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MAXSYM 400i

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1. AC Generator Starting Clutch Crankshaft Crankcase Cooling System Body Cover Brake System Steering Front Wheel Front Cushion Muffler Rear Wheel Rear Cushion Electrical System Wiring Diagram http www motorcycle in th Mechanism Illustration Front winker Luggage box Fuel tank Dimmer winker horn fuel pump seat open pass switch Main switch Coolant filler cap Taillight Headlight rear winker Air cleaner cap Main stand Back mirror Front brake lever Rear brake lever Muffler http www motorcycle in th 1 General Information Homepage Symbols and MarksScrctcssss sscsssssssssecssss 1 1 Torque Values rrsrssssssssssnsusu uuunuuuunununn General Safety P eee er ee re re ee T 1 2 Trou bleshooting eee ee ee rr ee ee 1 i 2 Before Servicing a a te 1 3 Lubrication Points ssssssss Specifications creer Tr ee er RANER er re 1 9 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed If supplemental information is needed for these symbols and marks explanations will be added in the text instead of using the symbols or marks A ami Means that serious injury or loss of life may happen if procedures are not arin correctly followed Caution Means that equipment damages may result if procedures are not followed Limits to use SAE 10W 30 API SG clas
2. c Power relay Air Injection Solenoid Valve 4 12 http www motorcycle in th To this chapter contents 4 Fuel Injection System Precautions in Operation General information A Warning e Gasoline is a low fire point and explosive material Always work in a well ventilated place and flame is strictly prohibited when working with gasoline e Before dismantling fuel system parts leak fuel out first or grip the fuel pipe by using pliers to prevent fuel from splashing A Cautions e Do not bend or twist the throttle cable Damaged cable will lead to unstable driving e When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly Specification Idle RPM 1550 100 rpm Fuel pressure 294 6kPa about 3 0kg cm Torque value Engine Temperature sensor 0 4 0 88 kgf m O2 Sensor 3 6 4 6 kgf m Special Tools Vacuum Gauge Fuel Pressure Gauge EFi System Diagnostic Scanner Fuel Pipe Pliers 4 13 http www motorcycle in th 4 Fuel Injection System To this chapter contents EFi System Components Description ECU Electronic Control Unit Functional Description e Powered by DC 8 16V and has 33 pin socket on the unit e The hardware component consists of a 16 bit microcomputer that is its control center It contains the functional circuit interface of engine condition sensing and the driving actuator for the fuel injector fuel
3. QO SYM 4 Fuel Injection System 3 FREEZED DATA Objective When a sensor fault the EMS system will record all the parameters of fault signals in order to facilitate fault diagnosis In the directory functions used A Y button select FREEZED DATA project press the ENTER key to the implementation SYM KEIHIN 4 a L ECU IG F DATA STREAM Wa PEEFED DATA i TROUBLE CODE Oo ERASE TB SODE CC J AD DAP ale AN ENTER contirm UP DOWN EXIT Exit LEFT RIGHT Only one page at any screen press the EXIT button the function can return to the directory screen In the FREEZED DATA of the screen use A Y button to move the left side of the project symbol selected items press the ENTER button lock of the project and press the F4 button showed that the wave of projects Able to use lt 4 left and right gt button can transform View wave numerical size 01 01 Dato stream sra 01 01 Data seam sra FAULT NG mm FAULT NGI r z 0 FAULT CO IDE Pood FALLI CODE Rood ENGINE SPD iii RPN WENGIN ESPL Eg RN ENGINE TEMIP 00 V 85 1187 E ENGINE TEMP ne OME TPS POSITION J Q dis a TPS POSITION oo MA Pave aaasasneeas 00g eatr 38K 9 WAP ee piv INTAKE AIR i Om Culside Temi INTAKE AIRS rey ic Juig kida Tamo 2 SENSOR is mem ole D 5a D i P ekki ceme OE ole D 58 O 6 3 BATT VOLT E ey Idle gt 124 BATT VOLT iu lhe gt 12 a aol Iiyed Ed wavelor
4. Caution Gasoline is highly flammable and may explode under some conditions keep it away from the children Used Engine Oil M Caution Prolonged contact with the used engine oil or transmission oil may cause skin cancer although it might not be verified yet We recommend that you wash your hands with soap right after contacting Keep the used oil beyond reach of the children Hot Components M Caution Components of the engine and exhaust system can be extremely hot after engine running They remain very hot even after the engine has been stopped for a period of time Before performing service work on these parts wear the heat insulation gloves or wait until the temperature drops Battery M Caution Battery emits explosive gases flame is strictly prohibited Keep the place well ventilated when the battery is being charged Battery contains sulfuric acid electrolyte which can cause serious burns be careful not to spill it on your skin or eyes If you get battery fluid on your skin flush it off with water immediately If you get battery fluid in your eyes flush it off immediately with water and go to hospital to see an ophthalmologist doctor If you swallow the battery fluid by mistake drink a lot of water or milk and take some laxative such as Epsom salts or vegetable oil and then go to see a doctor Keep the battery and battery fluid beyond reach of the children Brake Shoes
5. MAXSYM 4001 SERVICE MANUAL 20120303 http www motorcycle in th D SYM Foreword This service manual contains the technical data of each component inspection and repair for the Sanyang MAXSYM 400i scooter The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the motorcycle MAXSYM 400i are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department Sanyang Industry Co LTD http www motorcycle in th Homepage Contents How to Use This Manual D SYM This service manual describes basic information of different system parts and system inspection amp service for Sanyang MAXSYM 400i scooter In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information Th third to the twelfth chapter covers the engine and driving systems The thirteenth to the sixteenth is contained the parts set of assembly body The seventeenth chapter is electrical equipment The eighteenth chapter is wiring diagram Please see index of content for quick having the
6. EFi System Operation Crankshaft Position Intake Air Temperature Sensor gt Idle Speed Control Valve Stepper motor ISC Sensor Manifold Absolute Pressure Sensor INJECTOR Throttle Position TPS Sensor ECU IGN COIL Engine Coolant Temperature Sensor Engine Control Unit FUEL PUMP O2 Sensor LAMBDA CHECK LIGHT Roll Over Sensor Air Injection AISV Solenoid Valve Battery Voltage VBATT Tuning tools Diagnostic tool http www motorcycle in th To this chapter contents 4 Fuel Injection System EFi System Introduction Based on 4 stroke SOHC engine displacement 400 c c electronically controlled fuel injection fuel vapor absorbed by activated carbon canister The engine burns off the blow by fuel gas in the crankcase through the fuel air separating device The O2 sensor enhances the efficiency of the catalytic converter by dynamically controlling the Fuel Air ratio Electronic Fuel Injection Devices Consist of fuel supply devices fuel tank fuel pump fuel filter and fuel pressure regulator And fuel control devices fuel injector and ECU The fuel is pumped from electrical fuel pump in the fuel tank to the injector on the inlet pipe The fuel pressure regulator keeps the fuel pressure around 294 6kPa The signals from ECU enable the injector to spray fuel into the combustion chamber once every two crankshaft revolutions The excessive fuel flows back to the fuel tank through the fuel pressure regulator
7. Tighten the water pump shaft locknut Install the cam chain and tensioner 11 7 http www motorcycle in th To this chapter contents 11 Crankshaft Crankcase D SYM NOTE 11 8 http www motorcycle in th SYM 12 Cooling System Mechanism Diagram Precautions in Operation Troubleshooting System Test Mechanism Diagram ae aT iS T Reserve tank inlet pipe n PL lt Reserve tank ii E Tars J con F A a eC S la Radiator filler cap ot H T F i a i hr Thermo switch fan i E a Radiator Pai ee T a T Po ow a p a l a ali i a a ae _ eli ey at i a oa a wa ee a een Thermo unit 4 temp meter i ib E i WE a 4 i Ty l Thermostat Water pump Engine coolant outlet pipe oan Ei FE p y i i E of k giz x a ee a i Pe o i z i eee a r F To A E Engine coolant inlet pipe 12 1 http www motorcycle in th To this chapter contents 12 Cooling System Precautions in Operation A Warning e While the engine is running never attempt to open the radiator filler cap the pressurized hot coolant may shoot out and cause serious scalding injury No maintenance work is allowed to perform unless the engine is completely cooled down Add coolant to the reservoir the water thermometer Technical Specification Item Pressure to open filler cap Capacity of coolant Engine radiator Reservoir up
8. 12 Cooling System System Test A Warning e Never attempt to carry out service work on the cooling system unless the engine is completely cooled down otherwise you may get scalded Remove the reserve tank cap cover and then remove tank cap Reserve tank cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt gt p gprs pipe Refilling system with coolant and bleeding the air N i bubbles hs i T A S e Run the engine and remove by pass pipe J E UCT A e Check by pass hole for any bubble come out EA F f w pp e f there is no bubble emitted but only coolant E o flow out then joint on backflow pipe and turn i off the engine e Remove radiator filler cap e Starts the engine check if there is any bubbles come out from the radiator and the coolant is stable e Stop the engine and add coolant to proper level if necessary e Tighten the radiator filler cap Caution In order to avoid the radiator rusting please do not use the uncertified coolant Coolant recommended SYM Bramax radiator agent Concentration 50 12 4 http Awww motorcycle in th SYM Check reserve tank e Open the inner box lid e Check the liquid level in the tank e Add coolant to proper level if necessary Caution Add too much coolant in the reserve tank might cause overflow when the temperature increased Viewing window
9. Oil pump Clearance between outer rotor and body Disassembly 2000 c c Change with oil filter replaced SAE SAE ZOW 50 a cea SAE 2OW 40 Face oe Bell SAE 10W a0 rr i SAE 10W 30 TPE NN Yi Standard mm Limit mm 0 15 0 20 0 15 0 20 0 25 Clearance between rotor side and body 0 04 0 09 Torque value oil strainer 1 3 1 7 Kgf m Gear oil drain plug 1 1 1 4 Kgf m Gear oil inspection bolt 1 1 1 4 Kgf m Oil pump connection bolt 0 8 1 2 Kgf m Troubleshooting Low engine oil level Oil leaking Valve guide or seat worn out Piston ring worn out Low oil pressure Low engine oil level Clogged in oil strainer circuits or pipes Oil pump damage Dirty oil No oil change in periodical Cylinder head gasket damage Piston ring worn out 3 1 http www motorcycle in th To this chapter contents 3 Lubrication System Engine Oil Turn off engine and park the vehicle in a flat surface with main stand Check oil level with oil dipstick Do not screw the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Change A Caution Drain oil as engine warmed up so that to make sure oil can be drained smoothly and completely Place an oil pan under the vehicle and remove oil drain bolt After draining make sure washer can be re used Install oil drain bolt Torque value 1 1 1 5 Kgf m Fill out engine
10. Radiator Check Check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Remove Place a water pan under the water pump loosen the drain bolt to drain out the coolant Drain bolt Remove the front cover and under spoiler refer chapter 13 Loosen the radiator mounting bolts 4 bolts peaEach side 2 bolts http Awww motorcycle in th To this chapter contents 12 Cooling System To this chapter contents 12 Cooling System Disconnect the couplers for the thermo switch and fan motor Remove engine coolant inlet pipe reserve tank inlet pipe and radiator inlet pipe Remove reserve tank coolant inlet pipe Remove the radiator and the cooling fun Coolant inlet pipe Cooling fun Loosen the cooling fun mounting bolts 3 bolts Remove thermo switch 3 bolts Installation Install the removed parts in the reverse order of removal Install radiator in the reverse order of removal A completion check for any leakage Caution Liquid packing must be applied to the thermo switch before installation in order to avoid damaging the radiator 12 6 http www motorcycle in th Thermo switch SYM 12 Cooling System Technical Data Valve begins to open 71 80 C Valve stroke 3 5 4 5 mm at 80 C Installation Install i
11. Orange Voltage meter positive access to the wire harness sensor coupler first pin Red Yellow 2 Resistance Confirmation e Remove O Sensor and the wire harness between the coupler e Use of the meter Ohm stalls Measurement O Sensor heater resistance e Measurement resistance value Ohm meter negative access to the O sensor coupler 2nd pin White Ohm meter negative access to the O sensor coupler first pin White Resistance Confirmation 4 21 http www motorcycle in th To this chapter contents 4 Fuel Injection System e Connected the diagnosis tool to diagnosis coupler and open the main switch to start the engine e Engine to be completely warm up idling state operation 5 minutes above e Screen will switch to the diagnosis tool of DATA STREAM 01 01 screen select O2 Sensor project and switches to a wave of images turn the throttle engine speed to about 4500 rpm Observation O Sensor actuator circumstances bane voltage changes that e Observation O Sensor voltage values that the situation changes e situation Detection judge e Working voltage value above 10V e Resistance value 6 7 10 5Q e O Sensor amendment in the voltage value of between 100 900 mV beating representatives pollution closed loop control system to normal if contrary to maintain a fixed value for abnormalities Treatment of abnormal phenomena e O sensor damaged heater damaged or couplers to p
12. Remove Loosen 2 screws from the side cover side end 1 screw Loosen 2 screws from the side cover upper end 2 screws Remove the side cover Installation Install in reverse order of removal procedures 13 11 http Awww motorcycle in th To this chapter contents 13 Body Cover Rear Carrier Remove Loosen 4 bolts from the rear carrier and remove it Installation Install in reverse order of removal procedures 13 12 http www motorcycle in th V SYM 13 Body Cover Luggage Box Remove Open the seat Loosen 3 screws from the luggage box rear cover Disconnect the luggage box light and switch coupler Remove the luggage box rear cover Loosen 2 bolts from luggage box front side Loosen 4bolts from luggage box rear side Remove the luggage box Installation Install in reverse order of removal procedures 13 13 http www motorcycle in th To this chapter contents 13 Body Cover Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel Loosen right left side and middle screws from rear side of the body cover 3 screws Disconnect the tail light coupler 2 screws Remove the body cover Installation Install in reverse order of removal procedures 13 14 http www motorcycle in th To this chapter contents 9 SYM 13 Body Cover Floor Panel Remove Remove wind screen garnish wind screen meter visor
13. www motorcycle in th To this chapter contents Diagnostic Tool Use Note Diagnosis of connectivity 1 For the diagnostic tool coupler access to the motorcycle injection system diagnostic signal coupler main switch ON Open the diagnosis left power switch which turn on the LCD screen the screen brightness adjustment knob to the appropriate brightness SYM and cartridge content display on screen such as icon by the beginning of the implementation of any button Display diagnostic software release press the ENTER button to the implementation Engine of Life Cartridge BIKE_E70 Press any key FEAF BIKE_E7O 4 Fuel Injection System Test switch http www motorcycle in th Diagnostic coupler 4 45 To this chapter contents 4 Fuel Injection System D SYM Options main functional areas 1 ECU ID DATA STREAM FREEZED DATA TROUBLE CODE ERASE TB CODE CO ADAPTION Oo or BR DN Use A W button select mobile anti white subtitles implementation of the project and then press the ENTER key to the implementation SYM KEIHIN 4 1 ECU 1D DATA STREAM H EEZED DAIA ROUBLE CODE ERASE TB C e 5 ADA APTION Bi F in amp his F ENTER confirm lt UP DOWN EXIT exit LEFI RIGHT 4 46 http Awww motorcycle in th To this chapter contents D SYM 4 Fuel Injection System 1 ECU ID In the directory functions used A Y
