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SERVICE MANUAL

1. C oe runs sluggish TT anan in low speed and T an Check and Check and adjustment Faultcondition condition Probablecauses causes Check ignition timing using ignition lamp Normal Abnormal Adjust the air screw of carburetor Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground D Engine runs sluggish e speed 1 Incorrect ignition timing malfunction of CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack okWNM Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch O O AUN Checkand adjustment and Checkand adjustment Fault condition condition Probable causes Check ignition timing Check for fuel supplying system in automatic fuel cup Check if carburetor clogged No clogged Clogged 1 14 ok Malfunction of CDI 2 Malfunction of AC alternator 1 Insufficient fuel in fuel tank 2 Fuel filter clogged 3 Restricted fuel tank vent 1 Cleaning This chapter Contents SYM 1 General Information Trouble Diagnosis E Clutch driving and driving pulley 7 FAULT CONDITIONS PROBABL
2. Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining disc Low brake fluid Blocked brake pipe Warp bent brake disc Bent brake lever Hard operation of brake lever Ae a Blocked brake system Poor brake caliper Blocked brake pipe seized worn master cylinder piston Bent brake lever DRUM BRAKE Poor brake performance ee ees improper brake adjustment worn brake lining worn brake drum worn brake cam improper brake lining installation seized brake cable Dirty brake lining Dirty brake drum brake pad worn in brake cam area poor contact between brake arm and camshaft indent 13 4 SYM 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 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 Tight operation or low return speed of brake lever worn broken crack return spring worn drum Dirty brake lining brake seized caused from dirty brake drum seized brake cable worn brake cam improper brake lining installation rake noise worn brake lining worn drum Dirty brake lining Dirty brake drum SYM Hydraulic Brake System Inspectio
3. Make sure that there is no magnetic powder If so Clean up it Align insert on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel with flywheel holder and tighten its nut Torque value 5 0 6 0 kgf m Special service tool Universal fixture 10 8 This Chapter Contents SYM 10 Alternator Starting Clutch Install the cooling fan 4 bolts Install the cooling fan shroud 3 screws Install the rear bracket mounting bolts 2 bolts Install the exhaust pipe 2 bolts 2 nuts Install the right side cover 4 screws Add some engine oil according to specified quantity 10 9 This Chapter Contents 10 Alternator Starting Clutch SYM NOTE 10 10 SYM 11 Crankcase Crankshaft Mechanism Illustration Operational precautions Trouble diagnosis 0 8 1 2 kgf m 0 8 1 2 kgf m 3 5 4 5 kgf m This Chapter Contents 11 Crankcase Crankshaft SYM Operational precautions General Information e This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced e Complete following operations before disassembling crankcase Engine Chapter 5 Cylinder head Chapter 6 Cylinder piston Chapter 7 V belt Drive pulley Chapter 8 Alternator Foot Starting Clutch Chapter 10 Start motor Chapter 16 e If the crankshaft bearing or timing sprocket need be replaced then the crankshaft set have to replaced Specif
4. FORWARD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS SERVICE MANUAL SYM Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Euro MX 125 motorcycle The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the motorcycle are different from that of the photos pictures shown in this manual the actual vehicle shall prevail specifications are subject to change without notice This manual that contains all data illustration indication and specifications is based on current production information SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever No part of this manual can be duplicated by any means without written permission of SANYANG Service Department SANYANG Industry Co LTD How to Use This Manual SYM This service manual describes basic information of different system parts and system inspection amp service for SANYANG Euro MX 125 motorcycles In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance and special service tools informati
5. Secondary coil is good if resistance within standard Secondary coil is broken if resistance is infinite If the spark plug cap attached and the measured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary PULSATOR 4 Caution Checking pulsator can be done on engine But the spark plug must be installed onto the cylinder head and cylinder compression pressure must be in normal condition Check Remove body cover Remove the pulsator connector Measure the resistance between blue yellow terminal on engine side and frame ground Standard 50 200Q 20 C Replace the alternator if the measured value exceeds standard value Exciting coil Remove the exciting coil connector Measure the resistance between black red wire on engine side and frame ground Standard 400 8000 20 C Replace the alternator if the measured value exceeds the standard value 16 Electrical Equipment 16 11 This Chapter Contents 16 Electrical Equipment SYM Starting System Starting Circuit Main switch Battery TU UU Fuse 10A C P Start motor CM Brake switch Start relay Green yellow Start switch pal MOJA Start Relay Inspection Turn main switch to on and operate the brake lever Then press start button to check if there a click sound Itis normal if there is a click sound Rem
6. the oil seal Manufacturer s name Connector SYM e Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps Groove ao Clamp sy ea ot ie eee ee Pe ee ee ee ee F i F e Rubber and plastic boots should be properly reinstalled to the original correct positions as designed Boots 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 R tt Both of these examples can result in bearing damage This chapter Contents SYM 1 General Information Trouble Diagnosis e Lubricate the rotation face with specified e Before battery removal operation it has to lubricant on the lubrication points before remove the battery negative cable firstly assembling Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark e Check if positions and operation for installed parts is in correct and properly e After servi
7. 15 2 This Chapter Contents SYM 15 Rear Wheel Rear Shock Absorber Exhaust Muffler Removal Remove the front end nut of the exhaust muffler nut x 2 Remove the bolts bolts x 3 Remove the exhaust muffler Installation Install the exhaust muffler according to the reverse procedure of removal Caution Replace the exhaust muffler gasket if it is broken or deformed Torque value Exhaust muffler connection bolt 3 2 3 8 kgf m Exhaust muffler connection nut 1 0 1 2 kgf m Rear Wheel INSPECTION Measure wheel rim wobbling Service limit Radial 2 0 mm Axial 2 0 mm e If the wheel rim wobbling out of the specification except resulted from the wheel rim deformation it might be loosen or worn final driving shaft bearing or bend deformed driving shaft Removal Remove the exhaust muffler bolt x 4 amp nut x 2 Remove the rear wheel nut nut x 1 Remove the rear wheel nut and exhaust muffler rear mount This Chapter Contents 15 Rear Wheel Rear Shock Absorber Rear Shock Absorber Removal Remove the luggage box bolt x4 screw x1 Remove the body cover screw x 4 Remove the air cleaner bolt x2 Remove the under bolt of the rear shock absorber bolt x 1 Remove the upper bolt of the rear shock absorber bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution The rear shock absorb
8. A marks _ If so replace the brake ling with new one Brake Lamp Switch The brake lamp switch is to lit up brake lamp as brake applied Make sure that electrical starter can be operated only under brake applying 2 Maintenance Information 10 20mm ee Decreasing free play SF increasing ANN play 2 13 This chapter Contents 2 Maintenance Information Wheel Tire Check if both front amp rear tires pressure is in correct Caution Tire pressure check should be done as cold tire Appointed tire pressure Tire pressure roar io 1 75 2 25 single as cold tire TET persons Appointed Tire Front wheel 100 90 12 59J T L Rear wheel 130 70 12 59J T L Check if tire surface is ticked with nails stones or other materials Check if tire surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspection or depth gauge e Replace the tire if tire tread dent or unusual wearing out e The tire should be replaced if the wear limit mark A is in visible Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm A Caution The wear limit marks A are located around eden A W the tire wall even for inspection Wear limit indicator A mark 2 14 This chapter Contents SYM 2 Maintenance
9. A Caution a 3 a 4 4 ee Pull out sliding driven face and then insert So SN the drive belt into the driven pulley so that the drive belt set can be installed onto pulley more easily Install the clutch set with drive belt onto the drive shaft The other end of belt hook onto the movable drive face Install the clutch outer Install the clutch with universal fixture and then tighten nut to specified torque value Torque value 5 0 6 0 kgf m A Caution When install the driving belt if there is a arrow mark then the arrow mark must point to rotation motion If not the letters on the belt must be forwarded to assembly direction This Chapter Contents 8 V Belt Driving System Foot Starter Movable Drive Face REMOVAL Remove left crankcase cover Hold drive face with universal fixture and then remove drive face nut Remove drive face Take out the drive belt from the drive face Remove movable drive face set and drive face boss from crankshaft Crankshaft Remove ramp plate Remove weight rollers from movable drive face Movable drive face 8 6 Universal fixture Drive face boss This Chapter Contents SYM 8 V Belt Driving System Foot Starter Inspection The operation of movable drive face is means of the weight roller to pressing on it with centrifuge Weight roller force And then the speed is changed by the ramp plate rotation Thus if weight rollers are wear out or
10. Caution Check the steering column if it can be turned freely and no clearance in vertical motion 14 8 Steering lock Locking to 1 4 8 8 turns Top cone race SYM 15 Rear Wheel Rear Shock Absorber Mechanism Illustration Precautions in Operation Trouble Diagnosis Mechanism Illustration 3 2 3 8kgf m 15 1 This Chapter Contents 15 Rear Wheel Rear Shock Absorber SYM Precautions in Operation General Information As for the wheel removal service and installation procedures please refer to the service manual of high speed tire Specification Unit mm Wheel wobbling at Thickness of rear brake lining Torque values Rear axle nut 10 0 12 0 kgf m Rear brake arm bolt 0 8 1 2 kgf m Rear shock absorber upper mount bolt 3 5 4 5 kgf m Rear shock absorber lower mount bolt 2 4 3 0 kgf m Exhaust pipe connection nut 1 0 1 2 kgf m Exhaust pipe connection bolt 3 2 3 8 kgf m Trouble Diagnosis Rear wheel wobbling Braking Noise Poor brake performance e bend wheel rim e worn brake lining e Poor brake adjustment e poor tire e brake drum deformation e contaminated brake lining e loosen wheel shaft e improperly brake panel e worn brake lining installation e Air inside of the brake Shock absorber too soft e unparalleled brake drum or hose pipe e insufficient shock absorber wheel unparallel greased brake disc spring force Clogged brake pipe Bent brake pipe Insufficient brake fluid
11. Install the rear wheel Add gear oil x Recommended usage SYM HYPOID GEAR OIL SAE 85W 140 110 cc standard capacity 100 cc when replacement 7 bolts 9 6 SYM 10 Alternator Starting Clutch Mechanism Illustration Starting Clutch Precautions in Operation Right Crankcase Cover Installation Alternator Removal Mounted Coil Set Installation 10 8 Alternator Coil Set Removal 10 4 Flywheel Installation Right Crankcase Cover Removal D 9 0 10 0 kgf m E 1 0 1 4 kgf m 1 5 2 0 kgf m 1 3 1 7 kgf m 10 1 This Chapter Contents 10 Alternator Starting Clutch SYM Precautions in Operation General information e Refer to chapter 5 Engine removal and installation e Refer to chapter 1 The troubleshooting and inspection of alternator e Refer to chapter 16 The service procedures and precaution items of starter motor Specification Unit mm ID of starting driven gear OD of starting clutch cover 27 940 ID of starting idle gear 10 05 OD of starting idle gear shaft 9 94 Torque value Flywheel nut 5 0 6 0 kgf m Bolt 8mm 1 5 2 0 kgf m Oil screen cover 1 3 1 7 kgf m Starting clutch mounting bolt 9 0 10 0 kgf m with oil on the thread Starting clutch hex socket bolt 1 0 1 4 kgf m with adhesive Special service tools Flywheel puller Universal fixture 10 2 This Chapter Contents SYM 10 Alternator Starting Clutch Alternator Removal Crankshaft Fan shroud Drain ou
12. handle can be operated in vertical direction then adjust the handle top bearing Suspension System A Warning Do not ride the motorcycle with poor shock absorber Looseness wear or damage shock absorber will make poor stability and drive ability Front shock absorber Hold front brake lever and press down the front shock absorber for several times to check its operation Hold front brake lever and push forward the front shock absorber for several times to check its locking status Check if it is scratched or leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scratched or leaking Replace damaged and non repairable components Park the motorcycle with main standard Start engine and let the rear wheel rotate after increased engine rom Check engine for any parts loose or shaking Also check the engine suspension bushing for wear out Replace the bushing if worn out Tighten all nuts and bolts 2 10 This chapter Contents SYM Disk Brake System Front Disk Brake Brake System Metal Hoses Make sure the brake metal hoses for corrosion or leaking oil and also check brake system for leaking Brake Fluid Check brake fluid level in the brake fluid reservoir If the level is lower than the LOWER limit add brake fluid to UPPER limit Also check brak
13. valve cable Loosen the adjustment nut and fixing nut of throttle valve cable and release the cable from carburetor Remove fuel pipe vacuum hose Disconnect auto by starter connectors Release the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out Vacuum Chamber Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress spring and vacuum piston 4 4 This chapter Contents SYM 4 FUEL INJECTION SYSTEM Remove fuel needle seat spring and injector Fuel needle needle aver seat Check if the vacuum piston for wear out crack or ig other damage Fuel needle m Check if the diaphragm for damage or crack spring g T5 Cautions Injector Do not damage vacuum diaphragm needle Piston spring Installation Install injector needle spring and fuel needle seat to vacuum piston A Cautions e Note direction as installing the piston set because wrong direction of the piston cab not be installed e Align the indent of vacuum diaphragm with the carburetor body Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws This chapter Contents 4 FUEL INJECTION SYSTEM SYM Air Cut off Valve Removal Remove the vacuum hose clamp and then the vacuum hose Screws X2 d A r as e
14. 7 8 SYM 8 V Belt Driving System Foot Starter Mechanism Illustration Foot Starter Maintenance Description Drive Belt Trouble Diagnosis Movable Drive Face Left Crankcase Cover Clutch Driven Pulley Mechanism Illustration 5 0 6 0 kgf m 5 0 6 0 kgf m 8 1 _ This Chapter Contents 8 V Belt Driving System Foot Starter Maintenance Description PRECAUTIONS IN OPERATION SYM e Driving pulley clutch and driven pulley can be serviced on the motorcycle e Driving belt and driving pulley surface must be free of grease Specification Driving belt width ID of sliding pulley bushing OD of sliding pulley hub OD of weight roller ID of clutch jacket Thickness of clutch lining Free length of driving pulley spring OD of driving pulley ID of sliding pulley ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 5 0 6 0 kgf m Clutch jacket nut 5 0 6 0 kgf m driving pulley nut 5 0 6 0 kgf m Trouble Diagnosis Engine can be started but motorcycle can not be moved 1 Worn driving Belt 2 Worn tilt plate 3 Worn or damaged clutch lining 4 Broken driven pulley Shudder or misfire when driving 1 Broken clutch lining 2 Worn clutch lining 8 2 Unit mm 18800 eoo 128 400 33 965 33 985 34 000 34 025 4 000 4 100 2000 Special Service Tools Clutch spring compressor Bearing puller inner type Clutch mounting nut wrench Universal fixture Insufficient hor
15. Chapter Contents 14 Steering Front Wheel Front Shock Absorber With a plastic hammer to tap the steering ball race slightly and then remove the top ball bearing race Remove the lower end cone bearing race on the frame with a punch A Caution Do not damage the frame and the steering race Installation Install a new top cone bearing race onto the top of steering column And then push the lower cone bearing seat from bottom until to locking position A Caution Do not let the ball bearing in title motion as installation Apply with some grease onto the top amp bottom bearing balls and then install the balls into bearing race Press in a new lower cone race onto the steering column and lubricate it with grease Install the steering column Lubricate the top cone race with grease Drive the cone race into the steering column until contact with the top bearing seat no clearance Note return 1 2 turn and then tighten the top cone race to specified torque tighten the race around 1 4 3 8 turn more Torque value 0 2 0 3 kgf m Steering lock nut Caution Do not tighten the top cone race too tight to prevent from damage the ball bearing seat Top cone race when tightening the top cone race Install the steering lock nut and lock the top cone race Then tighten the nut Torque value 1 0 2 0 kgf m Steering Install the bearing seat according to the reverse column nut procedure of removal
