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SERVICE MANUAL XS 125

1. too much oil oil no replacement check cylinder head E hosecooceesecseceoccseoonce lubrication p tube clogged engine too hot remove dirt spark plug improper heat range Spark plug clearance misadjustment piston cylinder worn A lean mixture poor gasoline carbon in burning chamber too much ignition timing too early C D I faulty clutch slip carbon in burning chamber too much no knock shock poor gasoline clutch slip lean mixture ignition timing too early C D l faulty 1 5 This chapter Contents 1 GENERAL INFORMATION SYM C ROTATION ROUGH ESPECIALLY IN THE LOW SPEED AND IDLE SPEED inspection adjustment ignition timing adjustment faulty CDI unit gt A C Generator valve gap adjust faulty adjust carburetor fuel adjusting screw adjust OK adjust faulty Screw rich mixture tighten screw TN carburetor gasket has air inlet insulator plate gasket poor has air inlet carburetor locking nut loose insulator plate gasket torn vacuum tube crack Remove spark plug insert to the plugcap check spark by toucning engine irongrid poor or dirty spark plug faulty CDI unit faulty A C Genertor poor ignition coil spark plug cable open or short poor main switch L vacuum tube damaged s
2. 56 52mm This chapter Contents SYM 6 CYLINDER PISTON PISTON REMOVAL Remove the piston pin clip with pliers Press the piston pin out of piston remove the piston NOTE Avoid the clip falling into the crankcase PISTON PISTON RING INSPECTION Measure the piston ring to ring groove clearance Service limit Top ring 0 13mm Second ring 0 12mm Remove the piston rings Inspect the piston for damage or cracks Inspect the piston groove for wear Insert each piston ring into the cylinder and measure the ring end gap Top Second ring 0 5mm This chapter Contents 6 CYLINDER PISTON Measure the piston O D at the skirt Service limit 56 48mm NOTE Measure the piston O D at a point from the bottom Calculate the piston to cylinder clearance Service limit 0 11mm Measure the piston pin bore 1 0 Service limit 15 05mm Measure the piston pin O D Service limit 14 994mm Measure the top second ring thickness Service limit 1 460mm This chapter Contents SYM 6 CYLINDER PISTON PISTON RING INSTALLATION TES piston rings TOP RING 7A SECOND 22 RING rIo RING Avoid piston and piston ring damage during installation All rings should be installed with the markings facing up After installation the piston rings should be free to rotate in the grooves opace the piston ring end gaps 120 degree apart OIL RING This chapter Contents 6 CYLI
3. 5 11 This chapter Contents 5 INSPECTION ADJUSTMENT SYM If the contact area is too high on the valve the seat must be lowered using a 37 5 degree cutter then finish with a 45 degree cutter If the contact area is too low on the valve the seat must be raised using a 63 5 degree cutter then finish with a 45 degree cutter After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure 5 12 CUT END CONTACT AREA TOO HIGH CONTACT AREA TOO LOW X CUT BOTTOM END This chapter Contents 5 CYLINDER HEAD VALVE CYLINDER HEAD ASSEMBLY Compress the valve springs with a valve spring compressor and install the valve cotters into the valve retainer Do not compress the valve spring more than necessary gt xm O 2 Install new valve stem seal when assembling Lubricate each valve stem with the engine oil then insert them into the guides Install the valve spring and retainers NOTE Install the valve springs with the tightly wound coils facing the cylinder head Tap the valve stems gently with a plastic hammer to firmly seat the cotters 5 13 This chapter Contents 9 INSPECTION ADJUSTMENT CYLINDER HEAD INSTALLATION CAMSHAFT AND CAMSPROCKET Hocker arms must be installed at the right position Clean the cylinder head gasket surface of any gasket material Install the new gasket O ring and
4. Turn the stop screw to obtain the idling speed of 1100rpm Turn the air screw to the maximum speed then turn the stop screw to obtain the specified idling speed Idling speed 1500 100 rpm NOTE Turn the air screw clockwise for making fuel air mixture lean Turn counterclockwise for rich 2 11 2 INSPECTION ADJUSTMENT AIR CLEANER Remove the left side cover Remove the air cleaner cover Remove the air cleaner element NOTE Clean the cleaner element periodically Refer to maintenance schedule Assemble air cleaner element in reverse order of disassemble SZ AIR CLEANER ELEMENT CLUTCH ADJUSTMENT CLUTCH LEVER FREE PLAY Measure the clutch free play at the tip of the clutch lever Free play 10 20mm 10 20 2 12 2 INSPECTION ADJUSTMENT FREE PLAY ADJUSTMENT Loosen the lock nut and turn the adjuster Turn the adjuster clockwise for decreasing the free play counterclockwise for increasing the free play BRAKE ADJUSTMENT FRONT BRAKE LEVER FREE PLAY Measure the brake free play at the tip of the brake lever Free play 10 20mm BRAKE PAD WEAR INSPECTION Check for brake pad wear by operating the bake lever Check the brake pads for wear by looking through the slot indicated by the arrow cast on the caliper assembly Replace the brake pads if the wear line on the pads reaches the edge of the brake disc 2 13 2 INSPECTION ADJUSTMENT REAR BRAKE PEDAL FREE
5. 4 Fuel line restricted 5 Float level too low 6 Float valve faulty RICH MIXTURE 1 Choke stuck closed 2 Float valve faulty 3 Float level too high locations of the jets and place them individually SPECIAL TOOL Float gauge 10 1 This chapter Contents 10 CARBURETOR CARBURETOR REMOVAL Disconnect the fuel line Disconnect the all connect tubes Drain fuel from the carburetor WARNING Keep away from flames or sparks Wipe up spilled gasoline at once CARBURETO Loosen the carburetor band TT THROTTLE VALVE DISASSEMBLY Disconnect the throttle cable E Remove the needle spring Remove the needle Check the needle and throttle valve for wear or damage NEEDLE 10 2 This chapter Contents SYM 10 CARBURETOR Remove the carburetor assembly FLOAT FLOAT VALVE JETS DISASSEMBLE Remove the float chamber body WARNING Pour the float chamber gasoline into the tank Pull out the float pin remove the float and float valve FLOAT VALVE INSPECTION inspect the float valve surface for wear or damage FLOAT VALVE 10 3 This chapter Contents 10 CARBURETOR Remove the main jet needle jet and needle jet holder NOTE Avoid damage to the jets MAIN JE NEEDLE JET NEEDLE JET HOLDER Remove the air screw NOTE Before removeing air screw record the number of relations until it rests lightly so it can be returned
6. E STOPLIGHT SWITCH The stoplight should come on when the brake pedal is depressed 20mm from the standard pedal position If the action is abmormal adjust by turning the stoplight switch adjusting nut 55 a ADJUSTING NUT 2 18 3 LUBRICATION SYSTEM SYM CAM SHAFT OIL LINE OF CAM SHAFT PISTON MAIN SHAFT OIL ORIFICE OF CRANKSHAFT OIL PUMP COUNTER SHAFT OIL FILTER This chapter Contents 3 LUBRICATION SYSTEM TROUBLE SHOOTING TROUBLE SHOOTING OIL LEVEL TOO LOW 1 Natural consumption 2 Oil leaks 3 Worn piston rings OIL CONTAMINATION 1 Oil not changed often enough 2 Faulty cylinder head gasket OIL PRESSURE TOO LOW 1 Oil filter clogged 2 Oil pump damaged OIL PRESSURE TOO HIGH 1 Oil filter or line clogged 2 Oil not recommended NO OIL PRESSURE 1 Oil level too low 2 Oil pump damaged SERVICE INFORMATION NOTICE Inspection and service of oil pump can be serviced with the engine installed on the frame Oil pump service 7 9 Oil filter cleaning 2 4 2 5 SPECIFICATIONS Oil capacity 0 85 0 90 liter Oil recommended SAE 15W 40 API SH CD Oil pump delivery 3 5 liter above min 4600rpm 4 ENGINE REMOVAL INSTALLATION SYM SERVICE INFORMATION ENGINE REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS The following parts can be serviced with the engine installed on the frame Generator Clutch Oil pump Cam shaft Rocker arm
7. spark plug jump Fuel tube clogged engine dose not fire engine knocks but no starting muffler clogged remove and check the auto air cut poor action PM ipsios andis ignition timing incorrect carburetor fuel adjusting screw set faulty air cleaner clogged spark plug wet l carburetor fuel level too high auto air cut poor action throttle excessively spark plug dry start engine with choke closed 1 4 This chapter Contents SYM 1 GENERAL INFORMATION B ROTATION ROUGH LACKS POWER start engine and slightly apply iuel air cleaner clogged fuel tube clogged engine speed up air hole on the fuel tank cap blocked engine speed can t up exhaust tube clogged auto air cut faulty TOE E ON NT carburetor vacuum diaphragm worn adjust ignition timing use ds 1 0 auto fuel faulty ignition timing ignition timing al a valve adjuster poor valve clearance valve clearance misadjustment correct incorrect valve seat worn compression pressure check fualty valve seat cylinder piston worn compression normal pressure to low gasket leak valve timing incorrect carburetor block check piston ring worn gt no clogged remove and clean remove spark plug dirt and color change discolored check crankcase oil level hpaesasesseevesebuceystes for too much or dirt