14. Fuel pump is placed within the tank to reduce the working noise and the complicity of fuel pipes Electronically controlled ignition and injection system effectively reduce the fuel consumption rate and pollution In the traditional gasoline engine the carburetor supplies the fuel The process is done by the engine vacuum and the negative pressure in the carburetor by mixing fuel and air Under this condition three major processes are done simultaneously in the carburetor 1 Air quantity measurement 2 Fuel quantity determination 3 Mixing of fuel and air Electronic Fuel Injection System distributes the three major processes to three different devices 1 MAP TA sensor measures the air quantity and temperature and sends the signal to ECU as a reference 2 ECU determines the amount of fuel to be injected according to the default A F rate 3 ECU enables the injector to spray appropriate fuel amount The independence of these three functions will raise the accuracy of the whole process EFi engine uses computer programmed fuel injection the main features are 1 The quantity of fuel injected is decided according the condition of the engine The engine RPM and throttle position determines the fuel quantity and injection time length This throttle controlled fuel injection is better responding and more accurate 2 The quantity of fuel injection and the determination of injection time length are all controlled by 16 bit microcomp
15. Loosen the 3 mounting bolts by exhaust muffler right side Remove exhaust muffler Installation Install in reverse order of removal procedures M Caution e Replace the front side muffler pipe gasket if worn or deformed Torque Value Muffler mounting bolt 3 2 3 8kgf m Muffler mounting nut 1 0 1 2kgf m Rear Wheel Removal Remove the exhaust muffler Remove the rear brake caliper 2 bolts and brake hose clamp 1 bolt A Caution e Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out In case that the brake pad is accidentally squeezed out use a screwdriver to force it back to the place 2 bolts Remove the lower bolt of the right side rear 2 bolts x cushion Remove 2 bolts of the rear fork 16 3 http www motorcycle in th To this chapter contents 16 Rear Wheel Rear Fork Rear Cushion Remove rear wheel axle nut Remove rear fork and both side collars Remove the rear wheel Inspection rear wheel rim Place the wheel rim on a rotational support Rotate it by hand and measure the run out with a dial indicator Run out limit 2 0 mm Installation Install in reverse order of removal procedures Torque Value Rear wheel axle nut 11 0 13 0kgf m Rear cushion under bolt 2 4 3 0kgf m Rear fork mounting bolt 4 0 5 0kgf m Brake clipper mounting bolts 2 9 3 5kgf m 16 4 http www motorcycle in th To this chapter contents 16 R
16. Make sure that the wire harness is placed under pulse generator Right Crankcase Cover Installation Install dowel pin and new gasket Install right crankcase cover onto the crankcase Note that align the water pump shaft indent with the oil pump shaft Install right crankcase cover 12 bolts Connect water hose to the right crankcase cover Install the water pump cover onto crankcase cover 10 4 http Awww motorcycle in th D SYM 11 Crankshaft Crankcase Mechanism Diagram Crankshaft bearing replacement 11 5 Precautions in Operation Crankshaft bearing installation 11 5 Troubleshooting Crankcase Assembly Crankcase Disassembly Mechanism Diagram 0 7 1 1 kgf m 6 0 7 0 kgf m 1 0 1 4 kgf m 1 0 1 4 kgf m 1 1 1 5 kgf m eo o an 2 gt a Oil seal 35 55 7 5 Og 3 5 4 5 kgf m 1 0 1 4 kgf m 0 7 1 1 kgf m amp i EET 1 0 1 4 kgf m am 11 1 http Awww motorcycle in th To this chapter contents 11 Crankshaft Crankcase 9 SYM Precautions in Operation e This Section concerns disassembly of the crankcase for repair purpose e Remove following components before disassembling crankcase Engine section 5 Cylinder head Section 6 Cylinder and piston Section 7 Drive pulley and driven pulley section 8 AC generator Start driven gear Section 10 Starting motor Section 16 e Incase it requires replacing the crankshaft bearing the dri
17. and movable Guide pin driven face and then remove O ring amp oil seal seat from movable driven face Guide pin roller Inspection Clutch outer Measure the inner diameter of clutch outer Replace the clutch outer if exceed service limit Service limit 145 450 mm Inner sl _ l diameter Clutch outer 8 10 http www motorcycle in th To this chapter contents SYM 8 V Belt Drive System Clutch weight Measure each clutch weight thickness Replace it if exceeds service limit Service limit 3 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 97 400 mm Free length Driven pulley Check following items e f both surfaces are damaged or worn e f guide pin groove is damaged or worn Replace damaged or worn components Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm i Driven face ae E Movable driven face 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 Check if the bearing outer parts are closed and fixed Replace it if necessary Oute
18. front cover R L side cover front under spoiler inner box luggage box and body cover Loosen 4 bolts and 2 screws from floor panel Remove floor panel Installation Install in reverse order of removal procedures Front Fender Remove Loosen 4 screws from front cushion Remove the front fender Installation Install in reverse order of removal procedures http Awww motorcycle in th To this chapter contents 13 Body Cover D SYM NOTE 13 16 http www motorcycle in th Home page Contents Mechanism Diagram Brake Fluid Replacement Air bleed 14 6 Precautions in Operation Front Brake Calipers s stestestesseseeseeeees 14 7 Troubleshooting Rear Brake Caliperess sssssrrttteee 14 8 Disk Brake System Inspection Brake Disk TITTTITITTITi Trier T Adding Brake Fluid Master Cylinder 1 sssssessrecseseeees Mechanism Diagram Rear brake Master cylinder aN 0 8 1 0 kaf Pa i O m H Pg Am g i Y i _ hl a 5 3 0 4 0 kgf m Delay valve ai Ai 3 5 4 5 kgf m rk Bee re y D a E t hy a as 5 lal E i ea J J 3 5 4 5 kgf m ae ae Left front brake caliper E Rear brake caliper fi z aL a 1 F 7 2 4 3 0 kgf m 14 1 http www motorcycle in th To this chapter contents 14 Brake System SYM Precautions in Operation M Caution Inhaling asbestos may cause disorders of respiration system or lung cancer ther
19. http Awww motorcycle in th To this chapter contents 17 Electrical System Disconnect the positive cable of the starter motor Disconnect the coupler of the relay Connect an ohmmeter to the large terminal end Connect the yellow red cable to the battery positive terminal and the green yellow cable to the battery negative terminal Check the continuity of the large terminal end If there is no continuity replace the relay Removal of Starter motor Turns off the main switch Remove the luggage box Disconnect the coupler of the start relay Disconnect the cable negative terminal of the battery Disconnect the starter motor power cable Loosen 2 bolts amp remove starter motor Installation of starter motor Install in reverse order of removal procedures 17 12 http www motorcycle in th 7 To this chapter contents D SYM 17 Electrical System Meter Meter circuit diagram Meter Ignition Fuse 10A Turn right indicator Turn left indicator High beam indicator ___L W__Side stand warning light e Battery _WIB Parking right indicator UG Fuel injection indicator Oe a Meter illumination d r AE j SR ri ee N Ta Speed sensor j F 5 p Kal N My L A Sk OG fe i J Transistor ignition Sense 5 bolts of the disk R Red W B Black L_ Blue G Green SB Sky blue Y Yellow O _ Orange _ P Pink GR Gray M
20. lt EXIT gt Sexi 4 56 http www motorcycle in th To this chapter contents 4 Fuel Injection System Troubleshooting Table Comprehensive testing program closed Abnormal Power Ignition i jecti loop phenomena voltage state control Can t start Start state Difficult to start Without idle Idle not Idle smooth state Fault Throttle Engine Code position temp Detection sensor sensor ation Inability and slow Idle flameout Acceleratio n flameout Related spare parts oe e m EE re poeme sensor coil Fuel Secondary Power pressure Cylinder hee relay _ adjustment Spark plug Head Fuel pump injection solenoid valve Inlet ressure Pressure p adjustment sensor valve Main Fuel filter switch a gt P ff pt Notes 1 Integrated test motorcycle according to the Comprehensive Maintenance list implementation 2 Spare parts according to the EFI System components description implementation Security Fuel pump unit 4 57 http www motorcycle in th To this chapter contents 4 Fuel Injection System Comprehensive Maintenance List e Use meter direct measurement battery voltage e Use diagnosis tool detection of battery voltage Fuel e Use fuel pressure gauge pressure connected in series between the injector and the Pressure Regulating Valve e Main switch ON but not start engine e Check fuel pressure e Start engine idle e Check
21. www motorcycle in th To this chapter contents 2 Maintenance Information Periodical Maintenance Schedule 1 month 3 months 6 months No item every every every every 1 000KM 5 000KM_ 10 000KM 15 000KM X Air cleaner element Oo lI COC R Y Fuel filter Coo S S DE R at 1000 km Further replacement every 20 000km 4 XOilfilter screen l Cleaning every 10 000km at 1000 km Further replacement every 5 000km 6 Tire pressure ooo o CT o e o e _7 Batteryinspecton CT bo fo b o e 8 Brakefree play check fo E o e _9 Steering handle check __ o bo o foo b o e 10 Cushion operation check CE f o S D e 11 Every screw tightening check J CE o fo o b o o 12 Gear oil check for leaking bo o f b f D l XxSpark plug check or change pot CR 14 y Gearoilchange ss R Replacementfor every 10 000 km 15 Frame lubrication Z J o o S E E 16 Exhaustpipe CE E f O y D f E 17 yclgnitiontiming CE e f e f e f D 18 y xEmission check in Iding b f 1 J I f I 19 y Throttleoperation o o ooo o e S D f i 20 xEngine bolt tightening o o So D y D f E 21 xCVT driving device bet o S I R 22 xCVT drivingdevice roier CE CR O ee ee ee ee Main side stands amp springs Fuel lines a E 25 Fuellines gt f 26 Camchain Y TI 27 yValveclearance 1I 28 yCrankcase evaporative control system 1 29 yEvaporative control system
22. 1 To this chapter contents 16 Rear Wheel Rear Fork Rear Cushion SYM Operational Precautions General Please refer to the Maintenance Manual for tubeless tire in respect to the removal repair and installation of the tires Service data Unit mm Raa ooo o T oo o Run out of rear rim ma o f oo Torque Value Rear wheel axle nut 11 0 13 0kgf m Rear cushion upper bolt 3 5 4 5kgf m Rear cushion under bolt 2 4 3 0kgf m Rear fork mounting bolt 4 0 5 0kgf m Exhaust muffler mounting nut 1 0 1 2kgf m Exhaust muffler mounting bolt 3 2 3 8kgf m Brake clipper mounting bolts 2 9 3 5kgf m Brake disc mounting bolt 4 0 5 0kgf m Troubleshooting Run out of rear wheel Poor Performance of Brake e Deformed or bent wheel hub e Improper tires e Loose wheel shaft Improperly adjusted brake Contaminated brake disc Worn brake lining Air inside brake fluid pipe Grease on brake disc The brake fluid piping is clogged The brake fluid pipe is deformed or bent The brake fluid pipe is deformed or bent Insufficient amount of brake fluid in the reservoir Soft Cushion e The spring is too weak Noisy Brake e Worn brake lining e Offset brake disc e Improper assembly of brake caliper e Brake disc or wheel imbalance 16 2 http www motorcycle in th To this chapter contents 16 Rear Wheel Rear Fork Rear Cushion SYM Muffler Removal Loosen the 2 nuts from exhaust muffler front side
23. 30 Lines amp connections in cooling system I 32 Coolant e E 33 ECU input voltage _ 34 EFisensorcoupler oo Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1 000 kilometers as a reference which ever comes first Remarks 1 These marks yx in the schedule are emission control items According to EPA regulations these items must be performed normally periodical maintenance following the user manual instructions They are prohibited to be adjusted or repaired by unauthorized people Otherwise SYM is no responsible for the charge 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 c Replace worn out pistons cy
24. 4 Fuel Injection System D SYM ISC stepper motor 1m S sees Functional Description el e Use ECU provided power has the four pin socket e 4 pin coupler for the two motor coils of the power supply and grounding wire grounding ECU power through the control and management of the stepper motor actuators e If it s mainly low power DC motors drives idle speed control valve ISC of the movement to adjust the idle air flow channel size control of idle speed of the engine in the cold or hot Testing Procedures 1 Resistance Confirmation e Idle Air Control Valve will be demolished down coupler directly in the body can also measure e Use of the meter Ohm stalls QO measurement of the two step motor coil resistance values A phase ISCAP and ISCAN B phase ISCBP and ISCBN ISCBP ISCBN of the actuation testing can only be on engine not a single e Closure of the main switch e Use hand to touch Idle Air Control Valve body J e Open the main switch E E e Feeling the Idle Air Control Valve Actuation ISCAP ISCAN ISC PINS M Cautions e Dynamic checking for Idle Air Control valve can only be tested on the engine not a single test Detection judge 1 Resistance value A phase 80 100 Environmental conditions 15 25 C B phase 80 100 Environmental conditions 15 25 C 2 Actuator inspection In the above steps Idle Air Control Valve ISC Idling motor actuator control of inspecti
25. 4kgf m http www motorcycle in th To this chapter contents 7 Cylinder Piston Precautions in Operation General Information e Both cylinder and piston service cannot be carried out when engine mounted on frame Specification Unit mm I NOW LD 70 995 71 015 71 100 72 995 73 015 73 100 Clearance 0 015 0 050 0 090 0 015 0 050 0 090 between ring groove Piston gap ring 0 200 0 700 0 200 0 700 side rail Piston O D 2 70 430 70 480 70 380 72 430 72 480 72 380 Clearance between piston 0 010 0 040 0 100 0 010 0 040 0 100 and cylinder Troubleshooting 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 Knock or Noise Engine Overheat e Cylinder or piston ring worn out e Carbon deposits on cylinder head top side e Carbon deposits on cylinder head top side e Cooling pipe clogged or not enough in coolant e Piston pin hole and piston pin wear out flow 1 2 http www motorcycle in th To this chapter contents D SYM 7 Cylinder Piston Cylinder Piston Removal Remove cylinder head refer to chapter 6 Remove coolant hose from cylinder Remove cylinder oolant hose Cover the holes of crankcase and cam chain with a piece of cloth Remove piston pin clip and then remove piston pin and piston Remove cylinder gasket a
26. Above 98Kpa Intake Al p uige lemp 2nd Al VALVE i PRAA QO ig INJECT HME i n i T 4 Smp Sh ANGLE Wie 12 14 STEP MOTO Ro m i LE CRANE SHAFT ee y Ndle e W TEST TERMINAL OPER ttle OPEN IDLE SET EE 0 RPM ISC STER UP pry DOWN next Eni head Fi WEVEFOIIN EXIT emit LEFT Ppp RIGHT PoDn Fi Halp The screen showed the ECU captured by the engine of the state immediately The following data for the benchmark idling state e BARO kPa Above 98kPa Atmospheric pressure e Intake Air C Outside Temp Intake air temperature e 2nd AIR VALVE V Idle ON Secondary air solenoid valve actuator state e INJECT TIME mS Idle 1 3mS Injection time e IGN ANGLE Idle 12 14 lgnition timing e STEP MOTOR dle air control valve step motor actuator state e CRANKSHAFT Idle CW Crankshaft functioning direction e TEST TERMINAL Idle OPEN Test terminal state e IDLE SET RPM 1650 RPM ldle speed goal set value e ISC STEP Idle 75 95 lIdle Air Control Valve stepper motor learning step In the DATA STREAM of the screen use A Y button to move the left side of the project gt symbol selected items press the ENTER button lock of the project and press the F4 button showed that the wave of projects Able to use lt 4 left and right gt button can transform View wave
27. D C Oo O Wheel Base Rear 160 60 14 65H Front Brake System Rear DISK 275 mm Two 150 kg Max Speed gt 152 km hr Performance Climb Ability lt 24 Primary 248 Kg Reduction Secondary 379 kg Reduction pewuean 4 STROKE ENGINE Clutch Vertical below 0 no o Transmission center incline 80 Fuel Above 92 unleaded Speedometer 0 180 km hr 4 stroke Front DOUBLE DISK Curb 275 mm Rear D I Total Passengers Weight Front Total D G l ae a S Centrifugal dry type Installation and arrangement lt _ Full transistor ignition V Electrical starter Catalytic reaction control N system Max Torque Ignition lt O 4 3 83 0 mm aer Expansion amp Pulse D Type Stroke 73 8 mm Exhaust Pipe Position and Right side and Direction Backward Number Arrange SINGLE CYLINDER Lubrication System Foreed circulation amp ment splashing DO O W c Max HP 33 3 ps 7000 rpm 5 lt 0 15 g km Starting System os O http www motorcycle in th To this chapter contents 1 General Information Torque Values The torque values listed in below are for more important tightening torque values Please see standard values for those not listed in the table Standard Torque Values for Reference Tighten Torque Tighten Torque 5 mm bolt nut 0 45 0 6kgf m 5 mm screw 6 mm bolt gt nut 0 8 1 2kgf m 6mm screw gt
