’t block cap bolt.
Tighten the cap bolt, block it with the
locknut
For closed fork, put the inner tube in is
upper position and tighten the cap bolt
(20Nm ; 15Ibf.ft)
Open fork
Front fork cap bolt
Locknut
Damper rod
Inner tube
Recover oil and deposit it in the places envisaged
for this purposes (dechetery,..).
Oil level
Oil level measure
Steel rule
Inner tube in
lower position
Inner tube in lower position
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Chassis
13 Swing arm :
13.1 Swing arm removal :
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Remove the rear wheel (see « rear wheel
removal »).
Remove the license plate support (see “side
covers removal”).
Remove the quick disconnect fastener.
Unscrew the brake hose holder bolt.
Unscrew the swing arm axle and remove it.
Remove the swing arm.
Unscrew the sprocket drive cover bolts.
Unscrew the chain guard bolts and remove the
chain guard.
Unscrew the chain puller fixing bolts.
Unscrew the chain puller spring bolts, remove
the chain puller spring.
Unscrew the eccentric stop bolt.
Unscrew the driven sprocket protective plate
nuts.
Remove the protective plate bolts then remove
the protective plate.
Unscrew the rear brake calliper stop.
Unscrew the chain cover fixing bolt and nut,
remove the bolt then remove the chain cover.
13.2 Swing arm installation :
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Install the chain cover and the fixing bolts.
Screw the chain cover nut and bold (use soft
locking agent on the bolt).
Screw the rear brake calliper stop and the nut.
Install the protective plate with the fixing bolts.
Screw the chain cover nuts.
Screw the eccentric strop bolt (use hard
locking agent).
Install the chain puller and screw the chain
puller spring fixing bolt (with hard locking
agent).
Lubricate the chain puller spacer and screw the
chain puller fixing bolt.
Install the chain guard seal and screw the
fixing bolts.
Install the sprocket drive cover and screw the
fixing bolts.
Lubricate the swing arm bearings.
Install the swing arm and install the axle (by
the left side).
Screw the rear wheel axle nut.
Install the chain.
Install the rear wheel (see “rear wheel
installation”).
Install the license plate support (see “side
covers installation”)
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Manuel de l’
Chassis
14 Shock absorber :
14.1 Rear shock absorber removal :
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Remove the air cleaner case (see « air cleaner
case removal »).
Unscrew and take out the absorber upper
fixing bolt.
Hold the swing arm to avoid damages.
Unscrew and take out the absorber lower
fixing bolt.
Take out the absorber.
14.2 Rear shock absorber installation :
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Place the absorber.
Screw the absorber lower fixing bolt.
Place and hold up the swing arm.
Screw the absorber upper fixing bolt.
Install the air cleaner case (see “air cleaner
case installation”).
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Chassis
15 Clutch control
15.1 Clutch control removal :
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Remove the air cleaner case (see « air cleaner
case removal »).
Remove the fuel tank (see « fuel tank
removal »).
Unscrew the attaching slave cylinder bolt.
Remove the slave cylinder.
To remove the master cylinder from the
handlebar : unscrew the 2 master cylinder
bracket bolts.
To remove the master cylinder cover : unscrew
the 2 cover bolts (warning : this task must be
done the master cylinder fixed to the
handlebar, and the bike stable and straight).
To remove the lever : unscrew the nut then
unscrew the bolt and finally remove the lever
(be careful to the spacers).
To remove the hose, unscrew the pipe portion
bolt, near the slave cylinder then near the
master cylinder (warning : the liquid is
corrosive for the painting and dangerous for
the body).
15.2 Clutch control installation :
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To install the hose : screw the pipe portion bolt
to the master cylinder after changing the
washer seals, then screw the pipe portion bolt
the slave cylinder after changing the washer
seals.
To install the lever : put the 2 spacers then
screw the bold after positioning the lever and
finally, screw the nut.
To install the master cylinder cover : screw the
2 cover bolts.
To install the master cylinder on the handlebar
: install the bracket and screw the 2 fixing
bolts.
Install the slave cylinder.
Screw the slave cylinder fixing bolt with hard
locking agent.
Install the air cleaner case (see “air cleaner
case installation”).
Install the fuel tank (see “fuel tank
installation”).
Warning : if the hose has been removed, you
must air bleed the clutch control.
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Manuel de l’
Chassis
16 Side stand and footrest :
16.1 Side stand and footrests removal :
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Unscrew the side stand bracket bolts.
Remove the side stand bracket.
Unscrew the side stand axle nut.
Take out the bolt.
Take out the side stand.
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Unscrew the footrest nut.
Remove the footrest fixing bolt.
Take out the footrest from the bracket.
Take out the spacer (be careful of the spring).
Unscrew the footrest bracket fixing nuts.
Take out the bolts and take out the bracket.
16.2 Side stand and footrests
installation :
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Place the side stand on the bracket and put
the bolt and the spacer.
Screw the side stand axle nut.
Screw the side stand bracket fixing bolt (use
hard locking agent).
Place the footrest bracket on the frame and
put the bolts.
Screw the nuts.
Put the spacer in the footrest with the spring.
Place the footrest on the bracket and put the
bolt.
Screw the footrest axle nut.
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Chassis
17 Frame :
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17.1 Engine removal :
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Unscrew the 2 guard engine rear fixing bolts.
Unscrew the 2 guard engine front fixing nuts.
Remove the guard engine front bolts.
Remove the clutch control (see “clutch control
removal”).
Remove the handle crowns (see “handle crown
removal”).
Remove the swing arm (see “swing arm
removal”).
Remove the carburettor (see “carburettor
removal”).
Remove the fuel tank (see “fuel tank
removal”).
Remove the radiator (see “radiator removal”).
Remove the rear brake master cylinder (see
“rear brake control removal”).
Unplug the electric cables near the front light
and near the switches, then unscrew the bolt
linking the electric cables to the frame and
remove it.
Remove the footrests (see “side stand and
footrest removal”).
Unscrew the 3 right lower frame fixing bolts
and remove the lower frame.
Unscrew the 2 left lower frame fixing bolts and
remove the lower frame.
Remove the engine guard pad.
Unscrew the 2 engine fixing bolts and remove
it.
Remove the main frame from the motor.
Chassis
17.2 Engine installation :
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Install the main frame on the engine.
Place the 2 frame fixing bolts and place the
nuts.
Install the clutch control (see “clutch control
installation”).
Install the engine guard pad.
Install the left lower frame and place the 2
fixing bolts (with hard locking agent).
Install the right lower frame and place the 3
fixing bolts (with hard locking agent).
Install the swing arm (see “swing arm
installation”) (without installing the rear
wheel).
Screw the lower frames bolts.
Screw the engine fixing bolts on the frame
near the cylinder.
Screw the engine fixing bolts on the frame in
the front.
Install the footrests (see “side stand and
footrests installation).
Plug the electric cables near the front light and
near the switches, then screw the bolt linking
the electric cables to the frame.
Install the rear brake master cylinder (see
“rear brake control” installation”).
Install the radiator (see “radiator installation”).
Install the fuel tank (see “fuel tank
installation”).
Install the carburettor (see “carburettor
installation”).
Install the swing arm (see “swing arm
installation”).
Install the handle crowns (see “handle crowns
installation”).
Install the engine guard and place the rear and
front fixing bolts (use hard locking agent for
the rear bolts).
Screw the engine guard front fixing nuts then
screw the rear fixing bolts.
25
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