16. Contents 13 Brake SYM Remove the master cylinder cap and diaphragm Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder EO wN Master cylinder Clean dirty brake disc p Diaphragm plate A CAUTION ae Diaphragm Screw The dirty brake lining or disc will reduce the brake performance The mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing brake performance to be reduced or totally lost Brake Fluid Replacement Air Bleed Connect drain hose to drain valve Open the drain valve on the caliper and hold and release the brake lever alternatively until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder CAUTION To reuse the spent brake fluid will effect brake performance Connect one end of transparent hose to the drain valve and put the other end into a container Open the drain valve around 1 4 turns and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever Close the drain valve when finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 tur
17. Ea bolts comectontot OA 8 a connection bolt comectontar AEA 8 tote or or rT bolt Brakeleverbolts 2 jf 4 foto fp Front brake hose bolts 2 Front brake age MOULI bolts DE S E 0 7 1 1 a bolts Drum brake arm bolts front rear polis suspension bracket hee Engine connection bot 1 12 5070 Onengineside Main sendaran 1 o aes OOM Foot starting leverbot 1 6 teis O Air cleaner bots 2 6 toma The torque values listed in above table are for more important tighten torque values Please see standard values for not listed in the table Standard Torque Values for Reference a nut 2 408 005 mm bot rut 350 450 kgm 1 11 _ This chapter Contents 1 General Information Trouble Diagnosis SYM Troubles Diagnosis A Engine hard to start or can not be started Check and adjustment Fault condition Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to carburetor sufficient carburetor Remove spark plug install it into spark plug cap and perform a spark test against engine ground Check if sparks Weak sparks no spark Perform cylinder compression pressure test Cylinder compression Low compression pressure pressure normal or no pressure Re start by following the at all starting procedures There are some signs of No ignition ignition nut engine can not be started Remove
18. SYM Front Turn Signal Light Bulb Replacement Remove the light outer cover of the turn signal light Screw x 2 Remove the light inner cover of the turn signal lamp screw x 1 Replace the bulb with new one Rear Turning Signal Light Replacement Pry out the light cover from the preset slot onto the lower parts of cover Check if the bulb is burnt or damage and replace it if necessary Connect power to check if the bulb has been installed properly after installation Taillight Brake Light Replacement Remove the outer cover of the tail amp brake light Screw x 2 Check if the bulb is burnt or damage and replace it if necessary Connect power to check if the bulb has been installed properly after installation Screw x 2 16 Electrical Equipment 16 17 This Chapter Contents 16 Electrical Equipment SYM Switch Horn Main Switch Inspection Remove front fender bolts x2 screws x4 Disconnect main switch leads connector Check connector terminals for continuity Black we oe Ba Replacement Remove the handlebar bolt bolt x 1 Remove the handlebar assembly Remove the main switch connector and bolts bolts x 3 Remove the main switch Install a new main switch and tighten the bolts bolts x 3 16 18 This Chapter Contents _ 16 Electrical Equipment Handlebar switch Remove the rear handlebar cover chapter 12 section 3 Disconnect the connector of the ha
19. SYM Valve Seat Inspection lf the valve seat is too width narrow or rough correct it Valve seat width Service limit 1 6 mm Check the contact condition of valve seat Valve Seat Grinding The worn valve seat has to be grinded with valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat A Caution After valve guide had been replaced it has to be grinded with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper part out Use 60 cutter to cut a quarter lower part out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width A Caution Make sure that all roughness and uneven faces had been grinded Grind valve seat again if necessary 6 Cylinder Head Valve Roughness Old valve seat width Old valve seat width This chapter Contents 6 Cylinder Head Valve Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface A Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface to
20. Take out the bearing spacer and then remove the other bearing Tool Inner type bearing remover Speedometer gear dust seal Bearing Inspection Turn the inner race of bearing with fingers The bearing should be turn smoothly Also check if the outer collar is tightly connected to the wheel hub If the bearing do not turn smoothly or if they are too loose in the races or damaged then remove and replace the bearings with new ones Caution The bearing must be replaced in pair Installation Install the bearing according to the reverse procedure of removal Apply some grease into the bearing seat of the wheel hub Install the left bearing onto the seat Install the bearing spacer and then install the right bearing onto the seat 14 5 This Chapter Contents 14 Steering Front Wheel Front Shock Absorber A Caution Do not install used bearing and replace the bearing once it has been removed Do not the bearing in tile motion when installing Tool C type compressor or bearing compressor Align the flange part on the speedometer gear with the slot of wheel hub and then install the speedometer gear box Caution Contaminated brake lining will reduce brake performance so the brake lining brake drum and disc must be free of grease Place the front wheel between the front shock absorbers Align the flange part on the speedometer gear with the slot of shock absorber stopper Brake
21. a a E i F Clutch spring compressor Sliding driven face Oil seal Guide pin i Guide pin Guide pin roller Clutch outer 8 9 This Chapter Contents 8 V Belt Driving System Foot Starter Clutch lining Measure each clutch lining thickness Replace it if exceeds service limit Service limit 2 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 123 4 mm Driven pulley Check following items If both surfaces are damage or wear If guide pin groove is damage or wear Replace damaged or worn components Measure the outer diameter of driven surface and the inner diameter of driven 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 Replace it if necessary 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 Also check if bearing outer is installed properly Replace it if necessary 8 10 Clutch lining f AS Outer ball bearing i ici es i ines A L la ek z z s a Free length Driven face Sliding pulley Clutch Guide pin groove This Chapter Contents SYM 8 V Belt Driving System Foot
22. according to the reverse procedure of removal 12 4 coooog Screw x 4 Odometer cable ay n Switch wire connector _ This Chapter Contents SYM 12 Body Cover Front Fender Removal Remove the speedometer cable screw x 1 Remove the front fender screws left amp right x 2 Remove the front fender Installation Install according to the reverse procedure of removal 12 5 This Chapter Contents 12 Body Cover Front Under Spoiler Removal Remove the front fender front cover Remove the screw screw x 2 from the top end of front under spoiler Remove the inner cover screw left amp right each side x 1 Remove 2 screws on the left amp right each side of side cover Screw on each side x 1 Remove the front under spoiler Installation Install according to the reverse procedure of removal 12 6 SYM 12 Body Cover Inner Cover Removal Remove the front cover and front under spoiler firstly Remove the mounting bolts 2 bolts of floor Panel Remove 1 bolt and ignition switch cap Bolt x1 Take out the front inner cover Installation Install according to the reverse procedure of removal 12 7 This Chapter Contents 12 Body Cover Center Cover Removal Remove the 1 upper screw inside of the luggage box Remove the lower 2 screws in front of the center cover Take out the center cover Installation Install according
23. and remove the gear oil draining plug Place a measurement cup under the draining hole Check gear oil if enough A Gear oil Replacement refilling bolt At first remove the gear oil refilling bolt and then remove the draining plug Install the draining plug after drained oil out Torque value 0 8 1 2 kgf m Caution Inspect if washer is in good condition Replace it with new one if it was deformed or damaged Fill out specified gear oil from the engine oil filling opening Install the oil filling bolt Gear oil draining plug Torque value 1 0 1 4 kgf m Quantity 100 c c Recommended King Mate HYPOID GEAR OIL 140 Fuel pipes Fuel System Fuel Lines Remove luggage box Check all lines and replace it when they are deterioration damage or leaking Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it Fuel filter Remove luggage box Check if the fuel filter is clogged broken If so replace the fuel filter with new one Fuel filter 2 4 This chapter Contents 2 Maintenance Information SYM Air Cleaner Air element Remove the air cleaner cover 6 screws Remove the lock plate from the element of air cleaner Check the element if dirt or damaged If it dirt clean it with solvent and then soap it into cleaning engine oil after cleaned Finally squeeze it Replace it with new one if dirt or damaged A Caution
24. convex part of the cover Installation of the left crankcase cover Install the left crankcase cover 8 screws Install front vent tube of left cover and tighten the strap Install foot starter lever 1 bolt Tighten the air cleaner 2 bolts Install the body cover 8 3 This Chapter Contents 8 V Belt Driving System Foot Starter SYM Drive Belt Removal Remove left crankcase cover Hold drive face with universal fixture and remove nut and drive face Universal fixer Hold the clutch outer with the universal fixture and the remove the nut and the clutch outer Caution Using special service tools for tightening or loosening the nut Fixed rear wheel or rear brake only will damage reduction gear system Universal fixer Push the drive belt into belt groove as diagram in Drive belt shown so that the belt can be loosened and then remove A ee Drive belt and clutch at same time i ra Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Replace the belt if exceeds the service limit Service Limit 18 5 mm Caution e Using the genuine parts for replacement e The surfaces of drive belt or pulley must be free of grease 8 4 This Chapter Contents SYM 8 V Belt Driving System Foot Starter Installation Pull out the driven face and then insert the drive belt into the driven pulley
25. damage the centrifuge force will be effected 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 Service limit 19 50 mm Check the drive face boss if damaged or wear out Replace it if necessary Measure the drive face boss s outer diameter Replace it if exceed the service limit Service limit 23 94 mm Measure the drive face boss s inner diameter Replace it if exceed the service limit Service limit 24 06 mm Assembly Installation Install the weight roller Caution The both ends of weight roller are different In order to prolong the roller life soan and prevent abnormal wearing out install the closed end onto the movable drive face in the movement of CCW Install the ramp plate slide pieces 3 pieces onto the ramp plate Install the ramp plate Ramp plate Movable drive face Drive face boss This Chapter Contents 8 V Belt Driving System Foot Starter SYM Apply with grease 4 5 g to inside of drive face boss hole and install drive face boss A Caution The pulley surface has to be free of grease Clean it with cleaning solvent Install movable drive face assembly onto crankshaft Crankshaft MOVABLE DRIVE FACE INSTALLATION Press drive belt into movable drive face and then press down the up amp down sides of the drive belt to separate it away from the drive face boss Caution To
26. e Oil pump damage 3 2 This chapter Contents SYM 3 Lubrication System Engine Oil Turn off engine and park the motorcycle in flat surface with main stand Check oil level with oil dipstick after 3 5 minutes Do not screw the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Replacement A Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely Place an oil pan under the motorcycle and remove oil strainer cap Make sure if the aluminum washer of the draining bolt is damaged If so replace it with new one Install the drain bolt and tighten it Torque value 3 5 4 5 kgf m Cleaning Engine Oil Strainer Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer Recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it Torque value 1 3 1 7 kgf m Fill out oil to the oil filler Oil viscosity SAE 10W 30 Recommended King Mate serial oils Engine oil quantity Replacement 800 c c After oil replaced insert ignition key into the re set bottom under instrument panel so that the oil indicator is changed from red to green and set oil replacement mileage to zero Install dipstick start the engine
27. for running several minutes Turn off engine and check oil level again if within standard level after 3 5 minutes Check if engine oil leaks This chapter Contents Oil Pump Removal Remove the alternator refer to chapter 10 Remove the engine right cover Remove the one way clutch and starting gear 1 nut Make sure that the pump axle can be rotated freely Remove the oil pump cover 2 screws and then the oil pump driving gear clamp and the gear Remove oil pump body screws 3 screws Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pump as illustration shown Engine right cover Starting gear Starting clutch cover Oil pump outer cover 3 4 This chapter Contents SYM 3 Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit below 0 12mm Check clearance between inner and outer rotors Limit below 0 12mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw This chapter Contents 3 Lubrication System Install driving gear and clamp Caution Install the oil pump cover and fixing pin properly Oil Pump Installatio
28. from the two matching surfaces of cylinder and crankcase Caution To soap the residues into solvent so that the residues can be removed more easily Cylinder Inspection Exhaust side Intake side Check if the inner diameter of cylinder is worn out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y direction values respective in the cylinder Service limit 52 50 mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Check Cylinder Wrapage Service limit correct or replace as over 0 05 mm 7 4 This Chapter Contents SYM 7 Cylinder Piston Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling Hold another snap ring with pliers Push out the piston pin from the side that not removed the snap ring Remove piston rings A Caution Pay attention to remove piston rings because they are fragile Disassemble the piston rings Check if the piston rings are damaged or its grooves are worn Clean out the carbon deposit around the piston ring groove Piston Inspect
29. press down the up amp down sides of the drive belt can avoid to pressing and damaging the belt when installing the drive face and also can make sure that the drive face can be tighten Install drive face washer and nut A Caution Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold drive face with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover 2 p m Universal fixture i 8 8 This Chapter Contents SYM 8 V Belt Driving System Foot Starter 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 A Caution Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with special nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove oil seal collar from driven pulley Remove guide pin guide pin roller and sliding driven face and then remove O ring amp oil seal seat from sliding pulley INSPECTION Clutch outer Measure the inner diameter of clutch outer friction face Replace the clutch outer if exceed service limit Service limit 130 5 mm special nut wrench s Too oa in a a E
30. pressed it in hs When pressing in the new valve guide 4 cylinder head still have to be kept in h i na 100 150 C Adjust the valve guide driver and let valve guide height is in 138mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer A Caution e Using cutting oil when correcting valve guide with a reamer e Turn the reamer in same direction when it be inserted or rotated Correct valve seat and clean up all metal residues from cylinder head Tool Valve guide reamer 5 mm Valve Seat Inspection And Service Clean up all carbon deposits onto intake and exhaust valves Apply with emery slightly onto valve contact face Grind valve seat with a rubber hose or other manual grinding tool A Caution Do not let emery enter into between valve stem and valve guide Clean up the emery after corrected and apply with red paint onto contact faces of valve and valve seat Remove the valve and check its contact face A Caution a ee Ya i n a s Ta i ANNER Replace the valve with new one if valve seal is roughness wear out or incomplete contacted with valve seat Valve seat width See eee eee ee e If the valve and the valve seat still can not be matched sealing after grinded replace it with new one 6 10 This chapter Contents