8. CAMSHAFT REMOVAL NOTE The camshaft rocker arm and rocker arm shaft can be serviced with the engine installed on the frame Remove the cam sprocket cover Remove the crankshaft hole cap and the timing inspection hole cap Rotate the generator rotor counterclockwise and locate the piston at the T D C of the compressing stroke Remove the cam sprocket bolts and remove the cam sprocket NOTE Take care not to drop then bolt into the crankcase Suspend the cam chain with a wire to prevent it from falling into the crankcase Remove the camshaft 5 3 This chapter Contents 5 INSPECTION ADJUSTMENT CYLINDER HEAD REMOVAL Hemove the cam chain tensioner bolt Remove the 8mm bolt Remove the 4 cylinder head nuts Remove the dowel pins Hemove cam chain tensioner Remove the cylinder head 8mm BOLT Remove the rocker arm shaft Remove the rocker arms This chapter Contents 5 CYLINDER HEAD VALVE SYM CAMSHAFT INSPECTION Inspect the cams of the camshaft for wear Service limit Inlet 31 25mm Exhaust 30 87mm ROCKER ARM INSPECTION Inspect the rocker arm 1 0 and the rocker arm for wear damage or clogged oil holes Rocker I D Service limit 12 018mm ROCKER ARM SHAFT INSPECTION Inspect rocker arm shaft for wear or damage Hocker arm shaft O D Service limit 11 966mm 5 5 This chapter Contents 5 INSPECTION ADJUSTMENT CYLINDER HEAD DISASSEM
9. PLAY Measure the brake pedal free play before the brake start to engage Free play 20 30mm REAR BRAKE PEDAL ADJUSTMENT Turn the brake adjuster nut clockwise to decrease the free play and counterclockwise to increase the play CAUTION The adjuster nuts indentation should seat against the brake arm pin properly a A 4 a J b W 50 y SS b ADJUSTING NUTS DRIVE CHAIN ADJUSTMENT Place the motorcycle on its main stand and shift the transmission into neutral Remove chain cap and check the drive chain slack by moving up and down with the fingers Chain slack 10 20mm 2 14 2 INSPECTION ADJUSTMENT Loose the rear wheel axle nut for adjusting Turn the adjusting nuts on both adjusters as necessary CAUTION TORQUE 10 00 12 00 kgf m Recheck the drive chain slack and free wheel rotation Lubricate the drive chain with chain lubricant WHEEL RIM Front 2 25 kg c m Stand the motorcycle check the tires for cuts imbedded Cold tire Rear 2 50 kg c m nails or other sharp objects Two riders Front 2 50 kg c m pressure Rear 2 50 kg c m Check the tire pressure Tire size Front 2 75 18 Hear 90 90 15 Front 1 5mm Min depth of tread Rear 2 Omm 2 15 2 INSPECTION ADJUSTMENT SUSPENSION FRONT SUSPENSION Check the action of the front forks by compressing them several times with the front brake applied If there are abnormal noises or rattles check all the fasteners an
10. SCHEDULE SERVICE INFORMATION ENGINE OIL OIL FILTER SPARK PLUG COMPRESSION TEST VALVE CLEARANCE IGNITION TIMING CAM CHAIN TENSION ADJUSTMENT 2 9 THROTTLE GRIP ADJUSTMENT IDLING SPEED ADJUSTMENT FRAME AIR CLEANER CLUTCH ADJUSTMENT BRAKE ADJUSTMENT DRIVE CHAIN ADJUSTMENT WHEELS RIM SUSPENSION STEERING BATTERY HEAD LIGHT AIM STOPLIGHT SWITCH 2 INSPECTION ADJUSTMENT SYM MAINTENANCE SCHEDULE kilometer 1000KM 3000KM 6000KM 12000KM Interval o 1 C J J R 2 Gasolinefiter 1 d R 5 Engine Oit 71 8 Replacementforevey100RM 6 Wheelstires oo o 7 ety Fe ooo poo o 8 Brakeandoperationtreeplay 1 1 o 9 Steeringstembearing 10 FR RR Cushion 1 po o 11 screwsinuts EE 12 Spakpug FR 010014014041 0 0 14 Frame oflubrication 15 Exhaustmutter EF 1 ooo poo o 16 Carburetor 1o ooo poo oo 17 Jgntiontmng EE EE poo o 19 despeed o po o 20 Gasolinesystem 21 Twot ecabe EE o o poo o So Cylinder head cylinder Piston exhaust system The table is refered to the driving distance about 1000km per month l inspection cleaning adjustment or replacement if necessary R replacement C leaning L lubrication Ridden in unusually dusty areas require more frequently air filter element cleaning 2 2 2 I
11. SYM ENGINE TIGHTEN LOCATION Starting clutch outer bolt socket Cylinder stud bolt Shift drum stopper hex bolt Gear shift cam hex bolt Cylinder stud bolt Cylinder head cap nut Driven gear hex bolt Chain adjuster Oil filter screen cover Starter motor bolt Oil pump HEX bolt Primary drive gear nut Cylinder head bolt Cylinder head nut Fly wheel bolt Cylinder head cover Reduction gear cover bolt L Crank case cover bolt R Crank case cover Pluse bolt A C G flange bolt TIGHTEN LOCATION Front wheel axle nut Rear wheel axle nut Rear fork pivot nut Engine upper hanger nut Engine front hanger nut Handle pipe upper holder bolt Steering stem nut Front fork nut Rear shock absorber Rear brake torque link Front fork top bridge Front fork bottom bridge Final drive sprocket Seat bolt Drive sprocket bolt STANDARD TORQUE 5 mm bolt nut 6 mm bolt nut 8 mm bolt nut 10 mm bolt nut 12 mm bolt nut This chapter Contents 1 GENERAL INFORMATION THREAD DIA mm OD CO 5 5 5 5 Co N lt THREAD DIA mm nn A NNa Aa ca HAW HAH HAH A TORQUE kgf cm 5 mm bolt 6 mm bolt 6 mm flange bolt nut 8 mm flange bolt nut 10 mm flange bolt nut TORQUE Kkgf m 1 0 1 50 0 80 1 20 0 80 1 20 0 80 1 20 1 80 2 20 2 80 3 00 1 00 1 50 0 80 1 20 1 50 3 00 0
12. Shift spindle Cam chain tensioner Kick starter arm The following parts must be serviced with the engine removed off the frame Cylinder head Cylinder Piston Crankshaft Transmission Kick starter shift During removal and installation jack or adjustable support is required to maneuver the engine TORQUE VALUES Engine hanger 10mm bolt nut 4 50 5 50 kgf m Drain bolt 3 00 5 00 kgf m Gearshift pedal bolt 0 80 1 20 kgf m Kick starter pedal bolt 0 80 1 20 kgf m This chapter Contents 4 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Drain the engine oil Turn the fuel cock to OFF and disconnect the fuel tubes and all connect tubes Remove the right and left side covers Remove the gear change pedal and left crank case rear cover Disconnect the A C generator wire of the connector and remove the generator wire Remove the wire clamp screw and clamp 4 2 This chapter Contents 4 ENGINE REMOVAL INSTALLATION Remove the clutch cable CLUTCH CABLE Remove the spark plug cap Remove the muffler Loosen carburetor clip Separate the carburetor pipe and the cylinder head by removing the attaching bolts Remove the crankcase breather tube Loosen the rear wheel axle nut Loosen the drive chain adjusting nut and push the rear wheel forward Remove the drive chain clip and remove the drive chain 2 S id WHEEL AXLE NUT O 4 3 This chapte
13. absorber compressor Loosen the lock nut remove the upper holder gt je 2 SUEN jy y 21 4 12 6 This chapter Contents SYM 12 REAR WHEEL REAR SUSPENSION Remove the spring and rubber SPRING ADJUSTER UPPER BRACKET 4 94 LOCK NUT DAMPER s SPRING 2 SHOCK ABSORBER SPRING INSPECTION Measure the shock absorber spring free length Service limit 183mm Check the shock absorber for noisy or leaks SHOCK ABSORBER ASSEMBLY NOTE Install the spring with the tightly wound coils at the top TORQUE 1 50 2 50kgf m SPRING COMPRESSOR SHOCK ABSORBER INSTALLATION Tighten the shock absorber upper and lower mounting nuts TORQUE 3 00 4 00 kgf m Check the shock absorber operation NOTE e Adjust the right and left absorber to the same scales he standard position is 1 ADJUSTING POSITION tl NV STANDARD POSITION SOFT gt HARD This chapter Contents 12 REAR WHEEL REAR SUSPENSION REAR FORK REAR FORK REMOVAL Remove the muffler Remove the rear wheel 12 3 Remove the rear shock absorber 12 9 Remove the drive chain cover Remove the rear fork mounting bolts REAR FORK DISASSEMBLY ASSEMBLY NOTE Drive the bushings out with a soft hammer making sure that they are not damaged Lubricate with grease after installation R
14. bar Fill the crankcase with the recommended oil Adjust the clutch lever free play 7 6 This chapter Contents SYM 7 CLUTCH OIL PUMP GEAR SHIFT OIL PUMP OIL PUMP REMOVAL Remove the right crankcase cove Remove the oil filter rotor Remove the oil pump cover ee PUMP DRIVE GEAR Ka Remove the oil pump drive gear Remove the 6 mm screws and oil pump OIL PUMP DISASSEMBLY Remove the oil pump plate OIL PUMP INSPECTION Measure the inner rotor to outer rotor clearance SERVICE LIMIT 0 35mm This chapter Contents 7 CLUTCH OIL PUMP GEAR SHIFT SYM Measure the outer rotor to body clearance Service limit 0 40mm Measure the rotor to cover clearance NOTE Measure the clearance with the gasket installed Service limit 0 11 DRIVE SHAFT OIL PUMP ASSEMBLY Install the oil pump drive gear and gear shaft on the pump body Install the oil pump cover NOTE Align the cutout in inner rotor with the cutout on the shaft OIL PUMP COVER OIL PUMP BODY Check the oil pump for rotating freely This chapter Contents SYM OIL PUMP INSTALLATION Install new O rings Install the oil pump to the right crankcase GEARSHIFT LINKAGE GEARSHIFT LINKAGE DISASSEMBLY Remove the clutch Remove the gearshift pedal Remove the gearshift spindle 7 CLUTCH OIL PUMP GEAR SHIFT GEARSHIFT SPINDLE 7 9 7 CLUTCH OIL PUMP GEAR SH
