SYM DD 50 scooter Service manual

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MECHANISM ILLUSTRATIONS

DD 50

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG DD 50 series scooter. 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 scooter, DD 50 series, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

Service Department

Sanyang Industry Co., LTD.

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Contents

How to Use This Manual

This service manual describes basic information of different system parts and system inspection & service for Sanyang DD 50 scooters. 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.

Th third to the tenth nine chapters covers engine and driving systems.

The tenth to the fourteenth is contained the parts set of assembly body.

The fifteenth chapter is electrical equipment.

The sixteenth chapter is wiring diagram

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

All information, illustration, directions and specifications included in this manual are current as at the time of publication. Sanyang reserves the rights to make changes at any time without prior notice and without incurring any obligation whatever. Without written consent by SANYANG can not copy any part of this manual.

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CONTENTS

Page Content Index

1-1 ~ 1-16 GENERAL INFORMATION

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION

1

2

3 3-1 ~ 3-6 LUBRICATION SYSTEM

4-1 ~ 4-6 ENGINE REMOVAL

5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON

6-1 ~ 6-4 ALTERNATOR

7-1 ~ 7-14

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

8-1 ~ 8-6 FINAL DRIVING MECHANISM

9-1 ~ 9-6 CRANKCASE/CRANKSHAFT

4

5

6

7

8

9

10-1 ~ 10-10 FUEL SYSTEM

11-1 ~ 11-12 BRAKE SYSTEM

12-1 ~ 12-14 BODY COVER

13-1 ~ 13-10 STEERING/FRONT WHEEL/SUSPENSION

14-1 ~ 14-4 REAR WHEEL/SUSPENSION

15-1 ~ 15-18 ELECTRICAL EQUIPMENT

16-1 ~ 16-2 ELECTRICAL DIAGRAM

10

11

12

13

14

15

16

MODEL ILLUSTRATION

FT05V

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Contents

Light / Starter switch

Front turn signal

Head light

Fuel tank cap

Helmet hook

High & Low beam /

Turn signal / Horn switch

Battery / Fuses / C.D.I. /

Eng. Oil tank cap

Tail light /

Rear turn signal

Storage box

Air cleaner

Frame number

Front brake lever

Rear brake lever

Engine number

Ignition switch

Muffler

FT05T

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Contents

MODEL ILLUSTRATION

FT05U

FT05W

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Contents

INFORMATION

Symbols and Marks ·························· 1-1

General Safety ·································· 1-2

Service Precautions ························· 1-3

Specifications ··································· 1-5

Torque values···································1-6

Cables and Harness Routing ··········1-8

Troubleshooting ·······························1-11

Lubrication Points····························1-15

Symbols and Marks

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

Engine oil

Means that equipment damages may result if procedures are not followed.

Limits to use SAE 20 JASO FC class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil.

(Recommended oil: MAX-2 serial oils)

1

King Mate G-3 is recommended.

Grease

Gear oil

Locking sealant

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR

OIL # 140)

Apply sealant, medium strength sealant should be used unless otherwise specified.

Oil seal

Apply with lubricant.

Renew

Brake fluid

Replace with a new part before installation.

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools

Special tools.

O

Correct

Meaning correct installation.

X

Wrong

Meaning wrong installation.

Indication

Indication of components.

Indicates position and operation directions.

Directions

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility).

1-1

This chapter Contents

1. GENERAL INFORMATION

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 verified.

We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.

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 and then go to hospital to see an ophthalmologist. y 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.

Keep electrolyte beyond reach of children.

Brake shoe

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

Caution

Inhaling 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 the brake fluid beyond reach of children.

1-2


INFORMATION

Service Precautions

z

Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. z

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. z

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. z

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. z

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. z

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. z

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. z

Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later. z

Never bend or twist a control cable to prevent stiff control and premature worn out. z

Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position). z

Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

Caution

In addition to damaging paint finish, brake oil can also damage the structural integration of plastic or rubber parts.

1-3



z

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. z

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. z

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

Tighten assemblies with different dimension fasteners as follows: 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. z

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.

Boots

z

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.

Manufacturer's name

z

Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage.

Both of these examples can result in bearing damage.

z

Lubricate the rotation face as assembling.

Check if positions and operation for installed parts is in correct and properly.

1-4


INFORMATION

Specifications

Overall Length

Overall Width

Overall Height

Wheel Base

1660 mm

630 mm

1020 mm

1155 mm

Suspension

System kg

Tire

Specifications

Brake

Front

Rear

Front

Rear

Front

Rear

TELESCOPIC

UNlT SWING

3.00 - 10 42J(T/L)

3.00 - 10 42J(T/L)

DlSK (ψ160mm)

DRUM (ψ110mm)

DRUM (ψ95mm)

Passengers/

Weight

Front

Rear

Two /110 kg

54 kg

136 kg

Type

Installation and arrangement

Fuel Used

Cycle/Cooling

Bore

Gasoline

Vertical, below center, incline

Unleaded(92/95)

2-stroke/forced air cooled

39 mm

Max. Speed

Climb Ability

Primary Reduction

Secondary

Reduction

Clutch

48 km/hr Below

20° Below

BELT

Transmission C.V.T.

Speedometer

Horn

GEAR

Centrifugal, dry type

0 ~ 90 km/hr

80 ~ 112 dB/A

Muffler Expansion & Pulse Type

Right side, and Backward and Direction

Cylinder Number/Arran gement

Displacement

Compression

Ratio

Single Cylinder

49.4 cc

7.1 : 1

Lubrication System

Solid Particulate

CO

Separated-lubrication

15 %

3.5 %

↓

↓

Max. HP

Max. Torque

2.7 kw / 6250 rpm

4.41 Nm / 5000 rpm

HC

E.E.C.

Ignition C.D.I. P.C.V.

Starting System Electrical & kick

Catalytic reaction control system

Below 4000 ppm

Below 2g / test

X

○

1-5



Torque values

Standard Torque Values for Reference

Type Torque value Type Torque value

5 mm Bolt, nut

6 mm Bolt, nut

8 mm Bolt, nut

10 mm Bolt, nut

0.45 - 0.6 kg-m

0.8 - 1.2 kg-m

1.8 - 2.5 kg-m

3.0 - 4.0 kg-m

5 mm Bolt

6 mm Bolt, SH nut

6 mm Flange bolt, nut

8 mm Flange bolt, nut

0.35 - 0.5 kg-m

0.7 - 1.1 kg-m

1.0 - 1.4 kg-m

2.4 - 3.0 kg-m

12 mm Bolt, nut 5.0 - 6.0 kg-m 10 mm Flange bolt, nut 3.5 - 4.5 kg-m

The torque values listed in below table are for more important tighten torque values. Please see above standard values for not listed in the table.

Engine

Thread Dia.

Item Q’ty

(mm)

Cylinder head bolt

Spark plug

Flywheel nut

Sliding driving disc nut

Sliding driving disc nut

Clutch outer cover nut

4

Torque Value

1 10

1 10 3.8

1 28

(Kgf-m)

3.8

5.5

1 10 3.8

Remarks

When engine cooled

1 14 1.4

Drain bolts

Crankcase bolts

1 8 1.3

6 6 1.0

1-6


INFORMATION

Frame

Thread Dia.

Item Q’ty

(mm)

Bolt for engine suspension

1

Torque Value

(Kgf-m)

Remarks

10 5.0

Bolt for engine suspension bracket

1 12 6.0

Upper bolt for rear shock absorber

1 10 4.0

Lower bolt for rear shock absorber

1 8 2.7

Mounting screws for exhaust pipe connection

Nut for exhaust

2

6 1.2

2

8 3.3

Brake hose bolts

2 10 3.5

Brake caliper mounting bolts

2

8 3.1

Brake cushion guide bolts

2

6 1.8

Brake cushion guide bolts cap

2

6 1.0

Brake drain valve

1 6 0.6

Rear brake arm bolts

1 5 0.55

Tightening nut for steering rod

1 25.4 7.0

Front shaft nut

1 12 6.0

Mounting bolt for handle

1 10 5.0

Mounting nut for front hub

4 8 2.5

Mounting bolt for front brake disc

3 8 4.5

Rear shaft nut

1

14 11.0

Nut for rear hub

4

8 2.5

1-7



Cables and Harness Routing

•

•

Note the following when routing cables and wire harnesses:

•

A loose wire, cable or harness may cause

•

•

•

•

•

•

•

•

•

•

• safety hazard. After clamping, check each wire to make sure it is secured.

Do not squeeze wires against the weld or its clamp.

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.

Route harnesses so that they neither pull too tight nor have excessive slack.

Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner.

Route wire harnesses to avoid sharp edges or corners.

Avoid the projected ends of bolts and screws.

Keep wire harnesses far away from the exhaust pipes and other hot parts.

Be sure grommets are seated in their groves properly.

After clamping, check each harness to be certain that it is not interfered with any moving or sliding parts.

After routing, check that the wire harnesses are not twisted or kink.

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.

Thoroughly clean the surface where tape is to be applied.

Wrap electrical tape around the damaged parts or replace them.

O：Correct

X：Wrong

1-8


Speedometer

Headlight switch

Winker relay

Winker switch

High/low beam switch

Starter switch

INFORMATION

Front brake lamp switch

Throttle cable

Rear brake lamp switch

Horn switch

Headlight

Speedometer cable

Front brake cable

Rear brake cable

Winker light

Throttle cable

Main switch

Regulator

Resistor


Horn

Front brake cable

1-9



Battery/fuse/starting relay/CDI set

Throttle cable

Fuel unit

Spark plug cap

Carburetor

Fuel filter

Rear brake cable

Fuel pump

Throttle cable

Engine oil operation cable

Engine oil filling pipe

Fuel pump

Fuel unit

Oil pump

Engine oil return pipe

1-10


INFORMATION

Troubleshooting

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

No fuel is supplied to carburetor

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

Remove the spark plug again and check it.

Dry spark plug

Remove carburetor after 30 minutes and connect a hose onto fuel supplement circuit.

Then blow the hose with air

Blowing in normal

Week sparks or no spark at all

Low compression pressure or no pressure

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

Wet spark plug

Blowing clogged

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

6. Crankcase leakage for pre-compression

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

1. Malfunction of auto-starter

1-11



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)

Ignition timing correct

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if carburetor is clogged

Remove spark plug

Normal

No foul or discoloration

Check if engine over heat

Normal

Continually drive in acceleration or high speed

No knock

Engine speed can not be increased.

Incorrect ignition timing

No compression pressure

Clogged

Fouled and discoloration

Engine overheat

Knock

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

1. Malfunction of CDI


1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

5. Crankcase leakage for pre-compression

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

1. Too much carbon deposited in combustion chamber

3. Poor fuel quality

1-12


INFORMATION

C.

Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition


(using ignition lamp)

Normal

Adjust the air screw of carburetor

Good

Air sucked through carburetor gasket

No air sucked

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

Good spark

Abnormal

Poor

Air sucked

Poor

D.