31. rear brake cylinder bolt x 2 Take out rear brake cylinder With a wrench to hold the handlebar bolt and then remove the nut Take out the handlebar after removed the bolt Installation Install the handlebar according to the reverse procedure of removal Apply with some grease onto the handlebar moving parts when installing the throttle handlebar housing throttle handlebar and throttle cable Mounting ii 14 3 This Chapter Contents 14 Steering Front Wheel Front Shock Absorber Front Wheel F Removal Speedometer H i Support body bottom and lift front wheel free of ie ground Remove the screw and disconnect soeedometer cable from the gear box Remove the wheel axle nut and pull out the axle Then remove the front wheel Caution Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder Inspection Wheel axle Set the axle in V blocks and measure the run out Service limit 0 2 mm Wheel Rim Place the wheel onto a rotated bracket Turn the wheel with hand and measure its wobble value with a dial gauge Service limit Radial 2 0mm Axial 2 0 mm 14 4 _ Wheel axle nut This Chapter Contents SYM 14 Steering Front Wheel Front Shock Absorber Disassembly Remove the left axle ring and dust seal Remove the dust seal on the right side of speedometer gear Remove the bearing with the inner type bearing remover
32. side foot plate Installation Install according to the reverse procedure of removal Bolt x 1 Left amp Right Side Covers Remove the mounting screws 2 screws on left amp right each side Pull out the side cover backward so that the front clipper can be separated Remove the side covers Installation Install according to the reverse procedure of removal 12 Body Cover 12 11 This Chapter Contents 12 Body Cover Floor Panel o Removal e Remove the center cover luggage box body side covers and body cover firstly e Remove the front mounting bolts bolt x 2 of the floor panel Remove the battery cover screw x 3 Remove the battery bracket screw x 2 and power cables Take out the battery Remove the bottom mounting screws from the floor panel and then the floor panel Installation Install according to the reverse procedure of removal 12 12 This Chapter Contents SYM 12 Body Cover Rear Fender Removal Remove the upper bolts bolt x 2 from the rear fender Remove the left amp right side bolt 1 bolt on each side from the rear fender Remove the rear turning signal lamp wire and then the rear fender Installation Install according to the reverse procedure of removal F 1 bolt on left amp right each side 12 13 12 Body Cover SYM NOTES 12 14 SYM 13 Brake Front Disc Brake System Brake Fluid Replacement Air Bleed
33. the brake fluid to the reservoir and make necessary air bleeding 13 7 This Chapter Contents 13 Brake 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 Allowable limit 0 30 mm CAUTION e Do not let grease touch to the brake disc that will cause brake performance Do not clean the brake lining with air gun because the lining is contained asbestos Operator should wear mask amp glove and use vacuum cleaner to clean the brake lining Brake Master Cylinder Removal CAUTION Do not let foreign materials enter into the cylinder A CAUTION The whole set of master cylinder piston spring diaphragm and clip should be replaced after removal Remove the front and rear handlebar guards Remove the leads of brake lamp switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder Remove the rubber pad Remove the clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid 13 8 Ac cylinder aj ie Master r si Master cylinder This Chapter Contents SYM 13 Brake Inspection Check the
34. the spark plug again and check it Dry spark plug Wet spark plug Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing clogged 1 12 Probable causes _ gt O ou of Ss m o SS a s ee Se a S No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged Float valve clogged Lines in fuel tank evaporation system clogged Malfunction of fuel pump Loosen or damaged fuel pump vacuum hose Fuel filter clogged Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression parts Malfunction of throttle valve operation Air sucked into intake manifold Incorrect ignition timing Fuel level in carburetor too high Malfunction of throttle valve operation Throttle valve opening too wide Malfunction of automatic by starter SYM This chapter Contents 1 General Information Trouble Diagnosis B Engine run sluggish Speed does not pick up lack of power Probable causes Check and adjustment Try gradual acceleration and check engine speed Engine speed can b
35. to the reverse procedure of removal Luggage Box Removal Open the seat Remove the 1 upper screw inside of the front luggage box Remove the 2 mounting nuts and 2 bolts of the luggage box Lift the luggage box up by pushing the luggage box amp seat upward Installation Install according to the reverse procedure of removal 12 8 This Chapter Contents SYM 12 Body Cover Rear Carrier Removal Remove the hex socket bolts bolt x 4 of the rear Carrier Caution Do not open the fuel tank cap as removing the bolts so that prevent from bolts falling into the fuel tank Open the fuel tank cap with key Remove the rear carrier Installation Install according to the reverse procedure of removal 12 9 This Chapter Contents 12 Body Cover Body Cover Removal Remove the rear carrier luggage box and seat firstly Remove the body cover mounting screws and bolts 1 screw and 1 bolt on each side Screws and bolt on each side Remove 2 screw in rear of the body cover Remove the seat lock cable then remove the body cover Installation Install according to the reverse procedure of removal Seat lock cable 12 10 SYM This Chapter Contents SYM Left amp Right Side Foot Plate Removal Remove the foot plate connection screws 2 screws on left amp right each side Screws x 2 Remove the rear bolts 1 bolt on left amp right each side Remove the
36. with the universal fixture Remove the 22mm anti loosen mounting nut and gasket Special service tools Anti loosen mounting nut socket Universal fixture Caution The mounting nut is left turn thread Remove the starting driven gear Remove starting clutch starting idle gear and shaft Starting Clutch Inspection Install the starting clutch onto the starting driven gear Hold the starting clutch and turn the starting driven gear The starting driven gear should can be turned in the motion of C W and can not be turned in C C W 10 5 This Chapter Contents 10 Alternator Starting Clutch Check the starting driven gear for wear or damage Measure the ID of the starting driven gear Service Limit ID 32 06 mm or less Check the starting idle gear and shaft for wear or damage Measure the ID of the starting idle gear Service Limit ID 10 05 mm or less Measure the OD of the starting idle gear Service Limit OD 9 94 mm or more Disassembly Remove the hex blots 3 bolts inside the starting clutch Separate the clutch body and the clutch cover Remove the rollers plugs and springs on the one way Clutch Check each rollers and plugs for wear or damage Install rollers plugs and springs Measure the OD of the starting clutch cover Service Limit OD 27 94 mm or more 10 6 SYM This Chapter Contents SYM 10 Alternator Starting Clutch Installation Install the componen
37. 1 Presser for crankcase Name bushing SYM 1120300 H9A Valve clearance Name adjustment wrench SYM 9001200 Special Service Tools Catalogue This chapter Contents y 30mm Puller presser for Name crankcase bushing P Parts no SYM 1 120310 Name Valve spring compressor Parts no SYM 1471 100 Parts no SYM 221 0100 Puller presser for Name crankcase bushing SYM 1120320 d Name Vano spring compressor Parts no SYM 1471 110 20 Name Qlutch spring compressor _ Parts no SYM 2301000 Name Valve clearance adjuster Name Beating remover inner Name Beating remover outer type type Parts no SYM 9001210 Parts no SYM 6204002 2 16 Parts no SYM 6204001 This chapter Contents SYM 2 Maintenance Information 6301 6204 P20 POPUA Parts no SYM 9610000 Parts no SYM 91 10400 Parts no Ab Parts no SYM 9620000 SYM 9620000 27 42 7 25 40 8 20 32 6 Name Oil seal installer Name Oil seal installer Name Oil seal installer Parts no SYM 9125500 Parts no SYM 9121600 Parts no SYM 9120200 Clutch mounting bolt Valve cap Oil filter cap Name Name Parts no ISYM 9020200 Parts no ISYM 1236100 2 17 This chapter Contents 2 Maintenance Information SYM NOTE 2 18 SYM 3 Lubrication System Oil Pump Disassembly Oil Pump Inspection Oil Pump Re assembly Oil Pump Installation Cleaning Engine Oil Strainer Gear Oil Oil Pu
38. 2 3 minutes Turn of f engine and check if oil leaking 3 7 This chapter Contents 3 Lubrication System SYM NOTES 3 8 SYM 4 FUEL INJECTION SYSTEM Mechanism Illustration Float Chamber Precautions In Operation Installation Of Carburetor Trouble Diagnosis Idle Speed Adjustment Carburetor Removal Fuel Tank Air Cut off Valve Air Cleaner Auto By Starter Mechanism Illustration Fuel unit 3 Fuel vapor return hose Fuel tank Fuel hose Fuel cap Fuel filter Vacuum type Vacuum hose 4 1 This chapter Contents 4 FUEL INJECTION SYSTEM SYM Precautions In Operation General Information Warning Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline A Cautions Do not bend or twist throttle valve cable Damaged cable will make unstable drive ability e When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassemble automatic by starter and air cut off valve arbitrarily Specification Carburetor diameter Idle speed 1700 100 rom Fuel quantity adjustment screw 1 3 4 3 4 turns Torque value Fuel valve tightening nut 1 5 2 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level g
39. Between yellow green 0 1 0 80 Charging coil resistance 20 C Resistance 20 C 20W5 90 7 0 8 00 Resistor Resistance 20 C 5W5Q 4 5 5 50 Ignition System Standard NGK C7HSA Recommended usage Hot type NGK C8HSA Spark plug maa Starting System Start motor Capacity 0 5 KW 16 3 This Chapter Contents 16 Electrical Equipment Trouble diagnosis No power supply e Dead battery e Disconnect battery cable e Fuse burned out e Faulty ignition switch Low voltage e Weak battery e Loose battery connection e Charging system failure e Voltage current regulator failure Start motor does not work e The fuse is blown e The battery is not fully charge e Poor main switch e Poor start switch e The front and rear brake switches do not operate correctly e Starter relay is out of work e The ignition coil is poorly connected open or short circuited e The start motor is out of work Battery Removal Remove the rubber carpet Remove the battery cap screw x 3 Remove the battery mounting bracket bolt x 2 Firstly remove the negative post and remove the positive post Remove the battery Voltage Inspection Measure the voltage with a digital voltage meter Voltage Value Fully charged 13 0 13 2V at 20 C undercharged less 12 3V at 20 C 16 4 SYM Intermittent power supply e Loose charging system connection e Loose battery cables e Loose connection or sho
40. CTION Caution The coil need not be removed from engine as conduct this test At the alternator side from the regulator connector measure the resistor between pink and yellow wires Standard value 0 16 0 8O Regulator 16 8 This Chapter Contents SYM 16 Electrical Equipment Ignition System Ignition System Circuit Blue Yellow Green Black Yellow Black Red Exciter coil Pulsator Ignition Coil Alternator CDI UNIT Removal Remove the battery cover then the CDI unit can be removed from the battery cover Check Disconnect the connector from the CDI unit Make the following inspection at each terminal of the harness side connector Main Switch Continuity as main switch OFF Exciter Col 400 8000 Pulse Generator 50 2000 Ignition Coil Green high voltage cable w o Cap 3 5KO Secondary Green high voltage cable w Cap 7 12KO Primary Black yellow green 0 2104 10 16 9 This Chapter Contents 16 Electrical Equipment SYM IGNITION COIL ignition coil Removal Remove the luggage box central cover Remove spark plug cap Remove the primary coil wire of ignition coil Remove the fix bolts for the ignition coil and remove the coil Install the coil in reverse order of removal Caution Install primary coil with black yellow lead connected to black connector and green lead connected to green connector Spark plug confirmation Remove the spark plug and in
41. D of the cam rocker arm shaft and cam rocker arm Service Limit Replace when it is less than 11 91 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm 6 Cylinder Head Valve _ This chapter Contents 6 Cylinder Head Valve Remove cylinder head gasket and 2 lock pins Remove chain plate Clean up residues from the matching surfaces of cylinder and cylinder head A Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface A Caution Do not damage the matching surface of cylinder head Cylinder Head Check if spark plug and valve holes are crack Measure cylinder head plane with a straightedge and flat feeler gauge Service limit 0 5 mm Valve Spring Free Length Measure the free length of intake and exhaust valve springs Service limit 31 5 mm 6 8 This chapter Contents SYM 6 Cylinder Head Valve Valve Stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure amp record the valve stem outer diameter Service Limit IN gt 4 90 mm EX 4 90 mm Valve Guide Caution Bef
42. E CAUSES 1 Drive belt worn out or deformation 2 Ramp plate of movable drive face damaged Engine can be started but aye motorcycle can not be moved 3 Driving pulley spring broken 4 Clutch weights broken 5 Drive slide shaft gear groove broken 6 Transmission gear damaged Engine eee and misfire a 1 Clutch weights spring broken motorcycle initial forward moving or jumping suddenly rear wheel 2 Clutch outer stuck with clutch weights rotating as engine in running 3 Connection parts in clutch and shaft worn out or burned Drive belt worn out or deformation Weight roller worn out Movable drive face shaft worn out Poor initial driving Poor climbing performance Driven pulley spring deformation Driven pulley shaft worn out O oF UN Greased in drive belt and driven face 1 15 This chapter Contents 1 General Information Trouble Diagnosis SYM Parts To Be Greased Acceleration cable Front amp rear brake lever pivot M GREASE Seat lock catch Speedometer gear Side stand pivot Main stand pivot Rear wheel bearing front wheel bearing a GREASE GREASE SYM 2 Maintenance Information Precautions In Operation Spark Plug Periodical Maintenance Cylinder Compression Schedule Pressure Lubrication System Driving System Gear Oil Steering System Fuel System Suspension System Air Cleaner Disk Brake System Front Disk 2 Throttle Valve Operat
43. Information Battery Battery Removal Remove right cover 3 screws Battery cables removal 1 At first remove the negative cable 2 Then remove the positive cable 3 Remove the battery If there is some rust on battery posts clean it with steel brush Install the battery in the reverse procedures of removal A Caution If there is rust on the posts very serious spray some hot water on the posts Then clean it with steel brush so that can remove rust for more easily Apply some grease on the posts after rust removed to prevent from rust again Headlamp Adjustment Headlamp adjustment Remove the front fender Turn the headlamp adjustment screw to adjust headlamp beam height C W is for increasing beam height and C C W is for decreasing beam height Reinstall the front fender L Caution To adjust the headlamp beam follows Hea cler npc UstneE nt SGEN related regulations Do not adjust it arbitrarily if not necessary Improper headlamp beam adjustment will make in coming driver dazzled or insufficient lighting Nuts Bolts Tighteness Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check all fixing pins snap rings hose pipe clamps and wire holders for security 2 15 2 Maintenance Information Alternator fly wheel Name remover Parts no ISYM 3110A0
44. Make sure that the air cleaner cover had been installed properly after installation because improperly installation will cause foreign sucking into cylinder Do not wet the air cleaner as washing the motorcycle Or it may effect engine performance Throttle Valve Operation Have a wide open of throttle valve as handle bar in any position and release it to let back original full closed position Check handle bar if its operation is smooth Check throttle valve cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play 2 6 mm Adjustment can be done in either ends Secondary adjustment is conducted from top side Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment nut 6 screws Ru Adjustment nut Fixing nut This chapter Contents 2 Maintenance Information Primary adjustment is conducted from button side of cable on the throttle body Loosen fixing nut and adjust by turning the adjustment nut for its free play Tighten the fixing nut and check acceleration operation condition after adjusted Adjustment nut Crankcase Ventilation Pull out the plug from draining hose to clean deposits A Caution When always riding in rainy area or full throttle position maintenance travel must be shorted The deposits can be seen in the transparent section of