28. Dia mm Torque Value Kg m Remarks aaa D e a O Seomar rf eer emo M Frontwheetaent o e soro Rear wheetadent i e noro Front cushion mouningbok a o O a dP Rear cushion upper connection bot 1 10 ssas Rear cushion under connection bot 1 8 2430 Rear tork mounting bot 2 w soso Brake rosett 2 o soso Brake airbieeding vave 1 6 oso Front brake disc mounting sot 5 8 soas Rear brake aise mounting bot 5 soas Brake clipper mounting bot 2 2035 Engine hangerlinkbot 2 12 7595 onramesde Engine hangerlinkrut 1 12 7595 on engine side Main sendaran a o aoso OOo Ooo o rAircleanerbots 2 6 moma 1 11 http www motorcycle in th To this chapter contents 1 General Information Troubleshooting A Engine cannot be started or difficult to be started Check and Check and adjustment Faulteondiion condition Probable causes Press the fuel injector feed pipe and confirm whether there is fuel in the feed pipe Check the fuel amount in the fuel tank Check if the fuel pipe and the vacuum tube are blocked or not The fuel injector is not Malfunction of fuel pump relay or wiring Malfunction of fuel pump The fuel strainer is blocked or not The fuel supply to the fuel injector is sufficient Check the spark plug ignition condition Malfunction of spark plug Spark plug contamin
29. Do not use compressed air or brush to clean the components of the brake system Use a vacuum cleaner or the equivalent to avoid dust drifting in the air MA Caution Inhaling brake shoes dust may cause disease or even cancer of the respiratory system Brake Fluid M Caution Brake fluid spilled on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the top of the parts for protection when servicing the brake system Keep the brake fluid beyond reach of the children http www motorcycle in th To this chapter contents O SYM Before Servicing e Always use SANYANG genuine parts and recommended oil Using improper parts may cause damage to or destruction of the vehicle e Special tools are designed for removal and installation of component parts without damaging them Using wrong tools may result in parts damage e When servicing this vehicle use only metric tools Metric bolts nuts and screws are not interchangeable with the Britain system using wrong tools and fasteners may damage this vehicle e Clean the outside of the parts or the cover before removing it from the vehicle Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause damage e Wash and clean parts with high flash point solvent and then blow dry with compressed air Pay special attention to O rings or oil seals because most of the
30. Mechanism Final Drive Mechanism Disassembly Remove driven pulley Drain gear oil out from gear box Remove gear box cover bolts and then remove the cover Remove gasket and dowel pin Remove drive shaft Remove final driving gear and shaft Remove countershaft and gear Final Drive Mechanism Inspection Check if the countershaft is wear or damage Check if the final shaft and gear are burn wear or damage 9 3 http www motorcycle in th To this chapter contents 9 Final Drive Mechanism Check bearings on gear box 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 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 Check gear box cover bearing as the same way above and replace it if necessary Caution e f remove the drive shaft from the cover upper side then its bearing has to be replaced Check drive shaft and gear for wear or damage Bearing Replacement M 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 bearing puller Install new driving shaft bearing into left crankcase Tool Bearing 6301 driver Press the bearing into cover wi
31. Probable causes Check ignition timing 2 Malfunction of AC Generator Check the fuel pump supply condition a Poor 1 Insufficient fuel in the fuel tank 2 Pressed or cloaaed fuel pipe Check if fuel injector p Noma Clogged 1 Replace the fuel injector 1 14 4 Damaged ABV pipe Contaminated spark plug Malfunction of ECU Malfunction of AC Generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch oh WON http www motorcycle in th To this chapter contents A SYM 1 General Information E CLUTCH AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1 Worn out or damaged drive belt 2 Damaged movable drive face Engine can be started but the 3 Damaged driven face spring 5 Broken drive shaft groove 6 Worn out or damaged transmission gear Engine shuts down or trembles 14 Broken clutch spring when the vehicle is running 2 Clutch outer stuck with clutch weights rear wheel rotates during i Sion eee 3 Connection parts between clutch and shaft worn engine idling out or burned Worn or deformed drive belt Worn weight roller Worn driven face Deformed driven face spring Grease on drive belt or drive driven Poor initial driving poor climbing performance aPN 1 15 http www motorcycle in th To this chapter contents 1 General Information Lubrication Points Acceler
32. SH nut 8 mm bolt nut 1 8 2 5kgf m 6mm bolt nut 10 mm bolt gt nut 3 0 4 0kgf m 8mm bolt nut 12 mm bolt nut 5 0 6 0kgf m 10mm bolt gt nut Engine Torque Values 0 35 0 5kgf m 0 7 1 1kgf m 1 0 1 4kgf m 2 4 3 0kgf m 3 5 4 5kgf m item aty Thread Dia mm Torque Value kaf m Remarks NN Cylinder stud bolt Cylinder head nut Cylinder head right bolt Cylinder head side cover bolt Cylinder head cover bolt Cylinder head stud bolt inlet pipe Cylinder head stud bolt EX pipe Air inject pipe bolt Air inject reed valve bolt Tappet adjustment screw nut Spark plug Camshaft Chain Tensioner bolt Carburetor insulator bolt Oil pump screw Water pump impeller Engine left cover bolt Engine oil draining bolt Engine oil strainer cap Mission draining bolt Mission filling bolt Clutch driving plate nut Clutch outer nut Drive face nut ACG Flywheel nut Crankcase bolt Mission case bolt a aaa Muffler mounting nut TWDAAMDARDAANDSE ONWADS N oe oom Op Monn eee aan nnn On nNnNnNABAdnBNANNANDNA rN 1 10 http www motorcycle in th 1 0 1 4 3 6 4 0 2 0 2 4 1 0 1 4 1 0 1 4 1 0 1 4 2 4 3 0 1 0 1 4 0 07 0 09 0 7 1 1 1 0 1 2 1 0 1 4 0 7 1 1 0 1 0 3 1 0 1 4 1 1 1 5 3 5 4 5 1 3 1 7 0 8 1 2 1 0 1 4 5 0 6 0 5 0 6 0 8 5 10 5 5 0 6 0 0 8 1 2 2 6 3 0 1 0 1 2 Apply oil to thread To this chapter contents 1 General Information Frame ee Values Thread
33. boss from crankshaft EI Fa y i wl ha Crankshaft Drive face boss R Remove ramp plate amp plate Movable drive face Remove weight rollers from movable drive face Weight roller 8 7 http Awww motorcycle in th To this chapter contents 8 V Belt Drive System Inspection The weight rollers are to press movable drive face by means of centrifuge force Thus if weight rollers are worn out or damaged the centrifuge force will be affected Check if rollers are worn or damaged Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 19 0 mm Weight 17 2g Check if drive face boss is worn or damaged and replace it if necessary Measure the outer diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 30 060 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same In order to lengthen the roller life and prevented exceptionally wears the occurrence Please end surface of the closure surface counter clockwise assembles onto movable drive face Install ramp plate Weight roller Movable drive face Drive face boss Weight roller Closure surface Ramp plate Guide collar http www moto
34. cable terminal next the positive cable terminal The model of the spark plug and the tightening torque The ignition timing Adjustment of headlight Removal and installation of AC generator The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water To recharge the battery remove the battery from rack without removing ventilation caps Unless in emergency never rapid charge the battery The voltage must be checked with the voltmeter while charging the battery As ECU assembly does not require an ignition timing check In case ignition timing is incorrect check ECU and AC generator Verify with an ignition timing light after replacement if necessary Specification Charging system Capacity 12V10Ah Battery Charging rate 1 2A 5 10hr standard 5A 1hr rapid charging Charging current 1 2A 1500 rpm Control voltage in charging 14 5 0 5 V 2 000 rpm Ignition system NGK CR8E Recommended Spark plug Primary winding 2 80415 A Without cap 9 KO 20 resistance Secondary winding With cap 14 1 KO 20 Crankshaft position sensor resistance 20 C 80 160 Q At idle speed BTDC 10 1650 rpm Ignition timing advance Full advanced BTDC 30 17 2 http www motorcycle in th To this chapter contents D SYM Troubleshooting No voltage e Battery over discharged e The cable disconnected e The fuse is blown e Improper operation of the main switch e Low volt
35. charged one Connect a digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse M Caution e 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 M Caution e Do not use any short circuit cable e It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable positive terminal however while the starter motor is activated the surge current draws from the battery may damage the ammeter Use the kick starter to start the engine to prevent this happen 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 17 8 Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 6000 rpm Control Charging Voltage 14 5 V 1650 rpm M Caution When it comes to replacement make sure that the current and voltage of the new battery are the same as the old one The following problems are related to the charging system follow the instructions provided in the checking list t
36. damaged or coupler bad contact 2 Check whether the abnormal wire harness lines 3 Sensor coil anomaly the proposed replacement of the new one http www motorcycle in th To this chapter contents 4 Fuel Injection System Functional Description e Control power has two pin socket one for the power supply pin one for grounding pin e Secondary air injection solenoid valve at the Idle 3500 rpm below actuator At Idling ECU control solenoid valve by the grounding circuit to be moving or closing Testing Procedures Resistance Confirmation e Use of the meter Ohm stalls Q measurement of the secondary air injection solenoid valve resistance value Detection judge Resistance value 26 2 60 20 C Treatment of abnormal phenomena e Secondary air injection solenoid valve internal short circuit or open circuit or coupler bad contact e Check whether the abnormal wire harness lines e Secondary air injection solenoid valve anomaly the proposed replacement of the new one 4 29 http www motorcycle in th To this chapter contents 4 Fuel Injection System EFi System Circuit REDE T EEEk i EAI i ET 4 30 http Awww motorcycle in th To this chapter contents V SYM 4 Fuel Injection System ECU Pin Configuration ON ECU ECU Pin Note Pa e o w onono O e a A ROUNDS Ce eo oo wo oses OO 4 se o o _ SENSORGROUND OOOO Cs m wer THROTTLE POSITIONSEN
37. drain hose to air bleed valve Open the drain valve on the calipers and delay valve hold and release the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brake fluid 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 turn and at the same time hold the brake lever until there is no air bubble in the drain hose and also feeling resistance on the brake lever Close the drain valve when finish 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 loose please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turn and then close the valve A Caution Do not release the brake lever before the drain valve is closed Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enters into the system 2 Slowly release the brake lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1 and 2 until there is no air bubble at the end of the hose 4 Tightly close the drain valve 5 Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary 6
38. end should be forwarded to outside Apply with specified oil Install new inner bearing M 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 Install snap ring into the groove of drive face Align oil seal lip with bearing and then install the new oil seal if necessary http www motorcycle in th 8 V Belt Drive System Clipper Inner needle bearing Outer bearing Bearing end Inner bearing 8 13 To this chapter contents 8 V Belt Drive System Installation of Clutch Outer Driven Pulley Assembly Install new oil seal and O ring onto movable driven face Apply with specified grease to lubricate the inside of movable driven face Oil seal F Specified grease n Te Install the movable driven face onto driven face Guide pi Install the guide pin and guide pin roller Oil seal a ae uide pin Guide pin roller Install the collar Install friction plate spring and clutch weight into _ clutch spring compressor and press down the stom Clutch nut wrench assembly by turning manual lever until mounting oo nut that can be installed of a Hold the compressor by bench vise and tighten a a the mounting nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch outer driven pul
39. http www motorcycle in th To this chapter contents 13 Body Cover Meter Panel Remove Remove wind screen garnish wind screen meter visor and front cover Remove reserve tank cap Loosen 4screws from right amp left side of the meter panel Loosen 2 screws from in side of meter panel Loosen the meter cord coupler Remove the meter panel Installation Install in reverse order of removal procedures 13 8 http www motorcycle in th To this chapter contents 9 SYM 13 Body Cover Inner Box Remove Remove wind screen garnish wind screen meter visor front cover meter panel R L side cover and front under spoiler Loosen 1 screw from reserve tank stay Loosen 1 screw from fuse box and remove it Loosen 1 screw from main switch cap and remove the cap Loosen DC power output mounting nut and remove DC power output Loosen 1 screw from battery cover and remove it Remove the battery negative cable Remove the battery positive cable Remove the battery http Awww motorcycle in th To this chapter contents 13 Body Cover Loosen 2 bolts from inner box under side Loosen 2 bolts from inside of the inner box Disconnect the hazard light and foggy light switch couplers Remove inner box Installation Install in reverse order of removal procedures 13 10 http Awww motorcycle in th To this chapter contents 9 SYM 13 Body Cover Side Cover
40. if the fuel injector is clogged or Not clogged Remove and check the spark plug Incorrect ignition Malfunction of ECU 2 Malfunction of AC Generator Worn out cylinder or piston ring Cylinder gasket leakage Sand hole in compression parts Valve deterioration Jammed piston ring Abnormal compression pressure ah WN Clogged 1 Replace the fuel injector Check if the engine is over heated Continually drive in 2 Incorrect spark plug heat range Worn out piston or cylinder Abnormal fuel injector Poor fuel quality Carbon deposit in the combustion echamher kh OND acceleration or high enana 1 Carbon deposit in the combustion chamber 2 Malfunction of fuel injector Poor fuel quality Abnormal ignition timing 1 13 http www motorcycle in th To this chapter contents 1 General Information C Engine runs sluggish especially in low speed and idling Check and adjustment Probable causes It condition Check ignition timing using ignition lamp malfunction of ECU or AC Check for any air sucked in through the throttle body insulator gasket 1 Abnormal throttle body insulator gasket 2 Abnormal throttle body installation No air sucked in Air sucked in Abnormal inlet pipe gasket Remove the spark plug and check the spark D Engine runs sluggish High speed Check and adjustment Fault condition
41. is smoothly If handle turning is uneven and bending or the handle can be operated in vertical direction then adjust the handle top bearing Cushion Caution e Do not ride the motorcycle with poor cushion e Looseness wear or damage cushion will make poor stability and drive ability Front cushion Press down the front cushion for several times to check it operation Check if it is damaged Replace relative parts if damage found Tighten all nuts and bolts Rear Cushion Press down the front cushion for several times to check it operation Check if it is damage Replace relative parts if damage found Park motorcycle with main stand Turn the rear wheel forcefully and check if engine bracket bushing worn out Replace the bushing if looseness found Tighten all nuts and bolts 2 9 http www motorcycle in th To this chapter contents 2 Maintenance Information Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil 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 brake system for leaking if low brake level found M Caution e In order to maintain brake fluid in the reservoir in horizontal position do not remove the cap until handle stop e Do not operate the brake lever after the cap had been removed Otherwise the brake fluid w
42. left crankcase cover bearing setting plate Check bearing on left crankcase cover Rotate 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 cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing replacement Remove bearing with special service tools Special tools Inner bearing puller SYM 6204022 Install bearing with special service tools Special tools Right crank case bearing 6201 assembles tool SYM 9614000 HMA 6201 http Awww motorcycle in th To this chapter contents D SYM 8 V Belt Drive System Drive Belt Removal Remove left crankcase cover Hold drive face with universal holder and remove nut and drive face Special Tool Universal holder Hold clutch outer with universal holder and remove nut bearing stay collar and clutch outer Caution e Using special service tools for tightening or loosening the nut e Fixed rear wheel or rear brake will damage reduction gear system Push the drive belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 22 5