Engine runs sluggish (High speed)

CHECK AND ADJUSTMENT FAULT CONDITION


Normal

Check for fuel supplying system in automatic fuel cup

Good

Check if carburetor clogged

Abnormal

Poor

Probable causes

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

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

1. Spark plug fouled



4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

PROBABLE CAUSES



1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Normal

Clogged

1. Cleaning

1-13



E

. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITION

Engine can be started but motorcycle can not be driving

Engine running and misfire as motorcycle initial forward moving or jumping sudden (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 damage

7. Transmission gear worn out or burned

1. Clutch ling spring broken

2. Clutch outer cover stuck 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.

1-14


Lubrication Points

Throttle cable/

Front & rear brake lever pivot

Steering shaft bearing

Engine suspension bushing

INFORMATION

Seat lock

Speedometer gear/ front wheel bearing

Side stand shaft

Main stand shaft

Rear wheel bearing

1-15



Note:

1-16

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Contents

2. SERVICE MAINTENANCE INFORMATION

General Information··························2-1

Periodical Maintenance Schedule ···2-2

Air Cleaner ········································2-3

Fuel Lines··········································2-3

Fuel Filter ··········································2-4

Engine Oil Line ·································2-4

Oil Pump Control Cable ···················2-5

Tire ·····················································2-6

Battery ···············································2-6

Rear Brake Free Play: (Drum Brake Type)

····························································2-7

Brake System Hose: (Front Disc Brake

Type) ··················································2-8

Steering System································2-10

General Information

Specification

Suspension····································· 2-10

Transmission Oil ···························· 2-11

Spark Plug ······································ 2-11

Control Cable Lubrication ············· 2-12

Driver Belt ······································· 2-12

Ignition Timing ······························· 2-12

Throttle Valve Operation················ 2-12

Carburetor Idle Speed Adjustment 2-13

Carbon Removing For Exhaust Pipe &

Muffle ·············································· 2-13

Cylinder Compression Pressure Test

2-13

Headlight Adjustment ···················· 2-14

2

Tire dimension

Tire pressure at cold Only rider

Front: 3.00-10 42J

Rear: 3.00-10 42J

Front: 1.5kg/cm

2

Rear: 2.25 kg/cm

2

Front brake lever free play

Rear brake lever free play

10~20 mm

10~20 mm

Transmission oil

Spark plug

Recommendation

Recommendation

Type: HYPOID GEAR OIL

Oil: SAE #140

Quantity: 0.1 L

Type: NGK BR8HSA

Plug gap: 0.6-0.7mm

Driving belt width

Ignition timing F mark

Acceleration operation

Idle speed

Cylinder compression pressure

Standard 18.0mm

Allowable limit: replace it if below 16.5mm

17°, BTDC/1500 rpm

2~6 mm

2000±100 rpm

7±1 kgf/cm²

2-1



Periodical Maintenance Schedule

Check item

Maintenance kilometer

Maintenance interval

300KM

New

Every

1000KM

Every

3000KM

Every

6000KM

1 month 3 month 6 month

Every

12000KM

1 year

Reference

I C R

C

C C

☆ 3. Engine oil filter cleaning

☆

4. Oil pump linkage operation check

I I

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

☆ 16. Carburetor

17. Driving belt check

☆ 18. Ignition timing

☆ 19. Emission check in Idling

☆ 20. Idle speed check

I I

I I

I I

I I

I I

I I

I I

I R

R Replacement for every 5000km

L

I I

I I

I

I I

I I

I I

I I

I I

I I

I

☆ 22. Throttle operation

☆ 23. Engine bolt tightening

☆ 24. Engine screw torque

☆

25. Carbon cleaning for cylinder head, cylinder, piston head, and exhaust system.

I

Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement

C ~ Cleaning (replaced if necessary) L ~ Lubrication

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

Remarks:

1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is operated on dusty roads or in the Heavily- polluted environment.

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

2-2



Air Cleaner

• Remove the mounting screw from the air cleaner cover

• Remove the air cleaner cover

Remove the air cleaner element

Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

Mounting screw X 7

Air cleaner element

Caution

Never use gasoline or acid organized solvent to clean the element.

Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.

• Limit to use SAE 20 JASO FC class engine oil, otherwise, SYM is no responsible for the warranty.

• Recommended engine oil: MAX-2 serial oils.

Fuel Lines

Remove the body cover

Check fuel lines and replace damaged lines if found.

Install the body cover.

Clean

Squeeze oil out

Fuel pump

Soap

Squeeze out remaining oil

Carburetor

Fuel line

2-3



Fuel Filter

Remove the luggage box.

Remove the fuel line from the fuel filter.

Replace the fuel filter with new one.

Install the fuel filter. The arrow indicates the fuel flowing direction.

Check the fuel line for leaking.

Engine Oil Line

Remove the body cover.

Check the engine oil line and replace damaged parts.

Remove the filling pipe from the oil pump, and drain oil into a cleaning container.

Loosen the clamp under the engine oil tank, and then remove the oil pipe.

Bleed the air inside the oil pump and oil pipe if air found.

Install the body cover.

Fuel filter

Oil pump

Oil filling pipe

Engine oil pipe

2-4

Oil Pump Control Cable



Caution

To adjust the oil pump control cable after adjusted the throttle grip play.


Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.

Loosen the adjustment nut of the oil pump control cable.

Turn the adjustment nut and align with the point, then tighten the nut.

Mounting nut

Adjustment nut

2-5



Tire

Caution

Tire pressure should be checked when cold.

Check tire for cracks, damage, nail, or other object stuck in tread.

Recommended tire and tire pressure

Tire size

Front:

3.00-10 42J

Rear:

3.00-10 42J

Tire pressure

(cold) kg/cm

2

1.75 2.0

Check if the tire tread and wall rubber for crack or damage, and replace if necessary.

Check if foreign materials such as nail, metal pieces, and stones stuck on tire.

The thread depth can be checked by visual inspection or by a depth gauge.

• If the tread bend too much, replace the tire.

• If tire wear exceeds limitation, replace the tire, and check it for un-even wear.

Caution

Wear indicator “△” is distributed on average along the wall rubber for check.

Battery

Open the seat.

Loosen two screws of battery cap and then remove the cap. Check if the battery terminals are loosen. Remove the battery if its terminals are corroded obviously.

Battery Removal

1. Remove the Negative (-) battery cable at first.

2. Then, remove the Positive (+) battery cable.

3. Remove the battery.

Clean the rust with steel brush.

Install the battery in reverse order of removal, and apply with grease onto two terminals.

Caution

The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes, skin, or clothes. If touched by accident, flush them with clean water immediately. However, if the electrolyte sprays to eyes, medical care should be done quickly.

Wear indicator

2-6

△ Mark



Rear Brake Free Play: (Drum Brake

Type)

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

Free play: 10-20 mm (3/8-3/4 in)

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

Brake Confirmation

10∼20mm

(3/8∼3/4 in)

Adjustment nut

Caution

After brake adjustment, it has to check the brake operation to make sure the front and rear wheel can be braked.

Increasing free play

Decreasing free play

2-7



Brake System Hose: (Front Disc

Brake Type)

Make sure that the brake hose is corrosion or damage, and also check the 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 DOT-3 to UPPER limit. Also check brake system for leaking if low brake level found.

Caution

Lower limit

z

In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop. z

Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. z

Do not mix non-compatible brake fluid together.

Brake Lining Wear: (Rear Drum Brake

Type)

Replace the brake lining if the wear limit mark

“△” on the brake arm aligning with the indicator of brake drum.

Brake Lining Wear: (Front Disc Brake

Type)

The arrow 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

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

Arrow

Brake caliper

Brake fluid reservoir cap

Wear limit mark

Brake lining

Brake disc

2-8


z z z

Remove the pin bolt cap.

Loosen the bolt.

Remove the front wheel shaft bolt.

Take out the front wheel. z

Remove brake caliper mounting bolt and then remove the brake caliper.


Pin bolt cap

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 is clipped.

Remove brake lining bolt.

Take out the lining.

Tighten Torque:

Mounting bolt: 2.9-3.5 kgf-m

Pin bolt: 1.5-2.0 kgf-m

Pin bolt cap: 0.8-1.2 kgf-m

The brake light switch is to light up brake light as brake applied. Replace the switch if the light does not light up in properly.

Caution

The brake light switch is un-adjustable.

Mounting bolt

Brake lining

Pin bolt

Pin bolt

2-9



Steering System

Caution

The control cables can not interfere with the rotation of steering handle.

Lift the front wheel out of ground, and check if the steering handle turning is smoothly.

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

Suspension

Warning

Do not ride the scooter with poor suspension.

Looseness, wear or damage suspension system will make poor stability and drive-ability.

Front Shock Absorber

Press down the front shock absorber for several times to check it operation.

Check if the shock absorber assembly is damage.

Replace it if damage found and can not be repaired.

Tighten all nuts and bolts.

Rear Shock Absorber

Park the scooter with its main stand.

Shake the rear wheel side to side to check engine suspension bushing for wear.

Replace the bushing if looseness found. Check the shock absorber for damage.

Tighten all nuts and bolts.

Nuts, Bolts Tightness

Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule.

Check all split pins, snap rings, hose clamps, and wire holders for security.

2-10


Transmission Oil

Leak

Check if the transmission is leak.

Check

Caution

Park the scooter on flat ground with its main stand.


Draining bolt

Oil level check bolt

Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.

Replacement

Remove the oil level check bolt.

Remove the oil draining bolt, and then drain oil out.

Install the oil draining bolt.

Tighten torque: 1.3 kgf-m

Caution

Check if oil seal and washer is in good condition.

Replacement Quantity: 0.09 L (90 cc)

Recommended oil: King Bramax HYPOID

GEAR OIL #140

Spark Plug

Recommended plug: NGK BR8HSA

z

Remove the luggage box. z z z z z z z z z

Remove the spark plug cap.

Clean any dirt on the spark plug seat.

Remove the spark plug.

Visually inspect the spark plug electrodes for wear.

The center electrode should have square edges and side electrode should have a constant thickness. Replace the spark plug if there is apparent wear or if the insulator is cracked and/or chipped. If the spark plug deposits can be removed by sandpaper, the spark plug can be reused.

Measure the spark plug gap with feeler gauge.

Spark plug gap: 0.6-0.7mm (0.024-0.028in)

Adjust the gap by careful bending the side electrode.

Install the spark plug by screwing it with hands after installed the spark plug washer so that can prevent the plug from out of thread. Then, tighten the spark plug with a spark plug wrench.

Install the spark plug cap.

0.6~0.7mm

Center electrode

Side electrode

Oil level check bolt hole

2-11



Control Cable Lubrication

Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the cables thoroughly.

Driver Belt

z z z

Remove left crankcase cover.

Check if the belt is crack or worn out.

Replace the belt if necessary.

Measure the driving belt width

Allowable limit: 16.5mm

Ignition Timing

z

Caution

C.D.I ignition timing can not be adjusted. If the ignition timing is incorrect, check the

C.D.I. device and the alternator and replace damaged components. z

Check ignition timing with standard instrument.

Remove the right-side cooling fan cover.

Check ignition timing with the timing light.

When engine speed setting to 1800 rpm, and if the mark aligns with “F” mark, then it means that the ignition timing is correct.

Throttle Valve Operation

Check if each steering positions are operated in smooth, and handle bar if its operation is smooth as the throttle valve wide opening or fully closed.

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

Lubricate the cable if operation is not smooth

Measure throttle valve handle free play.

Free play：2~6 mm (1/8-1/4 in)

Loosen the mounting nut, and turn the free play adjustment nut of the throttle valve handle for adjustment.

Replace the cable if it can not be adjusted.

Tooth face

Ignition lamp

Belt width

“F” mark

2-12



Carburetor Idle Speed Adjustment

Pilot screw

Caution

z

Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. z

Idle speed check and adjustment have to be done after engine is being warn up. It around operates engine from stop to running for 10 minutes.


Park the scooter with main stand after warned up engine. According to the required idling and air screw to adjust to specified idle speed.

Idle speed: 2000±100 rpm

Carbon Removing For Exhaust Pipe

& Muffle


Remove the exhaust pipe & muffler.

Clean the carbon deposits on the muffler & cylinder exhaust edge.

Cylinder Compression Pressure

Test

Remove the left body cover, and warn up engine.

Stop the engine and remove the spark plug.

Insert the compression gauge and wide open the throttle, and then rotate the engine by means of the starting motor.

Compression pressure: 7.0±1 kg/cm

2

Probable causes for low compression pressure. z

Damaged cylinder head gasket. z z

Worn piston ring

Worn cylinder

Probable causes for high compression pressure. z

Carbon on the combustion chamber or cylinder head

Idle speed adjustment screw

Adjust the idling after warn up engine for 10 minutes.

1. Connect tachometer.

2. Adjust the idle speed screw to let engine speed in 2000±100 rpm.

3. Insert the sampling pipe of the CO/HC meter to the test hole on the front end of exhaust pipe. Adjust the idling emission value to standard range. (CO: 1.8-2.6%)

4. Slightly accelerate the throttle valve and release it. Repeat this operation for 1-2 times.

5. Read the engine idle speed and the emission value after engine speed in stable. Repeat the operation on step No. 2 – No. 4. until these value within standard range.

Compression pressure gauge

2-13



Headlight Adjustment

Loosen headlight mounting bolt.

Move the headlight for adjustment its light beam.

Tighten the headlight mounting bolt after adjusted.

Caution

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

Headlight mounting bolt

2-14

Home page

Lubrication System Diagram ············3-1

Precautions In Operation ··················3-2

Lubricant ············································3-2

Trouble Shooting ·······························3-2

Lubrication System Diagram

Contents

3. LUBRICATION SYSTEM

Oil Pump Removal ···························· 3-3

Oil Pump Installation ························ 3-3

Oil Pump/Oil Tube Air Bleeding ······· 3-4

Oil Tank ·············································· 3-5

3

Oil tank

Oil lever switch

Oil output tube

Oil tube

Oil pump

3-1



Precautions In Operation

z z z z

Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump.

If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation.

It should bleed the oil output tube (from oil pump to carburetor) as hose removed.

The adjustment of oil pump control cable. z z z

Lubricant

Appointed to apply SAE 20 JASO FC class oil. Otherwise, warranty shall not cover the damage.

Recommended Oil: MAX-2 oil.

Oil tank capacity: 1.2 lit.