45. Rear Drum Brake System Brake Caliper Precautions in Operation Brake Disc Trouble Diagnosis Brake Master Cylinder Hydraulic Brake System Inspection Drum Brake System Inspection Front Disc Brake System 13 1 N J of e O u a Q t O A sk j SYM 13 Brake Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m 13 2 _ This Chapter Contents SYM 13 Brake Precautions in Operation A Caution Inhaling asbestos may cause disorders of respiration system or cancer therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead e The brake caliper can be removed without removing the hydraulic system e After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system e While refilling brake fluid care should be taken not to let the foreign material entering into the brake system e Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage e Check the operation of the brake system before you go Specifications Unit mm Torque values Brake hose bolt 3 50 kgf m Bolt for brake caliper 3 30 kgf m Brake lining pin bolt 1 80 kgf m Cap of Brake lining pin bolt 1 00 kgf m Air bleed valve 0 55 kgf m 13 3 This Chapter Contents 13 Brake Trouble Diagnosis DISC BRAKE Soft brake lever 1 3 4 D 6 7 8 9 1 0
46. Starter Clutch Block Replacement Remove snap and washer and the remove U Driving clutch block and spring from driving plate eo Check if spring is damage or insufficient elasticity Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Apply with grease onto setting pins But the Shock absorption _ clutch block should not be greased If so replace rubber it Install new clutch block onto setting pin and then push to specified location Caution e Grease or lubricant will damage the clutch block and effect the block s connection Capacity Install the spring snap into groove with pliers 8 11 This Chapter Contents 8 V Belt Driving System Foot Starter Install snap ring and mounting plate onto setting pin REPLACEMENT OF DRIVEN PULLEY BEARING Remove inner bearing Caution Outer bearing e If the inner bearing equipped with oil seal on one side in the driven pulley then remove the oil seal firstly e Ifthe pulley equipped with ball bearing it has to remove snap ring and then the bearing Remove snap ring and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Recommended to use the KING MATE G 3 Install the snap ring and hold the bearing Specified oil pEr a Sealing Install a new inner bear
47. Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 12 0 02 mm EX 0 12 0 02 mm Install the valve clearance adjustment hole cap bolt x2 Start the engine after assembly Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head Stop the engine after confirmed and then install the intake valve adjustment hole cap Install the seat cushion and the central cover A Caution e The cylinder components will be serious wear out if lubricant did not flow onto the cylinder head So it has to be confirmed Intake valve adjustment hole cap It has to be in idle speed when conduct this procedure Never increase engine speed in high RPM 6 16 SYM 7 Cylinder Piston Mechanism Illustration Piston Removal Precautions In Operation Piston Inspection Trouble Diagnosis Piston Ring Installation Cylinder Removal Piston Installation Cylinder Inspection Cylinder Installation Mechanism Illustration 0 8 1 2 kgf m 1 1 7 Cylinder Piston SYM Precautions In Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame Specification Unit mm Cylinder eaa a c
48. When the probe is reversibly connected use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero ammeter at one direction only 16 6 This Chapter Contents SYM A Caution e Do not use short circuit cable e 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 foot lever to start the engine 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 headlamp to high beam and start the engine Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage current Charging Current 4 8A 1600 rpm Control Charging Voltage 14 030 5 V 2000 rpm A 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 t
49. a 2 foroen OOO O o o o 25 Lighisicectial equipmentimutimeters 1 1 dt a Mainside stands amp springs tt TdT C rems o o Ca lemon o a a meane O a S a o o Note Inspection A Adjustment R Replacement C Cleaning L Lubrication The 33 34 and 35 items are for the fuel injection system The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 These marks sx in the schedule are emission control items According to EPA regulations these items must be perform normally periodical maintenance following the user manual instructions 2 Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily polluted environment 3 Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage 4 Preventive maintenance a Ignition system Perform maintenance and check when continuous abnormal ignition misfire after burn overheating occur b Carbon deposit removal Remove carbon deposits in cylinder head piston heads exhaust system when power is obvious lower than ever c Replace worn out pistons cylinder head This chapter Contents SYM 2 Maintenance Information Lubrication System Engine Oil Capacity Caution e The vehicle must be parked on a level ground when checking o
50. ae Clearance between 0 025 0 060 piel ornninigs 0 015 0 050 lt a Ring end gap 0 250 0 400 me ring side 0 200 0 800 OD of piston 92 370 52 390 Piston OD measurement position Lower end up 9mm of piston skirt Clearance between piston and 0 010 0 040 cylinder ID of piston pin boss 15 002 15 008 OD of piston pin 14 994 15 000 Piston Piston ring Clearance between piston and piston pin 0 002 0 014 ID of connecting rod small end 15 016 15 034 Trouble Diagnosis Low Or Unstable Compression Pressure Smoking in Exhaust Pipe e Cylinder or piston ring worn out e Piston or piston ring worn out e Piston ring installation improperly e Cylinder or piston damage High Compression Pressure e Carbon deposit onto the piston amp combustion chamber Engine Overheat e Carbon deposits on cylinder head top side Knock or Noise e Cylinder or piston ring worn out e Carbon deposits on cylinder head top side e Piston pin hole and piston pin wear out 7 2 SYM 7 Cylinder Piston Cylinder Removal Remove cylinder head refer to chapter 6 Remove 2 bolts and then take out the cam chain auto tensioner Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase This Chapter Contents 7 Cylinder Piston Cover the holes of crankcase and cam chain with a piece of cloth Clean up all residues or foreign materials
51. ance bolt x 6 Firstly remove the camshaft stopper and then drive a 6mm bolt into camshaft Finally remove the camshaft and rocker arm Use a valve compressor to press the valve spring After removed valve split locks release the compressor and then take out spring retainer valve spring and valves A Caution Valve split lock In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve split locks in which can be removed Special Service Tool Valve spring compressor Or with the valve spring remover installer to compress the valve spring directly Then remove the valve and valve spring A Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve spring remover installer 6 6 SYM This chapter Contents SYM Remove valve valve stem and valve spring Cylinder Head Inspection Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 25 29mm EX Replacement when less than 25 12mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D Service Limit Replace when it is less than 12 10 mm Rocker Arm Shaft Measure the active O
52. ankshaft Crankshaft Inspection Measure left and right clearance of connecting rod big end Service limit Replace when it is more than 0 55 mm Measure the radical clearance of the big end at the vertical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Clearance Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 11 4 SYM Clearance This Chapter Contents SYM Assembly Of Crankcase Install cam chain into the chain hole of the left crankcase and then split out the cam chain Caution Do not damage the cam chain as installing the crankshaft Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket Install the right crankcase and tighten the 2 bolts crankcase bolts 2 bolts Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution The O ring must be installed into the bolt s groove 11 Crankcase Crankshaft This Chapter Contents 11 Crankcase Crankshaft Apply with some grease onto
53. auge 4 2 This chapter Contents 4 FUEL INJECTION SYSTEM SYM Trouble Diagnosis oe engine start No fuel in fuel tank e Clogged fuel tube e Too much fuel in cylinder e No spark from spark plug malfunction of ignition system e Clogged air cleaner e Malfunction of automatic by starter e Malfunction of throttle valve operation er after started Malfunction of automatic by starter e Incorrect ignition timing e Malfunction of carburetor e Dirty engine oil e Air existing in intake system e Incorrect idle speed oe idle Malfunction of ignition system e Incorrect idle speed e Malfunction of carburetor e Dirty fuel Intermittently misfire as acceleration e Malfunction of ignition system Late ignition timing e Malfunction of ignition system e Malfunction of carburetor Power insufficiency and fuel consuming Fuel system clogged e Malfunction of ignition system Mixture too lean e Clogged fuel injector Vacuum piston stick and closed e Malfunction of float valve e Fuel level too low in float chamber e Clogged fuel tank cap vent e Clogged fuel filter e Obstructed fuel pipe e Clogged air vent hose e Air existing in intake system Mixture too rich e Clogged air injector e Malfunction of float valve e Fuel level too high in float chamber e Malfunction of automatic by starter e Dirty air cleaner 4 3 This chapter Contents 4 FUEL INJECTION SYSTEM Carburetor Removal Throttle Remove the trunk
54. brake lining if the wear limit mark closed to the edge of brake disc Brake lining wear limit Caution It is not necessary to remove brake hose when replacing the brake lining Remove the brake clipper bolt and take out the clipper Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution In order to maintain brake power balance the brake lining must be replaced with one set Brake Lamp Switch The brake lamp switch is to lit up brake lamp as 3 Master brake applied SS cylinder Make sure that electrical starter can be operated H only under brake applying Brake lamp A switch 2 12 This chapter Contents SYM Drum Brake System Rear Brake Free Play Drum brake Measure free play of rear brake level at the end of the lever Free play 10 20 mm Measure the free play of the front brake lever at the end of the lever Free play 10 20 mm Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution e After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked Pull the brake lever and make sure that the wear limit marks of brake ling on the both front amp rear brake arm are closer and touch to the
55. ce completed make sure all connection points is secured 3 Battery positive cable should be connected moi firstly And the two posts of battery have to be 4h greased after connected the cables a SBC p e Make sure service safety each other when conducting by two persons e Make sure that the battery post caps are located in properly after the battery posts had been serviced e If fuse burned it has to find out the cause and solved it And then replace with specified Capacity fuse he il T capacity verification 1 5 This chapter Contents 1 General Information Trouble Diagnosis SYM e Before terminal connection check if the boot is e When separating a connector it locker has to crack or the terminal is loose be unlocked firstly Then conduct the service operation e Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up wy 5 Sa ak wW Aa eh C P a x g e Do not pull the wires as removing a connector R O or wires Hold the connector body s O x 2 ra P hy a eS N e Secure wires and wire harnesses to the frame Pe aes with respective wire bands at the designated a locations Tighten the bands so that only the insulated surfaces contact the wires or wire e Make sure if the connector pins are bent extruded or loosen harnesses O x x e Insert the connector completely e Wi
56. ded to up side e Make sure that all piston rings can be rotated freely after installed Top ring 2 ring Side ring Spacer Oil ring Side ring Top groove 2 groove Oil groove l 1 This Chapter Contents 7 Cylinder Piston Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to intake valve Install new piston pin snap ring A Caution Do not let the opening of piston pin snap ring align with the opening piston ring Place a piece of cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Clean up all residues and foreign materials on the matching surface of crankcase Pay attention to not let these residues and foreign materials fall into crankcase Caution To soap the residues into solvent so that the residues can be removed more easily Install 2 lock pins and new gasket Coat engine oil to inside of cylinder piston and piston rings Care to be taken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because this will cause the piston and the piston rings to be damaged Install the cam chain plate the cylinder gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto tensioner 2 bolts
57. dlebar Tighten the upper bolt of the seat to specified torque value and then tighten lower bolt to the same specified torque value Split ring Install the brake lever and connect leads to brake lamp switch Connect brake hoses with 2 new washes Tighten the brake hose bolt to the specified torque value Torque value 3 5 kgf m Make sure the hose is installed correctly f CAUTION Improper routing may damage leads hoses or pipes i A CAUTION Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system and conduct the air bleeding job for the system 13 10 This Chapter Contents SYM DRUM BRAKE SYSTEM INSPECTION BRAKE DRUM Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust 4 Caution e Inhaling asbestos dust may cause respiration system disorder even cancer Never use an air hose or a dry brush as to clean the brake parts e Grease on brake lining will reduce braking efficiency Remove wheel Remove brake drum from wheel hub Inspection Check the brake drum for wear and damage replace wheel hub if necessary Measure the ID of hub at several points and record the largest value Service limit Rear 131 0 mm A Caution e Remove the rust by using 120 sand paper e An inside micrometer must be used when measuring ID of brake drum because the b
58. draining hose Valve Clearance Adjustment A Caution Checks and adjustment must be performed when engine is cold below 35 C Remove luggage box Remove center cover Remove cylinder head left cap Remove the ignition timing check hole cap on the cooling fan cover With T type wrench turn crankshaft in clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TDC position in the compression stroke Caution The model that equipped with starting compression pressure reduction system can not be rotated in counter clockwise to prevent from operating compression pressure reduction function so that valve clearance can not be measured Ignition timing This chapter Contents SYM 2 Maintenance Information Valve Clearance Inspection And Adjustment Check amp adjust valve clearance with feeler gauge Valve clearance IN EX 0 12 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution It has to make sure that valve rock arm is be adjusted to standard level when adjusting it and re check the valve clearance after tightened the fixing nut Carburetor Idle Speed Adjustment A Caution e Inspection amp adjustment for idle speed have to be performed after all other part
59. e D Exhaust Pipe Position Right side and gt Z O O AU Er an Single Cylinder Lubrication System Separated lubrication 2 gement LI 103 1 Below 4 atio 11 0 ps 8250 rpm Below 2000 ppm Starting System Power amp Foot SAYU TEANN NO control system O 2 Cc C oO x O W c O O _ This chapter Contents 1 General Information Trouble Diagnosis SYM Torque Values Engine Qt Thread Dia Torque y mm Value Kg m Cylinder head nuts Cylinder cylinder head two ends af oes 0 7 1 1 bolts ommna a e tote Oninerheadioncoerbots 2 6 oa 10 Spark plug 1 eager Pe oe ee rarena fi e oes areon Jof oe sexri of e ome Gear oil filling bolt 1 1 C 8 ones Erge tse coreots e 6 toms Rubberwaser tates Canshatchantersenerbor 1 6 085 08 Revsosetbot Camsraroram ansero 1 6 o OOOO unawaona i a f soso uenon 1 soso o oo owna fo o C seo Oreway euentamentos s 6 10 14 aopn oeng seam eoe af e f seo corws r e a ewar e o os wapora 2 7 oso 1 10 This chapter Contents SYM 1 General Information Trouble Diagnosis Torque Values Frame mm Value Kg m Mounting bolt for steering 4 0 5 0 eullaer n a e a OOO Cone seatforsteeringrod 1 254 2038 O Frontwheelshaftnut 1 12 5o7o O Rear wheel shaftnut 1 16 nonso O Wheel hub rim mounting nuts 1 5 015703 O egoerek a e f eeso screw A R te
60. e increased Fault condition Engine speed can not be increased Check ignition timing Using ignition lamp Ignition timing correct Check cylinder compression pressure using compression pressure gauge Incorrect ignition timing Compression pressure correct No compression pressure Check if carburetor jet is clogged No clogged Remove spark plug No foul or discoloration Check if engine over heat Normal Continually drive in acceleration or high speed A Clogged Fouled and discoloration Engine overheat NO ok OO N gt A OUO N Air cleaner clogged Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Fuel level too low in carburetor Fuel nozzle clogged in carburetor Malfunction of CDI Malfunction of AC alternator Cylinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring Remove foreign Remove dirt Incorrect spark plug heat range Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber 5 Ignition timing too advanced 6 Poor circuit on the cooling system oe Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality Ignition timing too advanced 1 13 _ This chapter Contents 1 General Information Trouble Diagnosis SYM