15. dowel pins and chain guide NOTE Do not allow dust and dirt to enter the cylinder Install the cylinder head NOTE Support the cam chain to keep it from falling into the crankcase Install the cam chain tensioner set and bolt and washer Install dowel pins ROCKER ARM 8mm BOLT This chapter Contents 5 CYLINDER HEAD VALVE CAM SHAFT INSTALLATION Rotate the generator rotor and align the T mark with the index mark Install the camshaft comp When intalling camshaft set please take care that The line on the camsprocket should be in parallel with the surface of cylinder head The IN EX cam should be faced down Install the camshaft holder Install the cylinder head nuts TORQUE 2 80 3 00 kgf m CAUTION The cap nut of the four holder nuts must be installed Install the 6mm bolts Install the cam chain chain tensioner Install the auto tensioner Lock the spring cap bolt first Release the auto tensioner lock bolt Adjust the valve clearance 2 7 Install the cylinder head cover Install the R L cylinder head side cover Install the 6mm special bolts NOTE If the cylinder head side cover gasket is damaged or broken replace with a new one 9 15 SYM 6 CYLINDER PISTON TROUBLE SHOOTING PISTON PISTON RING INSPECTION SERVICE INFORMATION PISTON RING INSTALLATION CYLINDER REMOVAL PISTON INSTALLATION PISTON REMOVAL CYLINDER INSTALLATION TROUBLE SHOOTING LOW C
16. in light system B Y B R Y LIGHTS SWITCH CDI R ON unit REG REC 12V 8AH H gt ISILOSY 11 84 0 G LINN l JHSIMOVSH WOO NOLLINOI HOIVH3N3O O V LHD VL SYOLVOIGNI 13 1 This chapter Contents 13 BATTERY CHARGING SYSTEM SYM CHARGING SYSTEM FAILURE 1 Loose broken or shorted wire 2 Faulty voltage regulator 3 Faulty generator 4 Battery undercharged SERVICE INFORMATION GENERAL INSTRUCTIONS 1 Battery acid level should be checked and refill with distilled water when necessary 2 When charging the battery quick charging should only be done in an emergency slow charging is preferred 3 Remove the battery from the motorcycle for charging whenever possible If battery must be charged on the motorcycle keep away from flames or sparks 4 The parts of charging system can be tested on the motorcycle 5 Refer to section 8 for generator removal and installation SPECIFICATIONS Battery Capacity 12V amp 8AH Electrolyte specific gravity 1 260 1 280 20 C 68 F Charging current 0 9A A C generator Charging output 76W 5 000rpm Charging rom 1 200 rom max Day 2 400 rom max Night Rectifier One way full wave 13 2 This chapter Contents SYM 13 BATTERY CHARGING SYSTEM BATTERY BATTERY REMOVAL AND INSTALLATION Remove the right side cover Disconnect the battery negative cable first then the bat
17. neutral switch wire through the groove in the left crankcase cover Install the left crankcase rear cover Install the gearshift pedal This chapter Contents 8 A C GENERATOR STARTER MOTOR REMOVAL Disconnect the starter motor wire from the motor Remove the starter motor by removing the bolts Y ELECTRIC CONNECTOR STARTER DRIVEN GEAR REMOVAL Remove the left crankcase cover Remove the flywheel Remove the starter driven gear STARTER MOTOR STARTER DRIVEN GEAR STARTER MOTOR GEAR SET 1 Starter driven gear 2 Starter reduce gear 3 Starter motor Install the starter motor and gear in the reverse order of removal STARTER REDUCE GEAR 8 4 SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER TROUBLE SHOOTING TRANSMISSION DISASSEMBLY SERVICE INFORMATION TRANSMISSION ASSEMBLY CRANKCASE SEPARATION KICK STARTER DISASSEMBLY CRANKSHAFT REMOVAL CRANKCASE ASSEMBLY TROUBLE SHOOTING HARD TO SHIFT CRANKSHAFT NOISE 1 Shift fork bent 1 Worn connecting rod big end bearing 2 Shift fork shaft bent 2 Bent connecting rod TRANSMISSION JUMPS OUT OF GEAR on crankshaft bearing 1 Gear dogs worn GEAR NOISE 2 Shift fork bent or damaged 1 Worn transmission gears 3 Shift fork shaft bent 2 Worn spline shafts SERVICE INFORMATION GENERAL INSTRUCTION Transmission and crankshaft repairs require crankcase separation Remove the following parts before separating the crankcase Engine remova
18. oil Apply grease 1 GENERAL INFORMATION TORQUE VALUES TROUBLE SHOOTING 5 Clean all removed parts in or with solvent and lubricate their sliding surfaces upon disassembly 6 Coat or fill parts with specified grease where specified 7 Upon assembling check every possible part for proper installation and movement or operation 8 Work safely and give your work your undivided attention Exchange signals as frequently as possi ble when a work involves two or more workers Do not run the engine unless the shop or working area is well ventilated NOTE Things must be noticed CAUTION Things that could cause damage to the engine parts WARNING Things that could cause damage to the person or partner 1 1 This chapter Contents 1 GENERAL INFORMATION SYM SPECIFICATIONS 5125 Overall width 750mm Overall height 1100mm Wheel base 1280mm Ground clearance 150mm FRAME Drum type Fuel capacity 14 5 liter Fuel reserve capacity 2 0 liter Caster angle Front fork oil capacity Air cooled 4 stroke engine Cylinder arrangement Single cylinder 15 inclinde from vertical Bore amp stroke 56 5 x49 5mm Displacement 124 1 Oil capacity 0 80 0 95liter 0 9 liter for change 5 BTDC ENGINE intake valve oen 7 30 BBDC Exhaust valve 5 ATDC vo o o E TRAN Gear ratio 198 BTDC 29 5 2 4000rpm ELECTRICAL Valve clearance 1 2
19. rubbers for wear or damage and replace if necessary 12 3 This chapter Contents 12 REAR WHEEL REAR SUSPENSION FINAL DRIVEN SPROCKET ASSEMBLY Install the drive sprocket and new lock plates on the driven flange and tighten them with the bolts and nuts TORQUE 240 300 kg f cm Bend up the lock plate tabs against the nuts Install the driven flange on the wheel hub 12 4 This chapter Contents SYM 12 REAR WHEEL REAR SUSPENSION Measure the brake drum 1 0 Service limit 152mm REAR BRAKE PANEL BRAKE ARM BRAKE CAM NOTE Grease the place as figure BRAKE SHOE INSPECTION Measure the lining thickness Service limit 2 0mm BRAKE SHOE REPLACEMENT Separate the brake shoes with the brake cam Remove the brake shoes and springs Grease the brake cam Install the new brake shoes WARNING Contaminated brake lining reduces stopping power Keep grease off the lining 12 5 This chapter Contents 12 REAR WHEEL REAR SUSPENSION Install the hold arm Install the brake linkage Adjust the drive chain tension 2 13 Drive chain slack 10 20mm Tighten the chain tension adjusters Tighten the axle nut TORQUE 1000 1200 kg f cm Apply engine oil to the drive chain Install the step bar and the muffler SHOCK ABSORBER SHOCK ABSORBER REMOVAL Remove the left and right shock absorber assembly SHOCK ABSORBER DISASSEMBLY Compress the shock absorber spring with a shock
20. the pinion Service limit 24 96mm Measure the pinion sliding O D of the spindle Service limit 24 80mm 9 10 This chapter Contents SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER KICK STARTER ASSEMBLY Reverse the operation of diassembly for assembing CRANK CASE ASSEMBLY Install the gasket and dowel pins Install the left crankcase on the right crankcase NOTE Make sure that the gasket is in place 9 11 SYM 10 CARBURETOR TROUBLE SHOOTING SERVICE INFORMATION FLOAT FLOAT VALVE JETS ASSEMBLY 10 5 FLOAT LEVEL ADJUSTMENT THROTTLE VALVE ASSEMBLY CARBURETOR INSTALLATION CARBURETOR REMOVAL THROTTLE VALVE DISASSEMBLY 10 2 FLOAT FLOAT VALVE JETS DISASSEMBLY 10 3 TROUBLE SHOOTING ENGINE CRANKS BUT NOT START 1 No fuel in the fuel tank 2 No fuel in the carburetor 3 Too much fuel in the combustion chamber 4 No spark at the spark plug ignition malfunction 5 Air cleaner clogged ENGINE IDLE ROUGHLY 1 ldling speed incorrect 2 lgnition malfunction 3 Low compression 4 Rich mixture 5 Lean mixture 6 Air cleaner clogged SERVICE INFORMATION GENERAL INSTRUCTIONS Take cautions when dealing this operation Always work in a well ventilated area and away from sparks or open flames When assembling note the 7 Air leaking into intake pipe 8 Fuel contaminated LEAN MIXTURE 1 Carburetor jets clogged 2 Float chamber vent clogged 3 Fuel filter clogged
21. 80 1 20 0 70 1 10 4 00 5 00 2 80 3 20 2 80 3 20 4 00 5 00 0 80 1 20 0 80 1 20 0 80 1 20 0 80 1 20 0 40 0 50 0 40 0 70 TORQUE kgf m 6 00 8 00 10 00 12 00 8 00 10 00 4 00 5 50 4 50 5 50 1 80 2 50 6 00 9 00 4 00 5 00 3 00 4 00 1 50 2 00 4 00 5 50 4 00 5 00 2 0 3 30 2 00 2 50 1 00 1 40 TORQUE kgf m 0 35 0 50 0 70 1 10 1 00 1 40 2 40 3 00 3 50 4 50 1 3 This chapter Contents 1 GENERAL INFORMATION SYM Torque specifications listed below for respective locations TROUBLE SHOOTING A HARD START OR CANNOT START inspection adjustment loosen carburetor drain screw check inner side for gasoline no gasoline in the tank fuel tube between gasoline tank and carburetor clogged enough gasoline supplied no gasoline supplied float chamber fuel tube clogged for carbuertor for carburetor gasoline cover air hole clogged remove spark plug insert it TIS eee into plug cap check the fuel filter screen clogged spark by touching engine L gasoline auto fuel cup faulty grid spark weak or no spark spark plug faulty fouled spark plug CDI unit fualty pulse coil faulty high voltage coil cable open or short high voltage coil open or short main switch faulty A C G faulty Battery faulty valve too tight no gap valve seat faulty cylinder piston piston ring faulty cylinder gasket leak valve burnt out valve timing faulty crankcase leak when wmpress