Trouble Shooting

Too much smoke, carbon in spark plug.

1. Improperly oil pump adjustment (too much oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Over heat

1. Improperly oil pump adjustment (insufficient oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Piston seized

1. No oil in oil tank or clogged hose.

2. Improperly oil pump adjustment (insufficient oil).

3. Air in oil hose.

4. Malfunction of oil pump.

Oil did not flow out the oil tank

1. Clogged breath hole on the oil tank cover.

3-2


Oil Pump Removal

Caution

Before removing the oil pump, clean the oil pump and crankcase.

Remove the luggage box and seat.

Loosen the mounting nut of the oil pump control cable, and remove the control cable.

Remove the oil tube, and clip its end side to prevent oil from flowing out.

Remove the oil output tube form intake manifold.

Remove the oil pump mounting bolt, and then take out the oil pump.

Inspection

Inspect the following items on the removed oil pump. z z

Check if O-ring is damaged or softening.

Check if crankcase interface is damaged. z z z

Check if pump body is damaged.

Check if pump gear is damaged.

Check for oil leaking.

Caution

The oil pump can not be disassembled.

Oil Pump Installation

Install the oil pump onto the crankcase.

Caution

z z

Apply with some grease onto oil pump

O-ring.

The connection between both oil pump and crankcase has to be installed in position security.

Tighten the oil pump mounting bolt security.

Install the oil tube.

Installation in the reverse order of removal.

Caution

Inspection and adjustment following items as installed.

The adjustment operation of control cable.

Air bleeding operation of oil pump.

Air bleeding operation of oil tube.

Check each section for leaking.

Oil output tube


Oil tube

Control cable Mounting nut

Adjustment nut

Mounting bolt

3-3



Oil Pump/Oil Tube Air Bleeding

Caution

The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage.

Caution

After disconnect the oil tube, air enters oil tube due to oil leak out without added oil. There is why the oil tube and oil pump have to conduct air bleeding operation.

Oil Tube/Oil Pump

z z z z z z

It has to add some oil into the oil tank.

Place a piece of dry cloth around the oil pump.

Disconnect the oil tube.

Fill out oil to oil pump connection section by means of the oil pot so that the oil pump body is full with oil.

Fill out oil to oil tube connection section so that the oil tube is full with oil. Then, install the tube onto oil pump.

Make sure whether air is in the oil tube or not after installation.

Caution

After bleeding the oil tube and oil pump, the oil tube has to be conducted air bleeding operation too.

Oil Tube Air Bleeding

Remove the oil output tube and plug its input connector. Bend the oil tube into “U “shape, and fill out new oil into the output tube.

Connect the oil output tube to the oil pump connection part.

Start engine, and run it in idling as the oil control lever in wide open position. Make sure oil flows out from the oil output tube.

Caution

z z

Motorcycle’s exhaust gas includes with CO which causes human to coma or death so perform this operation in well-ventilation place.

Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube.

Oil output tube

Oil output tube

Oil tube

Oil tube

Control cable

Recommended oil

3-4


Oil Tank

Removal/Installation

Remove the battery and oil tank cap.

Remove the luggage box and seat.

Remove the oil input tube from oil pump, and then drain oil to a clean container.

Remove the oil level switch wire of the oil indicator.

Remove the mounting bolt on the oil tank upper side, and then remove the oil tank.

Installation in the reverse order of removal.

Air bleeding the oil tubes after installed.

Oil tank cap

Battery


Oil tube

Blot

Oil level switch

3-5


Notes:


3-6

Home page

Maintenance Information ····················4-2

Engine removal····································4-3

Contents

4. ENGINE REMOVAL

Engine installation ······························ 4-5

4

4.0kgf-m

3.3kgf-m

1.2kgf-m

6.0kgf-m

4-1



Maintenance Information

There are parts that require removal of engine for maintenance. y Crankcase y Crankshaft

Related bolts tightening torque for removal of engine:

Engine hanger bolt 5.0kgf-m

Engine bracket bolt

Rear shock absorber upper mounting bolts

6.0kgf-m

4.0kgf-m

Rear shock absorber lower mounting bolts

Exhaust pipe connection nut

Muffle mounting bolt

2.7kgf-m

1.2kgf-m

3.3kgf-m

4-2


Engine removal

Remove body cover.

Remove the spark plug cap from the spark plug section.

Remove the fuel output and the vacuum tubes from fuel pump.

Remove the oil control cable from oil pump.

Remove the oil tube from oil pump and then clip the tube.

Remove the wire connectors of auto by starter and AC.G.

Remove the upper parts and cable of the carburetor from its upper side.

Remove the vapor emission vacuum tube from carburetor intake manifold.

Oil control cable

Fuel pump

Wire connector

Upper parts


Spark plug cap

Oil tube

Fuel output tube

Vacuum tube

4-3



Remove rear brake cable from engine rear-lower side.

Remove air cleaner mounting bolts. (2 bolts)

Support the engine and then remove shock absorber lower mounting bolt.

Remove two exhaust pipe connection nuts.

Remove two bolts beside fan cover and exhaust pipe.

Mounting bolt

Brake cable

Shock absorber lower mo nting bolt

Connection nut

Exhaust pipe

Bolt

4-4

Remove engine mounting nut and bolt.



Engine mounting bolt

Engine installation

Install in the reverse order of removal procedures.

Tighten the engine mounting and rear shock absorber upper/lower bolts.

Torque value:

5.0kgf-m Engine hanger bolt:

Rear shock absorber upper mounting bolts:

Rear shock absorber lower mounting bolts:

Exhaust pipe connection nut:

Muffle mounting bolt:

4.0kgf-m

2.7kgf-m

1.2kgf-m

3.3kgf-m

Perform the following inspection and adjustment after installation. y Check if control cable is correct. y Check if throttle valve cable is correct. y Check if oil pump control cable is correct. y Oil input and output of the oil pump.

4-5


Note:


4-6

Home page

Contents

5. CYLINDER HEAD/CYLINDER/PISTON

Maintenance Information ···················5-2

Troubleshooting ·································5-2

Cylinder Head ·····································5-3

Cylinder/Piston···································5-5

5

5-1




Precautions in Operation

y The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. y It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. y Remove all washes from the interfaces of cylinder head, cylinder and crankcase. y Be careful do not damage cylinder head, cylinder and piston when removing. y Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces before installation.

Specification

Item

Cylinder head Deformation

Piston OD

Piston

Clearance between cylinder and piston

Piston pin hole

Piston pin OD

Clearance between piston and piston pin

Piston ring end gap

ID of connecting rod small end

FT05 series

Standard value (mm) Limit (mm)

- 0.100

39.030~39.045 38.935

0.040~0.050

12.002~12.008

11.994~12.000

0.002~0.014

0.100~0.250

17.05~17.015

0.100

12.030

11.970

0.030

0.400

17.025

Cylinder

ID: inner diameter

OD: outer diameter

Tighten torque value

Cylinder head

Spark plug

1.0kgf-m

1.4kgf-m

Exhaust pipe connection nut

Exhaust muffler mounting bolt

1.2kgf-m

3.3kgf-m

Troubleshooting

Compression Pressure Too Low/Difficult

To Start/Rough Idling

1. Cylinder head gasket leaking

2. Spark plug not tighten enough

3. Worn, seized or crack piston ring

4. Damaged, worn cylinder or piston

5. Poor reed

Compression Pressure Too

High/Overheat/Knock

1. Too much carbon deposit built up in combustion chamber

Piston Noise

1. cylinder and piston worn out

2. piston pin or piston pin hole worn out

3. connecting rod small end bearing worn out

Piston Ring Noise

1. Worn, seized or crack piston ring

2. Cylinder worn out or damaged

5-2



Tightening bolt

Cylinder Head

Cylinder Removal

Removal body covers.

Remove spark plug cap.

Remove fan cover.

Remove engine shield.

Remove two connection nuts of the exhaust pipe.

Remove exhaust muffle mounting bolt, and then remove the exhaust pipe.

Cylinder Head Removal

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

Muffle

Bolt x 2

Tightening bolts

Engine shield

Tightening bolt x 2

Caution

Loosen the cylinder head bolts with diagonal direction to avoid to damaging it.

Cleaning Carbon in Combustion Chamber

Clean carbon deposit in which built up in combustion chamber with shown chisel.

Caution

Do not scratch to the interfaces of combustion chamber and cylinder.

Chisel

5-3



Cylinder Head Inspection

Use a straight edge and a feeler gauge to measure the cylinder head for warp.

Service limit: 0.10 mm

Tightening bolts

Cylinder Head Installation

Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder.

Tighten the 4 bolts with diagonal direction and by

2-3 sequences.

Tighten torque: 1.0kgf-m

Install spark plug


Replace the exhaust pipe washer with new one and then install exhaust pipe.

Tighten exhaust pipe connection nut.


Tighten exhaust pipe mounting bolt.


Install the removed parts in the reverse order of removal procedures.

Inspect following item after installation.

Compression pressure test.

Check for engine noise.

Muffle

Bolt x 2

Tightening bolt x 2

5-4



Cylinder/Piston

Cylinder Removal

Be careful to pull the cylinder up and prevent piston from damage.

Caution

Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously.

Piston Removal

Place a clean rag onto crankshaft to cover the piston.

Remove piston pin clip (one piece) and then push piston pin out the piston.

Caution

y Do not damage or scratch the piston. y Do not apply with lateral force to connecting rod. y Do not let piston pin snap ring falling into crankcase.

Piston Ring Removal

Caution

Pry out the opening end of each piston ring and then remove the ring from piston.

Check if cylinder and piston are worn or damaged, and then clean carbon deposit on exhaust opening area as the diagram shown.

Caution

Do not scratch both the cylinder and the piston.

Piston pin clip

Piston pin

Piston

5-5



Use a straight edge and a feeler gauge to measure the cylinder head for warp.


In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure.

With the max. value to decide cylinder wear out condition.

Service limit : 39.05mm

Measure the OD of piston at the 7 mm from the bottom of the piston.

Service limit : 38.935 mm

Calculate the clearance between piston and cylinder.


Measure the ID of piston pin hole.

Service limit : 12.030mm

Measure the OD of piston pin.

Service limit : 11.970 mm

The ID of piston pin hole

7mm

The OD of piston pin

5-6

Piston Ring Inspection

Measure the end gap of each piston ring.




Caution

With the piston, push each piston ring into cylinder correctly.

Connecting Rod Inspection

Install bearing and piston pin onto connecting rod small end, and then check its clearance.

Measure the ID of connecting rod small end.

Service limit: 17.025mm

Piston/Cylinder Installation

Install the expanding ring into the groove of 2 nd ring.

Align the ring end with the lock pin in the ring groove.

Install the top ring and the 2 nd

ring onto the ring groove respective.

Clearance

Top ring

2 nd

ring

Piston ring mark

Caution

The top ring and the 2 nd

ring can not be changeable each other.

Push the rings into ring groove and then check rings’ mating condition.

If ring could not be push in the ring groove, it means that ring groove is dirty or wrong ring groove installation.

1T: top ring

2T: 2 nd

ring

Expanding i

Caution

y All rings should be installed with the marks facing up. y All rings should be replaced at same time, and it can not be replaced one ring only. y It should use same brand name piston ring in an engine and can not mix with other one.

5-7



Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase.

Apply with two-stroke engine oil onto needle bearing and piston pin, and then install the piston pin onto connecting rod. Install piston, and place

“EX” mark of the piston toward to exhaust side.

Install new piston pin snap ring.

Clean all gaskets onto the interfaces of cylinder and crankcase.

Place a new gasket onto the crankcase.

Make sure that the piston ring aligns with the lock pin in piston ring groove.

Piston

Piston pin snap ring

Caution

Make sure that all rings in the piston ring groove can not be rotated around the lock pin to avoid to damaging the rings, piston and cylinder.

Lubricate cylinder and piston with two-stroke engine oil. Hold the piston and then install it into cylinder.

Caution

To avoid to damaging the piston and the cylinder sliding surface.

Install the cylinder head.

Lock pin

〝EX〞mark

Piston pin

5-8

Home page

Contents

Maintenance Information ··········6-2

Alternator Removal ···················6-3

Alternator Installation ··············· 6-4

6

3.8kgf-m

6-1


6. ALTERNATOR



y The maintenance service of A.C. alternator can be carried out directly on the scooter. y Please refer to Chapter 15 for the relative alternator inspection.

Torque value:

Flywheel 3.8kgf-m

Tool

General tool

Rotor puller

Universal holder

Coil resistance value for the A.C. alternator

Earth 50~200Ω 0.2~0.8Ω 0.2~1.0Ω 400~800Ω

6-2


Alternator Removal


Remove two bolts and then take out cooling fan cover.