61. e system for leaking if low brake level found Caution In order to maintain brake fluid in the reservoir in horizontal position do not remove the cap until handle bar stop Do not operate the brake lever after the cap had been removed Otherwise the brake fluid will soread out if operated the lever Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Place the diaphragm in Operate the brake lever so that brake fluid contents inside the brake system hoses Air Bleed Operation Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution Before closing the air bleed valve do not release the brake lever Added Brake Fluid Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or DOT4 WELL RUN brake fluid Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance 2 Maintenance Information Brake metals hose Master cylinder cap Lower limi Screws Master cylinder cap Diaphragm plate Diaphragm Upper limit Draining valve Bubbles Transparent draining hose 2 11 This chapter Contents 2 Maintenance Information SYM Brake Lining Wear The indent mark on brake lining is the wear limitation Replace the
62. e bushing out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pressing ring and bolt in to press the bushing out Pressing In Place the flat section of the remover toward the bushing and then drive the bushing pressing ring and bolt in to install the bushing 5 REMOVAL OF ENGINE This chapter Contents 5 REMOVAL OF ENGINE Engine Suspension Frame Removal Remove the right side bolt of engine suspension frame Engine suspension bolt right side Remove the left side bolt of engine suspension frame Engine suspension bolt left side Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame Engine suspension frame nut Torque Value 4 5 5 5 kgf m 5 8 Weel Cmeenicnic SYM 5 REMOVAL OF ENGINE Installation Of Engine Check if the bushings of engine suspension frame and shock absorber for damaged If so replace with new ones Install the engine according to the reversing order of removal A Caution Note both feet and hands safety for squeezing as engine installation Do not bent or squeeze each wires or hose Route all cables and wires in accordance with the routine layout Engine suspension nut T
63. e stem seal wear out 6 3 This chapter Contents 6 Cylinder Head Valve Cylinder Head Removal Remove Remove the cooling fan cover screw x 2 bolt x 2 Remove the right cover of engine screw x 4 Remove the left cover of engine screw x 4 Remove the left cap bolt of cylinder head bolt x2 and then remove the left cap of cylinder head Remove the spark plug 6 4 This chapter Contents SYM Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Loosen the screw cap of camshaft chain tensioner and remove O ring With a flat screwdriver to tighten the screw of camshaft chain tensioner in a clockwise motion for release tensioner Remove the cam sprocket bolt x2 Remove the left bolt bolt x2 of cylinder head firstly and then remove the 4 nuts amp washers from the cylinder head top end Pry out the chain and take out the sprocket Then remove the cylinder head Caution e Loosen the nuts diagonally by 2 3 sequences Do not let the chain fall into the crankcase after removed the sprocket 6 Cylinder Head Valve The Bolt x m k z i A on ip T 2 This chapter Contents 6 Cylinder Head Valve Cylinder Head Disassembly Remove the adjustment hole cap for the EX amp IN valve clear
64. el hose and then remove the fuel tank A Caution Be sure that the fuel in the fuel bank had been drain out clearly before removing Fuel hose Installation Install the fuel tank in reverse procedure of removal 4 12 This chapter Contents 4 FUEL INJECTION SYSTEM SYM Air Cleaner Remove the air cleaner cover screw x 6 Remove the air cleaner assembly Installation Install the air cleaner in reverse procedure of removal Procedures for cleaning air cleaner element sponge type only Miele et ot 5 a ee 1 clean 2 squeeze dry 3 soak in engine oil 4 squeeze dry 4 13 This chapter Contents 4 FUEL INJECTION SYSTEM SYM NOTE 4 14 SYM Operational Precautions Engine Removal Removal Of Engine Suspension Bushing Operational Precautions General Information 5 REMOVAL OF ENGINE Engine must be supported by a bracket or adjustable tool in height The following parts can be serviced with the engine installed on the frame 1 Throttle valve 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Engine Oil Capacity Gear Oil Capacity Torque Values Engine suspension bolt Frame side Engine suspension nut engine side Bolt of rear shock absorber upper connection Bolt of rear shock absorber lower connection Bolt of rear brake clipper Nut of rear wheel axle Nut of exhaust c
65. er HHHH e Be careful not to damage various covers in disassembly or re assembly operation e Never injure hooks molded on the body covers in disassembly or re assembly operation e Align the buckles on the guards with slot on the covers e Make sure that each hook is properly installed during the assembly e Never compact forcefully or hammer the guard and the covers during assembly 12 2 This Chapter Contents SYM 12 Body Cover Front Cover Removal Remove the 8 mounting screws from the inside of front inner cover Screw x 8 Remove the upper screw screw x 1 from the front fender Screw x 1 Remove the front light wire coupler Remove the front cover Installation Install according to the reverse procedure of removal 12 3 This Chapter Contents 12 Body Cover Handlebar Cover Removal Remove the handlebar rear cover screw x 5 Disconnect the wire connectors of left amp right switches Remove the handlebar rear cover Caution e Open the hooks on the two end section of the handlebar cover as removing the cover The remove the handlebar cover Do not pull it forcedly to avoid to breaking the hooks Remove the front cover and odometer wire coupler Remove the odometer cable Remove the handlebar front cover and odometer set Screw x 4 Remove the odometer cover Screw x 3 Disassemble the odometer cover and the odometer set Screw x 2 Installation Install
66. er has to be replaced with one set and can not be replaced by unauthorized persons Otherwise it might damage the rubber bushing and construction Torque values Rear shock absorber lower mount bolt 2 4 3 0 kgf m Rear shock absorber upper mount bolt 3 5 4 5 kgf m 15 4 SYM 16 Electrical Equipment Mechanism Illustration Ignition System Precautions In Operation Starting System Specification Mechanism Illustration Horn switch Winker switch Dimmer amp Passing switch C D I unit Battery Ignition coil Starter relay Fuel gauge unit Light Light Bulb Switch Horn Fuel Gauge Unit Horn Winker relay Start switch Headlight switch Main switch ignition switch Fuse box Spark plug Regulator 16 1 _ This Chapter Contents 16 Electrical Equipment SYM Precautions In Operation C harging System 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 MF Maintenance Free battery does not need to check add electrolyte or distilled water Battery must be taken out from scooter when charging the battery But do not open the battery caps Do not quick charge the battery unless in emergency A voltmeter must be used when checking battery charging condition Battery can be charged or discharged alternately To set a discharged battery
67. f handlebar chapter 12 section 3 e aa Remove the instrument panel assembly screw x 4 Disassemble the instrument seat and the instrument Screw x 2 Instrument Panel Installation Install the panel in reverse procedure of removal 16 15 This Chapter Contents 16 Electrical Equipment Light Light Bulb Headlight Bulb Replacement Remove the front cover chapter 12 section 4 Disconnect the headlight wire connector and then remove the rubber boot Press down the bulb spring locker and then remove the locker with turning it in CCW motion Replace the bulb with new one if necessary A Caution e Do not touch the bulb surface with fingers because the bulb will create hot spot so that let it be burnt It has to be package with cloth or wear glove as installing e Wipe the bulb with cloth to prevent from damaged if the bulb be touched by hands Install the bulb in reverse order of removal Connect power to check if the bulb has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment screw located under the headlight Turn the screw to right or left to adjust the high or low beam of headlight Caution e This outer cover of headlight is a fixed type so that the lamp seat will be moved only when adjusting Headlight adjustment screw 16 16 This Chapter Contents
68. foot starting lever A Caution Rotate the engine until the reading in the gauge no more increasing j Spark plug Usually the highest pressure reading will be obtained in 4 7 seconds Compression pressure 10 3 0 2 Kg cm Check following items if the pressure is too low e Incorrect valve clearance e Valve leaking e Cylinder head leaking piston piston ring and 7 A _ Cylinder cylinder worn out h pressure If the pressure is too high it means carbon deposits in combustion chamber or piston head Driving System Gear teeth Drive Belt Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left side cover and the cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit 18 5mm or more Clutch Pad Start the motorcycle and gradually increase throttle valve openness to check clutch pad operation Z Se If the motorcycle moves with shaking then check i ee Clutch its clutch pad for wearing Replace it if t ji necessary This chapter Contents 2 Maintenance Information Steering System A Caution Check all wires and cables if they are interfered with the rotation of steering handle bar Lift the front wheel out of ground Turn handle from right to left alternative and check if turning is smoothly If handle turning is uneven and bending or the
69. for checking whether CDI function is in normal or Remove right side cover Remove ignition timing hole cap located on the cooling fan cap Connect tachometer and ignition lamp Start engine and set engine idle speed in 1600 rpm and if the mark aligns with the F then it means that ignition timing is correct Increase engine speed to 8000 rpm to check ignition timing advance If the detent aligns with advance mark n then it means ignition timing advance is in functional If not check CDI set pulse flywheel and pulse generator Replace these components if malfunction of these parts are found Spark Plug Appointed spark plug CR8E NGK Remove luggage box Remove central cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug gap 0 8 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Hold spark plug washer and install the spark plug by screwing it Tighten the plug by turning 1 2 turn more with plug socket after installed Torque value 1 0 1 2 kgf m Connect spark plug cap 2 8 This chapter Contents SYM 2 Maintenance Information Cylinder Compression Pressure Warn up engine and then turn off the engine Remove the luggage box and the center cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of stepping the
70. ft Finally install it on the brake panel Align the end part of the brake return spring with the hole of brake panel KA Align both the inner gear of wear indicator and Brake arm the mark on the brake arm with the indent gear a i Brake cam of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2kgf m Rear Brake Panel Apply a thin cost of grease between the oil seals on the brake cam shaft Install the brake cam Align the mark on the brake arm with the inner gear of the brake cam Tighten the bolts and nuts to specified torque Hook on the return spring Torque 0 8 1 2kgf m 13 12 SYM 14 Steering Front Wheel Front Shock Absorber Mechanism Illustration Front Wheel Precautions in Operation Front shock absorber Trouble diagnosis Front fork steering column Steering Handlebar Mechanism Illustration 14 1 This Chapter Contents 14 Steering Front Wheel Front Shock Absorber SYM Precautions in Operation General Information e Before remove front wheel use a jack to lift the body until front wheel free of ground and take care not to rotate body in reverse e Be careful not to allow oil or grease get on brake drum or linings Torque values Front wheel axle 5 0 7 0 kgf m Steering handlebar nut 4 0 5 0 kgf m Steering column top cone sliding ring 0 2 0 3 kgf m Steering column lock nut 1 0 2 0 kgf m Speedometer cable nut 0 15 0 3 kgf m Front shock absorbe
71. he 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 16 Electrical Equipment Main switch 16 7 This Chapter Contents 16 Electrical Equipment REGULATOR INSPECTION Remove the rear carrier refer to chapter 12 section 8 Remove the body cover refer to chapter 12 section 8 Disconnect the 5P connector of the regulator point Main switch Battery voltage connection wire ON Battery Check the parts onto the abnormal wire circuit if the measured values are not within standards If the parts is OK then it is the wire circuit abnormal Replace the regulator if both checks are OK CHARGING COIL INSPE
72. i E y Ir i E C a 4 i oe hs D F 4 ho n 1 i L cy are ML Tiz e i a Po ee z Pi z Remove the screws screw x 2 of the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the diaphragm for deterioration or crack Installation Install the valve as reverse order of removal A Cautions Do not damage the vacuum diaphragm or in opposite installation direction 4 6 This chapter Contents SYM Auto By Starter Inspection Turn off engine and waiting for over 10 minutes for cooling Check resistance across the two terminals of the auto by starter Resistance value Max 100 Measured after engine stopped for more than 10 minutes Replace the auto by starter with a new one if resistance value exceeds standard Remove the carburetor allow it to cool off for 30 minutes Connect a hose to fuel increase circuit Pump compressed air to the circuit Replace the auto by starter if the circuit clogged Connect battery posts 12V to starter s connectors After 5 minutes test the increase circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing plate screw and then remove the plate and auto by starter from carburetor Valve inspection Check if auto by starter and valve needle for damage or wear out Installation Install auto by starter to the carburetor body Install fixing plate to the upper groove
73. ication Unit mm Left right clearance of the big end of the connecting rod 0 100 0 300 0 550 Right angle clearance of the big end of the connecting rod 0 000 0 008 0 050 Run out 0 100 Torque value Bolts for crankcase 1 5 2 0 kgf m Bolts for cylinder cylinder head 0 7 1 0 kgf m Engine oil draining plug 3 5 4 5 kgf m Bolts for cam chain tensioner l 0 8 1 2 kgf m Special Service Tools Crankcase remover set Crankshaft installation puller Inner type bearing puller Outer type bearing puller Bearing pressing tools Oil seal pressing tools Trouble diagnosis Engine noise e Loose crankshaft bearing e Loose crankshaft pin bearing e Wear piston pin or piston pin hole 11 2 This Chapter Contents SYM 11 Crankcase Crankshaft Disassembly Of Crankcase Remove the cam chain tensioner hex socket bolt x 1 from the left crankcase side Remove the 2 bolts from the right side of Screw x 2 crankcase and then remove the right crankcase Remove the crankshaft from the left crankcase Remove the cam chain Remove the gasket and setting pin 2 bolts Scrape gasket residues off the crankcase contact surface Caution e Check if the right amp left bearings are press in the crankshaft e Do not damage contact surface of the crankcase e Soap the gasket residues into solvent and the residues will be removed easily Remove oil seal from the left crankcase side This Chapter Contents 11 Crankcase Cr
74. idle for a prolonged period will shorten its service life and reduce its capacity Usually battery s capacity will reduce after 1 2 years After low capacity battery was charged its voltage will increase If it connects to an additional load the voltage will reduce suddenly and then go up again Over charged battery Usually the over charged battery can be seen externally If a short circuit occurred inside the battery there will be no voltage on the terminals of battery if voltage regulator does not operate Then the battery s voltage will be too high that may reduce battery s life The battery will be self discharged if it was set idle for a long time An idle battery must be charged about every 2months A new battery filled with electrolyte will generate a voltage after filled out electrolyte The voltage should be in 12 5V or more after 10 minutes When electrolyte is not enough the battery must be filled with electrolyte and then charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage current regulator will be damaged The ignition switch must be turned OFF before performing any work Please do not replace with traditional type battery as replacement Please refer to the removal ins