22. BIY Remove carbon deposits from the combustion chamber Remove valve spring and valve spring and valve with a valve spring compressor VALVE COTTER CYLINDER HEAD INSPECTION Remove gasket from cylinder head with a scraper Check the cylinder head for crack Check the cylinder head for warpage with a straight edge and a feeler gauge Service limit 0 10mm VALVE SPRING INSPECTION Measure the free length of the inner and outer valve spring Service limit 39mm below 5 6 This chapter Contents 5 CYLINDER HEAD VALVE SYM VALVE VALVE GUIDE INSPECTION Inspect valves for scratches burning or wear Check the valve movement in the guide Measure the valve stem O D Service limit Intake 5 42mm Exhaust 5 40mm NOTE Remove any carbon buildup before checking the valve guide I D Guide 1 0 service limit Intake 5 50mm Exhaust 5 50 Measure the valve guide 1 0 and calculate the stem to guide clearance Service limit Intake 0 08mm Exhaust 0 10mm If the stem to guide clearance exceeds the service limit replace the valve or guide to fit NOTE The guide must be reamed when replacing a new one This chapter Contents 5 INSPECTION ADJUSTMENT VALVE GUIDE REPLACEMENT Drive out the valve guide from the combustion chamber side with a 5mm valve guide remover NOTE When driving out the valve guide do not damage the cylinder head Install the new valve guide from the to
23. EAR FORK INSPECTION Inspect the pivot bushing for cracks or damage Check each part for wear or damage 12 8 This chapter Contents SYM 12 REAR WHEEL REAR SUSPENSION REAR FORK INSTALLATION Install the rear fork TORQUE 8 00 10 00 kgf m Install the rear shock absorber and rear wheel Install the muffler REAR BRAKE PEDAL Remove the muffler Remove the brake linkage rod Remove the brake light switch spring Remove the brake return spring Adjust the rear brake after installation NOTE Do not forget to install the brake light switch spring AN 12 9 SYM 13 BATTERY CHARGING SYSTEM TROUBLE SHOOTING SERVICE INFORMATION TROUBLE SHOOTING NO POWER KEY TURNED ON 1 Dead battery Battery electrolyte evaporated Battery not charged Charging system failure 2 Disconnected battery cable 3 Main fuse burned out 4 Faulty ignition switch LOW POWER KEY TURNED ON 1 Weak battery Low battery electrolyte level Charging system failure 2 Loose battery connection LOW POWER ENGINE RUNNING 1 Battery undercharged One or more dead cells Low battery electrolyte level 2 Charging system failure 3 Generator failure 4 Faulty voltage regulator 5 Faulty ignition coil 6 C D I UNIT failure INTERMITTENT POWER 1 Loose battery connection 2 Loose charging system connection 3 Loose connection or short circuit in ignition system 4 Loose connection or short circuit
24. ECIFICATIONS Spark plug D7RC Spark plug gap 0 6 0 7mm 0 024 0 028in Ignition timing Initial 159 2 1500 Full advance 29 5 2 4000 14 2 SYM This chapter Contents SYM 14 IGNITION SYSTEM IGNITION COIL UF gt E IGNITION COIL IGNITION COIL REMOVAL T Remove the seat Remove the fuel tank Remove the spark plug cap Disconnect all wires to the ignition coil Remove the ignition coil IGNITION COIL TEST Check the ignition coil output using a tripolar tester NOTE Follow the instructions described in the user s manual BLACK YELLOW BLACK RED SPARK JUMP CDI YELLOW DISTANCE UNIT BLUE WHITE AT LEAST 6mm T PINK GREEN WHITE Check the primary circuit it is normal if there is conductivity when connecting a ohmmeter PRIMARY COIL 0 31 0 03 0 14 3 SYM 15 SWITCHES HORN TROUBLE SHOOTING HEADLIGHT SWITCH SERVICE INFORMATION START HAZARD SWITCH MAIN DIMMER SWITCH FRONT REAR BRAKELIGHT SWTICH WINKER HORN SWITCH HORN SWTICH HEADLIGHT SWITCH TROUBLE SHOOTING NO LIGHTS COME ON WHEN IGNITION SWITCH IS TURNED ON 1 Battery low 2 Wiring loose or blown 3 Fuse blown 4 Open or shorted wiring 5 Faulty combination switch 6 Bulb at fault or burned out ALL LIGHTS COME ON BUT DIMLY WHEN IGNITION SWITCH IS TURNED ON 1 Battery low 2 Wiring or switch has excessive resistance HEADLIGHT BEAMS DO NOT SHIFT WHEN HIGH LOW SWITCH IS OP
25. ERATED 1 Faulty dimmer switch 2 Faulty headlight switch 15 1 This chapter Contents 15 SWITCHESHORN CSM SERVICE INFORMATION GENERAL INSTRUCTIONS All electrical wires are color coded Check the color before connecting wires All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting A conductivity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a galvanometer or voltmeter to the terminals or connections SPECIFICATIONS Headlight 12V 35 35W Winker light 12V 10W Tail Stop light 12V 5W 21W Speedometer light 12V 3 4W x 2 Neutral pilot 12V 3 4W Winker indicator 12V 3 4W High beam pilot 12V 1 7W 15 2 This chapter Contents SYM 15 SWITCHES HORN MAIN SWITCH DIMMER SWITCH BROWN BROWN WHITE HAZARD SWITCH 15 3 15 SWITCHES HORN FRONT LIGHTBRAKE SWITCH Check that the front brakelight switch for conductivity between the BLACK and GREEN YELLOW wires The switch is normal if there is conductivity with the front brake applied REAR LIGHTBRAKE SWITCH The switch is normal if there is conductivity with the rear brake applied ADJUSTING SCREW HORN Connect the horn to a 12V battery for testing its performance Adjust the horn if the noise is not loud enough 15 4 i 8 Caia s ner BATTERY R HANDLE SW ASS Y XSI 25 K WIRING DIAGR ANI CORD COL
26. FICATIONS ITEM STANDARD SERVICE LIMIT e Rim runout 0 0 00 S _ 12 1 This chapter Contents 12 REAR WHEEL REAR SUSPENSION REAR WHEEL REAR WHEEL REMOVAL Raise the rear wheel off the ground on the main stand Remove the exhaust muffler Disconnect the brake rod from the brake arm Disconnect the brake torque link from the brake panel Remove the axle nut and loose the chain adjusting nut Pull out the axle shaft and remove the drive chain from the drive sprocket then remove the rear wheel AXLE INSPECTION Set the axle in the V blocks and measure the runout The actual runout is 1 2 of the total indicator reading service limit 0 2mm under 12 2 SYM 12 REAR WHEEL REAR SUSPENSION FREE PLAY BEARING FREE PLAY INSPECTION Mer ae Shake the bearing back and forth and spin it by hand replace it with a new one if it is noisy or has excessive free play FREE PLAY RADIAL WHEEL RIM RUNOUT INSPECTION Check the rim runout by placing the wheel in a turning stand Turn the wheel by hand and read the runout using a dial indicator gauge TORQUE 0 25 0 50 kgf m Runout Axial 2 0mm under Radial 2 0mm under FINAL DRIVEN SPROCKET INSPECTION Check the condition of the final driven sprocket teeth Replace the sprocket if it is worn NOTE The drive chain and drive sprocket must be also inspected for wear NOT GOOD DAMPER RUBBER INSPECTION Check the damper
27. IFT SYM Remove the gearshift drum stopper arm GEARSHIFT DRUM Remove the gearshift cam STOPPER ARM Check each part for wear or damage om GEARSHIFT LINKAGE ASSEMBLY Install the four 4mm roller Align the hole of the gearshift cam with the roller then install the gearshift cam Install the gearshift drum stopper NOTE After installation check the drum stopper operation 7 10 This chapter Contents SYM 7 CLUTCH OIL PUMP GEAR SHIFT Install the gearshift spindle NOTE Align the gearshift return spring on the projection of the crankcase Check the gearshift linkage for smooth operation Install the clutch oil pump and oil filter rotor RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket Install the right crankcase cover and tighten the SCrews Connect the clutch cable Install the kick starter pedal Fill the crankcase with the recommended oil Adjust the clutch lever free play 7 11 SYM 8 A C GENERATOR SERVICE INFORMATION LEFT CRANKCASE COVER INSTALLATION 8 3 LEFT CRANKCASE COVER REMOVAL STARTER MOTOR REMOVAL FLYWHEEL REMOVAL STARTER DRIVEN GEAR REMOVAL 8 4 FLYWHEEL INSTALLATION STARTER MOTOR GEAR SET 8 4 SERVICE INFORMATION GENERAL INSTRUCTION This section covers removal and installation of the AC generator and starter motor These operation can be done with the engine installed in the frame Special tool Roto
28. K B W BLACK WHITEBR BROWN BLACK YELLDUR GRAY G W GREEN YELLDWE LIGHT GREEN L W BLUE WHITE SB SKY BLUE
29. LATE CLUTCH PRESSURE CLUTCH FRICTION DISC INSPECTION Replace the clutch disks if they have any score or discoloration Measure the clutch friction disk thickness SERVICE LIMIT 2 8mm CLUTCH PLATE INSPECTION Check the plates for warpage on a surface plate using a feeler gauge Service limit 0 2mm 7 4 This chapter Contents SYM 7 CLUTCH OIL PUMP GEAR SHIFT Remove the 20 mm washer and clutch outer CLUTCH OUTER INSPECTION Check the clutch outer for cracks or indentation mui CLUTCH OUTER INSTALLATION Install the clutch outer 20mm washer on the main shaft NOTE When installing the washer it should fit with the main shaft groove Install the clutch pressure plate friction discs clutch plates and clutch center 7 CLUTCH OIL PUMP GEAR SHIFT Install and tighten the 20mm set ring Install the clutch springs lifter plate and tighten the bolts Install the bearing NOTE Tighten the bolts in a crisscross pattern in two or three steps TORQUE 0 80 1 20 kgf m Install the oil filter rotor Install the lock washer and 16mm lock nut Tighten the 16mm lock nut TORQUE 4 00 5 00 kgf m Install the filter rotor cover Check the oil through for a smooth operation without binding Install the lifter rod Install the dowel pins and a new gasket Install the right crankcase cover Connect the clutch cable Install the exhaust muffler and step