Remove four bolts, and then take out the cooling fan.

Hold flywheel with universal holder.

Support the flywheel and the remove the 10 mm nut on the flywheel.

Remove the flywheel with rotor puller.

Cooling fan cover

10mm flanged nut

Bolt

Cooling fan

Universal holder

Rotor puller

6-3


6. ALTERNATOR

Disconnect alternator wire connector and pulse generator connector.

Remove the pulse generator and alternator four

(4) bolts, and then take out the alternator assembly.

Caution

Care to be taken for not damaging the alternator coil.

Alternator Installation

Install the alternator assembly.

Connect the alternator connector.

Caution

Connect the alternator wire harness properly and then clip the harness with clipper.

Install the woodruff key onto the crankshaft groove.

Caution

y Clean dirt and metal pieces inside the flywheel. y Make sure that there is no foreign material inside the flywheel.

Install the flywheel

Tighten the flywheel 10 mm nut.

Torque value: 3.8kgf-m

Install the removed parts in reverse order of removal procedures.

Start engine and check its ignition timing.

10mm flanged nut

Wire harness connector


6-4

Home page

Contents

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Maintenance Information ················· 7-2

Trouble Shooting······························ 7-2

Left Crankcase Cover ······················ 7-3

Reassembly of Kick Starter ············· 7-4

Installation of the Left Crankcase Cover

··························································· 7-4

Drive Belt ···········································7-5

Movable Driven Pulley······················7-6

Clutch/Driven Pulley·························7-10

7

3.8kgf-m

5.5kgf-m

3.8kgf-m

7-1





The surfaces of drive belt and driven pulley must be free of grease.

Specification

Driving belt width

ID of movable driving pulley

OD of movable driving pulley boss

OD of weight roller

ID of clutch outer

Thickness of clutch weight

Free length of driven pulley spring

OD of driven pulley

ID of movable driven pulley

ID: Inner Diameter

OD: Outer diameter

Torque Values:

Movable drive face: 3.8kgf-m

Driven pulley: 5.5kgf-m

Clutch outer: 3.8kgf-m

18.0 16.5

20.035~20.085 20.120

20.010~20.025 19.98

15.92~16.08 15.40

107.0~107.2 107.5

4.0~4.1 2.0

98.1 92.7

33.965~33.985 33.94

34.000~34.025 34.06

Special Service Tools

Clutch spring compressor

Bearing driver

Clutch nut wrench 39x41 mm

Bearing driver accessory 39x41 mm

Universal holder

Driver

Trouble Shooting

Engine can be started but motorcycle can not be moved

1. Worn drive Belt

2. Worn ramp plate

3. Worn or damaged clutch weight

4. Broken driven pulley spring

Shudder or misfire when drive

1. Broken clutch weight

Insufficient horsepower or poor high speed performance

1. Worn drive belt

2. Insufficient spring capacity of driven pulley

3. Worn weight roller

4. Driven pulley operation un-smoothly

7-2

Left Crankcase Cover



Left crankcase cover

Left crankcase cover removal

Remove left body side cover.

Remove air cleaner.

Remove kick start arm.


Disassembly of Kick Starter

Remove snap clip and thrust washer from left crankcase cover.

Install kick start arm, rotate the lever slightly and then remove driven gear and washer.

Remove the kick starter arm, kick starter spindle, and return spring as well as socket.

Kick start arm

Return spring

Starter spindle

Driven gear

Inspection of kick Starter

Check if starter spindle, driven gear for wear or damage.

Bolt

Kick start arm

Snap ring

Thrust washer

Return spring

Bush

Starter spindle

Thrust washer

Driven gear

Friction spring

7-3



Reassembly of Kick Starter

Install bush, return spring and starter spindle as diagram shown.

Install thrust washer and snap clip onto starter spindle.

Install Kick starter lever temporary.

Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle.

Install the friction spring of drive gear onto convex part of the cover.

Installation of the Left Crankcase

Cover

Return spring

Dowel pin

Width-tooth

Kick starter spindle

Driven gear

Convex part

Friction spring

Install the dowel pin and gasket.

Install the left crankcase cover.

Install kick start arm.

7-4

Drive Belt



Nut

Removal


Hold clutch outer with universal holder, and remove nut and clutch outer.

Caution

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

Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley.

Remove driven pulley/clutch. Do not remove drive belt.

Remove the drive belt from the groove of driven pulley.

Inspection

Check the drive belt for crack or wear. Replace it if necessary.

Measure the width of drive belt as diagram shown.

Service Limit: 16.5 mm

Replace the belt if exceeds the service limit.

Caution

y Using the genuine parts for replacement y The surfaces of drive belt or pulley must be free of grease. y Clean up all grease or dirt before installation.

Installation

Caution

y Pull out driven pulley to avoid it closing.

Install drive belt onto driven pulley.

Clutch/drive belt

Belt tooth


Movable driven pulley

7-5



Install the driven pulley that has installed the belt

Drive face

onto drive shaft.

Clutch/driven pulley

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


Nut

Drive belt


Drive shaft

Clutch outer

Movable Drive Face


Removal


Hold generator flywheel with universal holder, and then remove drive face nut.

Remove drive face.

Flywheel

Nut

Drive face

7-6



Drive face boss

Removal

Remove movable drive face set and drive belt from crankshaft.

Remove ramp plate.

Remove weight rollers from movable face.

Crankshaft

Movable drive face


Ramp plate

Weight roller

Inspection

The weight roller is to press movable driven face by means of centrifuge force. Thus, if weight rollers are worn out or damage, the centrifuge force will be affected.

Check if rollers are wear out or damage.

Replace it if necessary.

Measure each roller’s outer diameter. Replace it if exceed the service limit.


Weight roller

7-7



Check if movable drive face boss is worn or damage and replace it if necessary.

Measure the outer diameter of drive face boss, and replace it if it exceed service limit.


Measure the inner diameter of drive face, and replace it if it exceed service limit.


Reassembly / Installation

Install weight rollers.

Install ramp plate.

Apply with grease 4~5g to inside of movable drive face, and install drive face boss.

Caution

y The drive face has to be free of grease.

Clean it with cleaning solvent.

Ramp plate

Drive face


Drive face boss

Weight roller

7-8



Install movable drive face assembly onto

Drive face boss Movable drive face

crankshaft.

Crankshaft

Drive Face Installation

Press drive belt into pulley groove, and then pull the belt on to crank shaft.

Install drive face, washer and nut.

Caution

y Make sure that two sides of drive face have to be free of grease. Clean it with cleaning solvent.

Hold flywheel with universal holder.

Tighten nut to specified torque.


Install left crankcase cover.

Flywheel

Press down

Drive belt


Nut

Drive face

7-9



Clutch/Driven Pulley

Disassembly

Remove drive 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

y Do not press the compressor too much.

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

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

Remove socket from sliding pulley.

Remove guide pin, guide pin roller, and driven 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 clutch outer if exceed service limit.


Sliding pulley

O-ring

Inner diameter

Oil seal

Clutch nut wrench

Clutch spring compressor

Guide pin or

Socket

Guide pin roller

Clutch outer

7-10



Clutch weight

Clutch weight

Measure each clutch weight 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: y If both surfaces are damage or wear. y If guide pin groove is damage or wear.

Replace damaged or worn components.

Measure the outer diameter of driven pulley and the inner diameter of sliding pulley. Replace it if exceeds service limit.

Service limit: Outer diameter 33.94 mm

Inner diameter 34.06 mm

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. Check if the bearing outer parts are closed and fixed. Replace it if necessary.

Caution

y Some of models are equipped with two ball bearings.

Outer ball bearing

Free length

Driven pulley

Sliding pulley

Guide pin groove

Needle bearing

7-11



Clutch Block Replacement

Remove clip and washer, and then remove clutch weight and spring from drive plate.

Spring

Caution

y Some of models are equipped with one mounting plate instead of 3 snap clips.

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 lock pins.

Install new clutch weight onto lock pin and then push to specific location.

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

Caution

y Grease or lubricant will damage the clutch weight and affect the weight’s connection capacity.

Install the spring into groove with pliers.

Clutch weight

Shock absorption rubber

Shock absorption rubber

Clutch block

Spring

Drive plate

Snap clip

7-12



Install snap clip and mounting plate onto lock pin.

Snap clip

Replacement of Driven Pulley Bearing

Remove inner bearing.

Outer bearing

Caution

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

Remove snap clip 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.

Install new inner bearing.

Snap clip

Inner ball bearing

Inner needle bearing

Sealing end

Clip

Specified grease

Snap ring

Outer bearing

Inner bearing

Sealing end

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 or driver.

Install snap clip into the groove of drive face.

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

7-13



Installation of Clutch/Driven Pulley

Oil seal

Assembly

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 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 clutch nut wrench.

Remove the clutch spring compressor.

Torque value: 5.0~6.0kgf-m

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

O-ring

Sliding pulley

O-ring

Mounting nut

7-14

Oil seal

Guide pin

Specified grease

Guide pin or

Guide pin roller

Socket

Clutch nut wrench

Clutch spring compressor

Home page


Troubleshooting ······························· 8-2

Disassembly of Final Driving Mechanism

···························································· 8-3

Contents

8. FINAL DRIVING MECHANISM

Inspection of Final Driving Mechanism

···························································· 8-4

Bearing Replacement ······················· 8-4

Re-Assembly of Final Driving

Mechanism ········································ 8-4

8

8-1




Limited usage of gear oil：gear oil #140

Recommended oil：Bramax serial oil.

Oil quantity：100 c.c. (90 c.c. as replacement)

Special tools:

Inner type bearing puller (SYM-6204020)

Outer type bearing puller (SYM-6204010)

Final shaft oil seal installer (SYM-9125500)

Drive shaft oil seal installer (SYM-9120200)

Bearing driver 6204 (SYM-9110400)


Bearing driver 6203/6004UZ (SYM-9620000)

L. crank puller (SYM-1130000-L)

L. crank shaft install bush (SYM-1130010)

Troubleshooting

Trouble Diagnosis

Engine can be started but scooter can not be moved.

1. Damaged drive gear

2. Burnt out or seized drive gear

Noise

1. Seized, worn or damage gear

2. Worn or loose bearing

Gear oil leaks

1. Excessive gear oil.

2. Worn or damage oil seal

8-2



Disassembly of Final Driving

Mechanism

Remove driven pulley

Drain gear oil out from gearbox.

Remove rear wheel.

Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side.

Remove final gear, final shaft and counter gear, counter shaft.

Oil filling hole

Oil draining hole

Final gear & shaft

Counter gear & shaft

Remove the drive shaft from left crankcase.

Drive shaft

Caution

y The bearing must be replaced when removing the drive shaft.

Remove drive shaft oil seal and bearing from left crankcase.

Oil seal

Bearing

8-3



Inspection of Final Driving

Mechanism

Check if the drive shaft, counter shaft and final gear shaft are worn or damage.

Check if the gear box cover bearing, oil seal and the inner diameter of counter shaft are worn or damage.

Check if the left crankcase cover bearing, oil seal and the inner diameter of countershaft are worn or damage.

Bearing Replacement

Countershaft

Drive shaft

Final driven gear & shaft

Caution

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

Remove gear box bearing from left crankcase and gear box cover using following tools:

Special tool:

Inner type bearing puller

Re-Assembly of Final Driving

Mechanism

Re-assemble the gearbox cover and left crankcase with special tools:

Special tool:

Gear Box Cover

Final shaft bearing:



Final shaft oil seal installer (SYM-9125500)

Left Crankcase

Drive shaft bearing:



L. crank puller (SYM-1130000-L)

L. crank shaft install bush (SYM-1130010)

Drive shaft oil seal installer (SYM-9120200)

With the special service tools to install drive shaft by through the bearing.

Install a new drive shaft oil seal.

Install a new final shaft oil seal.

Adapter

Driver

Punch guide

Drive shaft

8-4



Install countershaft, final driven gear and thrust washer.

Install new gasket and lock pin.

Final driven gear & shaft

Counter gear & shaft

Install gearbox cover.

Install clutch/driven pulley assembly.

Install driven pulley, drive belt, and left crankcase side cover.

Install body cover.

Install rear wheel.

Fill out specified oil quantity into gearbox.

8-5



Notes:

8-6

Home page

Contents

CRANKCASE/CRANKSHAFT

Maintenance Information ··················· 9-2

Troubleshooting ································· 9-2

Crankcase Disassembly ···················· 9-3

1.0kgf-m

Crankshaft Removal·····························9-3

Crankshaft Inspection··························9-4

Crankcase Installation ·························9-5

Apply liquid gasket

9

9-1


9. CRANKCASE/CRANKSHAFT


y This chapter concerns disassembly of the crankcase for repair purpose. y Before disassembling crankcase, except removing engine firstly, following components must be removed too.