43. m UP prew DOWA next Entire Fa wavelorin IRGAT PgDn FT help EXIT exil LEFT PUP RIGHT Pode F Help 4 53 http Awww motorcycle in th s F 4 Fuel Injection System Ds Lid 4 TROUBLE CODE In the functional directory select TROUBLE CODE project press the ENTER button implementation the message began to read fault Fault Code electronic injection system that had happened fault of the message whether or not completion of repair Without any fault is that showing System is OK Press the EXIT button the function can return to the directory screen STM KEIHIN 1ra p a Ta y p a TER ID inem it OK 2 DATA STREAM Ti j CO A DA PTI iON If the system has faulty code that is showing the fault code that can be used lt left and right gt or A WV button to select the fault code selected before the code e tags that press the ENTER button the code can be read ene and fault handling 3 KEI H IN a i Fy rsg Fault code in the note and treatment of the pages if the first one page did End they can press the A Y button to turn the pages to read all content T8 code deseritpian SC Idle Speed Control Motor Faull frouble Sho Gling check steeping Molor And Connected Circul 2 Check Clreuir sf sion i Iropen Lj a al i Gesecriipian 3 0 hec Sieeping Motor is Error or NE Errar Replac EAEan se ond Check Again II Ef ar Replace Compomen and Gade PMS OT Ge C
44. main switch coupler Check the continuity between two points as indicted below Replacement of main switch Remove main switch cap Disconnect the coupler of the main switch and loosen the mounting bolts 3 bolts Remove the main switch Install the new main switch and tighten the mounting bolts Install the main switch coupler and cap Right handle switch Remove the handle cover and front cover Disconnect the coupler of right handle switch Check the continuity between two points as indicated in the table below Headlight switch Black Yellow Bi blue me co wT http www motorcycle in th 17 Electrical System Left handle switch Remove the handle cover and front cover Disconnect the coupler of left handle switch Check the continuity between two points as indicated in the table below High and low beam switch Sky blue Gray Brake Switch While grasp the brake lever firmly the terminals of white green and green yellow of the brake should have continuity Replace the switch if damaged Horn Remove the front cover and front under spoiler Apply 12 V power source to two terminals of the horn the horn should work Replace the horn if necessary 17 18 Brake switch http www motorcycle in th Winker switch To this chapter contents SYM Fuel Unit Open the seat Remove the luggage box Remove the rear carrier Remove right amp left side cover Remove the
45. mm Replace the belt if exceeds the service limit ST TT OA ee eee A Caution pee Se bee ee ne i a ea eee e Using the genuine parts for replacement ee ll e The surfaces of drive belt or pulley must be Belt tooth Width free of grease e Clean up all grease or dirt before installation http Awww motorcycle in th To this chapter contents 8 V Belt Drive System Installation Caution e Pull out driven face to avoid it closing e Cannot oppress friction plate comp in order to avoid creates the distortion or the damage Install drive belt onto driven pulley Install the driven pulley that has installed the belt onto drive shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value Torque value 8 5 10 5kgf m http Awww motorcycle in th Driven face To this chapter contents 9 SYM 8 V Belt Drive System Drive Face a Ser eee Universal holder Removal gt Remove left crankcase cover Hold drive face with universal holder and then remove drive face nut Remove drive face and drive belt Movable drive face Remove movable drive face comp and drive face
46. not let these residues and foreign materials fall into crankcase MA Caution e Soap the residues into solvent so that the residues can be removed more easily Install dowel pins and new cylinder gasket 4 Dowel pins http www motorcycle in th 7 Cylinder Piston To this chapter contents 7 Cylinder Piston Coat some 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 M Caution e Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 http Awww motorcycle in th D SYM 8 V Belt Drive System Mechanism Diagram Drive Bolier Precautions in Operation Drive Face ee a a a a T Troubleshooting Clutch Outer Driven Pulley sr Left Crankcase Cover Mechanism Diagram 0 7 1 1kgf m 0 7 1 1kgf m 8 1 http Awww motorcycle in th To this chapter contents 8 V Belt Drive System Precautions in Operation General Information e Drive face clutch outer and driven pulley can be serviced on the motorcycle e Drive belt and drive pulley must be free of grease Specification ltem Drive belt width OD of movable drive face boss ID of movable drive face OD of weight roller ID of clutch outer Thickness of clutch weight Free length of driven
47. numerical size 02 03 Data steam MBAR intake Al j JaN AIR VALVE INJECT TIME Nat AN ete ANK EHAFI TEST TERMINAL at DLE SET ISC STEP Pi prey DOWN next ised Fa wevetorr T eit LEFT Pplip CRIGHT PgDn F1 Hap Numerical analysis of images 2 3 the waveform can be displayed as shown in the following items BARO Intaje Air INJECT TIME IGN ANGLE IDLE SET ISC STEP 4 51 http Awww motorcycle in th 4 Fuel Injection System Data stream 3 3 tO 3 iK Data sirean m E LEARNED HEP E Gipi i an E Agyi EXIT axit LEFT PgUp The screen showed the ECU captured by the engine of the state mer The following data for the benchmark idling state e LEARNED STEP Set by ECU ldle Air Control Valve stepper motor learning step In the DATA STREAM of the screen use A W button to move the left side of the project symbol selected items press the ENTER button lock of the project and press the F4 button showed that the wave of projects Able to use lt left and right gt button can transform View wave numerical size CELEJ Date ieam LEARNED STEF NO OG WLEARNED STEP 2E Set by UP prey OONN next enii xed ExiT uri LEFT Polin Rich innr UN Numerical analysis of images 3 3 the waveform can be displayed as shown in the following items e LEARNED STEP NO 4 52 http Awww motorcycle in th
48. pulley spring OD of driven pulley boss ID of driven face Weight of weight roller Torque value e Drive face nut 8 5 10 5kgf m e Clutch outer nut 5 0 6 0kgf m e Drive plate nut 5 0 6 0kgf m Troubleshooting Engine can be started but motorcycle can not be moved 1 Worn drive Belt 2 Worn drive face 3 Worn or damaged clutch weight 4 Broken driven pulley Shudder or misfire when driving 1 Broken clutch weight 2 Worn clutch weight Oo r 17 700 18 300 g 17 200 g Special Service Tools Clutch spring compressor SYM 2301000 Inner bearing puller SYM 6204002 Clutch nut wrench 39 x 41 mm SYM 9020200 Universal holder SYM 2210100 Bearing driver SYM 9100100 Insufficient horsepower or poor high speed performance 1 Worn drive belt 2 Insufficient spring force of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly http www motorcycle in th To this chapter contents O SYM Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover amp remove it Remove left crankcase cover 8 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal http Awww motorcycle in th 8 V Belt Drive System Bearing setting plate Z ie shaft holder bearing RE A To this chapter contents 8 V Belt Drive System Left crankcase cover inspection Remove 2 bolts to remove
49. pump as well as ignition coil e Its major software is a monitor strategy operation program that includes controlling strategy and self diagnosis programs Testing Procedures 1 Connect the diagnostic scanner to the diagnostic coupler on the vehicle 2 Key on but not to start engine confirm ECU and the diagnostic scanner can be connected or not Diagnostic scanner will automatically display Version certification of the screen Confirm the application model version is correct or not Check if the fault codes exist Remove the fault codes Start engine and check the parameters which shown on the diagnostic scanner OO NOD Detection judge e Fault codes can be read and cleaned and the fault codes will not appear again after re start Treatment of abnormal phenomena 1 Disconnected First check whether the cartridge is correct and ECU is normal or not 2 Unable to start ECU or relevant parts abnormal Re confirm after the replacement of abnormal parts 3 Fault codes appear ECU or relevant parts abnormal Troubleshoot and re confirm http www motorcycle in th D SYM 4 Fuel Injection System Throttle Body T Functional Description e Throttle body is the inlet air flow regulating device similar to the carburetor e Throttle valve pivot drives the throttle position sensor synchronously and makes ECU detect the throttle opening immediately e Throttle valve positioning screw has been adjust
50. the posts Then clean it with steel brush so that can remove rust for more easily e Apply some grease on the posts after rust removed to prevent from rust again Nuts Bolts Tightness 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 13 http www motorcycle in th To this chapter contents 2 Maintenance Information Special Tools List Valve rocker arm shaft L Cover Radial Ball Brg 6006 Valve cotter remove amp disassemble tool Drive assembly tool NO SYM 1445100 01 NO SYM 9615010 REA 6006 NO SYM 1471110 20 NAME Clutch spring compressor NAME Tappet adjusting wrench NAME Oi seal driver 45 65 10 NO SYM 2301000 L4A NO SYM 9001200 NO SYM 9125500 L4A Crank Shift Oil Seal Driver PULLEY DRIVEN FACE Drive Shaft 25 40 7 Oil Seal 35 55 7 OPENER Drive NO SYM 9120900 L4A NO SYM 2321000 REA No SYM 9120200 L4A NAME Inner bearing puller NAME Outer bearing puller No SYM 6204022 No SYM 6204010 2 14 http Awww motorcycle in th To this chapter contents 2 Maintenance Information NAME Driven pulley bearing installer NAME Drive shaft bearing installer NAME Counter shaft bearing driver NO SYM 9100600 L4A DPB NO SYM 9100420 A6305 No SYM 9610000 L4A N1820 No sym 9020200 No SYM 221
51. then screw out the cane race 1 4 3 8 turn Torque value 0 25kgf m Caution Steering lock nut Return 1 2 turn e Check the steering stem that should be rotated freely and no clearance in vertical direction Locking to 1 4 3 8 turn Top cone race Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 0 2 0kgf m Install in reverse order of removal procedures 15 10 http www motorcycle in th To this chapter contents SYM NOTE Steering stem adjustment When the steering stem is too tight Steps please refer to figure 1 1 Stay front wheel on the ground and make sure that the component are connected all together appropriately 2 Lock the component 53220 HMA 00 STRG HEAD TOP THREAD COMP with the torque of 350 50Kgf cm 3 Turn the steering stem right to left for 5 6 times in order to make the bearing fit in 4 Keep the front wheel on the ground loosen the component 53220 HMA 00 over 1 4 turn and make the lock torque to zero 5 Start second lock procedure To begin with the component 53220 HMA 00 Make sure that the lock torque is between 100 130 Kgf cm Turn the steering stem and adjust it to appropriate position 6 Lock the component 50306 M9Q 00 with the torque of 300 350 Kgf cm Please be aware that component 53220 HMA 00 is not allowed to rotate along with the component 50306 M9Q 00 during this l
52. this chapter contents D SYM 6 Cylinder Head Valve Remove the side cover mounting blots of cylinder head and then take out the side cover Remove left crankcase cover and turn the Turn the drive face and align the timing mark on the sprocket with that of cylinder head piston is at TDC position Remove cam sprocket bolts and then remove the sprocket by prying chain out Remove the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side Remove the cylinder head b 2 dowel pins ur EN i in Remove cylinder head gasket and 2 dowel pins Remove chain guide Clean up residues from the matching surfaces of cylinder and cylinder head Caution Do not damage the matching surfaces of cylinder and cylinder head e Avoid residues of gasket or foreign materials falling into crankcase as cleaning http Awww motorcycle in th To this chapter contents 6 Cylinder Head Valve Cylinder Head Disassembly Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller SYM 1445100 5 roa Rocker arm shaft and cam shaft puller Remove cam shafts Cam shafts Special Service Tool Rocker arm and cam shaft puller SYM 1445100 Rocker arm shaft and cam shaft puller Use a valve cotter remove amp assembly tool to press the valve spring and then remove
53. to correct valve seat when replacing valve guide http www motorcycle in th 5 0 mm valve guide reamer J 6 Cylinder Head Valve To this chapter contents 6 Cylinder Head Valve Valve Stem Replacement Heat up cylinder head to 100 150 C with heated plate or toaster MA 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 Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 5 0 mm MA Caution e Check if new valve guide is deformation after pressed it in e When pressing in the new valve guide cylinder head still have to be kept in 100 150 C Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer M 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 0 mm 6 10 http www motorcycle in th Te Tiz a ker it A Valve guide driver 5 0 mm Valve guide reamer 5 0 mm To this chapter co
54. with that of the inner rotor Install the driving shaft Install fixing pin http Awww motorcycle in th To this chapter contents D SYM Install the oil pump cover and fixing pin properly 3 Lubrication System SCREWxt1 Tighten screw Make sure that oil pump shaft can be rotated freely Oil Pump Installation Install the oil pump and then tighten bolts Torque value 0 8 1 2 Kg m Make sure that oil pump shaft can be rotated freely Install oil pump driving chain and sprocket and then install snap ring onto oil pump shaft Install starting gear and generator http Awww motorcycle in th To this chapter contents 3 Lubrication System Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand Turn off the engine and remove oil inspection bolt Gear lubrication oil quantity has to be measured with measurement device If oil level is too low add gear oil Recommended using King serial oils Install oil inspection bolt Torque value 1 0 1 4 Kgf m Gear oil drain plug Gear Oil Change Remove oil level inspection bolt Remove drain plug and drain oil out Install the drain plug after draining Torque value 1 0 1 4 Kgf m Make sure that the drain plug washer can be reused Add oil to specified quantity from the inspection hole Gear Oil Quantity 330 c c when replacing it Make sure that the bolt washer can be re used and install the bolt
55. 0100 No SYM 31 40000 HMA i NAME Final shaft bearing installer NAME Water pump bearing installer NO SYM 9615000 L4A A6206 NO SYM 1923100 L4A A6203 Water pump seal driver Water pump mechanical seal Water pump mechanical aa driver bearing driver N1010 SYM 9120500 L4A SYM 1721700 H9A SYM 9100100 L4A 2 15 http www motorcycle in th To this chapter contents 2 Maintenance Information Pratik snan Degg A Crankshaft bearing install tool Fuel pressure gauge remove tool No SYM 9100310 L4A SYM 9100310 L4A No SYM HTO7010 NAME Vacuum pressure gauge NAME Cylinder pressure gauge NANE Vehicle circuit test tool kit NO SYM HTO7011 No SYM HT07008 NO SYM HE170008 a Pitre r ay NAME Vehicle circuit test harness kit Multi meter 2 16 http Awww motorcycle in th Homepage Precautions in Operations Troubleshooting Engine Oil Oil Pump Removal Oil Pump Disassembly Precautions in Operation Contents 3 Lubrication System Oil Pump Inspection Oil Pump Reassembly Oil Pump Installation Gear Oil This chapter contains maintenance operation for the engine oil pump and gear oil replacement Specifications Engine oil quantity 1900 c c Change 1800 c c Gear oil Disassembly 350 c c Change 330 c c Oil Oil viscosity SEA 10W 40 Recommended King serial oils Gear oil Gear oil viscosity SEA 85W 140 Recommended SYM Hypoid gear oils Inner rotor clearance
56. 1 2 kg m Cam sprocket bolt 1 0 1 2 kg m 6 2 http www motorcycle in th To this chapter contents V SYM 6 Cylinder Head Valve Troubleshooting Engine performance will be affected by troubles on engine top parts The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated Low compression pressure 1 Valve e Improper valve adjustment e Burnt or bent valve e Improper valve timing e Valve spring damage e Valve carbon deposit 2 Cylinder head e Cylinder head gasket leaking or damage e Tilt or crack cylinder 3 Piston e Piston ring worn out High compression pressure e Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto tensioner wear out or damage Camshaft sprocket Rocker arm or rocker arm shaft wear out http www motorcycle in th To this chapter contents 6 Cylinder Head Valve Cylinder Head Removal Remove engine Refer to chapter 5 Remove 2 bolts of thermostat and then remove the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system Al pipe mounting bolts Remove spark plug Remove cylinder head cover 4 bolts http Awww motorcycle in th 4 bolts To