30. NDER PISTON SYM PISTON INSTALLATION Install the piston piston pin and piston pin clip NOTE Position the IN mark on the piston to the carburetor side Do not let the piston pin clip fall into the crankcase Use new piston pin clip whenever disassembling Do not align the piston pin clip end gap with the piston cutout CUTOUT CYLINDER INSTALLATION Install the cylinder gasket and dowel pins Clean the cylinder gasket surface of any gasket material NOTE Avoid damaging the cylinder gasket surface during this operation Install the cylinder NOTE Avoid piston and piston rings damage during installation Install the cylinder gasket and dowel pins Install the cylinder head 5 8 NOTE Coat the cylinder and piston with the engine oil before installing the cylinder 6 6 SYM 7 CLUTCH OIL PUMP GEAR SHIFT TROUBLE SHOOTING OIL PUMP SERVICE INFORMATION GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL 7 2 RIGHT CRANKCASE COVER INSTALLATION 7 11 CLUTCH TROUBLE SHOOTING Faulty clutch operation can be corrected by adjusting the clutch lever free play CLUTCH SPINS WHEN ACCELERATING HARD SHIFTING 1 No free play 1 Stopper plate bent 2 Discs worn 2 Improper clutch adjustment GEARSHIFT PEDAL WON T RETURN CLUTCH DISENGAGED MOTORCYCLE 1 Return spring broken or weak 1 Too much free play JUMPS OUT OF GEAR 2 Plates warped 1 Stopper arm spring broken EXCESSIVE LEVER PRESSURE LO
31. NSPECTION ADJUSTMENT SERVICE INFORMATION SPECIFICATION ENGINE Oil capacity 0 9 liter Spark plug gap A6RTC Spark plug gap 0 6 0 7mm Valve clearance IN 0 08mm EX 0 10mm Cylinder compression 9 5kg c m 1kg c m SPECIAL TOOL Valve clearance adjuster TORQUE VALVES Right crankcase cover Front fork top bridge bolt Front fork bottom bridge bolt Rear wheel axle nut Rear shock absorber nut Rear fork pivot bolt FRAME Clutch lever free play Drive chain stack Front brake lever free play Rear brake pedal free play Throttle grip free play 0 80 1 20 kgf m 1 00 1 40 kgf m 2 00 2 50 kgf m 4 00 5 50 kgf m 3 00 4 00 kgf m 3 50 4 50 kgf m SYM 10 20mm 10 20mm 10 20mm 20 30mm 2 6mm 2 INSPECTION ADJUSTMENT OIL OIL FILTER OIL LEVEL CHECK Start and warm up the engine for few minutes then stop the engine Check the oil level with oil level gauge after a few minutes If the oil level is near the lower mark fill the crankcase to the upper level mark with the recommended grade oil OIL FILTER SCREEN COVER OIL REPLACEMENT NOTE Drain the engine oil while the engine is warm Remove the oil filter screen cover and drain the engine oil NOTE Make sure that the oil filter screen cover O ring is in good condition Fill the crankcase up to the upper level mark on the oil level gauge with the recommended oil SAE15W 40 API SH CD 2 4 2 INSPECTION ADJUSTMENT OIL FILTER SCREEN CLEANING
32. OMPRESSION OVERHEATING 1 Worn cylinder or piston rings 1 Excessive carbon build up on piston or EXCESSIVE SMOKE combustion chamber wall 1 Worn cylinder piston or piston rings KNOCKING OR ABNORMAL NOISE 2 Improper installation of piston rings 1 Worn piston or cylinder 3 Scored or scratched piston or cylinder wall 2 Excessive carbon build up SERVICE INFORNATION GENERAL STRUCTIONS 5125 STANDARD CERVICE LIMIT Cylinder LD 56 495 56515mm Cylinder Piston ring to Top 0 025 0 055mm 0 060mm ring groove clearance 0 015 0 040mm 0 045mm End gap Piston rings Piston O D 06 485 56 505mm 56 48mm t 1508mm enne P 15 002 15 008mm Connecting rod small end I D 15 016 15 034mm 15 07mm Piston pin O D 14 994 15 000mm 14 994mm Piston ring 0 97 0 99mm 1 460mm 097 099 1 460mm This chapter Contents 6 CYLINDER PISTON CYLINDER REMOVAL Remove the cylinder head Remove the dowel pins and gasket Remove the cylinder NOTE Avoid the dowel pins falling into the crankcase during removing the cylinder Remove the dowel pins and gasket Clean the cylinder gasket surface of any gasket material NOTE Avoid damaging the cylinder gasket surface during this operation CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D NOTE According to the right picture measure the cylinder runout Service limit ITEM 5125
33. OR FULL NAME LIGHTING S STOP SW START SW FRSTOP SW COLL REG REC COMP FUEL UNIT RR STOP SW WINKER REL ODI UNIT FRAME EARTH FULL NAE SPEEDOME TER FUEL METER 6 Br 0 100108 9 e PITTI I Bo m om 297 lt E G R CREEN REDI 20 8 LG RED PED 1 8 BROWN RED ll l hv mm et a i E EB rms E lt EL in SS LS _ __ T ex lu r 12V 54 LH FR WINKEI 0 12V 16W 5 LIGHT 12V 21 54 c E c 1 0 WINKER 6 12V 16 BAT EARTH CABLE BATASS Y 12V 7AH LG 0 Gr SB LG B M ACC ASS Y START MOTOR 8 HANGE SW CONNECTOR FOR GUARD AGAINST THEFT SYSTEM WINKER SW SW L HANDLE SW ASS Y ASI223 K ELEU UIS TRIDU HON SE SILICON FR STOP 5 e gt ee G RR STOP SW B R B Y IGN COIL LIGHTING SW POSITION LIGHT 12V 3W TAIL LIGHT 12V 5W ILLUMI LIGH METERT2V 2W 2 9 0 WINKER PILOT 12V Z Go 8 5 CORD COLOR FULL NAME WSL NAME ILG R LIGHT GREEN RED ORANGE G R GREEN RED R RED LY W YELLOW WHI B BLACK G Y GREEN YELLDW WHITE Y R YELLOW REI Y YELLOW B R BLACK RED G GREEN W E WHITE BLACKP PIN
34. Remove the oil filter cap oil filter screen and drain the engine oil Operate the kick starter several times to drain residual oil completely Clean the oil filter screen with compressed air Install the oil filter screen spring and screen cap Fill the crankcase with the recommended oil OIL CAPACITY 0 9L SPARK PLUG Disconnect the spark plug cap and 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 Discard 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 sandblasting or wire brushing the spark plug can be reused Inspect the gap with a feeler gauge and adjust by bending the side electrode Standard gap 0 6 0 7mm NOTE To install turn finger tight then tighten with a spark plug wrench 0 024 0 028 in 2 INSPECTION ADJUSTMENT COMPRESSION TEST Warm up the engine Stop the engine Remove spark plug Insert the compression gauge Push in the choke lever Open the throttle grip fully Electrical start engine several times NOTE Watch for compression leaking at the gauge connection e Crank the engine until the gauge reading stops rising The maximum reading is usually reached in several times Compression 9 5kg c m 1kg c m Low compression can be caused by Improper calve adjustmen
35. SERVICE MANUAL 5 125 SYM PREFACE PREFACE e This shop manual describes the technical feature and servicing procedures for the SANYANG 5125 e information illustrations directions and specifications included in this publication are base on SANYANG 5125 SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever SANYANG INDUSTRY CO LTD SERVICE DIVISION SYM CONTENTS CONTENTS GENERAL INFORMATION INSPECTION ADJUSTMENT LUBRICATION SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEAD VALVE CYLINDER PISTON CLUTCH OIL PUMP GEAR SHIFT A C GENERATOR CRANK SHAFT CRANK CASE TRANSMISSION CARBURETOR HEADLIGHT STEERING FRONT WHEEL FRONT FORK REAR WHEEL REAR SUSPENSION BATTERY CHARGING SYSTEM IGNITION SYSTEM SWITCHES HORN WIRING DIAGRAM SYM SERVICE RULES SPECIFICATIONS SERVICE RULES 1 Use new packings gaskets O rings and cotter pins space and clipes whenever reassembling 2 When tightening bolts or nuts begin on center or larger diameter bolts and tighten them in criss cross pattern in two or more steps if necessary 3 Use genuine SANYANG parts and lubricants or those equivalent When parts are to be reused they must be inspected carefully to make sure they are not damaged or deteriorated and in good usable condition 4 Use special tool when use of such a tool is specified Symbol Marks B Apply engine
36. W OIL PRESSURE 1 Clutch cable kicked damaged or dirty 1 Oil pump drive gear worn 2 Lifter mechanism damaged 2 Faulty oil pump SERVICE INFORMATION GENERAL INSTRUCTION This section covers removal installation and servicing of the clutch oil pump filter and gearshift linkage All these operations can be accomplished with the engine in the frame COMMON TOOLS 22mm wrench socket Air wrench TORQUE VALUES Right crankcase cover 0 80 1 20 kgf m Kick starter pedal 1 00 1 50 kgf m otep bar 1 80 2 00 kgf m SPECIFICATIONS TEM STANDARD SERVICE LIMIT aa ola meme a 7 1 This chapter Contents 7 CLUTCH OIL PUMP GEAR SHIFT RIGHT CRANKCASE COVER REMOVAL Drain oil from the engine Disconnect the clutch cable Remove the kick starter arm Remove the right crankcase cover CLUTCH CLUTCH REMOVAL Remove the clutch lifter rod Remove the oil filter rotor cover Remove the 16mm lock nut with a lock nut wrench Remove the oil filter rotor 2 LTER ROTOR 29 7 2 This chapter Contents SYM 7 CLUTCH OIL PUMP GEAR SHIFT Remove the bearing clutch bolt clutch lifter plate and clutch spring CLUTCH SPRING INSPECTION Measure the clutch springs free length Service limit 28 6mm Remove the 20mm set ring Remove the clutch center disks plates and pressure plate This chapter Contents 7 CLUTCH OIL PUMP GEAR SHIFT SYM CLUTCH CENTER CLUTCH P
37. al runout is 1 2 of the total indicator reading Service limit 0 2mm under WHEEL BEARING INSPECTION Shake the bearing back and forth and spin it by hand replace the bearing with a new one if it is noisy or has excessive play FREE PLAY RADIAL 11 4 This chapter Contents SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK FRONT BRAKE FRONT BRAKE DISC INSPECTION DISC BRAKE Replace the brake pads if the wear indicator mark is pointed Measure the brake disc thickness Service limit 3 5mm FRONT BRAKE DISASSEMBLY Remove the caliper by removing the two caliper mounting bolts Remove the pad guide bolts Remove the brake pads CAUTION Do not operate the brake lever after the caliper removal to avoid brake pads sticky FRONT BRAKE ASSEMBLY Reverse the procedures of disassembly to install the brake pads Tighten the brake pad guide bolts FRONT BRAKE LINING INSPECTION DRUM BRAKE Measure the brake lining thickness Service limit 2 0mm 11 5 This chapter Contents 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK FRONT BRAKE PANEL INSPECTION Remove the brake shoes and springs Remove the brake arm and brake cam Remove the speedmeter drive gear and dust seal BRAKE CAM FRONT BRAKE PANEL ASSEMBLY Install a new dust seal Apply grease to the speedometer gear and install the gear Apply grease to the sliding surfaces of the brake cam and shoes as shown in the figure above Inst