• Carburetor (chapter 10)

• Oil pump (chapter 3)

• Reed valve (chapter 10)

• Driving belt (chapter 7)

• Alternator (chapter 6)

• Cylinder head/cylinder/piston (chapter 5) y Except above components are needed be removed, when disassembling L crankcase, following components must be removed too.

• Final driving mechanism (chapter 8) y When assembling both crankcase and crankshaft, it has press the inner ring edge of the crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service tools. The old bearing onto the crankshaft has to be removed. Then install a new bearing onto the crankshaft on the crankcase side. Oil seal has to be replaced with new one after assembled the crankcase.

─

─

─

─

0.60

0.04

0.10

0.10

Lateral clearance of the big end of the connecting rod

Radial clearance of the big end of the connecting rod

Crankshaft run-out point A

Crankshaft run-out point B

Special Tools

Crankcase disassemble tool (SYM-1120100-G5)

Outer bearing puller (SYM-6204010)

R. Crank shaft puller (SYM-1130000-R)

R. Crank shaft install bush (SYM-1130020)

L. Crank shaft puller (SYM-1130000-L)

L. Crank shaft install bush (SYM-1130010)

20*32*6 Oil seal driver (SYM-9120200)


Troubleshooting

Engine noise

1. Worn bearing of connecting rod bog end

2. Bend connecting rod

3. Worn crankshaft bearing

9-2



Crankcase Disassembly

Remove the crankcase bolts.

Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown.

Disassemble the right crankcase.

Crankshaft Removal

As the diagram show with 3 special bolts to install the crankcase puller onto the left crankcase.

Remove the crankcase.

Caution

Do not use iron hammer to knock out the crankshaft.

Remove crankshaft bearing with outer bearing puller.

Remove the right and left side oil seals.

Caution

Replace the oil seal with new one as removing the crankshaft.

Right crankcase

Special bolts

Shaft protection collar

Bolts

Crankcase puller

Crankcase puller

Outer bearing puller

9-3



Crankshaft Inspection

Measure the clearance of connecting rod big end.


Measure the radial clearance of connecting rod big end at X-Y directions as diagram show.


Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.

Service limit: A: 0.10 mm

B: 0.10 mm

Check the crankshaft bearing by means of turning it with hand. If any noise and bigger clearance are detected, replace the bearing with new one.

A

70mm

Clearance

37mm

B

Clearance

Lateral Radial

9-4



Crankcase Installation

Clean the crankshaft with solvent and blow it with compressed air. Then, check for damage or other foreign materials attached.

Install new bearing into right crankcase.

Bearing driver 6204

Caution

y All rotation and sliding surfaces have to be applied with clean engine oil. y Remove all gaskets onto the crankcase interfaces and flat it with special tool.

Install new bearing into left crankcase.

Install crankshaft onto the left crankcase.

Install left crankshaft puller and install bush onto crankshaft.

Screw the left crankshaft puller onto crankshaft.

Turn the puller in C.W. direction and then completely screw the puller to bottom.

Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Apply liquid gasket and dowel pin onto the interface of left crankcase.

Bearing driver 6204

Collar

L. Crank shaft install bush

L. Crank shaft puller

Apply liquid gasket

Dowel pin

9-5



Assemble the right crankcase with assembly tools.

Install right crankcase onto the crankshaft.

Install right crankshaft puller and install bush onto crankshaft.

Screw the right crankshaft puller onto crankshaft.

Turn the puller in C.W. direction and then completely screw the puller to bottom.

Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Install the bolts and tighten them.


With right crank shaft install bush, install new oil seal into the right crankcase. Its installation depth is 4mm as the diagram shown.

With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown.

Caution

Make sure that the crankshaft can be rotated freely after tightening the bolts.

Install the following components:

~ Final driving mechanism (chapter 8)

~ Alternator (chapter 6)

~ Piston/cylinder/cylinder head (chapter 7)

~ Oil pump (chapter 3)

~ Reed valve and carburetor (chapter 10)

~ Engine (chapter 4)

Oil seal

9-6

R. Crank shaft puller

R. Crank shaft install bush

Bolts

R. Crank shaft install bush

Oil seal driver

Home page

Maintenance Information··················10-2

Troubleshooting································10-2

Throttle Valve ····································10-3

Carburetor Remove···························10-4

Auto By-Starter··································10-4

Float/Float Valve/Jet ·························10-6

Contents

10. FUEL SYSTEM

Flaot Level Inspection ······················10-7

Carburetor Installation ·····················10-7

Reed Valve·········································10-7

Fuel Pump ·········································10-8

Air Cleaner·········································10-9

Throttle valve cable

Air hose

Oil tube

Vacuum hose

10

Carburetor

Fuel pump

Fuel unit

Fuel tank

Fuel filter

Vacuum tube

10-1


10. FUEL SYSTEM


Precautions in Operations

Warning

Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. y Care must be taken when dealing with gasoline, and always work in a well-ventilated place and strictly prohibit flame. y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly y It has to conduct air bleeding operation as removed the oil tube. y Idle speed adjustment.

Specification

14 mm

8.6±1.0mm

1 3/8

2000±100 rpm

2~6 mm

PB2BE

#82

20 c.c. minimum.

Venturi diameter

Fuel level

Air screw opener

Idle speed

Throttle handle free play

I.D. number

Main jet

Fuel pump output

Troubleshooting

Engine can not be started

1. No fuel in fuel tank

2. Fuel can not reach to carburetor

3. Too much fuel in cylinder

4. Clogged air cleaner

Stall after started

1. Incorrect idle speed adjustment

2. No spark on the spark plug

3. Low compression pressure

4. Rich mixture

5. Lean mixture

6. Clogged air cleaner

7. Inlet pipe leaking

8. Polluted fuel

10-2

Lean Mixture

1. Clogged carburetor jet

2. Clogged hose from carburetor to canister

3. Bend, squeezed or clogged fuel lines

4. Clogged fuel filter

5. Malfunction of float valve

6. Low fuel level in float chamber

7. Clogged vent pipe

8. Malfunction of fuel pump

Rich Mixture

1. Malfunction of float valve

2. Low fuel level in float chamber

3. Clogged carburetor air injector


Throttle Valve

Removal


Remove the carburetor upper part, throttle valve spring and sealed cap.

Remove the throttle valve cable from the throttle valve.

Remove needle clamp and fuel needle.

Carburetor upper part

10. FUEL SYSTEM

Oil hose

Inspection

Sealed cap

Throttle valve cable


Throttle valve spring

Needle clamp

Fuel needle clip

Fuel needle

Washer

Throttle valve

Installation

Place the fuel needle onto the throttle valve and clip it with needle clamp.

Install the sealed cap, carburetor upper part, and throttle valve spring.

Connect the throttle valve cable to the throttle valve.

Install the throttle valve into the carburetor body.

Caution

Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.

Tighten the carburetor upper part.

Install carburetor protector.

Adjust the free play of throttle valve cable.

10-3


10. FUEL SYSTEM

Carburetor Remove


Disconnect the auto by-starter connector.

Loosen draining screw and then drain out fuel inside the carburetor.

Loosen carburetor upper part and remove carburetor upper part.

Remove fuel and oil hoses from carburetor.

Remove carburetor mounting bolt and carburetor.

Auto By-Starter

Bolt

Fuel hose

Inspection

Connect resistor meter to the terminals of auto by-starter, and then measure its resistance.

If the resistance value exceeds specification too much, it means that the PTC in the auto by-starter is malfunction. Then, replace the auto by-starter.

Resistance value: Max. 10Ω(at cold engine)

Caution

If the resistance value exceeds the standard a little bit, the auto by-starter may still in normal.

However, it is necessary to check other relative components for damage.

Draining screw

Auto by-starter

Carburetor

Auto by-starter


Connection hose clamp

10-4


Remove carburetor, and allow it to cool off for 30 minutes.

Connect fuel rich circuit with a hose and pump compressed air to the hose.

Air should flow into fuel rich circuit.

Replace the auto by-starter if the circuit clogged.

Connect battery to starter’s connectors and wait for several minutes.

Pump compressed air into the fuel rich circuit.

Air should not flow into the circuit.

If air flow through the circuit, then, replace the starter.

Check resistor to make sure that the auto by-starter is in normal. Engine is running.

If the resistor is in open-circuit, then current will not flow into the PTC. Thus, the auto by-starter is not operated.

However, if the resistor is in short-circuit, current higher than specification will flow into the PTC.

Then, it will cause the fuel rich circuit close rapidly, and difficult to start the scooter.

Resistance value: 10.2Ω

Alternator

Automatic By-Starter Removal/Installation

Remove the cover of the auto by-starter.

Remove screw and mounting plate.

Remove the auto by-starter from carburetor.


Auto by-starter

10. FUEL SYSTEM

Battery

Resistor

Screw

Mounting plate

10-5


10. FUEL SYSTEM

Float/Float Valve/Jet

Removal

Remove the float from carburetor body.

Remove the float pin and then remove float and float valve.

Check the valve seat for worn out or damage.

Check float for bend and if fuel inside the float.

Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as installation.

Caution

Do not tighten the screw forcedly to avoid to damaging the valve seat.

Remove main jet, needle jet seat and idle jet and clean them and each component with compressed air.

Installation

Install the idle jet, the needle jet seat and main jet.

Then install the throttle valve stopper and air screws to their original position according to the marks as removal. Adjust the screws if replace with new ones.

Float cap

Air inlet for idle speed

Air inlet for fuel rich circuit

Air screw

Float

Float valve

Float pin

Throttle valve stopper screw

O-ring

Idle jet

Needle jet

Needle jet seat

Float cap

Main jet

Screw

Draining screw

10-6


Float Level Inspection

Measure float fuel level to have the upper end of float just contact with the float.

Float fuel level: 8.8 mm

Carefully bend the float arm for adjustment.

Check the float operation and the install it.

Carburetor Installation

Fuel hose

10. FUEL SYSTEM


Caution

Do not let foreign materials into the carburetor.

Install the carburetor and insulator onto intake pipe with bolts.

Install fuel and vent pipes onto carburetor.

Install the carburetor upper part.

Tighten the connection hose.

Tighten the draining screw.

Connect the automatic by-starter connector.

Install air cleaner cap.

Conduct following operations y Adjustment of throttle valve cable. y Adjustment of oil pump. y Adjustment of idle speed.

Reed Valve

Bolt

Draining screw

Connection hose clamp

Inlet pipe

Reed valve

Removal


Remove the carburetor.

Remove carburetor insulator.

Remove inlet pipe.

Remove the reed valve.

10-7


10. FUEL SYSTEM

Inspection

Check the reed valve for damage and its reed strength.

Check the reed valve seat for crack, damage and the clearance between the seat and the valve.

Replace reed valve if necessary.

Reed valve

Caution

Do not bend the reed valve stopper.

Otherwise, it will cause its strength insufficient and rough engine running. If the reed valve or its seat is damaged, replace with a set.

Installation


Check for leaking after installed.

Fuel Pump

Reed valve seat

Carburetor

Inspection


Warm up the engine and adjust idle speed.

Remove fuel hose from carburetor and then wait for 5 minutes.

Measure the output of fuel pump. Its output time is 10 seconds.

Output quantity: Min. 20 c.c.

If the output quantity is lower than 20 c.c., check fuel hose, vacuum hose and fuel filter.


Remove floor plate.

Remove fuel inlet, outlet and vacuum hoses.

Remove 2 bolts and fuel pump.

Install the fuel pump in the reverse order of removal procedures.

Fuel hose

Fuel inlet hose

Bolt

Inlet pipe

Reed stopper

Fuel hose connector

Fuel outlet hose

Vacuum hose

10-8


Air Cleaner


Remove the EEC hose from the air cleaner outer case.

Loosen connection hose clamp.

Remove 2 bolts and then remove the air cleaner outer case.


Install the air cleaner outer case.

10. FUEL SYSTEM

Mounting screw X 7

Air cleaner element

10-9

10. FUEL SYSTEM

Notes:


10-10

Home page

Contents

SYSTEM

Front Disc Brake System ················ 11-1

Front Drum Brake System··············· 11-2

Rear Drum Brake System················ 11-3

Maintenance Information ················ 11-4

Troubleshooting ······························ 11-5

Hydraulic Disc Brake ······················· 11-6

Front Disc Brake System

Disc Brake -Air Bleed ·························11-7

Disc Brake - Caliper····························11-7

Brake Disc ···········································11-8

Disc Brake - Master Cylinder ·············11-8

Drum Brake ·········································11-11

2.5kgf-m

0.55kgf-m

3.5kgf-m

11

1.8kgf-m

1.0kgf-m

4.5kgf-m

6.0kgf-m

11-1

11. BRAKE SYSTEM

Front Drum Brake System


11-2

2.5kgf-m

0.55kgf-m

6.0kgf-m

Rear Drum Brake System

11.0kgf-m

2.5kgf-m


SYSTEM

0.55kgf-m

11-3





Caution

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

y The brake caliper can be removed without removing the hydraulic system. y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system. y While refilling brake fluid, care should be taken not to let the foreign material entering into the brake system. y Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage. y Check the operation of the brake system before you go.