57. 10 945 mm Rear brake 13 945 mm Master Cylinder Assembly Caution e It is necessary to replace the whole set comprising piston spring piston cup and cir clip e Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be faced inside of master cylinder while installing the master cup Install the cir clip Caution e Never install cup lip in the opposite direction e Make sure the cir clip is seated securely in the groove Install the rubber pad into groove properly 14 10 Rubber pS Cir clip boot Re j q a a Piston J A Spring a E Piston Master cylinder Rubber sS ya Cir clip boot Piston Master cylinder http www motorcycle in th To this chapter contents SYM Master Cylinder Install Install the rubber pad into the groove correctly Place the master cylinder onto handlebar and install the bolts Install the brake lever and connect leads to brake light switch 14 Brake System Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully to avoid twisting them together Caution Te A Improper routing may damage leads h
58. 70 Cable connector AutetslaScan V70 LCD monitor Link cable Information transmission indicator Function I oO aa ee Button to turn the 3 pages and numerical adjustment Beit 5 Leave Executive Ac tore ele button Function button Digital button Software Software cartridge slots cartridge Note e When problems occurred can be used for diagnosis tool of the fault is detected and exclusion e In addition to testing troubleshooting another of the operation can be carried out data analysis type monitor Method of Use 1 Maintain engine flameout state do not open main switch 2 Opened the luggage box lighting light cover screw x2 connected to the diagnostic connector for diagnosis tool 3 Then open the main switch and the diagnosis tool power switch after diagnosis display screen appeared the words connection 4 Press the ENTER button into the main screen there are 6 major functions ECU ID DATA STREAM FREEZED DATA TROUBLE CODE ERASE TB CODE and CO ADAPTION 5 Use A V select button under the function press the ENTER button access into various functions Example select DATA STREAM by the ENTER button the screen showed that the existing fault codes indicates no fault system is OK 6 Press EXIT button to leave of the various functions 7 Must to close the main switch or power switch of the diagnosis tool after and then can removal of diagnosis tool coupler 4 44 http
59. Caution e In order to maintain brake power balance the brake lining must be replaced with one set Remove the brake pad shafts and pads 2 11 http www motorcycle in th To this chapter contents 2 Maintenance Information Brake Light Switch Start Switch The brake light switch is to light up brake lamp as brake applied Make sure that starter motor can be operated only under brake applying Wheel Tire A Caution e Tire pressure check should be done as cold engine Appointed tire pressure Tire size Load for cold engine Hagel usd Kg cm Full loaded Check if tire surface is stuck with nails stones or other materials Check if front and rear tires pressure is in normal Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5mm Rear tire 2 0 mm 2 12 http www motorcycle in th To this chapter contents 2 Maintenance Information O SYM Battery Open the inner box lid Loosen screw amp remove the battery cover Battery cable remove 1 Disconnect the cable negative terminal 2 then the cable positive terminal 3 Remove the battery from the motorcycle If there is some rust on battery posts clean it with steel brush Install the battery in the reverse procedures of removal Caution If there is rust on the posts very serious spray some hot water on
60. Cover the cap A Caution Divulges the air to have to pump by the minute first divulges then to caliper May use fluid the replacement machine the replacement fluid the time is quicker the air bubble also Compared with cannot remain Transparent hose 14 6 http www motorcycle in th To this chapter contents SYM Front Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolts and finally remove the brake hoses A Caution Do not spill brake fluid on painted surfaces Remove two caliper mounting bolts and the caliper Installation Install the brake caliper and tighten the mounting bolts Torque 2 9 3 5kgf m M Caution e Use M8 x 35 mm flange bolt only e Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Remove brake caliper Remove brake pad caps Remove the brake pad guidance shafts cotter pins Remove the brake pad guidance shafts and locking spring and then remove brake pads Install the new brake pads onto brake caliper Install the brake pad guidance shafts and locking springs Install the brake pad guidance shafts cotter pins Install the brake caliper and tighten the mounting bolts F oa i tm i T a j z F 7 W V
61. SOR e vee Yi SENSORPOWER OUTPUT SV E a A Te T 9 Pci POWERGROUNDT A a a Ca p a OO o o ARTE SENSOR is es oo w esw E NN T a SSCS T e l e S C2 eom Ro O2SENSORHEATER Ca orm ow CRANKPULSESENSORGND Ca w ReR WATERTEMP SENSOR a a E C Ro O ve Ronoversenson Ca m eR MANIFOLD PRESSURE SENSOR Ca so e o a a E a RPM SIGNAL O71 NM gt 4 31 http www motorcycle in th To this chapter contents 4 Fuel Injection System Troubleshooting EFi Circuit inspection Bulbs broken Fuse broken Battery voltage is too low ECU Power line bad contact Poor contact the main power switch ECU fault Warning lights extinguished after 2 seconds OK Charging line anomaly NG Battery voltage above 12 5V SS NG nee aa storage NG Short circuit leakage OK Battery voltage amp ECU of voltage less than 0 2 V Main switch OFF Removed ECU coupler Main switch ON Use voltage meter measurement of the power pin lt a 1 Lines anomaly voltage difference Confirmed ECU and battery supply voltage differential pressure within the 0 2 V voltage OK Battery voltage drive parts voltage of less than 0 2 V Main switch OFF Removed the injector fuel pump O2 sensor roll NG over sensor ignition coil couplers Measurement of the voltage between the couplers and ground of the voltage difference Confirmed voltage
62. Start engine and run engine for 2 3 minutes Turn off the engine and make sure that oil level is in correct level Make sure that no oil leaking 3 6 http www motorcycle in th 4 Fuel Injection System EFi System Components Integrated Troubleshooting Procedure TTTTTITILITT Eire ire eLireeeereeeceeeeeeeere eee eee 4 36 Air Cleaner TrreT eT Cree eee eT eer ere eer er rrr re 4 39 EFi System Diagnosis Methods 4 40 Check Light Flault Codes Differentiation a E E Lert 4 41 Fault Code And Sensors Table 4 42 Fault Code and Check Light Flashing Precautions in Operation Lighting Identification Table 4 43 EFi System Components Description 4 14 EFi System Diagnostic Tool V70 4 44 EFi System Circuit Diagnostic Tool Note ia i ii i st a pa i a 4 45 ECU Pin Configuration Troubleshooting Table TTTTTITIT Tiree 4 57 Troubleshooting Comprehensive Maintenance List 4 58 EFi System Vehicle Configuration EFi System Operation EFi System Introduction Fuel System Ignition System Sensors Drivers Diagnostic tool EFi Check light Roll over sensor TA Sensor aN a ISC Stepper motor 4 1 http www motorcycle in th To this chapter contents 4 Fuel Injection System EFi System Vehicle Configuration Right O2 Sensor Diagnostic coupler TA Sensor Fuel pump Test switch http www motorcycle in th To this chapter contents 4 Fuel Injection System
63. Testing Procedures e Dismantled engine temperature sensor e Use of the meter Ohm stalls inspection sensor resistance Detection judge Resistance value and the temperature between relationships as follows Temperature C Resistance value KQ 20 18 8 2 4 1 136 0 1 0 1553 0 007 Treatment of abnormal phenomena e Temperature sensor damaged or couplers to poor contact e Check whether the abnormal wire harness lines e Temperature sensor anomaly the proposed replacement of the temperature sensor Resistivity measurements 4 20 http www motorcycle in th To this chapter contents SYM 4 Fuel Injection System O2 Sensor Functional Description e Use 8 16V DC power supply has the 4 pin coupler a power supply pins for heater for a heater control pin signal for a grounding pin O3 for a signal pin e O Sensor output feedback signal to the ECU fuel ratio control in the vicinity of 14 5 14 7 a closed loop fuel control e When the air fuel ratio control in the near equivalent CO HC Nox to have the highest conversion efficiency G R L O Testing Procedures 1 Voltage confirmed e Removed O Sensor and the wire harness between the coupler e Open the main switch but not to start engine R O R Y e Use voltage meter DC stalls DCV to check inlet pressure sensor voltage e Confirmed working voltage Voltage meter negative access to the wire harness sensor coupler 2nd pin Red
64. Use voltage meter DC stalls DCV to check fuel pump voltage e Confirmed working voltage Voltage meter negative access to the wire harness fuel pump coupler 2nd pin Green Voltage meter positive access to the wire harness fuel pump coupler first pin Black Purple AN Cautions e Conducting fuel pump voltage measurement if the main switch to open three seconds after the engine did not started the ECU will automatically cut off the fuel pump power supply Detection judge 1 1 Working voltage value Above 10V 2 Resistance value 1 5 0 50 3 Fuel pressure 294 6kPa about 3kg cm 4 25 http www motorcycle in th To this chapter contents 4 Fuel Injection System SYM Testing Procedures 3 Fuel pressure measurement e Use fuel pressure gauge connected in series between the injector and the fuel tank Cautions e Inthe implementation of the fuel pressure measurement will go to the demolition of the fuel hose such as injector or fuel pump hose hydraulic measurements after be sure to confirm whether there is a leakage of fuel situation in order to avoid danger Fuel system pressure measurement Detection judge 3 1 Fuel pressure 294 6kPa about 3kg cm Treatment of abnormal phenomena 1 Fuel pump damages internal coil break or coupler bad contact 2 Fuel filter blockage 3 Fuel pump anomaly the proposed replacement of the fuel pump Fuel pressure measurement 4 Fuel unit
65. Use 45 cutter to grind the valve seat to specified width MA Caution e Make sure that all roughness and uneven faces had been ground Grind valve seat again if necessary 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 Te ia valve but do not rotate it so that a seal track will be kaana oid valve seat width created on contact surface i Contact surface too high MA Caution e 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 Contact surface too low Old valve seat width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat to specified width http www motorcycle in th To this chapter contents D SYM After the valve seat ground coat valve seat surface with emery and then slightly press the ground surface Clean up all emery coated onto cylinder and valve after ground 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 Caution e The closed coils of valve spring should face down to combustion chamber Put the valve cotters onto valve spring retainer Use a valv
66. aft and final driving er ee S Final shaft ined a A i Final driving gear 9 6 http Awww motorcycle in th D SYM To this chapter contents 9 Final Drive Mechanism Install dowel pin and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4 kgf m Install driven pulley clutch outer belt Install movable drive face drive face and left crankcase Install rear wheel Add gear oil http Awww motorcycle in th 9 7 To this chapter contents 9 Final Drive Mechanism V SYM NOTE 9 8 http www motorcycle in th D SYM Mechanism Diagram Precautions in Operation 10 AC Generator Starting Clutch Flywheel Removal Flywheel Installation Right Crankcase Cover Removal 10 3 A C G Set Installation A C G Set Removal 0 7 1 1 kgf m qe a 8 5 10 5 kgf m pa E 2 8 3 2 kgf m t i vv Fe T t i uf ms in _ fil y Ta m i i fm Right Crankcase Installation a W m 7 di fi 0 7 1 1 kgf m 10 1 http www motorcycle in th To this chapter contents 10 AC Generator Starting Clutch Precautions in Operation SYM Refer to chapter 5 Engine removal and installation e Refer to chapter 16 The troubleshooting and inspection of alternator e Refer to chapter 16 The service procedures and precaution items of starter motor Specification ID
67. age e The battery is not fully charged e Poor connection e Poor charging system e Poor voltage regulator No spark produced by spark plug e The spark plug is out of work e The cable is poorly connected open or short circuited e Poor connection between ECU and ignition coil e Poor connection between ECU and main switch e Poor main switch e Poor ECU e A C G is out of work Starter motor does not work e The fuse is blown e The battery is not fully charged e Poor main switch e Poor starter 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 starter motor is out of work 17 Electrical System Intermittent power supply e The connector of the charging system becomes loose e Poor connection of the battery cable e Poor connection or short circuit of the discharging system e Poor connection or short circuit of the power generation system Charging system does not operate properly e Burnt fuse e Poor contact open or short circuit e Poor regulator rectifier e Poor ACG Engine does not crank smoothly e Primary winding circuit Poor ignition coil Poor connection of cable and connectors Poor main switch e Secondary winding circuit Poor ignition coil Poor spark plug Poor ignition coil cable Current leakage in the spark plug e Incorrect ignition timing PoorACG Improper inst
68. allation of CPS Poor ECU Weak starter 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 starter motor pinion e The starter motor runs in reverse direction e Poor battery 17 3 http www motorcycle in th To this chapter contents 17 Electrical System Battery Removal Loosen 1 screw and remove the battery cover Disconnect the negative cable terminal first then the positive cable terminal Remove the battery Voltage Check Use the digital voltmeter to check the voltage of the battery Voltage Fully charged 12 8V 1 at 20 C Undercharged Below 12 0 V at 20 C A Warning e Keep flames away while recharging e Charging is completely controlled by the ON OFF switch on the charger not by battery cables Charging Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Charging time e Keep flames away while recharging e Charging is completely controlled by the ON OFF switch on the charger not by battery cables Never rapid charge the battery unless in emergency Verify the battery is recharged with current and duration prescribed above Large current and fast time to charge will render damage to the battery W
69. alue such as CO value deviated from the normal range check O2 Sensor and other agencies anomaly Idle flameout Throttle line is not too jammed to revert to full closure Connect with the diagnosis tool into to view data steam screen Link diagnosis tool to view EFI fault content its Idle CO value amend anomalies Start engine and warm to 70 C 95 C confirmed engine speed idle control valve and fuel injection timing oxygen sensor is abnormal Gasoline whether enough Whether loose battery connecter Voltage is adequacy Idle CO value is set beyond the scope of 1 5 2 5 Idle functioning of 3 5 minutes to confirm the engine is running normally after engine flame out eliminating fault code operations EFi system more relevant institutions each recognized by the detection if still unable to rule out the idling flameout problem it is recommended that engine checks whether there are other traditional institutions abnormal 4 35 http www motorcycle in th To this chapter contents 4 Fuel Injection System Integrated Troubleshooting Procedure Checking adjusting Project Battery voltage Diagnosis fault code inspection Fuel quantity and fuel pressure Ignition situation 4 36 Detection of maintenance projects and steps Use meter direct measurement battery voltage Use diagnosis tool detection battery voltage Use of the diagnosis tool detection
70. aly Is Fuel system anomaly Spark plug there sparks Spark plug humid Spark plug cover loose Crankshaft position sensor Short Circuit Is Circuit anomaly The high voltage power lines loose ECU anomaly Leaking oxygen sensor connector corrosion short circuit Without valve clearance Valve timing is not correct Valve jam Cylinder and piston ring wear Throttle adjustment screw adjustment of the air improper Is Engine anomaly End 4 33 http www motorcycle in th To this chapter contents 4 Fuel Injection System Idle flameout diagnosis Idle flameout Throttle line is not too jammed to revert to full closure 1 Link diagnosis tool to view EFI fault content 2 In accordance with Troubleshooting procedures on troubleshooting Idle CO value is set beyond the scope of 1 5 2 5 Gasoline whether enough Throttle body whether coke serious Whether loose battery connecter Idle Air Control Valve Actuation whether or failure EFi system more relevant institutions each recognized by the detection if still unable to rule out the idling flameout problem it is recommended that engine checks whether there are other traditional institutions abnormal 4 34 http www motorcycle in th To this chapter contents 4 Fuel Injection System CO value revised anomaly O2 Sensor equipped with the system in principle not adjusted CO LLLv