38. all the brake cam and brake arm aligning the punch mark on the brake arm with the panch mark on the cam Install the brake shoes and springs FRONT WHEEL RIM INSPECTION Check the wheel rim runout by placing the wheel on the turning stand Service limit Axial 2 0mm under Radial 2 0mm under FRONT WHEEL ASSEMBLY Apply grease to the wheel bearings Install the right bearing and center collar Install the left bearing and dust seal Install the side collar NOTE Install the bearing with the sealed end facing the outside 11 6 BRAKE SHOES SYM This chapter Contents SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK FRONT WHEEL INSTALLATION Install the front wheel Install the axle shaft from the right side Tighten the axle nut TORQUE 6 00 8 00 kgf m Connect the speedometer cable FRONT FORK FRONT FORK REMOVAL Remove the front wheel Remove the brake caliper bolts Remove the front fender Remove the fork top bridge bolts E J 3 Rd Soe AONNE 4 S 54 EM ix M i NONI toe VA LM TN Ll ai a y E CN Sa k EN 2 bh UM e NES NOR QR TOPBRID PREN ENN e SANA a a eee Loosen the fork bottom bridge remove the front shock absorber assembly 11 7 This chapter Contents 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK SYM If the front fork is too soft or too ha
39. d tighten them to the specified torque TORQUE Front fork top bridge bolt 1 00 1 40 kgf m Frint fork bottom bridge bolt 2 40 3 00 kgf m Axle nut 6 00 8 00 kgf m REAR SUSPENSION Check for abnormal noises and leaks by compressing the rear suspension several times Check the rear suspension nut for loosing Torque 3 00 4 00 kgf m Move the rear wheel side ways with force to see if the swing arm bushings are worn Rear fork torque 8 00 10 00 kgf m 2 16 2 INSPECTION ADJUSTMENT STEERING Raise the front wheel off the ground and check that the handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head nut BATTERY Inspect the battery fluid level if the fluid level nears the lower level mark fill with distilled water to the upper level mark Clean the battery terminals with warm water Check the specific gravity of the battery electrolyte 13 3 TES Do not overfill Add only distilled water Tap water will shorten the service life of the battery WARNING Keep the electrolyte away from eyes skin and clothes If touched it wash them with clean water quickly 2 17 2 INSPECTION ADJUSTMENT HEADLIGHT AIM Adjust vertically by turning headlight up and down with the headlight bolts loosening Fasten the bolts after adjustment tie ye F 4 enmt d 3 P4 m di M NR
40. ector Disconnect the meter cables Remove the setting screws Remove the meter NW M NE Z n setting crews HANDLEBAR HANDLEBAR REMOVAL Remove the wire harness Remove the light switch and throttle cable remove the turn signal switch assembly Remove the handlebar upper holder bolts Disconnect the front brake and clutch cable from the lever Remove the handlebar holders and take off the handlebar HANDLE BAR INSTALLATION Connect the front brake and clutch cable to the lever Install the handlebar on the lower holder NOTE Align the punch marks on the handlebar with the top of the handlebar lower holder Install the handlebar holders NOTE Tighten the forward bolts to the specified torque first then tighten the rear bolts to the same torque TORQUE 100 140 kg m Install the light switch and throttle grip 11 3 This chapter Contents 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK SYM NOTE Coat the throttle grip hole with grease Install the winker switch assembly NOTE Align the punch mark on the handlebar with the split in the housing FRONT WHEEL FRONT WHEEL REMOVAL Raise the front wheel off the ground by placing a block under the engine Disconnect the speedometer cable and front brake cable Remove the axle nut Pull out the axle remove the front wheel FRONT WHEEL AXLE SHAFT INSPECTION Place the axle on V blocks and measure the runout the actu
41. et steering stem be able to rotor freely L TOP BRIDGE BOLT Install the front fork Tighten the front fork bottom bridge bolts TORQUE 4 00 5 50 kgf m Install the front fork top bridge FRONT FORK TOP BRIDGE Tighten the steering stem nut TORQUE 6 00 8 00 kgf m Tighten the front fork top bridge bolts TORQUE 4 00 5 50 kgf m Install the handlebar meter headlight and front wheel 11 10 SYM 12 REAR WHEEL REAR SUSPENSION TROUBLE SHOOTING SHOCK ABSORBER SERVICE INFORMATION REAR FORK REAR WHEEL REAR BRAKE PEDAL REAR BRAKE PANEL TROUBLE SHOOTING HARD SUSPENSION 1 Bent damper shaft WOBBLE OR VIBRATION IN 2 Faulty shock absorber stopper rubber MOTORCYCLE SUSPENSION NOISE 1 Loose rear wheel bearing 2 Distorted rim 3 Tire pressure too high 4 Loose axle nut 1 Loose fasteners 2 Faulty shock absorber stopper rubber 3 Damper leaking 4 Damper and spring binding SOFT SUSPENSION POOR BRAKE PERFORMANCE 1 Weak spring 1 Improper brake adjustment 2 Shock absorber faulty or too soft P bid ao 2 Brake linings oily or worn 3 Worn brake drum 4 Brake arm serrations improperly engaged SERVICE INFORMATION TORQUE VALUES Rear wheel axle nut 10 00 12 00 kgf m Rear fork pivot bolt nut 8 00 10 00 kgf m Rear brake torque link nut 1 50 2 00 kgf m Shock absorber nut 3 00 4 00 kgf m Final driven sprocket 2 70 3 30 kgf m Drive sprocket bolt 1 00 1 40 kgf m SPECI
42. if they have excessive free play or noisy FREE PLAY FREE PLAY RADIAL BEARING INSTALLATION Install the bearings into the left right crankcase with special tools NOTE Install the bearing horizontally to prevent bearing damage This chapter Contents 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER SYM TRANSMISSION ASSEMBLY NOTE Before assembling coat each gears with engine oil Counter shaft Assemble the gears of the countershaft and mainshaft NOTE Seat the snap ring in the ring groove properly 9 8 This chapter Contents SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER Install the crankshaft assemblies in the right crankcase Install the mainshaft and countershaft assemblies in the right crankcase NOTE Keep the thrust washers in place during installation Install the mainshaft countershaft and shift forks Install the gearshift drum Install the shift fork shaft NOTE Engage the shift fork guide pin with the drum groove by raising the shift fork After assembling check each part for moving freely p CU v Fh SHIFT FORK SHAFT ME GEARSHIFT DRUM This chapter Contents 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER SYM KICK STARTER DISASSEMBLY Remove the kick starter spindle assembly Remove the kick starter spindle from the engine Remove the thrust washer and drive ratchet Measure the I D of
43. l 4 2 Cylinder head removal 5 2 Cylinder Piston removal 6 2 Clutch oil pump Gearshift linkage removal 7 2 Left crankcase cover removal 8 2 Flywheel removal 8 2 SPECIAL TOOLS Bearing driver Bearing driver pilot SPECIFICATIONS ITEM STANDARD SERVICE LIMIT ub 12 000 12 018mm 205mm Gearshift fork Claw thickness 4 925 5 000mm Connecting rod small I D 15 016 15 034mm 15 08mm Connecting rod big 0 10 0 30mm End side clearance Crankshaft 0 000 0 008mm 0 080mm This chapter Contents 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER SYM CRANKCASE SEPARATION Remove the right crankcover and internal parts 7 3 7 13 Remove left cover and internal parts This chapter Contents SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER Remove the left crankcover all 6mm attaching bolts Separate the left crankcase from the right crankcase Remove the gasket and dowel pins CRANKSHAFT REMOVAL Remove the left crankcase Remove the crankshaft CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge Service limit 0 60mm Measure the connecting rod big end radial clearance Service limit 0 05mm CRANKCASE This chapter Contents 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER Support the crankshaft bearings on a V block and measure the runout using a gauge NOTE Coat the bearing and connecting rod big end wi
44. ment Replace the coil if there is no sparks at plug IGNITION COIL IGNITION TIMING INSPECTION IGNITION COIL Remove the generator cover and check the ignition CONTINUITY TEST timing with a timing light Timing is correct if the index mark aligns with the F mark within 3 at 1500rpm Ignition timing 10 BTDC 1500rpm Ignition coil continuity test Check the resistance of the primary coil and secondary coil 1 Primary coil 0 31 0 03 9 2 Secondary coil 4 0 0 4k Q IGNITION COIL 2 6 2 INSPECTION ADJUSTMENT Inspect the C D I unit with C D I tester Replace the faulty C D I unit SWITCH C D I normal C D faulty no sparks no sparks no sparks sparks no sparks sparks no sparks CAM CHAIN TENSIONER ADJUESTER The cam chain tension is kept by the tensioner push rod that is compressed by the spring CAUTION If remove any parts that is related with the cam chain remove the cam chain tensioner adjuester first OPERATING SWITCH C D E MAT C D I UNIT CONVERTER CAM CHAIN TENSIONER ADJUESTER 1 i rt 3 ee M E pu MR 2 INSPECTION ADJUSTMENT SYM CARBURETOR THROTTLE GRIP FREE PLAY Check throttle grip free play 2 6 mm 0 08 0 24 in Free play 2 6mm THROTTLE GRIP ADJUSTMENT Loosen the lock nut and turn the adjuster to adjust 2 10 2 INSPECTION ADJUSTMENT IDLING SPEED ADJUSTMENT Warm up the engine