Specifications

Item Standard (mm) Limit (mm)

The thickness of front brake disc

Front brake disc run-out

Master cylinder inner diameter

Master cylinder piston outer diameter

ID of front brake drum

ID of rear brake drum

Thickness of front brake lining

Thickness of rear brake lining

Torque values

Brake hose bolt

Bolt for brake caliper

Bolts for the lining guide pin

Bolts for the lining guide pin cap

Air-bleed valve

Bolts for the brake disc

Nuts for the wheel rim

Nuts for the front wheel

Nuts for the rear wheel

Bolt for rear brake arm

3.5kgf-m

3.3kgf-m

1.8kgf-m

1.0kgf-m

0.55kgf-m

4.5kgf-m

2.5kgf-m

6.0kgf-m

11.0kgf-m

0.55kgf-m

3.5

< 0.10

12.700 – 12.743

12.657 – 12.684

110.0

95.0

4.0

4.0

2.0

0.3

12.55

12.654

110.5

95.5

2.0

2.0

11-4


SYSTEM

Troubleshooting

Disc Brake

Soft brake lever

1. Air inside the hydraulic system

2. Hydraulic system leaking

3. Worn master piston

5. Poor brake caliper

7. Low brake fluid

8. Blocked brake pipe

9. Warp/bent brake disc

10. Bent brake lever

Hard operation of brake lever

1. Blocked brake system

2. Poor brake caliper

3. Blocked brake pipe cylinder piston

5. Bent brake lever

Uneven brake

1. Dirty brake lining/disc

2. Poor wheel alignment

3. Clogged brake hose

4. Deformed or warped brake disc

5. Restricted brake hose and fittings

Drum Brake

Poor brake performance

1. Improper brake adjustment

5. Improper brake lining installation

6. Seized brake cable

7. Dirty brake lining

8. Dirty brake drum

9. Brake pad worn in brake cam area.

10. Poor contact between brake arm and camshaft indent

Tight operation or low return speed of brake lever

1. Worn/broken/crack return spring

2. Worn drum


4. Brake seized caused from dirty brake drum

5. Seized brake cable

6. Worn brake cam

7. Improper brake lining installation

Tight brake

1. Dirty brake lining/disc

2. Poor wheel alignment

3. Deformed or warped brake disc

Brake noise

1. Dirty lining

2. Deformed brake disc

3. Poor brake caliper installation

4. Imbalance brake disc or wheel

Brake noise

1. Worn brake lining

2. Worn drum


4. Dirty brake drum

11-5



Hydraulic Disc Brake

Close the drain valve of the hydraulic disc brake.

Replace the brake fluid.

Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, then remove the brake fluid reservoir.

Cover the painted surfaces, plastic or rubber components with a rag when servicing brake system.

Lower level

Caution

Spilled brake fluid on painted surfaces, plastic or rubber components may result in their damages.

Remove the master cylinder cap and diaphragm.

Use brake fluid to clean the dirty brake disc.

Air bubble

Caution

The dirty brake lining or disc will reduce the brake performance.

Refill up same grade brake fluid into the reservoir.

Caution

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

Connect drain hose to drain valve.

Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.

Recommended brake fluid: WELLRUN DOT 3 brake fluid

Caution

To reuse the spent brake fluid will effect brake performance.

Drain valve

Cap

Cap plate

Diaphragm

Upper level

Drain hose

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.

11-6


SYSTEM

Disc Brake -Air Bleed

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

Caution

y Do not release the brake lever before the drain valve is closed. y Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter 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.

4. Tightly close the drain valve.

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

6. Cover the cap.

Disc Brake - Caliper

Removal

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

Caution

Do not spill brake fluid on painted surfaces.

Remove the bolt cap and loosen the lining guide bolts.

Remove two caliper bolts and the caliper.

Air bubble

Caliper bolt

Collar bolt

Drain valve

Drain hose

Brake hose bolt

Installation

Install the brake caliper and tighten the attaching bolts securely.

Torque: 3.3kgf-m

Caution

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

Tighten the lining guide bolt.


Install bolt cap.


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.

11-7



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.


Disc Brake - Master Cylinder

Master Cylinder Removal

Caution

Do not let foreign materials enter into the cylinder.

Brake disc

Caution

The whole set of master cylinder, piston, spring, diaphragm and cir clip should be replaced as a set.

Remove the front and rear handlebar covers.

Remove the leads of brake light 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 cir clip.

Remove the piston and the spring.

Clean the master cylinder with recommended brake fluid.

Rubber pad

Piston

Spring

Brake hose

Clip

Micrometer

Master cylinder

Master cylinder

11-8


SYSTEM

Master Cylinder Inspection

Check the master cylinder for damage or scratch.


Measure the cylinder inner diameter at several points along both X and Y directions.

Replace the cylinder if the measured values exceed allowable limit.


Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds allowable limit.


Master Cylinder Assembly

Caution

y It is necessary to replace the whole set comprising piston, spring, piston cup, and cir clip. y 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 cir clip.

Caution

y Never install cup lip in the opposite direction.

y Make sure the cir clip is seated securely in the groove.

Install the rubber pad into groove properly.

Master cylinder

Piston

Rubber bush

Cir clip

Piston

Sub-cup

Sub-cup

Spring

Cylinder gauge

Micrometer

Master cylinder

11-9



Install the rubber pad into the groove correctly.

Place the master cylinder onto handlebar, and install the bolts.

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

Connect brake hoses with 2 new washers.

Tighten the brake hose bolt to the specified torque value.


Make sure the hose is installed correctly.

Install all wires, hoses, and components carefully so avoid to twisting them together.

Master cylinder

Washers

Brake lamp switch

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.

Brake hose

11-10


Drum Brake

To use vacuum cleaner or other alternatives to avoid danger caused from dusts.

Caution

y Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts. y Brake performance will be reduced by grease on brake lining.

Remove wheel and brake drum.

Inspection

Check brake drum for damage or wear out, and replace it if necessary.

Measure the inner diameter of brake drum and record the max. value.

Allowable limit: Front (110.5mm)

Rear (95.5mm)

Caution

y Clean the rust onto the brake drum with

#120 sand-paper. y Measure the inner diameter of brake drum with micrometer.

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

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

Service limit: Rear: 2.0 mm

Removal

Caution

Brake linings must be replaced as a shoes.

Remove the brake linings from brake panel.

Font brake drum

Rear brake drum

Brake lining

Brake shoes

SYSTEM

Brake shoe spring

11-11



Installation

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

Install brake cam.

Never allow brake linings to be contaminated by oil or grease.

Wipe off the excessive grease from brake cam and the anchor pin.

Caution

Brake efficiency will be reduced if brake linings is contaminated by oil or grease.

Install the brake cam and arm after aligning it with the punched point.

Tighten the bolts and nuts to specified torque:


Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated.

Caution

Brake efficiency will be reduced if brake linings is contaminated by oil or grease.

Install spring onto the brake shoes.

Install the brake shoes to the brake panel one after one, and make sure the shoe springs are in correct position.

Install the wheel.

Brake shoes

Brake shoes

Rear brake arm

Bolt

Wear indicator plate

Brake arm


Bolt

Brake arm big indent


11-12

Home page

Body Overview································ 12-1

Maintenance Information ··············· 12-3

Side Covers ····································· 12-4

Luggage Box ··································· 12-5

Body Cover······································ 12-6

Front Cover ····································· 12-8

Body Overview (FT05U / FT05W)

Handle rear cover

Contents

12. BODY COVER

Front Under Spoiler ························12-9

Front Inner Box ·······························12-10

Floor Panel ······································12-11

Front Fender····································12-11

Steering Handle Cover····················12-12

Under Cover ····································12-13

Luggage box

Handle front cover (FT05W)

Handle front cover (FT05U)

Battery cover

Front cover stripe

Front cover

Front under spoiler

Front inner upper cover

Right side cover

Front inner under cover

Frame number cover

Floor panel

Right body cover

Left body cover

12

Left side cover

Tail light

Rear fender

Front fender

Under cover

12-1


12. BODY COVER

Body Overview (FT05T / FT05V)

Handle front cover (FT05V)

Handle rear cover Luggage box

Handle front cover

(FT05T)

Front cover stripe

Front cover

Front inner upper cover

Battery cover

Right side cover

Frame number cover

Right body cover

Left body cover

Left side cover

Tail light

Front inner under cover

Front under spoiler

Floor panel

Rear fender

Under cover

12-2



12. BODY COVER

Body covers disassemble sequence:

Handlebar Front Cover

Handlebar Rear Cover

Front Fender

Front Cover

Front Spoiler

Front Inner Cover

Luggage Box/Seat

Left/Right Side Cover

Body Cover

Left/Right Side Cover

Floor Panel

Rear Fender

Under Cover 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.

12-3


12. BODY COVER

Side Covers

1. Removal:

y Remove 2 screws (front/middle) from two side covers. y Slide the side cover backward so that their hooks are out of slots. y Take out the side cover end part and then remove the cover.

2. Installation:

y Install in reverse order of removal procedures.

Caution

The tail of each cover is held with buckles and slot, never pull them with force, or it would crack the buckles.

12-4

Screws


Luggage Box

1. Removal:

y Lift up seat cushion. y Remove luggage box mounting screws (1 screw). y Remove luggage box bolts (4 bolts) y Remove oil tank cap and oil guide rubber. y Hold the luggage box in both front and rear sides by two hands, and then lift up the box to remove it.



12. BODY COVER

Oil tank cap

Bolts

Bolts

12-5


12. BODY COVER

Body Cover

1. Removal:

y Remove 3 bolts from rear carrier, and then remove rear carrier. y Remove the luggage box. y Remove 4 screws from the two side cover, and then remove the side cover. y Remove 4 screws from the both sides.

Bolts

Screws

Screws

12-6


y Remove 1 screw from the front side. y Remove the body cover.



12. BODY COVER

Screw

12-7


12. BODY COVER

Front Cover

1. Removal:

y Remove 2 screws from the inner cover and front cover. y Remove 1 screw from the front cover. y Push the front guard up and then remove it.

2. Installation


Screws

Screws

12-8


Front under Spoiler

Removal:

y Remove the front cover and right / left side cover. y Remove 4 screws from the front inner box. y Remove 2 screws from the front upper part of the front spoiler and the front inner box. y Remove front wheel bolt and wheel. y Remove 2 screws from the lower part of the front spoiler. y Remove the front spoiler.


y

Install in reverse order of removal procedures.

12. BODY COVER

Screw

Screws

Bolt

Screw

12-9


12. BODY COVER

Front Inner Box

1. Removal:

y Remove the front cover. y Remove the front under spoiler. y Remove 2 bolts from the floor panel. y Remove 5 screws of the fuel filling cap. y Remove hook and 1 screw. y Remove 1 screw from main switch cover. y Remove main switch cover. y Remove the front inner box.

Screws

Screw



Bolts

Hook & 1 screw

Main switch cover

12-10


Floor Panel

1. Removal:

y Remove the luggage box, rear carrier, right / left side covers and body cover. y Remove 4 plugs of the floor panel. y Remove the floor panel. (4 bolts)



Front Fender

1. Removal:

y Remove speedometer cable screw and cable. y Remove front wheel bolt and then remove the wheel. y Remove 3 screws of front fender. y Remove the front fender.



3 Screws

12. BODY COVER

4 plugs and 4 Bolts

12-11


12. BODY COVER

Steering Handle Cover

1. Removal:

y Remove 1 screw under front light. y Remove 3 screws from the handle rear cover. y Remove handle front cover. y Remove 2 inner screws. y Disconnect each switch connectors. y Remove speedometer cable. y Remove rear handlebar guard. y Remove handle rear cover and meter.

Screw



Caution

Push the front connection part of rear handle cover at first when removing front cover so that the buckles are out of the cover. Never push it forcefully to cause buckles broken or cover damaged.

12-12

3 Screws

Screws

2 Screws


Under Cover

1. Removal:

y Remove the right and left side cover. y Remove 2 bolts from the under cover. y Remove under cover.