71. am rocker arm shaft and cam rocker arm Service Limit Replace when it is less than 11 936 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 8 http www motorcycle in th To this chapter contents Valve spring free length Measure the free length of intake and exhaust valve springs Service limit Inner spring 35 20 mm Outer spring 36 90 mm 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 4 90 mm EX 4 90 mm Valve guide i Caution e Before measuring the valve guide clean carbon deposits with reamer Tool 5 0 mm valve guide 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 M Caution e f 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 i Caution e It has
72. anel Remove under cover Refer to chapter 14 Remove fuel pump lines coupler Release the fuel tube folder removed the fuel tube Remove the fuel tank fixed bolts Bolt x 2 on both sides remove the fuel tank Remove Install fuel pump and fuel unit Remove fuel pump fixed bolts Bolt x 6 remove fuel pump Install In the anti demolition order A Cautions Pressure Regulating Valve Then remove fuel pump fuel in fuel tank internal to confirm not excessive Then install fuel pump and fuel unit attention direction Confirm whether the fuel filter dirt obstructive Fuel pump installation to confirm whether it is normal to the fuel out the pressure about 3 kg cm2 Fuel filter http www motorcycle in th To this chapter contents D SYM Air Cleaner Clean air cleaner element Remove air cleaner cover boltx8 Remove air cleaner filter boltx6 Use compressed air to remove the adhesion of dirt if not too much dirt cleared please new replacement A Cautions e Air cleaner filter for paper products must not soak or cleaning by water Install air cleaner element Install In the anti demolition order A Cautions e Air cleaner filter and air filter cover should be covered formation is the installation not to skew a seam resulting dust foreign body aspiration in the engine 4 Fuel Injection System Bolt x 6 4 39 http www motorcycle in th To this chapter c
73. anomaly the proposed replacement of the fuel unit demolition injector Fuel pressure measurement demolition fuel pump 4 26 http www motorcycle in th O SYM Fuel Injector To this chapter contents 4 Fuel Injection System Functional Description e Powered by DC 8 16V and has two pin socket on the injector e Its major component is the solenoid valve of high resistance driven by electronic current e The two terminals are connected to power source and ground respective It is controlled by ECU to decide the injection timing and the injector pulse width Testing Procedures 1 Resistance Confirmation Use of the meter Ohm stalls Q measurement of the injector resistance value 2 Injector injection state examination e Removed the injector fixed bolt and removed the injector from intake manifold but not removal of harness coupler e Injector and injector cap tightly by hands fuel spills should not be the case e Key on and start the engine injector injection state examination Detection judge 1 Between the two pin resistance values 10 5 0 530 2 injection state e Fuel atomizing good with a clear scattering angle judged as normal e Injection state such as water no obvious scattering angle found abnormal Treatment of abnormal phenomena 1 Injector abnormal the proposed replacement of the new one injector 2 Injection state abnormal for the following reasons e Injector o
74. arter motor 1 Caution e Rotate the engine until the reading in the gauge no more increasing e Usually the highest pressure reading will be obtained in 4 7 seconds Compression pressure 12 542 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 cylinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head Drive Belt Remove mounting bolt located under air cleaner Remove 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 22 5 mm or above Clutch Disc Wear Run the motorcycle and increase throttle valve Opening gradually to check clutch operation If the motorcycle is in forward moving and shaking check clutch disc condition then replace it http www motorcycle in th 7 ta ih Compression gauge Reade tain A E AO AAAA RAAE P Le a perm ee ee Hy a DARA age ret al es Clutch lining Clutch weight To this chapter contents 2 Maintenance Information Steering Handle Top Bearing A Caution e 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
75. ation Week sparks or no spark Malfunction of ECU Malfunction of the AC Generator Ignition coil is in open or short circuit Perform cylinder compression Malfunction of main switch pressure test Normal cylinder compression pressure Low or no compression pressure Restart the engine No ignition With signs of ignition but 1 Malfunction of throttle valve operation the engine cannot be 2 Air sucked into intake manifold started 3 Incorrect ignition timing Piston ring seized Malfunction of cylinder valves 2 3 Worn cylinder and piston ring 4 Cylinder gasket leakage 5 Sand hole in the compression parts Remove and check the spark plug 1 Contaminated or clogged fuel injector Dry spark plug Wet spark plug 2 Malfunction of throttle valve operation 3 Malfunction of fuel pressure regulator 1 12 http www motorcycle in th To this chapter contents 1 General Information B Engine runs sluggish Speed does not pick up lack of power Check and adjustment Fault condition Probable causes Vv Accelerate gradually and check engine RPM 1 Clogged air cleaner Engine RPM can be Engine RPM cannot be 2 Poor fuel supply increased increased 3 Clogged exhaust pipe 4 Clogged fuel injector Check ignition timing Using ignition lamp Correct ignition timing Check cylinder compression pressure using compression Normal compression pressure Check
76. ation cable Front amp rear brake lever pivot T Seat locker Front wheel bearing Side stand pivot Main stand pivot Rear wheel bearing _ ee ee E 1 16 http www motorcycle in th 2 Maintenance Information V SYM Precautions in Operation Cylinder Compression Pressure 2 8 Periodical Maintenance Schedule Drive Belt tsrrrrrrssssssssnnnnnnunununnnnnnnnnnnnnnn 2 8 Engine Oil Steering Handle Top Bearings 2 9 Engine Oil Strainer Clean CUSNION rrsrssssssnsnnnnunununununnnnunnnnnnnnnnnna 2 9 Gear Oil Disk Brake System Eee 2 10 Fuel Lines Cable Brake Light Switch Start Switch 2 12 Air Cleaner Wheel Tir ecrcccccctttccssscccccssssssesecesnnsaeeees 2 12 P C V System Battery EPI eee 2 13 Valve Clearance Nuts Bolts Tightness s 1 sr srerrtseee eee 2 13 Spark Plug Special Tools List pipe E E E E E 2 14 Precautions in Operation Fuel Tank Capacity 14 200 500 c c Ernane Oi change with oil filter 1 900 c c g replaced Di Transmission ada Capacity of Engine radiator 1400 c c Spark plug CR8E gap 0 6 0 7 mm Timing advance idle speed BTDC 10 1 550 rom Idling speed 1 550 100 rom Cylinder compression pressure 12 5 2 kgf cm Valve clearance 120 70 15 568 Tire dimension 160 60 14 65H Tire pressure Front 2 00 kg cm Rear 2 25 kg cm cold Load 90 Kg full load Front 2 00 kg cm Rear 2 50 kg cm Battery 12V 11 2Ah MF battery TTZ14S 2 1 http
77. ault throttle position sensor fault Engine temperature sensor fault Intake temperature sensor fault Manifold pressure sensor fault O2 Sensor fault Crankshaft position sensor fault ECU fault Roll over sensor fault Notes 1 Fuel pressure gauge connected between the fuel tank and injector open the main switch to repeatedly shut down fuel system makes pressure stability 2 Injector and injector cap tightly by hands fuel spills should not be the case 4 58 http www motorcycle in th os O SYM 5 Engine Removal L Te Precautions in Operation Removal of Engine Precautions in Operation The engine has to be supported with special service tools that can be lifted or adjustable The following parts can be serviced as engine mounted on frame Carburetor Cylinder head cylinder and piston Driving pulley driving belt clutch and driving disc assembly Final gear reduction mechanism Specification Replacement 1800 c c Engine oil capacity oa a 1900 c c Disassembly 2000 c c Gear oil capacity Engine amp radiator 1400 c c Coolant capacity 350 c c as indicator shown Torque Value Engine mounting bolt 4 0 5 0kgf m Engine hanger bolt 3 5 4 5kgf m Rear shock absorber connection bolt under 2 4 3 0kgf m Engine hanger stopper nut 1 8 2 2kgf m Engine bracket nut 4 0 5 0kgf m 5 1 http www motorcycle in th To this chapter contents 5 Engine Removal Removal of Engine Disconnect t
78. body cover Remove the floor panel Disconnect the coupler of the fuel unit Loosen 4 bolts from fuel unit and remove it M Caution e Great care shall be taken not to damage or bend the float arm of the gauge When the float arm shifts to the F position or the E position the resistance measured shall be as follows Poon Resistance E Empty 90 100 Q Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupler to the wire harness Turn on the main switch Move the float arm to verify the proper position of the fuel gauge needle indicates Up Full F Full Down Empty E Empty M Caution e While conducting the test turn on the direction indicator lamp to make sure that the battery is in serviceable condition http www motorcycle in th 17 Electrical System Fuel Pump and unit 17 19 To this chapter contents 17 Electrical System Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor In case that the fan motor fails working disconnect the green and black blue leads and connect jump wires to the terminals then turn on the main switch The fan motor should operate afterwards If the fan motor still fails running measure the battery voltage between the green and black blue leads If there is no voltage check for blown fuse loose connection or short circuit If the fan motor runs c
79. bsolute Pressure sensor fault lighting long 0 short 9 MAP sensorand wire Fault detection procedures Please refer to the EFI System components description manifold Absolute Pressure sensor MAP chapter oa ons Engine temperature sensor fault water lighting long 1 short 2 Engine temperature sensor and wire Fault detection procedures Please refer to the EFI Sysiem components description engine temperature sensor WPS chapter 4 o9 Engine oil temperature sensor fault oil lighting long 1 short 1 Engine temperature sensor and wire The current reservation os ono Intake temperature sensor fault lighting long 1 short 3 Intake temperature sensorand wire Fault detection procedures Please refer to the EFI System components description intake temperature sensor TAS chapter 6 630 Roll over sensor fault lighting long 1 short 5 Roll over sensor and wire Fault detection procedures Please refer to the EFI System components description Roll over sensor chapter or oo O sensor fault lighting long 1 short 7 O2 Sensorand wire T Fault detection procedures Please refer to the EFI System components description O2 sensor chapter 8 ozo N J 1 fault lighting long 3 short 3 Injector and wire Fault detection procedures Please refer to the EFI System components description fuel injector chapter o oas IG 1 fault lighting long 3 short 7 Ignition coil and wire Fault detection procedure
80. bstructive the proposed replacement of the new one injector e Fuel pressure shortage confirmed hydraulic pressure the proposed replacement fuel pump to confirm l A Warning e Gasoline is lower ignited explosive materials in the ventilation premises operations and prohibited fire e In the inspection injector fuel injection state the outflow of gasoline and the application of appropriate collection containers so as to avoid danger 4 27 http www motorcycle in th To this chapter contents 4 Fuel Injection System D SYM Transistor ignition coil measurement First circuit coil resistance Functional Description e Use 8 16V DC power supply has the two pin socket e Two pin socket for the power supply and grounding Its main components for the high conversion ratio transformer e Through computer programs when the ignition is controlled from ignition timing TDC crank position sensor the throttle valve position sensor engine temperature sensor the inlet pressure sensor and O Sensor issued by the signal with the engine Speed through the ECU to determine the appropriate ignition is by the current of a crystal intermittent control a 25000 30000 volts of secondary hypertension flashover triggered spark plug this approach will not only enable the engine to achieve maximum output function also help to improve the efficiency of fuel consumption and pollution improvements Testing Procedu
81. button select ECU ID project press the ENTER buttom to the implementation of information systems function ECU ID containing two functions 1 1 ECU ID Datas 1 2 ECU Pin Assign SYM KEIHIN lt 9 4 A ore Ee r 2 ECU Pin Assign G a fi j m L m B p f N EXITS Exit LEFT gt RIGHT 1 1 ECU ID Datas Use A W button select ECU ID projects press the ENTER buttom to the implementation A total of 2 page use lt 4 left and right gt button view ECU information 4 47 http Awww motorcycle in th 4 Fuel Injection System D SYM 1 2 ECU Pin Assign Use A W button select the ECU pin project and press the ENTER button to the implementation of the ECU pin functions ECU pin assign total of 5 pages that can be used lt lt left and right gt button view the page note T Aa p mi ed i LENITION POWER LOG TL BRUUND HEGO SENROF CCW GRAND THROTTLE POSITION SER CES POWER CTP W HATTERY E eRe lef ty TH 4 48 http Awww motorcycle in th E 4 Fuel Injection System 2 DATA STREAM In the directory functions used A Y button select DATA STREAM project press the ENTER key to the implementation SYI KEIHIN 7 irux 1 ECUID 2 DATA 4 STREAI j FREEZED DATA A TROUBLE CODE 5 ERASE 1B CODE OCO ADAPTION ENTER contirm UP lt DOWN EXIT Exit LEFT RIGHT A total of 3 pages are able to use lt lt left and right gt butt
82. ch the oil seal is to be installed for smoothness and for burrs that may damage the oil seal m OREAHE 4 Manufacturer s name Both of these examples can result in bearing damage http www motorcycle in th To this chapter contents D SYM e Lubricate the rotation face with specified lubricant on the lubrication points before assembling e Check if positions and operation for installed parts is in correct and properly e Before battery removal operation it has to remove the battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark 1 General Information After service completed make sure all connection points is secured Battery positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables Make sure that the battery post caps are located in properly after the battery posts had been serviced lf fuse burned it has to find out the cause and solved it And then replace with specified Capacity fuse itt Capacity x verification su http www motorcycle in th To this chapter contents 1 General Information e When separating a connector it locker has to be unlocked firstly Then conduct the service operation e Do not pull the wires as removing a connector or wires Hold the connector body e Make sure if the co
83. change of the fuel pressure e throttle several rotation echeck to the change of fuel pressure again 3 Ignition state Power and voltage e The spark plug removed from the cylinder head but the power lines still ring e Start engines or use for the diagnosis tool of output View spark plug ignition conditions Engine e Diagnosis tool to detect the vacuum use of Injection The injector removed from state the throttle body but not dismantle pipeline Main switch ON but not start engine Investigation the injector it s leaking fuel Once again start engines or use for the diagnosis tool of output function Check injector fuel injection and the injection situation Use of diagnostic tool observation O2 Sensor voltage changes Closed loop control system 7 Fault Code Detection Use of the diagnosis tool existing fault detection code or historical Fault Code Elimination of the implementation of fault codes check can be eliminated Once again start engine Check fault is it happen again e Battery voltage Open the main switch but do not to start the engine of pressure Pressure in idle Rotating throttle situation of pressure changes Spark plug specifications Whether the spark plug ignition Spark plug sparks whether it is normal strength Manifold pressure of diagnosis tool Open the main switch but did not start engine the injection situation Injector state when start S
84. cleaning agents have bad effect on them 1 General Information e Never bend or twist control cables to avoid unsmooth control and premature worn out Tin Rubber parts may become deteriorated when old and be damaged by solvent and oil easily Check these parts before installation to make sure that they are in good condition replace if necessary 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 with a wire for ease of installation later Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions depth distance or position Components not to be reused should be replaced when disassembled including gaskets metal seal rings O rings oil seals snap rings and split pins http www motorcycle in th To this chapter contents 1 General Information A SYM e The length of bolts and screws for assemblies e Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation grind with a grindstone if another be sure they are correctly installed In the contact surface has any damage cas