45. ng or damaged head gasket Warped or cranked cylinder head HIGH COMPRESSION 1 Excessive carbon buildup on piston or combustion chamber ABNORMAL NOISE Incorrect valve clearance 2 Broken valve spring 3 Worn rocker arm or camshaft 4 Loose or worn cam chain 5 Worn cam chain tensioner 6 Worn cam sprocket teeth This chapter Contents 5 INSPECTION ADJUSTMENT SYM SERVICE INFORMATION GENERAL INSTRUCTIONS Camshaft rocker arm shaft and rocker arm can be serviced with the engine installed on the frame Camshaft lubrication oil is fed to the cylinder head through an oil control orifice in the engine case Be sure this orifice is not clogged and the O ring and dowel pins are in place before installing the cylinder head During assembly apply molybdenum disulfide grease to the camshaft bearings and pour clean engine oil into the cylinder head TORQUE VALUES Cylinder head bolt 2 80 3 00 kgf m Cylinder 6mm bolt 1 40 1 80 kgf m Cam sprocket 0 80 1 20 kgf m SPECIFICATIONS ITEM STANDARD SERVICE LIMIT 32 382mm 31 26mm below Cam lift Camshaft 31 987mm 30 87mmbelow Hocker 1 0 12 000 12 018 12 018 Hocker arm shaft EE 11 966 11 984 mm 11 966mm below Free Freelength 39 95 40 55 39mm below Valve Sial lengt e EMIL Valve clearance IN 0 06 2 0 02mm 10 0 02 Valve Guide I D TE TEET This chapter Contents 5 CYLINDER HEAD VALVE
46. ng stem nut too tight 1 Bent front fork 2 Faulty steering stem bearing 2 much fluid in the front forks 3 Insufficient tire pressure STEERS TO ONE SIDE FRONT SUSPENSION NOISE 1 Bent front axle 1 Bent front fork 2 Bent front fork 2 Insufficient fluid in the front fork 3 Faulty front wheel 3 Loose front fork fasteners 4 Misadjusted shock absorber SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers the removal inspection and installation of the front wheel front fork and steering Before removing the front wheel place a block under the engine TORQUE VALUES Front wheel axle nut 6 00 8 00 kgf m Handlebar upper holder 1 00 1 40 kgf m oteering stem nut 6 00 8 00 kgf m Front fork top bridge 4 00 5 50 kgf m Front fork bottom bridge 4 00 5 50 kgf m SPECIFICATIONS ene mm 11 1 This chapter Contents SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK HEADLIGHT HEADLIGHT REMOVAL Remove the headlight screw Remove the headlight case Disconnect the wire connector HEADLIGHT WIRING Route the wires through the headlight Connect the wires Color to color HEADLIGHT INSTALLATION Install the headlight Install the headlight case aligning the mark to the holder tighten the bolts 11 2 This chapter Contents SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK wrR NE a METER REMOVAL Remove the headlight case Disconnect each wire and conn
47. ositive cable to the battery positive terminal negative cable to the battery negative terminal Charge the battery until the specific gravity of the electrolyte is 1 260 1 280 20 6 Charging current 0 7A max WARNING Before charging a battery remove the cap from each cell Keep flames and sparks away from a charging battery Connect the cables first then turn on the power Discontinue charging if the electrolyte temperature exceeds 45 113 F CAUTION Quick charging only be done in an emergency slow charging is preferred After installed the battery coat the terminals with clean grease to keep from oxidation CAUTION Route the breather tube as shown on the battery caution label CHARGING SYSTEM PERFORMANCE TEST VOLTMETER AMMETER Warm up the engine before taking readings Connect a voltmeter and an ammeter to check charging output NOTE Use a fully charged battery to check the charging system output 13 4 This chapter Contents SYM 13 BATTERY CHARGING SYSTEM STATOR COILS TEST NOTE This test can be made with the stator on the frame Disconnect and measure the A C generator connectors with a multi meter Conductivity should exist between Pink yellow blue white green white black red ground Pink yellow blue white green white should not conduct electricity with ground RECTIFIER RECTIFIER Disconnect the rectifier connector and check i
48. p of the cylinder head and ream it with a reamer then clean the cylinder head 5 8 SYM X V VALVE GUODE REMOVER M This chapter Contents 5 CYLINDER HEAD VALVE SYM VALVE SEAT INSPECTION REFACING Clean intake and exhaust valves to remove carbon deposits Apply a light coating of prussian blue to each valve face Insert each valve into the guide and rotate them two cycles Remove the valve and inspect the face CAUTION If the valve face is burned or damaged or unevenly replace the valve CONTACT AREA VALVE SEAT Inspect the valve seat If the seat is too wide or too narrow the seat must be refinished SERVICE LIMIT SERVICE LIMIT 1 5mm 1 8mm This chapter Contents 5 INSPECTION ADJUSTMENT SYM VALVE SEAT GRINDING NOTE Follow the instructions described in the cutter instruction manual Remove any roughness from the seat by applying 4 5 kg pressure turning the cutter left and right NOTE Add engine oil to the face when operating CUTTER CUTTER HOLDER Using a 45 degree cutter remove any roughness from the seat ROUGHNESS VALVE SEAT This chapter Contents 5 CYLINDER HEAD VALVE Using a 32 degree cutter remove 1 4 of the existing valve seat material 32 CUTTER VALVE SEAT Remove the bottom 1 4 of the old seat by using a 60 degree cutter 60 CUTTER Finish the seat to the proper width by using a 45 45 CUTTER degree cutter
49. parking well poor sparking air inlet duct clogged damaged 1 6 This chapter Contents SYM 1 GENERAL INFORMATION D ROTATION ROUGH HIGH SPEED inspection adjustment ee ignition timing adjustment abnormal Rar CDI unit aulty pulse generator poor adjustment check auto fuel n TES cup for fuel supplied normal too little fuel in the fuel tank fuel tube fuel filter clogged air hole on the fuel tank colgs auto fuel cup faulty valve timing adjusting inspection cam sprocket aligning marks incorrect check valve spring 1 7 This chapter Contents 1 GENERAL INFORMATION SYM E POOR CHARGE BATTERY OVER DISCHARGE OR OVER CHARGE inspection adjustment measure battery voltage aic battery voltage battery voltage rise to reach battery life can t rise normal value after i faulty battery engine stops the voltage return to original check voltage regulator rectifier coupler check the voltage between voltage red wire NORUNT ERO and frame body grou nding with mult meter terminals measure the resistance of AC generator coil abnormal poor charge over charge normal coupler poor contact red wire open voltage adjuster white wire open oil faulty onnector poor contact AC generator white wire open faulty battery after engine
50. r Contents 4 ENGINE REMOVAL INSTALLATION Remove the front engine hanger bolt NOTE Places jack or padded block under the engine before removing the front engine hanger Disconnect the starter motor wire FRONT ENGINE HANGER BOLT Remove the 10mm bolts of the rear engine hanger Remove the engine NOTE Prevent damage to wire harnesses and cables during operation ENGINE INSTALLATION Follow the reverse procedure of removal to install the engine Notice the following items during installation e Route all wire harnesses and cables properly e Adjust the throttle grip free play P2 10 e Adjust the clutch lever free play P2 12 e Adjust the drive chain slack 2 14 e Fill the crankcase with the recommended grade oil to the proper level SAE 15W 40 API SH CD EN E Se 4 i f 4l j E 2 e 4 A sl gt cd XS 22 i 4 4 5 CYLINDER HEAD VALVE TROUBLE SHOOTING VALVE GUIDE REPLACEMENT SERVICE INFORMATION VALVE SEAT INSPECTION REFACING 5 9 CAM SHAFT REMOVAL VALVE SEAT GRINDING CYLINDER HEAD ROCKER ARM CYLINDER HEAD ASSEMBLY 5 13 REMOVAL CYLINDER HEAD INSTALLATION 5 14 CYLINDER HEAD DISASSEMBLY CAM SHAFT INSTALLATION 5 15 VALVE VALVE GUIDE INSPECTION TROUBLE SHOOTING LOW COMPRESSION 1 Valve Incorrect valve clearance Burned or bent valves Incorrect valve timing Broken valve spring 2 Cylinder head Leaki
51. r puller TORQUE VALVE Flywheel bolt 2 60 3 20kgf m This chapter Contents 8 A C GENERATOR LEFT CRANKCASE COVER REMOVAL Remove the gearshift pedal Remove the left crankcase rear cover Disconnect the AC generator and pulse generator wire connector Remove the left crankcase cover NOTE Generator stator is in the left crankcase cover it can be removed by removing the attaching screws FLYWHEEL REMOVAL Remove the flywheel bolt LEFT CRANKCASE REAR COVER FLYWHEEL SETTING BOLT O Remove the flywheel with the rotor puller This chapter Contents SYM 8 A C GENERATOR STATOR COIL INSPECTION NOTE This inspection can be made with the stator in the frame Check the starter for continuity Continuity should exist between Yellow and pink Black red and ground Blue white and green white Pink yellow blue white and green white should not continue with the ground Yellow and green Replace the stator and pulse generator assembly if necessary FLYWHEEL INSTALLATION Reverse the procedure of removal to assembly NOTE e Check wire for security in its place Do not interfere the wire with the flywheel Install and tighten the flywheel TORQUE 4 00 5 00 kgf m FLYWHEEL BOLT 5m s GENERATOR WIRE CONNECTORS LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover with stator coil Connect the generator wire connectors Route the