12. BODY COVER

12-13

12. BODY COVER

Note:


12-14

Home page

Contents

13. STEERING/FRONT WHEEL/SUSPENSION


Troubleshooting ······························· 13-2

Steering Handle ································ 13-3

Front Wheel ······································· 13-4

Front Shock Absorber ······················ 13-8

Front Fork·········································· 13-9

1.5kgf-m

0.25kgf-m

4.5kgf-m

3.3kgf-m

13

2.7kgf-m

6.0kgf-m

13-1




Specification

Item

Shaft bending

Standard value (mm)

─

Limit (mm)

0.2 (0.01 in)

Rim wobbling

Radial

Axial

─

─

2.0 (0.08 in)

2.0 (0.08 in)

Torque Value

Steering handle nut

Front wheel axle

4.5kgf-m Front brake caliper bolt

6.0kgf-m Steering stem mounting nut

3.3kgf-m

1.5kgf-m

0.25kgf-m

Front shock absorber mounting nut 2.7kgf-m Top cone race

Special Tools

Inner bearing puller

Bearing driver

Troubleshooting

Hard To Steer The Front Wheel Wobbling

1. The steering shaft bolt is too tight.

2. The steering shaft bearing are damaged

3. The ball and the top cone of the steering shaft are damaged.

4. Insufficient tire pressure.

The Steering Handle Is Tilted

1. Uneven arrangement of the front shock absorbers.

2. The front fork is bent.

3. The front wheel axle is bent.

1. The rim is bent.

2. The wheel axle nut is not tightened improperly

3. Bend wheel rim

4. Side-worn or poor tire.

5. The bearing play of the wheel axle is too large.

Soft Shock Absorber

1. Weak front shock absorber spring

Noise In Front Shock Absorber

1. Shock absorber outer tube noise

2. The joint of the shock absorber gets loose.

13-2


Steering Handle

Removal


Remove handle cover, front cover and inner box.

Remove throttle grip after mounting screw removed.

Remove master cylinder (disc brake) after 2 bolts removed.

Remove rear brake lever bracket after mounting bolt removed.

Remove handle mounting bolt and nut, and then remove the handle.

Installation

Rear brake lever seat

Nut

Master cylinder

Bolt

Install handle and align with bolt hole.

Install bolt and nut and then tighten it.


Apply with grease onto throttle cable and the sliding surface of handle.

Align the lock pin of the handle outer tube with the hole on the handle, and then install the handle.

Tighten the bolt.

Caution

Align the lock pin with the hole on the handle and also install brake lever seat. Then, tighten the lever with clamp and bolt.

13-3



Place master cylinder onto handle and align its

Master cylinder

connection surface with bolt hole on the handle

(disc brake).

Install the mounting seat.

Tighten the upper part bolt, and then tighten lower bolt.

Install all components in reverse order of removal procedures.

Conduct following adjustment: y Oil pump control cable.

Brake lever free play

Front Wheel

Removal

DISK TYPE

Remove speedometer cable from speedometer gear box.

Remove front brake cable. (Drum type)

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


Bolt

DURM TYPE

Axle nut


Brake cable

Axle nut

13-4



Inspection

Place the axle onto a V-block to measure its run-out with a dial gauge.

The dial gauge indicated 1/2 run-out.


Place the wheel on to a rotation seat, and turn the wheel to check its bearing free play. If the bearing is noisy or its free play is too much, replace it.

Place the wheel on to a rotation seat to check its rim wobbling. Turn the wheel with hand and measure its rim wobbling value with a dial gauge.

Service limit:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Free play

Wheel axle

Free play

Bolts

Remove 3 bolts and brake disc.

13-5



Remove wheel hub from wheel rim after 4 nut

DISK TYPE

removed.

Remove dust seal, bearing and side collar.

Special tools

Inner bearing puller (SYM-6204020)

Installation

Dust seal

DRUM TYPE

Bearing

Fill out the block of bearing by grease.

Drive the left bearing and install the dist. collar.

Install the right bearing.

Caution

y Carefully install the bearing in correct and evenly. y Bearing outer face should be faced up as bearing installation.

Install the brake disc and then tighten the bolts

(disc brake).


13-6

Dust seal

Bolts

Dist. collar

Dust seal

Bearing

Dist. collar

Bearing



Lubricate the speedometer gear with grease and install the gear into the wheel hub. (Drum type)

Lubricate the speedometer gear box with grease

(Disk type)

Align the flange part on the speedometer gear with the slot of wheel hub.

Stopper

Caution

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

Apply with grease onto the dust seal.

Install the dust seal and side collar.

Place the front wheel between the front shock absorbers.

Caution

Align the brake disc groove with the stopper flange.

Insert the wheel axle into the wheel and the install the wheel axle nut.

Tighten the nut to specified torque.


Connect the speedometer cable to the speedometer gear.

Front fork groove

DRUM TYPE

Front fork groove

Stopper

DISK TYPE


Shaft nut


13-7



Front Shock Absorber

Removal

Hose clamp

Bolt

y Front under spoiler

Disc Brake

Remove the caliper mounting bolts and the caliper.

Take out the hose from hose clamp.

Remove the hose clamp mounting bolt and the clamp.

Drum Brake

Remove the cable clamp mounting bolt and the clamp.

Remove the front shock absorber upper bolt and the shock absorber.

Installation

Align the cover flange with upper level of the shock absorber clamp, and then tighten bolts.


Install the removed components in reverse order of removal procedures.

Caliper bolts

Bolts

Shock absorber

Cable clamp

Bolt

13-8


Front Fork

Removal

y Handle y Front wheel y Front shock absorber

Remove the steering stem mounting nut.

Remove top cone race and front fork.


Steering stem mounting nut

Caution

Place the steel ball onto a parts container to prevent from missing.

Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats.

Remove bottom cone race body with a punch.

Caution

Do not damage the steering stem.

Installation

Install a new bottom cone race onto the steering stem.

Push the cone race until to mounted position.

Caution

Do not tilt the ball bearing seats as installation.

Apply with grease onto the ball bearing seats, and install steel balls onto the seats.

(Top: 26 balls, bottom: 29 balls)

Lubricate the top cone race seat with grease.

Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race

1/4~3/8 turns.


Caution

Check the steering stem that should be rotated freely and no clearance in vertical direction.

Steering lock nut

Top cone race


Top cone race

Top ball bearing seat

Bottom ball bearing seat

Steel balls

Bottom cone race

Return 1/2 turns

Locking to

1/4~3/8 turns

Top cone-race

13-9



Install the steering stem mounting nut and tighten


the nut by means of holding the top cone race body.



Top cone race

13-10

Home page

Maintenance Information ·················14-2

Troubleshooting ·······························14-2

Contents

14. REAR WHEEL/SUSPENSION

Rear Wheel ······································· 14-3

Rear Shock Absorber ······················ 14-4

2.7kgf-m

4.0kgf-m

11.0kgf-m

3.3kgf-m

14-1

14



Specification


Item Standard value (mm)

Rear wheel rim run out

-

Torque Value

Rear shock absorber upper mounting bolt: 4.0kgf-m

Rear shock absorber lower mounting bolt: 2.7kgf-m

Rear wheel nut: 11.0kgf-m

Rear wheel hub: 2.5kgf-m

Exhaust muffler nut: 1.2kgf-m

Exhaust muffler bolt: 3.3kgf-m

Troubleshooting

Rear wheel wobbling

1. Bend wheel rim

3. Loosen wheel shaft

Shock absorber too soft

1. Insufficient shock absorber spring force

Poor brake performance

1. Poor brake adjustment

2. Contaminated brake lining

3. Worn brake lining cam

4. Worn brake cam lever

6. Improper installation of brake arm gear set.

Limit (mm)

2.0 (0.08 in)

14-2


Rear Wheel

Remove

Remove exhaust pipe nut. (2 connection nuts)

Remove exhaust muffler bolt (2 bolts), then remove the muffler.

Remove rear wheel shaft nut and then remove the rear wheel.


Bolts

Connection nuts

Shaft nut

Inspection

As the diagram shown, measure wheel rim wobbling with a dial gauge.

Service limit:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Brake Hub Replacement

Remove 4 nuts of cover and wheel rim, and then remove the wheel hub.

Install the wheel hub and tighten the nuts.


Hub nut

14-3



Shaft nut

Installation

Install the rear wheel and tighten the nut.


Install exhaust pipe & muffler.

Tighten torque (bolt): 3.3kgf-m

Tighten torque (nut): 1.2kgf-m

Rear Shock Absorber

Removal

Remove body cover.

Remove air cleaner.

Remove rear shock absorber upper & lower bolts.

Remove rear shock absorber.

Bolts

Lower mounting bolt

Installation

Install the rear shock absorber.

Tighten the upper & lower mounting bolts to specified torque.

Torque value:

Upper mounting bolt: 4.0kgf-m

Lower mounting bolt: 2.7kgf-m

Press down the tail of the scooter for several times to check shock absorber operation.

Installation all components in reverse order of removal procedures.

Install air cleaner.

14-4

Connection nuts

Upper mounting bolt

Home page

Contents

Maintenance Information ················ 15-2

Troubleshooting ······························ 15-3

Battery ·············································· 15-4

Charging System ····························· 15-5

Ignition System ································ 15-9

Starting System ······························ 15-12

Oil Level Switch ······························ 15-14

Fuel Unit ·········································· 15-15

Switch/Horn····································· 15-16

Bulb Replacement ·························· 15-18

Reg. Rec. Comp

Horn

Winker Relay

Horn / Winker /

Dimmer Switch

Fuel Unit

Resistor Comp

CDI Unit

Main Switch

Start / Headlight Switch

Spark Plug

Start Relay

Battery

AC. Generator

IG. Coil

Fuse Box

Oil Level Switch

15-1

15


15. ELECTRICAL EQUIPMENT



y

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.) y The model of the spark plug and the tightening torque. y

The ignition timing. y Adjustment of headlight. y Removal and installation of AC generator. y

The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled water. y To recharge the battery, remove the battery from the motorcycle without removing ventilation caps. y Unless in emergency, never rapid charge the battery. y

The voltage must be checked with the voltmeter while charging the battery. y As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary. y

The starter motor can be removed after the engine is removed.

Specification

Charging System

Item Specification

Battery

Leak current

Charging current

Capacity 12V3Ah

Charging rate 0.4A / 5 hours (standard), 4A / 0.5 hour (fast charging)

< 1 mA

1.2 A / 5000 rpm

Control voltage in charging 14.0 ~ 15.0 V / 5000 rpm

Control voltage in headlight

Ignition System

12.6 ~ 13.6 V / 5000 rpm

Item Specification

Spark plug

Ignition coil and resistance

Gap

Primary coil

Secondary coil

Ignition timing “F” mark

0.6 ~ 0.7 mm

0.19 ~ 0.23

Ω

2.8 ~ 3.4 K

Ω

17

° BTDC / 1800 rpm

15-2


Troubleshooting

No voltage

y

Battery y The cable disconnected y The fuse is blown y

Improper operation of the main switch

Low voltage

y The battery is not fully charged y Poor y

Poor charging system y Poor voltage regulator

No spark produced by spark plug

y The spark plug is out of work y

The cable is poorly connected, open or short-circuited

- Between AC.G. and C.D.I. y

Poor connection between C.D.I. and ignition coil

- Poor connection between C.D.I. and the main switch y Poor main switch y Poor y

AC.G. is out of work

Starter motor does not work

y The fuse is blown y The battery is not fully charge y

Poor main switch y Poor starter switch y The front and rear brake switches do not operate correctly y Starter relay is out of work y The ignition coil is poorly connected, open or short-circuited y The starter motor is out of work

Intermittent power supply

y

The connector of the charging system becomes loose y Poor connection of the battery cable y

Poor connection or short-circuit of the discharging system y Poor connection or short-circuit of the power generation system

Charging system does not operate properly

y Burnt y

Poor contact, open or short circuit y Poor y Poor

Engine does not crank smoothly

y

Primary coil circuit

- Poor ignition coil

- Poor connection of cable and connectors

- Poor main switch y Secondary coil circuit

- Poor ignition coil

- Poor spark plug

- Poor ignition coil cable

- Current leakage in the spark plug cap y

Incorrect ignition timing

- Poor AC.G.

- Improper installation of the pulse sensor

- Poor C.D.I.

Weak starter motor

y Poor charging system y The battery is not fully charged y

Poor connection in the windings y The motor gear is jammed by foreign material

Starter motor is working, but engine does not crank

y

Poor starter motor pinion y The starter motor run in reverse direction y Poor

15-3



Battery

Battery Removal/Installation

Turn off main switch.

Open seat.

Remove screw and the open battery cover.

Disconnect the negative cable terminal first, then the positive cable terminal.

Remove the battery from the scooter.

Install the battery in reverse order of removal.