85. closed loop control system 2 When the air fuel mixture is near the stoichometic ratio CO HC NOx are converted most efficiently 3 O2 Sensor heater resistance 6 7 10 5 Q 4 O2 Sensor amendment in the voltage value between 100 900 mV http www motorcycle in th To this chapter contents 4 Fuel Injection System Throttle Position Sensor TPS TPS oo ee TPS output voltage abelo O N A OD 50 100 150 Throttle valve opening angle Basic Principle TPS is a rotary variable electric resistor When it is rotated both electric resistance and voltage value change determining the throttle position Function TPS determines the throttle valve position and sends signal to ECU as reference of engine control 4 10 http Awww motorcycle in th To this chapter contents D SYM 4 Fuel Injection System Idle Speed Control Valve ISC stepper motor i kL F Function ECU controls ISC stepper motor to adjust the bypass intake air quantity and stabilized the idle speed 4 11 http www motorcycle in th To this chapter contents 4 Fuel Injection System D SYM Air Injection Solenoid Valve AISV Function AISV introduces appropriate air quantity to reduce pollutant emission Basic Principle When the engine RPM and throttle opening are higher than the default value ECU controls AISV opening or closure Fresh air Power relay oe Reed VINE al ee Gi
86. ct it to engine ground Turn on the main switch The needle of the water temperature meter should move to other end H position M Caution Do not ground the sensor more than 5 seconds or the meter will be damaged 17 21 http www motorcycle in th To this chapter contents 17 Electrical System O SYM NOTE 17 22 http www motorcycle in th D SYM 18 Wiring Diagram aoue je p m n HHEH i i lE Ti M a l a e 1 e I O 4 a TUL a a o SS n e M Sc A AeHa SEDEN ma e 1 J E TEE EEEE D E E ee I III E O E l E a M E e e e E O E E E E E E S e e O E E E Ee re iL a 1M x JP f ESH c tiie i SSS SS SS SST 1 I m No aa Gill cata co ci LR ECH e i 7 J 3 E ai We a 0030Z L4A 0003 aes mi 18 1 http www motorcycle in th 18 Wiring Diagram NOTE 18 2 http www motorcycle in th
87. culate clearance between piston pin and its hole Service Limit 0 02 mm Measure the piston outer diameter M Caution Service limit LM25W5 70 380 mm LM30W 72 380 mm Compare measured value with service limit to calculate the clearance between piston and cylinder http www motorcycle in th 7 Cylinder Piston To this chapter contents 7 Cylinder Piston SYM Piston Ring Installation Clean up piston top ring groove and piston surface Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown MA Caution e Do not damage piston and piston rings as installation e All marks on the piston rings must be forwarded to up side e Make sure that all piston rings can be rotated freely after installed Top ring 2 ring Oil ring ee are Le iit v in i he Pree deid CT ee http www motorcycle in th To this chapter contents D SYM Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip M Caution e Do not let the opening of piston pin clip align with the piston cutout e Place a piece of cloth between piston 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
88. difference and battery voltage of 0 2 V gap within ECU 5V voltage sensor voltage of less than 0 2 V Main switch OFF Use probe inserted throttle sensor engine temperature sensor the inlet pressure sensor 1 Lines anomaly power connector 2 ECU anomaly Main switch ON Use voltage meter measurement of the sensor connector voltage Voltage standard value 5 0 0 1V Battery voltage fuel pump voltage of less than 0 2 V Main switch OFF Removed fuel pump power coupler Potential probe then pumped two pin connector 1 Lines anomaly 2 Relay fault 3 ECU anomaly Main switch ON Pumped in three second record supply voltage values Confirmed pump and battery supply voltage differential pressure within the 0 2 V voltage 4 32 http www motorcycle in th To this chapter contents 4 Fuel Injection System Can not Start the engine or difficult to start inspection Difficulties or can not to start engine Warning lights extinguished after 2 seconds 1 Inspection process in accordance with circuit inspection Z G Use diagnosis tool to view EMS fault content In accordance with Troubleshooting procedures on troubleshooting Display warning lights Fault Code Fuel tank inadequate Fuel injector pressure less than 294 6kpr Pipeline fuel spills Pressure Regulating Valve anomaly Fuel pump pipe leakage Fuel pump anomaly Fuel injector anom
89. e B Black SB Sky blue use 15 R 6 Green GR Gray A R winker indicator Main switch Li FR R winker light Fuse 29A sls ie 9 H RR R winker light ob SB Winker amp 5 F ik aa Hazard control inker 2 2 s Sit unit switch TEE G SB SL FR L winker light Hazard i RR L winker light P switch Battery ye B L winker indicator 17 15 http www motorcycle in th To this chapter contents 17 Electrical System Headlight bulb replacement Pull out the rubber socket and press the 2 springs then remove light bulb Specification Lo beam bulb 12V 55W H11 Hi beam bulb 12V 55W H11 M Caution e t would be much easier to replace the light bulb if dismounting the front cover e Never touch the bulb with bare fingers which i i re t may create a heat point and lead to premature bulb failure e Clean the fingerprint left on the bulb with alcohol Installation Install the bulb of the headlight in reverse order of removal Front winker bulb replacement Hold the winker bulb socket Rotate the winker bulb and remove it Replace with new bulb if necessary Specification Winker light bulb 12V 21W Installation Install the bulb of the headlight in reverse order of removal 17 16 http Awww motorcycle in th To this chapter contents D SYM 17 Electrical System Switch Horn Main switch Inspection Remove the front cover Disconnect the
90. e cotter remove amp assembly tool to press the valve springs and then install valves 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 cotter remove amp assembly tool SYM 1471110 SY125 Tap the valve stems gently with a plastic hammer to make sure valve retainer and valve cotter is settled Caution e Place and hold cylinder head on to working table so that can prevent from valve damaged 6 Cylinder Head Valve Valve spring retainer _ gt gt 4 Valve stem seal te Valve cotter Inlet valve W by if ose ie Valve sprin ag ie Exhaust va a maL Valve cotter remove and assembly tool http www motorcycle in th 6 Cylinder Head Valve D SYM Install camshaft into cylinder head 2 bolts Cam shaft setting plate Install valve rocker arm rocker arm shaft and cam shaft setting plate om z i r i Li ON a i i z Cylinder Head Installation wa a Pi Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head Install chain guide dowel pins and a new cylinder head gasket onto the cylinder la S a a Fo N Caution Do not damage the matching surfaces of cylinder and cylinder head e Avoid residues of gasket or foreign mater
91. e 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 e 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 e Tighten assemblies with different dimension lt Clamp fasteners as follows Tighten all the fasteners 2 with fingers then tighten the big ones with ell Connector 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 e Rubber and plastic boots should be properly reinstalled to the original correct positions as designed e 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 e When oil seal is installed fill the groove with grease install the oil seal with the name of the manufacturer facing outside and check the shaft on whi
92. ead Valve Valve Clearance Adjustment Loosen Air Injection system Al pipe upper side bolt 2 bolts Remove cylinder head cover Remove the cylinder head side cover Remove left crankcase cover and turn the drive face and align the timing mark on the cam sprocket with that of cylinder head piston is at TDC position 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 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side cover Start the engine and make sure that engine oil flows onto the cylinder head Stop the engine after confirmed and then install the cylinder head cover and Al pipe Caution If lubricant does not flow to cylinder head engine components will be worn out seriously Thus it must be confirmed When checking lubricant flowing condition run the engine in idle speed Do not accelerate engine speed 6 16 http Awww motorcycle in th Timing mark 7 Cylinder Piston Mechanism Diagram Piston Ring Installation Precautions in Operation Piston Installation srr rte Troubleshooting Cylinder Installation ss sees Cylinder Piston Removal Mechanism Diagram 1 2 1 6kgf m I i 4 3 gn pimes L i i E oe a ai T ns i O i 1 0 1
93. ear Wheel Rear Fork Rear Cushion SYM Rear Fork Free play Inspection rear fork bearing Rotate the inner ring of the bearing with a finger The bearing should move smoothly and quietly Check the fit of the bearing and rim Replace the bearing if its motion is not smooth or noisy Replacement of rear fork bearing Remove the bearing lock cir clip Uses the bearing driver drive out the bearing Special tool Bearing driver Install new rear fork bearing and bearing puller 6303 onto rear fork Install assembly directs puller bearing puller Special Service Tools Rear fork bearing 6303 bearing puller SYM 6303000 HMA H9A 6303 Assembly directs puller SYM 2341110 Use screw driver hold bearing puller lower part and turn the bearing puller upper part to install the rear fork bearing http Awww motorcycle in th To this chapter contents 16 Rear Wheel Rear Fork Rear Cushion Install the bearing lock cir clip 2 a clip Y Bearing fal 6303UU Outside collar Rear Cushion Removal Remove the luggage box rear carrier and body covers Loosen the mounting bolts of the air cleaner 2 bolts Remove the exhaust muffler 3 bolts 2 nuts Remove the under bolts by left and right rear cushions Remove the upper bolts by left and right rear cushions and then remove the cushion Installation Install in reverse order of removal procedures i Upper bolt Caution k T e The r
94. ear cushion must be replaced as a unit eS Never disassemble the rear cushion as that would damage the structure Torque Value Rear cushion upper bolt 3 5 4 5kgf m Rear cushion under bolt 2 4 3 0kgf m 16 6 http www motorcycle in th Contents Home page D SYM Mechanism Diagram 17 Electrical System Precautions in Operation Specification Charging System Ignition System Mechanism Diagram Speed sensor Rollover sensor Winker amp Hazard control unit Headlight hi beam relay Thermo switch Cooling fan Battery Start relay Passing Beam Winker Horn Seat open switch AISV Side stand switch Spark plug Fuel injector MAP Sensor ISC TPS TA Sensor Seat open linear motor a nN ee http www motorcycle in th Light Bulb Switch Horn Fuel Unit rrer Cooling Fan Thermo Switch ss Thermo Unit ese Water Temperature Meter t Horn Headlight lo beam relay Power relay Key relay Engine stop relay Fuse box Main switch Start Headlight Engine stop switch Fuel pump fuel unit O2 Sensor Ignition coil Thermo unit TW Sensor CPS A C Generator ECU Reg Rec 17 1 To this chapter contents 17 Electrical System Precautions in Operation e When removing the battery the disconnection sequence of cable terminals shall be strictly observed First disconnect the negative
95. ear voltage signal provided ECU perception and judgment then throttle position opening and in this signal with have the most appropriate fuel injection and ignition timing control M White Brown Signal output Yellow Black 5V voltage input Green Red Testing Procedures Sensor connected properly using the probe tool or can be removed connector to voltage measurements direct measurement 2 Opened the main switch but do not to start engine 3 Use voltage meter DC stalls DCV to check sensor voltage 4 Confirmed working voltage e Voltage meter negative access to the inlet pressure sensor third pin Green Red e Voltage meter positive access to the inlet pressure sensor first pin Yellow Black 5 Throttle output signal recognition using the probe tool e Voltage meter negative access to the sensor third pin Green Red e Voltage meter positive access to the sensor first pin white Brown e Measurements were full throttle at full throttle closed the values of the output voltage A Cautions e Attentions to the tools required close to the probe wire waterproof apron penetrate skin and internal terminal before measurements to the correct value TPS output voltage throttle fully a closed Detection judge e Working voltage value 5 0 0 1V e PS output voltage throttle fully closed 0 640 02V e IPS output voltage throttle fully opened 3 78 0 26V TPS output voltage thr
96. ector Eight hole type injector provides two intake valves fuel injection quantity enhances the effect of fuel atomization and reduces HC emissions Short type injector cap can easily fix the injector receive the fuel from the fuel pump and limit injector rotation sliding The signals from ECU control the fuel pressure regulator using the diaphragm and spring to maintain the fuel pressure in 294 6kPa about 3 kg cm and determine the fuel injection quantity by adjusting injection time width under different engine conditions Fuel Pump Electrical fuel pump is placed inside the fuel tank powered by the battery and controlled by ECU Fuel pressure 294 6kPa about 3 kg cm http www motorcycle in th To this chapter contents 4 Fuel Injection System D SYM Ignition System Intake air temperature Manifold absolute pressure _ Engine coolant temperature Throttle position lt ame Ignition coil Oxygen content SAS n a M a a a a e a ACG Flywheel Gear 23 1 Long teeth 3 Crankshaft g position Power relay LEETE oe ns s REG REC Principle The computer programmed ignition system receives the signals from the Crankshaft position sensor Throttle position sensor O2 Sensor MAP sensor Intake air temperature sensor Engine coolant temperature sensor Calculating the engine RPM the 16 bit microcomputer determines the appropriate ignition timing controls the ignition coil and tr
97. ed and marked on the production line Readjustment is not suggested Treatment of abnormal phenomena e If all fuel injection associated components identified no adverse and other traditional engine components are also normal the engine is still not smooth please confirm whether the throttle body coke serious e If coke serious please clean throttle body and then adjust the injection system Throttle positioning screw 4 15 http Awww motorcycle in th To this chapter contents 4 Fuel Injection System MAP Sensor Functional Description e Powered by 5V DC from ECU It has 3 pin sockets on the sensor One terminal is for power and 1 terminal are for signal output And the rest one is for ground e The major component of the intake pressure sensor is a variable transistor IC Its reference voltage is DC 5V and output voltage range is DC 0 5V e It is a sensor by sensing pressure and can measure the absolute pressure in intake process It also conducts fuel injection quantity correction based on environmental position level Testing Procedures 1 Inlet pressure sensor connector to properly using the probe tool 2 Open the main switch but not to start engine 3 Use voltage meter DC stalls DCV to check inlet pressure sensor voltage 1 4 Confirmed working voltage e Voltage meter negative access to the inlet pressure sensor third pin Green Red e Voltage meter positive access to the inlet pres
98. efore never use compressed air or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead The brake caliper can be removed without removing the hydraulic system Air should be bled from the hydraulic system when remove it or the brake system is slack While refilling brake fluid avoid mixing any other substances Do not spill brake fluid on the painted surfaces because plastic or rubber parts might be damaged Check the operation of the brake system before riding Specifications unit mm The thickness of the front brake disk The thickness of the rear brake disk Front and rear brake disk eccentricity Front brake master cylinder inner diameter Front brake master cylinder piston outer diameter Rear brake master cylinder inner diameter Rear brake master cylinder piston outer diameter Diameter of front disk 280000 fe Diameter of rear disk 2200000 fo Thickness of the front brake lining Thickness of the rear brake lining Torque values Brake hose bolts 3 0 4 0kgf m Bolt for front brake caliper 2 9 3 5kgf m Brake lever nut 0 8 1 0kgf m Air bleed valve 0 8 1 0kgf m 14 2 http www motorcycle in th To this chapter contents SYM Troubleshooting Slack brake lever 1 Air inside the hydraulic system 2 Hydraulic system leaking 3 Worn master piston 4 Worn brake pad 5 Poor brake caliper 6 Worn brake lining disk 7 Low brake fluid 8 Blocked brake hose 9 Deformed bent brake dis