75. il capacity Run the engine for 3 5 minutes then stop wait about 3 5 more minutes allowing engine oil to settle before checking the oil level Remove dipstick to check the oil level If oil level is below the lower limit mark add oil to the specified upper limit mark Engine Oil change Shut off the engine and remove dipstick Remove the oil drain plug on the bottom left of crankcase to drain oil After draining out oil clean oil plug and its gasket and reinstall Replace the gasket if it is damaged Torque value 3 5 4 5 kgf m Caution Warm up the engine This will make the oil flow out easily Add oil to the specified capacity Oil Viscosity SAE 10W 30 or equivalent recommended using King Mate serial oil Engine oil capacity Disassembly 1050cc Change 800cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen wash it off with suitable solvent recommended using compressed air to cleaning the foreign Check O ring for damage replace if necessary Reinstall strainer spring O ring and strainer cover Torque value 1 3 1 7 kgf m This chapter Contents 2 Maintenance Information Gear Oil Inspection Check gear oil if leaking Park the motorcycle with main stand on flat level place Turn off engine
76. in jet fuel needle jet seat fuel needle jet slow speed jet and fuel amount adjustment screw Cautions Set the adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking Fuel Level Cautions e Check again to ensure float valve float for proper installation To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 17 5 mm Installation Of Carburetor Install carburetor in the reverse order of removal Following adjustments must be made after installation Throttle valve cable clearance adjustment Idle speed adjustment Idle Speed Adjustment A Caution Fuel amount adjust screw was set at factory so no adjustment is needed Note the number of turns it takes to screw it all the way in for ease of installation Never screw in forcedly to avoid damaging the screw seat The main stand must be used to support the motorcycle to perform the Use a tachometer when adjusting engine RPM Screw in adjustment screw gently then back up to standard turns Standard turns 1 3 4 3 4 turns Warm up engine adjust throttle valve stopper screw to standard RPM Idle speed rpm 1700 100 rpm Connect the sampling hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the air volume adjustment screw and read CO reading on
77. inal driving gear and shaft Inspection Of Final Driving Mechanism Check if the countershaft and the gear are wear out or damage Check if the final driving shaft and gear are burn wear or damage 9 Final Driving Mechanism This Chapter Contents 9 Final Driving Mechanism SYM Check bearings on gear box and cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on gear box amp cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary A Caution e Do not remove the driving shaft from the cover top side e f remove the driving shaft from the gear box then its bearing has to be replaced Check driving shaft and gear for wear or damage Bearing Replacement A Caution e Never install used bearings Once bearing removed it has to be replaced with new one Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Special tool Press the bearing into cover with C type hydraulic presser or bearing installer 9 4 This Chapter Contents SYM 9 Final Driving Mechanism Press out the driving shaft from the gear box Remove oil seal from the gear box Remove the driving shaft bearing fro
78. inder head Nut 1 8 2 2kgf m apply with oil on bolt thread amp seat Sealing bolt of timing chain auto tensioner 0 8 1 2kgf m Bolt of timing chain auto tensioner 1 0 1 4kgf m Timing gear cover bolts 0 7 1 1kgf m apply with oil on bolt thread amp seat Spark plug 1 0 1 4kgf m Tools Special service tools Valve reamer 5 0mm Valve guide driver 5 0mm Valve spring compressor 6 2 _ This chapter Contents SYM 6 Cylinder Head Valve Troubleshooting Engine performance will be effected by troubles on engine top end The troubles usually can be determinated or by performing cylinder compression test and judging the abnormal noise generated Rough Idle e Low compression pressure Low compression pressure 1 Valve e Improper valve adjustment Burnt or bended valve Improper valve timing Valve spring damaged Valve carbon Poor sealing on valve seat Improper spark plug installation 2 Cylinder head e Cylinder head gasket leaking or damage e Tilt or crack cylinder surface 3 Piston e Piston ring worn out High compression pressure e Too much carbon deposit on combustion chamber or piston head Noise e Improper valve clearance adjustment e Burnt valve or damaged valve spring e Camshaft wear out or damage e Cam chain wear out or looseness e Auto tensioner wear out or damage of cam chain e Camshaft sprocket wear out e Rocker arm or rocker arm shaft wear out White smoke e Valve guide or valve stem wear out e Valv
79. ing A Caution e Its sealing end should be forwarded to outside as bearing installation e Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Align oil seal lip with bearing and then install the A Ss Inner bearing new oil seal if necessary 8 12 bearing Sealing end This Chapter Contents SYM INSTALLATION OF CLUTCH DRIVEN PULLEY ASSEMBLY Install new oil seal and O ring onto sliding driven face Apply with specified grease to lubricate the inside of sliding driven face Install sliding driven face onto driven face Install guide pin and guide pin roller Install oil seal collar Install driven pulley spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with special nut wrench Remove the clutch spring compressor Torque value 5 0 6 0 kgf m Install clutch driven pulley and driving belt onto driving shaft 8 V Belt Driving System Foot Starter Oil seal 7 Specified grease Sliding driven face Oil seal Guide pin Guide pin roller Mounting nut wrench D 8 13 This Chapter Contents 8 V Belt Driving System Foot Starter SYM NOTE 8 14 SYM 9 Final Driving Mechanism Mechanism Illustration Inspection Of Final Driving Mechanism Operat
80. ion Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09 mm 2 ring replace if over 0 09 mm Feeler gauge Take out the piston rings and place them respective into cylinder below 20mm of cylinder top Measure each piston ring gaps A Caution Push the piston rings into cylinder with piston top end in parallel motion Service Limit Top ring replace if over 0 5 mm Piston rings 2 ring replace if over 0 65 mm Biickeinacaencnc 7 Cylinder Piston Measure the outer diameter of piston pin Service Limit 14 96 mm Measure the inner diameter of connecting rod small end Service Limit 15 06 mm Measure the inner diameter of piston pin hole Service Limit 15 04 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 52 30 mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 6 SYM 7 Cylinder Piston Piston Ring Installation Clean up piston top ring groove and piston shirt Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown A Caution e Do not damage piston and piston rings as installation e All marks on the piston rings must be forwar
81. ion Drum Brake System Wheel Tire Crankcase Ventilation Valve Clearance Adjustment Battery Valve Clearance Inspection And Adjustment Headlamp Adjustment Carburetor Idle Speed Nuts Bolts Tighteness Adjustment Special Service Tools Ignition System Catalogue Precautions In Operation Specification Fuel Tank Capacity 7500 c c Capacity 1000 c c E Oil 7 Capacity T Clearance of throttle valve Spark plug NGK CR8E Gap 0 8 mm F Mark in idling speed BIDC 13 1700 rom Front 2 Tire pressure cold Front 1 75 kg cm rear 2 25 kg cm j Front 1 75 kg cm rear 2 50 kg cm Battery 12V8Ah MF battery type YTX9A BS 8Hr This chapter Contents 2 Maintenance Information SYM Periodical Maintenance Schedule Maintenance Initial 1 Month 3 month 6 month 1 year e a S S CT a maes a o e e e GO Oa pom O foet T To oo C s fennen O R OOO Renen or vey 000m e Trepeswe a a T E a a TC a s Brake amp teepaychek 4 Tooo 9 Steehnghandiecheck 1 t ti SO a o Cushion operatoncheck o 4 d n every screwtghtoningcheck O 4 dS 12 Gearcichesktorteakng 1 f dsSSS 18 Sparkpugcheckorchange sdf S SST S 14 frGearoichange n ___ Replacementfor every 5000Km OO 15 Framewbrcaion OO O S y o e fes o a a a e a Sa dP A S e feemssoncnena a a o o ooo e TSC S a foegen a o o o ooo a porone OO O o o o
82. ional precautions l l Bearing Replacement Trouble Diagnosis l _ Re Assembly Of Final Driving Disassembly of Final Driving Mechanism Mechanism Final driving shaft Countershaft Ne Bs a Final driving gear 0 8 1 2 kgf m a hs l ET Countershaft E j gear Driving gear S 2 0 2 4 kgf m 1 0 1 4 kgf m 9 1 This Chapter Contents 9 Final Driving Mechanism Operational precautions Specification Application gear oil 4 stroke lubricant Recommended oil KING MATE serial gear oils Oil quantity 110 c c 100 c c when replacing Tools Special service tools Inner type bearing puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer Trouble Diagnosis Engine can be started but motorcycle can not be moved e Damaged driving gear e Burnt out driving gear e Broken driving belt Noise e Worn or burnt gear e Worn gear 9 2 SYM Torque value Gear box cover 2 0 2 4 kgf m Gear oil drain plug 1 0 1 4 kgf m Gear oil filling bolt 0 8 1 2 kgf m Gear oil leaks e Excessive gear oil e Worn or damage oil seal This Chapter Contents SYM Disassembly of Final Driving Mechanism Remove the rear wheel refer to chapter 15 Remove the clutch Drain gear oil out from gear box Remove gear box cover bolts 7 bolts and then remove the cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove f
83. l tools Special service tools Meaning correct installation o Indicates where the bolt installation direction means that bolt cross through the component invisibility _ This chapter Contents 1 General Information Trouble Diagnosis 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 4 Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verdict We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components A 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 insu
84. lated gloves and wait until cooling off SYM Battery A Caution Battery emits explosive gases flame is strictly prohibited Keep the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist 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 compressed air or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid asbestos dust flying 4 Caution Inhaling asbestos dust may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep brake fluid beyond reach of children This chapter Contents SYM Service Precautions e Always use with SANYANG genuine parts and recommended oils Using non designed parts for SANYANG motorcycle may damage the motorcycle e S
85. m in UP amp DOWN and then check if the fuel gauge indication needle is in correct position A Caution Turn on the turn signal light to make sure battery is in good condition before this test Float arm position Indicator needle UP full E empty DOWN empty F full 16 21 This Chapter Contents 16 Electrical Equipment SYM NOTE 16 22 SYM 17 Wiring Diagram ais m 4 T 5 ro g D me 3 n 17 Wiring Diagram SYM NOTE 17 2
86. m the gear box cover with the inner type bearing puller Caution e Using the bearing protector as pressing out the driving shaft from the gear box cover Specified tool Inner type bearing puller lf the driving shaft is pulled out with its bearing then remove the bearing with bearing puller and bearing protector Special tool Multi functional bearing puller Bearing protector Te i Universal bearing puller inner type Install a new driving shaft bearing onto gear box cover Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a new final driving shaft bearing onto gear box cover Specified tool Press the bearing in with C type hydraulic presser or the bearing installer Apply with some grease onto the lip section of oil seal and then install the seal This Chapter Contents 9 Final Driving Mechanism SYM Re Assembly Of Final Driving Mechanism Final k Final driving Counter l _ l o driving shaft gear shaft Install final driving shaft and final driving gear shaft E o countershaft and countershaft gear Install the setting pins 2 pins and new gasket Apply with grease onto the oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 0 2 4 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover
87. master cylinder for damage or scratch la ne ylinder Replace it if necessary see oe Measure the cylinder inner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit Allowable limit 11 055 mm Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit 10 945 mm Assembly CAUTION Rubber Sub rubber D ae e It is necessary to replace the whole set boot washer comprising piston spring piston cup and oF clip e Make sure there is no dust on all components before assembling Pisto Main rubber Apply clean brake fluid to the piston cup and Masher then install the cup onto the piston Install the larger end of the spring onto the master cylinder t A Ms os The master cup s cavity should be face inside of Sa Master master cylinder when installing the master cup cylinder 5 Install the clip CAUTION e Never install cup lip in the opposite direction e Make sure the clip is seated securely in the groove Install the rubber pad into groove properly 13 9 This Chapter Contents 13 Brake INSTALLATION l Place the master cylinder onto handlebar and Bea aol Mounting install the split ring and bolts The UP mark on a 3 seat the split ring should face upward Me i Align the split ring on the master cylinder seat with the alignment point on the han
88. mp Removal Rock Arm Forcedly lubrication Cam Shatt Scoop lubrication Inner passage Connecting rod Forcedly lubrication Crankshaft Oil strainer 3 1 This chapter Contents 3 Lubrication System SYM Operational Precautions General Information e This chapter contains maintenance operations for the engine oil pump engine oil and gear oil Specifications a Oil viscosity Engine oil quantity Disassembly 1000 c c See Gee E Replacement 800 ee AAE 20 50 Oil viscosity SAE 10W 30 or equivalent 5 i i Recommended King Mate SAE 20W 40 serial oils OOO i Gear Oil Disassembly 110 c c SAE TOW 40 Replacement 100 c c ee ee SAE 10W 30 Oil viscosity of gear oil SAE 85W 140 Recommended King Mate gear oil series SYM HYPOID GEAR OIL unit mm coma N A N 0 12 Oil pump Clearance between outer rotor and body a o o2 Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5 kgf m Engine oil filter cover 1 3 1 7 kgf m Gear oil drain plug 0 8 1 2 kgf m Gear oil filling bolt 1 0 1 4 kgf m Oil pump connection screw 0 1 0 3 kgf m Trouble Diagnosis Low engine oil level Dirty oil e Oil leaking e No oil change in periodical e Valve guide or seat worn out e Cylinder head gasket damage e Piston ring worn out e Piston ring worn out Low Oil Pressure e Low engine oil level e Clogged in oil strainer circuits or pipes
89. n Inspection Visual inspect for brake fluid leaking or damage Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something Is interfered with the brake system or brake components Hose connection Operate the brake system and check the brake lining Check the front brake from front side and replace the brake lining with new one when T the brake lining wear limitation groove reaches to T Brake lining the brake disc a wear limitation e a i groove Park the motorcycle on a flat ground and check its brake fluid level Recommended brake fluid WELL RUN DOT 3 brake fluid CAUTION e The fluid level will not be correct if parking the motorcycle in title or just parking It has to waiting for around 3 5 minutes e Never use faked brake fluid to prevent from chemical reaction e It has to apply with same brand brake fluid to sure the brake performance BRAKE FLUID ADD Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or rubber components when conduct brake system maintenance CAUTION e Do not over the upper level when adding brake fluid and avoid to spilling brake fluid on painted surfaces plastic or rubber components to result in their damages Split ring 7 UP mark 13 5 This Chapter
90. n Install the oil pump 3 screws A Caution The elliptical hole on the driving gear is not match with the screw hole Thus the elliptical hole has to align with the screw hoe before tightening it Install oil pump outer cover 2 bolts Install the starting gear and the alternator Refer to chapter 10 3 6 SYM _ This chapter Contents SYM 3 Lubrication System Gear Oil Oil Level Inspection Park the motorcycle on flat surface with main stand Turn off engine and remove both engine oil filling bolt and oil draining plug on wl Filling bolt Remove gear oil filling hole bolt and place a measurement cup under the draining plug Remove the oil draining plug and the pour gear oil into the measurement cup Measure the gear oil quantity if within standard value Add specified gear oil if the oil level too low Standard quantity 110cc replacement 100 CC Draining plug Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it with new one Torque Value 0 8 1 2 kgf m Add new gear oil 100 c c from the gear oil filling hole and then install the gear oil filling hole bolt after added oil And then tighten the bolt Torque Value 1 0 1 4 kgf m x Recommended to apply with SYM HYPOID GEAR OIL SAE 85W 140 Start engine and run it for