Negative terminal

Voltage Check

Open seat and battery cover.

Remove wires from battery.

Check battery voltage.

Voltage:

Fully charged: 13.0 ~ 13.2V

Undercharged: 12 V

Charging

Remove the battery.

Connect the positive terminal (+) of the charger to the battery positive terminal (+).

Connect the negative terminal (-) of the charger to the battery negative terminal (-).

Standard charging current/time: 0.4A/5 hrs.

Fast charging current/hrs: 4A/0.5 hr.

Caution

Strictly keep flames and sparks away while recharging to avoid to explosion causing by hydrogen.

Stop charging battery when electrolyte temperature is over 45℃(117℉).

Caution

Fast charging the battery is for in emergency only. Battery should be charged in standard.

Positive terminal

15-4

Charging System

White

Yellow


Green

Red

Green/

Black

Pink

AC. Generator

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.

Caution

y 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. y 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 1mA

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

Ground circuit

Digital voltmeter

Fuse connector

Ammeter

Battery (-) terminal

Ammeter

15-5



Charging Voltage Inspection

Caution

y Before conducting the inspection, be sure that the battery is fully charged. If undercharged, the current changes dramatically. y Use a fully charged battery having a voltage larger than 13.0 V y While starting the engine, the starter motor draws large amount of current from the 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 an ammeter having an indication that shows both positive and negative direction current.

The measurement would be at zero, if the ammeter is one direction only.

Caution

y Do not use short-circuit cable. y 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 starter to start the engine. y

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.

Connect a tachometer.

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

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

Specified Charging Current: 1.2 A / 5000 rpm

Control Charging Voltage: 14.0~15.0 V / 5000 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.

-

Bulbs used exceed their rate and consume too much power.

-

The replacement battery is aged and does not have enough capacity.

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

-

The replacement battery is aged and does not have enough capacity.

-

Battery used do not have enough electricity or is over charged.

-

The fuse of the ammeter is blown.

-

The ammeter is improperly connected.

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

-

The fuse of the voltmeter is blown.

15-6


Headlight Voltage Inspection

Connect a tachometer.

Do not disconnect the headlight harness connector after engine started.

Turn the headlight ON and to high beam position.

Measure the voltage between the blue wire (+) and green wire (-) while the headlight harness is still in connection. Measure alternating current voltage with a voltmeter.

Gradually increase engine speed and read the voltage in each specified rpm.

Control voltage: 12.0~14.0 V / 5000 rpm

Resistance Measurement of Resistor at 20℃.

Resistor (10.2Ω5W) Green/Black and Body

ground: 9.0Ω~10.0Ω

Resistor (5.9Ω5W) Pink and Body ground: 5.6

Ω

~6.2Ω

Front cover

Resistor

Headlight connector

15-7



Voltage Regulator Inspection

Check the each pins of connector on the voltage regulator.

Voltage regulator

Voltage regulator connector

Check voltage between battery terminal (red) and ground

(green).

Check continuity between ground and frame.

Check charging coil (white to ground) if its resistance is within 0.2~1.0Ω

Check charging /illumination coil (yellow to ground) if its resistance is within 0.2~0.8Ω

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

Voltage Regulator

Multi-meter(+)

White

A

Multi-meter (-)

White A

Yellow B

Red B

Yellow

L

Red

B

Green

E

∞

4~7

∞

4~7

∞

∞

2.4~4.8

∞

Green E

∞

2.4~4.8 ∞

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

Red (B)

Blown fuse or poor main switch contact

Open-circuit wire

Open-circuit in alternator charging coil or in illumination switch.

White (A)

Yellow (L)

Green (E)

Caution

y If the probe is touched by finger, then the resistance values will be incorrect. y It contains semi-conductor in circuit so the measured resistance value will be in different if different testers are used. Thus, these values cannot be judged with standards.

AC Generator Inspection

Remove body cover.

Disconnect the generator harness connector.

Measure the resistance on both charging coil (the white to ground) and illumination coil (the yellow to ground).

Resistance Measurement: (20℃)

Charging coil (white - green): 0.2~1.0Ω

Illumination coil (yellow - green): 0.1~0.8Ω

AC. Generator harness connector

15-8

Ignition System

Blue/Yellow

Black/Red

Black/White


Green

Black/Yellow

15-9



Ignition Coil Inspection

y Remove body cover.

Measure the primary coil resistance.

Resistance :0.19~0.23KΩ (A)→(B)

Measure the secondary coil resistance.

Resistance : 8.2~9.3KΩ (A)→(C)

(A)

(C)

(D)

(B)

Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance.

Resistance : 3.1~3.2KΩ (A)→(D)

(C)

(A)

(B)

(D)

Ignition coil

15-10


Electrical System Circuit Inspection

Pulse Generator / Exciting Coil

Remove body cover.

Disconnect alternator connector.

Resistance Measurement: (20℃)

Pulse generator coil (blue/yellow - ground):

50~200Ω

Exciting (yellow - ground): 400~800Ω

CDI Electrical System Circuit Inspection

Remove front cover.

Disconnect the CDI set connector, and check its circuit to diagnosis related ignition components.

C.D.I.

AC generator harness connector

CDI Electrical System Circuit Inspection

Main Switch Black/white-green Continuity as main switch OFF

Exciter Coil Black/Red-Green 400 ~800Ω

Pulse Generator Blue/Yellow-green 50 ~200Ω

Primary Black/yellow-green 0.21Ω±10%

Ignition Coil

Green-high voltage cable -w/o Cap 3~5KΩ

Secondary

Green-high voltage cable - w/ Cap 7~12KΩ y If above checks are in normal but spark plug is still no spark. Then it probable causes from CDI set or high voltage coil. y If abnormal circuits are found in above checks, at first check all items, and then check each item one by one.

15-11



Starting System

Starter Relay Inspection

Remove luggage box.

Connect both the green/yellow (-) and the yellow/red (+) pins to battery posts directly.

If the red and red/white pins are also in continuity, it means it is in normal.

Starter relay

Starter relay

Battery

Starter Motor Pinion Removal /

Installation


Remove starter motor pinion.

Install the starter motor pinion in reverse order of removal.

Starter Motor Pinion Inspection

y Pinion, reduction gear for wear out or damage

→

replace it with new one. y Gear journal for wear out or damage → replace it with new one.

Check the pinion for sliding in axial direction smoothly. y The pinion sliding in axial direction not in smooth → replace it with new one.

15-12

Starter motor pinion


Starter Motor Removal / Disassembly

Remove body cover.

Remove bolt and oil pump control cable.

Disconnect starter motor harness connector.

Remove 2 bolts for separation starter motor and gasket.

Remove 2 bolts for disassembly the starter motor.

Starter motor

Connector

Armature

Motor housing

Carbon bracket

Armature Inspection

Check the armature for discoloration or other damage. It may be short-circuit if dark surface on the shifter found.

Caution

Do not clean the shifter surface with sandpaper.

Check continuity 1) both the shifter surface and shaft, 2) among the shifter surfaces. It can be in continuity among the shifter surfaces, but both the shifter surface and the shaft can not be in continuity.

Starter Motor Re-Assembly / Installation

Re-assemble and install the starter motor in reverse order of removal procedures.

Front bracket

Spring

O-ring

15-13



Oil Level Switch

Troubleshooting

y

If the oil level in oil tank is in specified level, but the oil level indicator still goes on.

1. Remove body cover.

2. Disconnect oil gauge wire, and turn the main switch to ON position.

Indicator light up Indicator not light up

Short-circuit between indicator and oil gauge

Malfunction of oil gauge

y If there is no oil in oil tank or low oil level, but the oil level indicator still not goes on.

1. Remove body cover.

2. Disconnect oil gauge wire and connect a jump wire among connector, and then turn the main switch to ON position.

Indicator not light up

Poor wire connection

Indicator light up

Malfunction of oil gauge

3. Disconnect oil gauge connector, and check voltage between wire and ground.

No voltage

y Open-circuit between

oil gauge and indicator.

y Blown bulb

Voltage

y Malfunction of oil

gauge

y Poor connection of oil

gauge

Main switch

Indicator

Indicator


Fuse


Main switch

Fuse


Removal / Installation

Remove oil tank.

Remove oil level switch from the oil tank.

Install the oil level switch in reverse order of removal procedures.

15-14


Fuel Unit

Removal / Installation

Remove 4 bolts and floor panel.

Disconnect fuel unit connector.

Remove the fuel unit plastic cap.

Turn the snap ring in CCW direction and then remove the fuel unit.

Caution

Do not bend the float arm.


Remark: Aligning the slot of fuel unit with the ring of oil tank as installation, and then turn the snap ring in CW direction until matching to the arrow.

Inspection

1. Connect the fuel unit connector.

Turn the main switch ON.

Move the float in up and down, and make sure that the fuel indicator can be reached to

F (Full) and E (Empty) positions.

Conduct the step 2 if the needle on the fuel indicator is not moved.

2. Measure the connector resistance while the float in up and down positions.

Float position Resistance value

Up (full) 3~10Ω

Down (empty) 90~100Ω

Check the fuel indicator if the resistance is in normal.

Replace the fuel gauge if the resistance is abnormal.

Float

Fuel unit

Fuel unit plastic

15-15



Switch / Horn

Remove handle covers and front cover.

Remove main switch cover.

Remove front inner box.

Check continuity on each switch.

The connected circles with a line are that they should be in continuity.

Main Switch

Wire color

Black

Black /

White

Green Red

Mark BAT2 IG E BAT1

LOCK

OFF

ON

Winker light switch

Wire color Gray Light blue Orange

Mark WR R L

R

N

L

Horn Switch

Wire color Light green Black

Mark HO BAT2

FREE

PUSH

High/Low Beam switch

Wire color Brown White Blue

Mark HL LO HI

LO

(N)

HI

High / low beam switch

Horn switch

Winker light switch connector

15-16

Winker light switch

High / low beam switch connector

Horn switch connector


Headlight Switch

Wire color Brown Yellow Pink

Mark HL CI RE

OFF

ON

Starter Switch

Wire color Yellow / Red Green

Mark ST E

FREE

PUSH

Headlight switch connector

Starter switch connector

Front / Rear Brake Light Switch

If the switch is in continuity as braking, it is in normal. The switch is non-adjustable.

Horn

If the horn give out sound as connecting to 12V battery, it means that it is in normal.

Horn

Headlight switch

Starter switch

15-17



Bulb Replacement

Headlight

Remove handle front cover.

Remove bulb seat and replace the bulb.

Install the all removed parts.

Front winker light

Remove front cover.

Remove front winker light lens.

Replace front winker light bulb.


Screws

Tail light / Brake light / Rear winker light

Remove 2 screws and then remove outer cover.

Remove 2 screws and then remove inner cover.

Replace tail light or winker light bulb.


Outer cover Screws

Headlight

Inner cover Screws

15-18

Home page

Contents

16. ELECTRICAL DIAGRAM

16-1

16

Home page

16. ELECTRICAL DIAGRAM

Notes:

Contents

16-2

SYM DD 50 scooter Service manual

Assistant Bot

SERVICE MANUAL

Forward

How to use this manual,

Mechanism

Illustrations

Contents

This chapter contents

Page Content Index

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

Symbols and Marks

O

X

General Safety

Service Precautions

Specifications

Torque values

Cables and Harness Routing

Troubleshooting

Lubrication Points

General Information

Periodical Maintenance Schedule

Air Cleaner

Fuel Lines

Fuel Filter

Engine Oil Line

Oil Pump Control Cable

Tire

Battery

Rear Brake Free Play: (Drum Brake

Type)

Brake System Hose: (Front Disc

Brake Type)

Steering System

Suspension

Transmission Oil

Spark Plug

Control Cable Lubrication

Driver Belt

Ignition Timing

Throttle Valve Operation

Carburetor Idle Speed Adjustment

Carbon Removing For Exhaust Pipe

& Muffle

Cylinder Compression Pressure

Test

Headlight Adjustment

Lubrication System Diagram

Precautions In Operation

Lubricant

Trouble Shooting

Oil Pump Removal

Oil Pump Installation

Oil Pump/Oil Tube Air Bleeding

Oil Tank

Maintenance Information

Engine removal

Engine installation

Maintenance Information

Troubleshooting

Cylinder Head

Cylinder/Piston

Maintenance Information ··········6-2

Alternator Removal ···················6-3

Alternator Installation ··············· 6-4

Maintenance Information

Alternator Removal

Alternator Installation

Maintenance Information

Trouble Shooting

Left Crankcase Cover

Reassembly of Kick Starter

Installation of the Left Crankcase

Cover

Drive Belt

Movable Drive Face

Clutch/Driven Pulley

Maintenance Information

Troubleshooting