52. rd refill or drain the shock absorber fluid Shock absorber fluid CUSHION OIL Standard capacity 160 FRONT FORK INSTALLATION Install the front fork from the bottom NOTE Turn the front fork left and right by hand while installing Tighten the fork top bridge bolts TORQUE 4 00 5 50 kgf m Tighten the fork bottom bridge bolts TORQUE 4 00 5 50 kgf m Install the front fender Install the front wheel STEERING STEM FRONT FORK TOP REMOVAL Remove the handlebar Remove the headlight and meter assembly Remove the front fork Remove the steering stem nut and washer 11 8 This chapter Contents SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK STEERING STEM DISASSEMBLY Remove the front fork top bridge bolts NOTE Do not let the steel balls fall Remove the steel balls cone brace steering stem and steel balls Check the top and bottom cone races and steel balls for wear or damage and replace if necessary STEEL STEEL M a BALLS STEERING STEM ASSEMBLY BALDO S gt STEERING 7 Stor CONE lt STEERING C PN oron LOCK CONE BRACE Install the steel balls cone brace DRIVER DRIVER HOLDER This chapter Contents 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK SYM Grease the steel balls and cone braces install the steering stem Install the steering top nut and tighten it until snug against the upper cone braces Back the top nut out 1 8 turn to l
53. starter measure the voltage between voltage regulaton m M rectifier red wire and green wire connected with frame body voltage normal check voltage regulator P rectifier coupler for poor normal poor contact contact Coupler poor contact green wire poor grounding measure the resistance of voltage adjuster unit faulty voltage regulator rectifier can t meet specification 1 8 This chapter Contents SYM 1 GENERAL INFORMATION F SPARK PLUG NO SPARK Inspection adjustment replace with new spark plug H End esten spark strong original spark plug faulty Check spark cap and high voltage cable orsiack slack n check CDI unit plug for slack E poor contact Check the resistance between the wires spark wear of no spark normal terminals of CDI unit normal abnormal ES Check related portions r fualty main switch faulty trigger magntic coil poor pulse coil poor IGN coil normal control cable open connector socket poor contact E CDI tester for CDI unit faulty CDI unit use CDI tester to check EOE X ignition voltage coil faulty IGN coil 1 9 2 INSPECTION ADJUSTMENT ENGINE MAINTENANCE
54. t Valve leakage Blown cylinder head gasket Worn piston rings or cylinder Worn piston High compression can be caused by e Carbon deposits in combustion chamber or on piston head SYM ELECTRICAL START ENGINE 2 INSPECTION ADJUSTMENT VALVE CLEARANCE NOTE Inspect and adjust the valve clearance while the engine is cold Remove the timing inspection hole cap and crankshaft hole cap Rotate the generator rotor counterclockwise and align the T mark on the generator rotor with the index mark in the left crankcase piston must be at T D C of the compression stroke Inspect the intake and exhaust valve clearance by inserting a feeler gauge between the adjusting screw ADJUSTING CREW and valve stem valve clearance Intake 0 08mm Exhaust 0 10mm Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag in the feeler gauge NOTE Inspect the valve clearance again after tightened the lock nut 2 INSPECTION ADJUSTMENT Install the valve adjuster caps and generator cap NOTE Check the O ring for damage and spread oil before installing the caps IGNITION TIMING The C D l ignition timing is not adjustable If the ignition timing is not correct check the C D l unit and A C generator and replace any faulty parts _ ES SPECIAL Use the standard tester to check the ignition timing CONVERTER opark plug inspection and adjust
55. tery positive cable Disconnect the battery band remove the battery BATTERY INSTALLATION Put the battery on the battery rack Install the battery band Connect the battery positive cable first then the battery negative cable Install the right side cover SPECIFIC GRAVITY TEST Test each cell by using a hydrometer SPECIFIC GRAVITY 1 260 1 280 Fully charged 1 220 or below Undercharged 20C 68 F NOTE The battery must be recharged if the specific gravity is below 1 23 The specific gravity varies with the temperature as shown in the accompanying table Replace the battery if sulfating is evident The battery must be replaced if there are pastes on the bottom of each cell WARNING The battery electrolyte contains sulfuric acid Protect your skin eyes and clothing Note the followings 1 In case of contact flush thoroughly with water 2 In case of drinking drink mass of water or milk and eat the white of an egg or drink vegetable oil 3 Cover the eyes when operating at short distance in case of contact flush thoroughly with water and spread of eye ointment 4 Keep flames and sparks away from a charging battery 5 Place the charging battery in a ventilated area HYDROMETER 1 SPECIFIC GRAVITY 0 32 10 50 20 68 30 86 40 104 ELECTROLYTE TEMPERATURE F 13 3 This chapter Contents 13 BATTERY CHARGING SYSTEM SYM Connect the charger p
56. th engine oil before installation Service limit 0 050mm Measure the connecting rod small end I D Connecting rod small end I D Service limit 15 08mm CRANKSHAFT BEARING INSPECTION opin the crankshaft bearing by hand and check for play The bearing must be replaced if it is noisy or has excessive play SYM FREE PLAY This chapter Contents SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER TRANSMISSION DISASSEMBLY Remove the crankshaft Remove the shift fork shaft Remove the shift drum Remove the shift forks rei Wie m 1 COUNTER SHAFT MAIN SHAFT SHIFT DRUM SHIFT FORK SHIFT FORK AND SHIFT FORK SHAFT INSPECTION Check the shift fork for wear bending or damage Measure the shift fork I D Service limit 12 05mm CHECK FOR WEAR OR DAMAGE Measure each shift fork claw thickness Service limit 4 80mm 9 5 This chapter Contents 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER SYM Measure the shift fork shaft O D Service limit 11 976mm SHIFT DRUM INSPECTION Check the gearshift drum for wear or damage Disassemble the transmission gears Check each gear for wear or damage and replace if necessary Check the crankcase oil orifice for clogged blowing through with compressing air if necessary This chapter Contents SYM 9 CAMSHAFT CRANKSHAFT CRANKCASE TRANSMISSION KICKSTARTER Check the crankcase bearings replace them
57. to 15 original position Check each part for damage Blow open all body openings with compressed air 10 4 This chapter Contents SYM 10 CARBURETOR FLOAT FLOAT VALVE JETS ASSEMBLY Install the stop screw air screw main jet needle jet and needle jet holder NOTE Do not damage jets at the time of assembly MAIN JET FLOAT LEVEL ADJUSTMENT If the float level is too high or too low bend the float arm for adjusting Float level 24mm THROTTLE VALVE ASSEMBLY Install the jet needle in the valve and secure it with the clip retainer 10 5 10 CARBURETOR Connect the throttle cable NOTE Route the throttle cable end through the adjuster and the carburetor top Make sure that the throttle cable is pulled tightly NOTE When installing the throttle valve align the throttle vale groove with the pilot screw CARBURETOR INSTALLATION Installation is essentially in the reverse odrer of removal After Installation adjust Throttle grip free play 2 10 Idling speed 2 11 10 6 SYM 11 HEADLIGHT STEERING FRONT WHEEL FRONT FORK TROUBLE SHOOTING HANDLE BAR SERVICE INFORMATION FRONT WHEEL HEADLIGHT FRONT FORK STEERING STEM TROUBLE SHOOTING FRONT WHEEL WOBBLING SOFT SUSPENSION 1 Axle not tightened properly 1 Weak rear fork spring 2 Worn front wheel bearing 2 Insufficient fluid in the front forks 3 Distorted rim HARD STEERING HARD SUSPENSION 1 Steeri
58. ts performance WARNING Do not use high voltage power especially the ohmmeter or the rectifier will be burnt out Rectifier is normal if there is continuity only in the direction shown Replace the rectifier if there is continuty in reverse direction 13 5 SYM 14 IGNITION SYSTEM TROUBLE SHOOTING SERVICE INFORMATION TROUBLE SHOOTING ENGINE CRANKS BUT NOT START Biue white 1 No sparks at the spark plug 2 Improper ignition timing 3 Faulty plug NO SPARKS AT THE SPARK PLUG 1 No current in primary circuit 2 High tension cord broken 3 Faulty ignition coil 4 Faulty A C generator 5 Faulty C D I unit ENGINE RUNS BUT ROUGHLY failure Black red Black white Faulty A C generator Faulty ignition coil Loose wires Poorly contacted switch terminals 2 Secondary circuit Faulty spark plug Faulty high tension cord Faulty ignition coil 3 Ignition timing Faulty A C generator Faulty C D I unit C D I UNIT os GREEN ITION SWI E TCH BLACK WHITE BLACK YELLOW GREEN WHITE 3 BLUE WHITE x c IGNITION COIL 14 1 This chapter Contents 14 IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTION This section contains the ignition system Be sure that the battery is fully charged before diagnosing troubles in the ignition system Also refer to the following pages Spark plug 2 5 Ignition timing adjustment 2 8 SP

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