91. ndlebar switch Check the continuity of follow pins listed below columns Start switch Start motor switch Wire color Yellow Red Green Headlight switch 16 19 This Chapter Contents 16 Electrical Equipment Turn signal light switch Horn switch Remove the front fender Connect 12V power to the 2 pins on the horn Then the horn should sound Replace it if necessary Brake light switch The circuit of black wire and the green yellow wire on the brake light switch should be in continuity when operating the brake lever If the switch damaged replace it with new one Brake lamp switch 16 20 This Chapter Contents SYM 16 Electrical Equipment Fuel Gauge Unit Fuel gauge unit remove Open the seat cushion Remove the luggage box assembly bolts x4 screw x1 Remove the rear carrier bolts x4 Remove the central cover screws x 2 Remove the left amp right body covers bolts x 2 screw x 4 Disconnect the fuel gauge unit coupler Turn the plastic cap in CCW direction and then remove the fuel unit plastic cap Remove the fuel gauge unit A Caution Do not damage or bend the float arm as removing Inspection The resistance values are listed below when the float arm in F and E positions Float arm position Resistance value E empty 97 5 107 5Q F full 4 10Q DOWN empty Connect the fuel gauge unit to the main harness Turn the main switch ON Move the float ar
92. ns and then close the valve CAUTION e Do not release the brake lever before the drain valve is closed e Always check the brake fluid level when Transparent draining hose carrying out the air bleeding procedure to avoid air entering into the system 2 Slowly release the brake lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1 and 2 until there is no air bubble at the end of the hose Tightly close the drain valve 4 Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary 5 Cover the cap 13 6 This Chapter Contents SYM 13 Brake Brake Caliper Removal Bolts x 2 Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hoses CAUTION e Do not spill brake fluid on painted surfaces e The exhaust pipe has to be removed before remove the rear brake caliper Remove the bolt cap and loosen the lining guide bolt Remove two caliper bolts and the caliper INSTALLATION Install the brake caliper and tighten the attaching bolts securely Torque 3 3 kgf m CAUTION e Use M8 x 35 mm flange bolt only e Long bolt will impair the operation of brake disc Tighten the lining guide bolt Torque 1 8 kgf m Install the bolt cap Torque 1 0 kgf m Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5 kgf m Refill up
93. o low grind the valve seat with 60 cutter Then grind the valve seat to specified width After the valve seat grinded coat valve seat surface with emery and then slightly press the grinded surface Clean up all emery coated onto cylinder and valve after grinded Cylinder Head Reassembly Lubricate valve stem with engine oil and then insert the valve into valve guide Install new valve stem oil seal Install valve springs and retainers A Caution The closed coils of valve spring should face down to combustion chamber 6 12 Contact surface too high Contact surface too low Valve split locks Spring retainer 3 A Valve spring Old valve seat E width lt Valve stem oil seal This chapter Contents 6 Cylinder Head Valve SYM Use valve spring compressor to press valve spring Install valve split locks and release the valve compressor A Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve split locks in which can be removed Special Service Tool Valve spring compressor Or with the valve spring remover installer to install valve and spring Firstly install valve spring retainers onto the valve as assembling A Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compres
94. of auto by starter and install its flat surface to carburetor Install screw and tighten it Cautions Align the round point of the starter with the screw hole of air intake side 4 FUEL INJECTION SYSTEM Fixing plate Screws x 2 Valve needle This chapter Contents 4 FUEL INJECTION SYSTEM SYM Float Chamber Disassembly Remove 4 mounting screws and then the float chamber cover Remove the float pin and float valve Checking Check float needle valve and valve seat for drop Drain bol Ba difference damage wear out dirty or clogged ane Float needle Cautions La valve In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel Float pin level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one Remove main jet fuel needle jet holder fuel H Main jet needle jet slow jet fuel amount adjustment Fuel needle screw holder A Cautions Take care not to damage jets and adjust screw Before removing adjustment screw turn it all the way down and note the number of turns Do not turn adjustment screw forcefully to avoid damaging valve seat face Main jet Clean jets with cleaning fluid Then use compressed air to blow dirt off Blow carburetor body passages with compressed air 4 8 This chapter Contents SYM 4 FUEL INJECTION SYSTEM Installation Install ma
95. on The third to the eleventh chapters cover engine fuel systems and driving systems The twelfth to fifteenth chapters are contained the parts set of assembly body The sixteenth chapter is electrical equipment The seventh chapter is for wiring diagram Please see index of content for quick having the special parts and system information YMA Contents i Page Content Index 1 1 1 16 1 General Information Trouble Diagnosis 2 1 2 18 Service Maintenance Information 3 1 3 8 W Lubrication System 4 1 4 14 A Fuel System 5 1 5 10 Ul Engine Removal 6 1 6 16 0 Cylinder Head Valve 7 1 7 8 Cylinder Piston 8 1 8 14 0 V Type Belt Driving System Foot Starter 9 1 9 6 O Final Driving Mechanism 10 1 10 10 Alternator Starting Clutch ba HE EO 11 1 11 6 fa Crankcase Crankshaft N 12 1 12 14 Body Cover 13 1 13 12 E W Brake System 14 1 14 8 Steering Front Wheel Suspension i Om EN 15 1 15 4 Rear Wheel Suspension 16 1 16 22 Electrical Equipment 17 1 17 2 17 Wiring Diagram bal 0 Model illustration SYM Battery Fuse Spark plug Winker relay uji a AC Generator Horn F a IG Coil Start relay Fuel tank Headlight Carburetor Frame number Seat lock Front winker light Tail light Rear winker light Gear oil drain Engine numbe
96. onnection Bolt of exhaust fixed Bolt of rear bracket 4 5 5 5 kgf m 4 5 5 5 kgf m 3 5 4 5 kgf m 2 4 3 0 kgf m 2 9 3 5 kgf m 11 0 13 0 kgf m 0 5 1 0 kgf m 3 0 3 6 kgf m 3 0 3 6 kgf m 5 1 This chapter Contents 5 REMOVAL OF ENGINE Engine Removal Remove the battery cap screw x3 Remove the battery negative cable Remove the battery positive cable Open the seat Remove the luggage box assembly bolt x 4 screw x 1 Remove center cover screw x2 Remove rear carrier and fuel tank cap hex socket bolt x 4 Remove both left amp right body covers and center upper cover set screw x 4 Remove both left amp right side covers screw x4 Remove both left amp right pedals screw x 8 Remove the connector of rear lamp power wire and generator wire Remove the starter motor cable on the relay 5 2 This chapter Contents SYM 5 REMOVAL OF ENGINE Remove the spark plug Remove the engine temperature sensor connector 4 Caution Open the latch located under the temperature sensor before disconnect It so that the connector can be pull out and not be damaged Loose the throttle valve cable fixed nut and remove the throttle valve cable Throttle valve cable fixed nut Remove fuel hose vacuum hose Fuel hose Disconnect auto by starter line coupler Auto by starter line tS This chapter Contents 5 REMOVAL OF ENGINE Loosen the clamp of the air cleaner duc
97. ontents 16 Electrical Equipment SYM Current Leakage Test Current Leakage Inspection Turn the main switch to OFF position and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal as shown on left diagram Battery terminal i Caution e Inthe 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 Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit Charging Voltage Current Inspection A Caution e Before conducting the inspection be sure that the battery is fully charged Use a fully charged battery having a voltage larger than 13 0 V If undercharged the current changes dramatically e While starting the engine the starter motor draws large amount of current from the battery Thus do not start the engine with battery Digital meter 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 A Caution
98. or installation pins terminals if found And then conduct O 4 connection operation later axl e 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 e Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction Do you know how to set the instrument to its measurement position and the insert locations of its two probes _ This chapter Contents SYM 1 General Information Trouble Diagnosis Specifications Maker SANYANG MODEL HF12W 6 Overall Length 1945 mm Suspension TELESCOPE Z O o Overall Width 700 mm System UNIT SWING gt Overall Height 1160 mm Tire 100 90 12 61L O Wheel Base 1335 mm Specifications 130 70 12 64L Front 48 kg Curb Front DISK 273 mm Rear 75 kg Brake System Weight Total 123 kg Rear DRUM 130 mm H Passengers e Weight Two 110 kg PERFOR Max Speed 96 km hr Above TT MANCE gt 84 kg Climb Ability 28 Below Total 162 kg Bier BELT Weight Total 246 kg _ a GEAR 4 STROKE ENGINE Clutch Centrifugal dry type Installation and Vertical below center o ee A Transmission C V T arrangement incline 80 Fuel Used Unleaded Speedometer O 140 km hr Cycle Cooling A a Horn 70 90 dB A cooled 52 4 mm Muffler Expansion amp Pulse Typ
99. ore measuring the valve guide clean carbon deposits with reamer 5 0mm valve guide Special Service Tool 5 0mm valve guide reamer reamer Measure and record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide Service Limit IN gt 0 08 mm EX 0 10 mm A Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too A Caution It has to correct valve seat when replacing valve guide Valve Stem Replacement 5 0mm valve Heat up cylinder head to 100 150 C with heated guide driver plate or toaster A Caution e Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating it e Wear on a pair of glove to protect your hands when operating This chapter Contents 6 Cylinder Head Valve SYM Hold the cylinder head and then press out old valve guide from combustion chamber side 7 Val ide dri Tool Valve guide driver 5 mm SP egal rem kiadl 5 0mm A Caution A i L s Check if new valve guide is deformation ees AN after
100. orque Value 4 5 5 5 kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5 kgf m Down 2 4 3 0 kgf m Rear wheel axle nut Torque Value 11 0 13 0 kgf m 5 9 This chapter Contents 5 REMOVAL OF ENGINE SYM NOTE 5 10 SYM 6 Cylinder Head Valve Mechanism Illustration Valve Stem Replacement Precautions In Operation Valve Seat Inspection And Service Troubleshooting Cylinder Head Reassembly 6 12 Cylinder Head Removal l l Cylinder Head Installation Cylinder Head Disassembly l l Valve Clearance Adjustment 6 16 Cylinder Head Inspection Mechanism Illustration 1 0 1 4 kgf m 0 7 1 1 kgf m 2 0 2 4kgf m 0 8 1 2kgf m 1 0 1 4kgf m 6 1 This chapter Contents 6 Cylinder Head Valve SYM Precautions In Operation General Information e This chapter is contained maintenance and service for cylinder head valve and camshaft as well as rocker arm e Cylinder head service cannot be carried out when engine is in frame Specification Unit mm Compression pressure 12 2 kg cm se Exhaust ID of valve rocker arm 12 000 12 015 12 100 OD of valve rocker arm shaft 11 966 11 984 11 910 OD of valve stem Glesrance beween Intake 0 010 0 037 valve stem and guide 0 025 0 062 0 100 Free length of valve spring 35 000 31 500 Valve seat width 1 000 1 600 Torque Value Camshaft Height of cam lobe Cylinder head bolt 1 0 1 4kgf m Cylinder head bolt LH 1 0 1 4kgf m Cyl
101. ove the luggage box assembly Disconnect the battery negative terminal Remove the battery positive connection and starting motor wires from the start relay large pin Remove the power control connector of the start relay Connect a Ohmmeter between the start relay large pins Connect the green yellow wire to battery positive terminal and the green yellow wire to battery negative terminal Check the continuity between the start relay large pins If it is not continuity then replace the start relay 16 12 This Chapter Contents SYM 16 Electrical Equipment START MOTOR REMOVAL Remove the luggage box chapter 12 section 6 Remove the air cleaner chapter 4 section 10 Remove the battery negative terminal Remove the battery positive terminal and the start motor wire from the big terminal of start relay Remove the start motor mounting bolts and the motor Remove the start motor mounting bolts and the motor Starting Motor Installation Install the motor and other components in reverse procedure of removal This Chapter Contents 16 Electrical Equipment Meter Removal Remove the front cover chapter 12 section 4 Remove the power coupler of the meter Remove the rear cover of the handlebar chapter 12 section 3 Remove the odometer cable Remove the winker relay coupler 16 14 This Chapter Contents SYM 16 Electrical Equipment Remove the front cover o
102. panel slot Install the front wheel axle from right shock absorber side Install the wheel axle nut and tighten it to specified torque value Torque value 5 0 7 0 kgf m Connect the speedometer cable to the speedometer gear box 14 6 1 This Chapter Contents SYM 14 Steering Front Wheel Front Shock Absorber Front shock absorber Removal Remove the front fender front under spoiler front cover and front wheel as well as front brake components Remove the brake fluid hose clipper or cable guide on the left shock absorber bolt x 1 As for disc brake remove the cable guide on the right shock absorber bolt x 1 fluid hose clipper Remove the top connection bolt of the right shock absorber bolt x 4 Remove the shock absorber from the front fork Installation Install the shock absorbers according to the reverse procedure of removal Align the shock absorber top edge with the top end level of the front fork when installing the front shock absorber onto the front fork Then tighten the nut Torque value 2 4 3 0 kgf m Front fork steering column Removal Firstly remove the handlebar front wheel front brake set and front shock absorbers Remove the steering lock nut Remove the top cone race and then remove the steering column Caution Place the steering column bearing balls into a parts container to avoid to missing or F d Steering top cone race shortage 14 7 This
103. pecial tools are designed for remove and install of components without damaging the parts being worked on Using wrong tools may result in parts damaged e 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 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 e 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 1 General Information Trouble Diagnosis e Never bend or twist a control cable to prevent stiff control and premature worn out e 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 e 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 Store complex components such as transmission parts in the proper assemble order and tie them together
104. r Upper nut 2 4 3 0 kgf m Tools Special service tools Steering column wrench Bearing remover Inner type bearing remover Attachment 32x 35 mm Attachment 42x 47 mm Steering column nut wrench Steering column top cone ring nut wrench Trouble diagnosis Front wheel wobbling Hard steering stem e Bent wheel rim e Over tightening of steering stem lock nut o Loose wheel axle nut e Damaged steering stem steel ball and Poor wheel or wearing steering stem bearing seat e Too much clearance on wheel bearing e Insufficient tire pressure Soft front suspension Steering stem off center Front shock absorber spring worn out e Uneven left right cushion e Oil leaking on cushion oil ring e Bend fork e Bent front wheel tire offset Front suspension noise e Bent shock absorber linkage e Loosen shock absorber nut 14 2 This Chapter Contents SYM 14 Steering Front Wheel Front Shock Absorber Steering Handlebar REMOVAL Remove handlebar front amp rear cover and the front cover refer to chapter 12 Disc Brake Remove the 2 bolts of the brake master cylinder and then take out the master cylinder and the split ring Caution Do not operate the front brake lever to avoid to pressing out the brake lining when seat removing the master cylinder Remove throttle handlebar housing screw and then remove the handlebar throttle cable and handlebar upper housing amp under housing Remove the mounting bolt of the
105. r plug Engine oil drain plug High amp Low beam Passing Turn signal Horn switch lever Oil level Oil strainer Exhaust muffler SYM 1 General Information Trouble Diagnosis Symbols And Marks Torque Values Frame General safety Standard Torque Values for Reference Service Precautions Troubles Diagnosis Specifications Parts To Be Greased Torque Values Engine 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 Means that serious injury or even death may result if procedures are Warning not followed Means that equipment damages may result if procedures are not Caution followed Limits to use SAE 10W 30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil _Semm Grease King Mate G 3 is recommended KING MATE G 3 Gear oil King Mate gear oil SYM HYPOID GEAR OIL is recommended SAE 85W 140 F Apply sealant medium strength sealant should be used unless E Locking sealant Aa otherwise specified Oil seal Apply with lubricant Replace with a new part before installation aes Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid toa Specia
106. rake drum has a friction back plate BRAKE LINING Inspection Measure the thickness of the brake lining at three points both ends and center lf the thickness is less than specified or if it is contaminated by oil or grease replace as a set Service limit Rear 1 1mm Removal Caution Brake linings must be replaced as a set Remove brake shoes from the brake panel by pulling out the brake linings with two hands Installation Apply a thin coat of grease to the brake cam and the anchor pin Hook the brake spring onto the brake cam Pull out the brake linings and install them onto the brake panel Wipe off the excessive grease from the brake cam and the anchor pin after installation ee i ae 13 Brake Brake spring calla p y f EN Brake shoes 13 11 This Chapter Contents 13 Brake Slightly grind the brake lining surfaces with sand paper to clean the surfaces dk Caution Braking efficiency will be reduced if brake lining is contaminated by oil or grease BRAKE PANEL Removal Remove the brake arm bolt and then remove the brake arm wear indicator brake return spring and brake cam as well as the oil seal from the brake panel Wear indicator Installation Front brake panel Apply a thin cost of grease onto the brake cam shaft Install the brake cam Apply a thin cost of grease onto the oil seal lip and then install the oil seal onto the brake cam sha
107. re band and wire harness have to be lf there are two lockers on two connector sides clamped secured properly make sure the lockers are locked in properly Check if any wire loose e Check if the connector is covered by the twin connector boot completely and secured properly e Do not squeeze wires against the weld or its clamp This chapter Contents SYM e Do not let the wire harness contact with rotating moving or vibrating components as routing the harness e Keep wire harnesses tar away trom tne not parts NEVER TOUCH e Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws e Route harnesses so that they neither pull too tight nor have excessive slack 1 General Information Trouble Diagnosis Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied e Secure the rubber boot firmly as applying it on wire harness Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace them e Never clamp or squeeze the wire harness as installing other components Never clamp or squeeze the wire harness This chapter Contents 1 General Information Trouble Diagnosis SYM e Do not let the wire harness been twisted as e With sand paper to clean rust on connect
108. recious 4 valves mechanism so tighten torque can not be over the limited value and tightening the bolts diagonally by 2 3 sequences It can prevent from cylinder head deformation and then cause noise or leaking problems so that effect motorcycle s performance With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the alternator flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other single hole of the cam sprocket is in upward Then install the cam chain onto the cam sprocket Install the spark plug and tighten it Torque value 1 0 1 2 kgf m 6 14 This chapter Contents SYM Tighten the cylinder head right side cover bolt x 2 With flat screwdriver turn the cam sprocket tensioner in counter clockwise motion so that the tensioner is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the tensioner hole Tighten the bolt cap of the tensioner adjustment hole A Caution The O ring must be installed into glove Install the left side cover of the engine body bolt x 1 Install the right side cover of the engine body screw x 4 Screw x 2 6 Cylinder Head Valve pE Screw x 2 6 15 _ This chapter Contents 6 Cylinder Head Valve Install the cooling fan cover Screw x2 bolt x 2 Screw x 2
109. rt circuit in discharging system e Loose connection or short circuit in lighting system Charging system failure e burn Fuse e Loose broken or shorted wire or wire connection e Faulty voltage regulator e Faulty alternator Weak start motor e Poor charging system e The battery is not fully charged e Poor connection in the windings e The motor gear is jammed by foreign material Starter motor is working but engine does not crank e Poor start motor pinion e The start motor run in reverse direction e Poor battery This Chapter Contents 16 Electrical Equipment SYM Charging system Charging wire circuit Main switch T y Charging Connect the battery charger s positive terminal to battery s positive post Connect the battery charger s positive terminal to battery s positive post Standard Max 0 9A Charging current Charging time A Warning e Strictly keep flames away from a charging battery e The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires amp Caution Quick charge a battery should be used only in an emergency e Make sure the current and charging time of above description The battery will be damaged by too much current or too rush charging Alternator Regulator After installing the battery coat the terminals with clean grease 16 5 This Chapter C
110. s in engine that needed adjustment have been adjusted Idle speed check and adjustment have to be done after engine is being warm up around 10 minutes Park the motorcycle with main stand and warn up engine Connect tachometer the wire clamp of tachometer is connected to the high voltage coil Open the carburetor cover from the trunk Turn the throttle valve stopper screw to specified idle speed Specified idle speed 1700 100 rpm Emission adjustment in Idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 3 A 1 Connect the tachometer onto engine b E A es 2 Adjust the idle speed adjustment screw and Throttle valve stopper screw let engine runs in 1700 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value within standard aa p Emission standard CO below 4 0 z j pem il HC below 2000 ppm i Air adjustment screw This chapter Contents 2 Maintenance Information Ignition System Ignition Timing fi Caution C D I ignition system is set by manufacturer so it can not be adjusted Ignition timing check procedure is
111. sepower or poor high speed performance 1 Worn driving belt 2 Insufficient spring capacity of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly This Chapter Contents SYM 8 V Belt Driving System Foot Starter Left Crankcase Cover Removal of Crankcase Cover Remove body cover Remove foot starter lever bolt x 1 Remove the outer cover of engine left side cover screw x 3 Loosen vent strap on the front left side of cover and then remove the vent Remove air cleaner bolt x 2 Remove the engine left side cover bolt x 8 Outer cover screw x 3 Foot Starter Disassembly Remove snap ring and thrust washer from engine left side cover Install foot starter lever rotate the lever slightly and then remove driving gear and washer Remove the lever foot starter starter shaft and return spring as well as socket Inspection Check if starter shaft driving gear socket and bearing hole for wear or damage Replace it with new one if necessary Starter shaft Return spring Driving gear Check the return spring and friction spring for spring force or damaged Replace it with one if poor parts found Reassembly Install socket return spring and starter shaft as diagram shown Install thrust washer and snap ring onto starter shaft Install foot starter lever temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install the friction of driving gear onto
112. sing the valve spring directly With the valve spring remover installer compress the valve spring directly Then remove the valve and valve spring Special Service Tool Valve spring remover installer Tap valve stem to make valve retainer and valve stem sealing properly A Caution Place and hold cylinder head on to working table and place a rag against onto the valve so that can prevent damage valve stem and cylinder head This chapter Contents 6 Cylinder Head Valve SYM Install the camshaft onto the cylinder head and EX rocker arm shaft _ Lock plate then the rocker arm and the rocker arm shaft p p Lock the lock plate after rotate the rocker arm shaft to properly position A Caution There is different shapes on the top end of rocker arm shaft The machined surface on the rocker arm shaft has to face toward exhaust side and then the larger surface has to align with the bolt hole of cylinder E air IN rocker arm shaft Cylinder Head Installation Install the lock pins and new cylinder head gasket onto the cylinder head Install the camshaft chain plate i bs Chain plate ON EF Cylinder head gasket Install the cylinder head li i Bolt x 2 Tighten the 4 nuts onto the cylinder head top end yf 7 EE ee ee nf and then the 2 cylinder head mounting bolts on Ki its side Torque value 2 0 2 4 kgf m A Caution This model is equipped with p
113. stall a good plug into plug cap and then ground it to engine ground Make sure its spark condition If it is in not good or burnt spark plug replace the spark plug with new one A Caution Make sure each wire connection is correct and test as required Even the wire connection is in correct sometimes it might not be tested occurred Connect the high voltage shunt with a multi meter or input a resistor in the 10M 10CV of voltage meter Connect ignition coil wires and connect a shunt between primary terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to black yellow side Min voltage Above 95 V A Caution Do not touch metal parts on the test probe with fingers to avoid electric shock Primary coil check Disconnect the primary coil connector and check the resistance between primary coil terminals Standard 0 210 10 Q at 20 C Primary coil is good if resistance within standard Primary coil is broken if resistance is infinite Replace the coil 16 10 This Chapter Contents SYM Secondary coil Attached the spark plug cap measure the resistance between plug cap side and green terminal Standard value 7 12 kQ 20 C Remove the spark plug cap measure the resistance between plug cap side and green terminal Standard value 3 5 kOQ 20 C
114. t and then remove the duct Loosen the clamp of the inlet pipe and then remove the carburetor Remove the kick starter arm boltx 1 Remove the engine left cover protecting cover screwx3 Loosen the clamp of the engine left cover air duct and then remove the duct Remove the air cleaner fixed bolt blotx2 K u i i Engine left cover duct clamp Remove the front end nuts of exhaust muffler Nut x2 5 4 This chapter Contents SYM 5 REMOVAL OF ENGINE Remove the rear end bolts of exhaust muffler Bolt x3 Remove the exhaust muffler Bolt x 3 Remove the rear wheel and muffler rear bracket nut x 1 Remove the rear brake adjustment nut Engine suspension removal Remove the rear shock absorber lower bolt bolt x 1 Bolt x 1 This chapter Contents 5 REMOVAL OF ENGINE Remove the side hole cap of cooling fan Remove the engine suspension nuts and then remove the bolt from the side hole Caution With a bracket to support the engine to prevent from it damage by falling down as removing the engine Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so 5 6 This chapter Contents SYM Removal Of Engine Suspension Bushing If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged Then with the bushing remover pressor 28mm amp 20mm to press th
115. t the engine oil Remove the right side cover 4 screws Remove the exhaust muffler 2 bolts 2 nuts Remove the fan shroud 2 screws Remove the cooling fan shroud bolt x 2 screw X 2 Remove the cooling fan 4 bolts Hold the flywheel with the universal fixture Remove the 10mm nut on the flywheel Universal fixture Special Service Tools ehr Ri a l Universal Fixture i This Chapter Contents 10 Alternator Starting Clutch Remove the flywheel with the flywheel puller Special service tools Flywheel puller shaft protector A Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller Alternator Coil Set Removal Remove the couplers of the alternator and pulse generator Remove the 6 bolts for the pulse generator the alternator coil and cable guide Then remove the alternator assembly Caution Do not damage the alternator coil Right Crankcase Cover Removal Remove the right crankcase cover 8 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase Caution Do not damage the connection surfaces 10 4 5 Flywheel puller Pulse generator coupler Pulse generator This Chapter Contents SYM 10 Alternator Starting Clutch Starting Clutch Starting Clutch Removal Hold the starting driven gear
116. the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rom and CO value are in standard values after engine running in stable If rom and CO value fluctuated repeat the procedures described above for adjusting to standard value Throttle valve cable adjustment nut Air volume adjustment screw This chapter Contents 4 FUEL INJECTION SYSTEM Fuel Tank Removal of fuel unit Open the seat Remove the luggage box assembly bolt x 4 screw x 1 Remove the rear carrier bolt x 4 Remove both the left and right body covers screw x 4 bolt x 2 Remove the fuel unit coupler Turn the plastic cap in CCW direction and then remove the fuel unit plastic cap Remove the fuel unit A Caution Do not bend the float arm Install in reverse order of removal procedures Remark Aligning the slot of fuel unit with the ring of fuel tank as installation 4 10 This chapter Contents SYM 4 FUEL INJECTION SYSTEM Removal of fuel tank Open the seat Remove the luggage box assembly bolt x 4 screw x 1 Remove the body cover screw x 4 Remove the rear lamp and rear fender assembly screw x 4 Bolt x 3 Bolt on each side x 1 Remove the fuel inlet bolt x 2 Remove the fuel tank mounting bracket bolt x 4 This chapter Contents 4 FUEL INJECTION SYSTEM SYM Loosen the fuel inlet clamper and then remove the fuel vapor return hose Remove the fu
117. the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x37x6 Special service tools the oil seal installer 25x37x6 11 6 SYM 12 Body Cover Mechanism Illustration Luggage Box Maintenance Information Rear Carrier Front Cover Body Cover Handlebar Cover Left amp Right Side Foot Plates 12 11 Front Fender Left amp Right Side Covers Front Under Spoiler Floor Panel Inner Box Rear Fender Center Cover Mechanism Illustration Seat Pi ad ri Luggage box Handlebar rear cover Handlebar side Rear Carrier cover RH i x ak iL Right body m4 ey cover y N th 4 Sentai SF Fi OP Ight side cover a 4 iy Center body 12 cl EA cover a Left body Handlebar cover Handlebar side Right foot plate i ya Left foot plate zi F4 Inner rear Rear ba 7 7 Pw fender fender Left side cover Foot mat rd JAY Front under rd spoiler Under Cover 12 1 _ This Chapter Contents 12 Body Cover SYM Maintenance Information Body covers disassemble sequence Handlebar Rear Fronteovei Cover Handlebar Left right side cover Handlebar front Center cover Front fender Luggage box amp seat Rear carrier Inner cover Body cover Rear fender Tail light set Left Right foot plates Left right Inner rear fender side covers Floor Panel Under Cov
118. truction when removing the alternator and the pulse generator Ignition System Please follow the procedure of trouble diagnosis chart to check ignition system The ignition system equipped with a auto advanced timing device in CDI unit Thus ignition timing need not to be adjusted In case of incorrect ignition timing occurred check the CDI unit or alternator system It has to check the ignition timing with the ignition timing lamp if replaced these components Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by impact Therefore take care when disassembling Most of ignition system problems were resulted from poor connecting connector Please check the connectors first when servicing Make sure that the heat range of spark plug is suitable Improper spark plug is the main cause of poor engine operation or combustion Inspection procedures in this manual are based on Max voltage This manual also contains methods of how to check ignition coil resistance and component operation Please follow the continuity chart to check ignition switch Starting System Starting motor can be removed directly from engine Please refer to chapter 10 for starting clutch removal procedures 16 2 _ This Chapter Contents SYM 16 Electrical Equipment Specification Charging System Battery STD 0 6A 5 10hrs emergency charging 6A 0 5hrs Full charged Alternator Lighting coil resistance 20 C
119. ts in the reverse procedures of removal Caution Add adhere seal onto the thread of hex socket bolt Torque value 1 0 1 4 kgf m Starting clutch Installation Install idle gear shaft and idle gear Install starting clutch Install the starting driven gear onto the starting clutch Hold the starting driven gear with the universal fixture Tighten the 22mm anti loosen mounting nut and gasket Caution Add engine oil onto the thread of mounting nut Special service tools Anti loosen mounting nut socket Universal fixture Torque value 9 0 10 0 kgf m Mounting nut socket 10 7 This Chapter Contents 10 Alternator Starting Clutch Right Crankcase Cover Installation Install setting pin and new gasket on the crankcase Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip Install right crankcase cover onto the right crankcase 8 bolts Torque value 1 5 2 0 kgf m Mounted Coil Set Installation eee Pulse i 7 generator Install the coil set onto right crankcase cover 2 screws Install crankshaft position sensor 2 screws Tighten the cable guide 2 screws Torque 1 5 2 0 kgf m Tie the wire harness hose onto the indent of crankcase Caution Make sure that the wire harness is placed under the crankshaft position sensor Connect the connectors of alternator and crankshaft position sensor Pulse generator coupler Flywheel Installation
120. with a wire for ease of installation later e Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions depth distance or position e Components not to be reused should be replaced when disassembled including gaskets metal seal rings O rings oil seals snap rings and split pins This chapter Contents 1 General Information Trouble Diagnosis 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 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 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

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