99. er bolt Torque value UPPER 3 5 4 5 kgf m LOWER 2 4 3 0 kgf m 5 4 http www motorcycle in th 6 Cylinder Head Valve Mechanism Diagram TITTTITITTTTTiTriri eee 6 1 Valve Stem Replacement TTTTTITTTTTiTi tte Precautions in Operation seese 6 2 Valve Seat Inspection and Service 6 11 Troubleshooting TTTTTITITTTTTi irre eee eee 6 3 Cylinder Head Reassembly e TTT 6 13 Cylinder Head Removal ssssssssssssrsesse 6 4 Cylinder Head Installation 6 14 Cylinder Head Disassembly 6 6 Valve Clearance Adjustment Cylinder Head Inspection se 6 8 Mechanism Diagram 1 0 1 4 1 0 1 4 kgf m 2 0 1 0 1 2 kgf m 1 0 1 4 kgf m 0 7 1 1 kgf m 6 1 http www motorcycle in th To this chapter contents 6 Cylinder Head Valve O SYM Precautions in Operation This chapter is contained maintenance and service for cylinder head valve and camshaft as well as rocker arm Remove the engine from the frame before repairing the cylinder head Specification Compression pressure 124 2kglem2 fe Camshaft Height of cam lobe bee eel ee a l aw OD of valve rocker arm shaft 11 966 11 984 11 910 Valve OD of valve stem 4 975 4 990 4 900 Tilt angle of cylinder head pe 0B Torque Value Cylinder head bolt LH 2 0 2 4 kg m Cylinder head Nut 2 0 2 4 kg m Sealing bolt of cam chain auto tensioner 0 8 1 2 kg m Bolt of cam chain auto tensioner 1 2 1 6 kg m Cam sprocket cover bolts 0 8
100. eter coupler Wire harness coupler 10 1 1 KWOUUUULILILS 10 11 1 j 20 20 000000000011 L Wire harness coupler Yellow Green Red Yellow Gray Orange Green Pink Green White White black Sky Orna White Green Se Blue Ie Black Blue NN Blue Yellow White Blue Side 17 13 http www motorcycle in th To this chapter contents 17 Electrical System Removal of meter Remove wind screen garnish wind screen meter visor front cover meter visor Refer chapter 14 Disconnect the coupler of the speedometer and take off the meter panel and meter Loosen 4 screws from meter panel Remove the speedometer Installation of meter Install in reverse order of removal procedures 17 14 http www motorcycle in th To this chapter contents SYM 17 Electrical System Light Bulb Headlight and foggy light circuit diagram Headlight Fuse 15A aw R Red W White ee ce eee ee B Black L Bue 1 Poan E maler G Green BR Brown illumination light i x Light switch Lo beam relay Lo beam light Tele BR Beam switch wy a a mil LIW j a 1 ee cme ny 1 HEC g Hi beam relay Hi beam light ll Oe ke Lt Main switch B Tp L gi eie w G Fuse 20A A EO fr ra EH H Passing switch Hi beam indicator Fo Te R Key relay G R L 7 Thermo switch 2 pe PS Fc Battery Fan Winker light circuit diagram y R Red_ O Orange e
101. fault code Elimination of fault codes and then start engine Removed the injector on the intake manifold but not removal of harness coupler Injector and injector cap tightly by hands fuel spills should not be the case Start the engine Examine whether injector fuel injection Between the tank and injector installation the pressure gauge check fuel pressure adequacy Removed the spark plug from the cylinder head but then power lines still ring Start the engine check spark plug sparks Fault status determination e Battery voltage is 10 V above Diagnosis tool show whether the voltage of 10 V above YES Diagnostic tool show whether or not a fault code Fault Code cleared after show again Injector whether Injection Injector spray angle is normal Fuel pressure enough YES Examine whether the spark plug ignition Check spark plug sparks strength is normal YES Continued next page http www motorcycle in th YES Fault reasons e Battery electricity Battery connector loose Harness circuit opening ECU coupler not connected properly TPS fault ETS fault CPS fault MAP fault O2 sensor fault ROS fault ECU fault less than fuel tank Injector fault Fuel pump relay fault Fuel pump fault ECU fault Fuel pump filter obstructive Spark plug fault Roll over sensor fault ECU fault Ignition coil fault Crankshaft position sensor fault Parts
102. ged e Insufficient tire pressure The steering handlebar is tilted e Uneven arrangement of the front cushion e The front fork is bent e The front wheel axle is bent 5 0 7 0kgf m 4 0 5 0kgf m 1 0 2 0kgf m 0 2 0 3kgf m 0 15 0 3kgf m 2 4 3 0kgf m 4 0 4 5kgf m SYM 5321100 The front wheel rim run out e The rim is bent e The wheel axle nut is not tightened enough e Side worn or poor tire e The bearing clearance of the wheel axle is too large Soft front cushion e The front cushion spring is worn out e The oil seal of the front cushion is leaking Noise in front cushion e Front cushion rod is bent e The joint of the front cushion gets loose 15 2 http www motorcycle in th To this chapter contents Steering Handle Remove Remove the right and left handle side cover handle upper cover and front cover Refer to chapter 13 Loosen the lock bolts for the master cylinder of the front brake Loosen the deceleration throttle cable fixing nut Loosen 1 screw from the acceleration throttle fixing plate Loosen 2 screws from the throttle holder Remove throttle holder handle switch cables and grip http Awww motorcycle in th Master cylinder 15 3 SYM Loosen 2 bolts from the master cylinder of the rear brake Remove holder and master cylinder Loosen left handle switch connecter Loosen 2 screws from left side handle switch holder Remove the r
103. gna http www motorcycle in th 14 Brake System r i T Fa Locking spring 14 7 Tothis chapter contents 14 Brake System Rear Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hose A Caution Do not spill brake fluid on painted surfaces Remove two caliper mounting bolts and the caliper Installation Install the brake caliper and tighten the mounting bolts Torque 2 9 3 5kgf m M Caution e Use M8 x 35 mm flange bolt only e Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill the brake fluid to the reservoir and bleed the air if necessary Socket bolt Brake pad replacement Remove the brake caliper upper parts 2 socket bolts Take out the brake pads Install the new brake pads onto brake caliper bracket Install the brake caliper upper parts and tighten the socket bolts 14 8 http www motorcycle in th To this chapter contents SYM Brake Disk Inspection Visually check the brake disk for wear or break Measure the thickness of the disk at several places Replace the disk if it has exceeded the service limit Allowable limit Front brake disk 2 5mm Rear brake disk 3 5mm 14 Brake System Remove the brake disk from wheel Check the di
104. he seat dampers Remove the air box cover Disconnect the air temperature sensor coupler Remove the air box Disconnect the starter motor wire aai i w vN E SM Bee Starter motor wire J E Remove the spark plug cap http Awww motorcycle in th To this chapter contents V SYM 5 Engine Removal Remove fuel pipe vacuum tube and throttle valve wire from the throttle body Disconnect the EFi system coupler Remove water hose from water pump Remove the thermo sensor wires Remove the muffler 3 bolts 2 nuts Bolt X3 http www motorcycle in th To this chapter contents 5 Engine Removal Remove the parking brake cable Remove the rear brake caliper 2 bolts A Caution Do not operate brake lever after the caliper is removed to avoid clipping the brake pad Remove the mounting bolt of rear right cushion Bolts X2 Remove the mounting bolt of rear left cushion Remove the engine hanger lock nut Remove the engine hanger axle Remove the engine Engine Installation Check if the bushings of engine suspension parts and shock absorber for damage Install engine in the reverse procedures of removal Caution e Pay attention of foot amp hand safety as engine installation to avoid hurting e Do not bend or twist wires e Cables wires have to be routed in accordance with normal layout Engine Mounting Bolt Torque value 4 0 5 0 kgf m Rear shock absorb
105. heck the thermo switch in the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures To confirm the switch is close circuited at room temperature Increase the coolant temperature gradually and the switch should have a continuity at 95 101 C M Caution e Keep the coolant at a constant temperature at least for three minutes Suddenly increase the coolant temperature will give rise to wrong readings of thermometer and the tester to indicate wrong readings Never let the thermometer and the thermo switch contact the wall of the bowl which may result in wrong readings e The thermo switch shall be placed in the coolant until the teeth are completely submerged 17 20 http www motorcycle in th To this chapter contents D SYM 17 Electrical System Thermo Unit Thermo unit Remove the thermo unit Hang the thermo unit in an oil heater heat the oil and ie the resistance at each temperature Temperature 50 C sore 120 C Standard Q ren 5 57 0 em 14 8 17 2 M Caution e Wear gloves and goggles when performing this test M Caution e Engine oil should be used as a heating medium and the test temperature must be higher than 100 C e Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Water Temperature Meter Disconnect the thermo sensor coupler and conne
106. hen installing the battery coat the cable terminal with grease 17 4 http Awww motorcycle in th To this chapter contents D SYM 17 Electrical System Fuse Fuse circuit diagram Fuse ignition coil 20A Power rt Relay Fuel Pump Relay AISV Diagnostic Tool 10A FAJ ECU Rollover Sensor 15A PJ ht i USB Charge i Hlumination REG REC f Others els 17 5 http www motorcycle in th To this chapter contents 17 Electrical System Charging System Charging alreci Main Sailer Siart ralay l H G Green tari _ oni Inspection on regulator rectifier wire Remove the luggage box rear carrier and body covers Disconnect two 3 pin couplers of the regulator rectifier Inspect the rectifier coupler to the wire harness passes the condition Check Points Standard Value Battery voltage ON Battery voltage If the readings measured are not normal check parts in the circuit If the parts are normal then trouble is in the wiring If there is nothing wrong with parts and wiring 17 6 http www motorcycle in th To this chapter contents Inspection on AC Generator coil Remove the luggage box rear carrier and body covers Disconnect 3 pin couplers of the generator coil Connect an ohmmeter to the each terminal end Check the continuity of the each terminal end and engine ground with short circuit If there is no continuity or short c
107. ials falling into crankcase as cleaning Chain guide Dowel pins Install 4 washers and tighten 4 nuts on the cylinder basil tc head upper side and then tighten 2 cylinder head a a mounting bolts of cylinder head right side ae a Torque value to A O Nut 3 6 4 0kgf m e h Be Bolt 1 0 1 4kgf m Install cam chain on to sprocket and align the a 1 eine ate timing mark on the sprocket with that of cylinder wil k head Align sprocket bolt hole with camshaft bolt hole Tighten the sprocket mounting bolts Caution e Make sure timing marks are matched 6 14 http www motorcycle in th To this chapter contents D SYM 6 Cylinder Head Valve Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and spring Install tensioner and install spring and adjustment bolt Install cylinder cover 4 bolts Install Air Injection system Al pipe 4 bolts Install inlet pipe onto cylinder head Install and tighten spark plug Torque value 1 0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation engine noise and leaking so that motorcycle s performance be effected Install the engine onto frame refer chapter 5 6 15 http Awww motorcycle in th To this chapter contents 6 Cylinder H
108. iggers the spark plug This way can not only make the engine achieve the maximum power output but also help improve fuel consumption rate Specifications 1 Ignition timing BTDC 10 1550RPM 2 Spark plug NGK CR8E Clearance 0 6 to 0 7 mm 3 ACG crankshaft position sensor coil resistance 80 160 Green White Blue Yellow 4 Ignition coil primary circuit resistance 2 8 Q 15 20 C Red Yellow Black Yellow 5 Battery Type Capacity TTZ14S 12V 11 2Ah http www motorcycle in th Bnd yueds To this chapter contents 4 Fuel Injection System Sensors Drivers Crankshaft Position Sensor CPS Crankshaft position sensor Flywheel Description The magnetic field type sensor generates a voltage signal to calculate engine speed with ACG gear ring 18 1 tooth There is one tooth every 20 degree on the gear ring But one of the teeth is blank for the TDC calculating base http www motorcycle in th To this chapter contents 4 Fuel Injection System D SYM Manifold Absolute Pressure MAP Engine Water Temperature TW Intake Air Temperature TA Sensors MAP Sensor TA Sensor TW Sensor Engine water temperature Intake air temperature sensor Use the variable resistor of negative temperature coefficient thermistor to sense the outside temperature The electrical resistance value goes down when the temperature rises On the contrary the electrical resis
109. ight handle switch Loosen handle mounting nut Remove handle mounting bolt and then remove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 5 0kgf m Apply grease to throttle cable and the sliding surface of handle Align the lock pin with the hole on the handle After the installation completes carry on the following inspection and adjustment e Throttle grip operation e All electric appliances the meter function To this chapter contents Master cylinder t i qa T i se Holder 2 bolts 2 screws 15 4 http www motorcycle in th To this chapter contents SYM Front Wheel 2 screws amp Loosen 2 bolts from the front brake caliper and _ remove it A Caution e Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out In case that the brake pad is accidentally squeezed out use a screwdriver to force it back to the place C o E 1 LE ae a E i Si j a S gt S s a tite oS Axle nut P Loosen screw amp remove speedometer cable Turn loose the axle nut Pull out the front wheel axle Remove the front wheel and both side collar http www motorcycle in th 15 5 To this chapter contents SYM Inspection Wheel axle Place the wheel axle on a V block measure its displacement Service limit 0 2 mm Bearing Use finger
110. ill soread out if operated the lever e Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid fulfilled Master cylinder cap inside the brake system hoses Added Brake Fluid Diaphragm Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or DOT4 WELL RUN brake fluid Caution e Never mix or use dirty brake fluid to prevent from damaging brake system or reducing brake performance Air Bleeding 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 e Before closing the air bleeding valve do not release the brake lever 2 10 http www motorcycle in th To this chapter contents 2 Maintenance Information Brake Lining Wear The indent mark on brake lining is the wear limitation Replace the brake lining if the wear limitation mark closed to the edge of brake disc Caution e It is not necessary to remove brake hose when replacing the brake lining Brake caliper prako Cigs Remove the brake clipper bolt and take out the clipper Caution e Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat driver if lining is clipped Remove 2 cotter pins
111. ion bolt Remove drain plug and drain oil out Install the drain plug after draining Torque value 0 8 1 2kgf m Add gear oil to specified quantity from the inspection hole Install the inspection bolt Torque value 1 0 1 4kgf m Gear Oil Quantity 330 c c when replacing it Make sure that the bolt washer can be re used and install the bolt Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is in correct level Make sure that no oil leaking Fuel Lines Cable Remove luggage box Remove rear carrier Remove body covers Check all lines and replace it when they are deteriorated damaged or leaking Warning e Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it Acceleration 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 acceleration 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 end Secondary adjustment is conducted from top side Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment nut http www motorcycle in th To this chapter contents O SYM Primary adjustment is conducted from bot
112. ircuit replace the AC Generator And you can check voltage when engine is running Current Leakage Inspection Turn the main switch OFF and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit Allowable current leakage Less than 10mA M Caution e In the current leakage test set the current range at the largest scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse e 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 http www motorcycle in th 17 Electrical System Battery negative terminal 17 7 To this chapter contents 17 Electrical System Inspection on Charging Voltage Voltmeter Ammeter o Fuse connector M Caution e Before conducting the inspection be sure that the battery is fully charged If undercharged the current changes dramatically e Use a fully charged battery having a voltage larger than 13 0 V to prevent the current fluctuation e While starting the engine the starter motor draws large amount of current from the battery After the engine is warmed up replace the original battery with a fully
113. k 10 Bent brake lever Malfunction of the brake lever Blocked brake system Poor brake caliper Blocked brake pipe Seized worn master cylinder piston Bent brake lever oe a Uneven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or bent brake disk Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or bent brake disk Brake abnormal noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance of brake disk or wheel http www motorcycle in th 14 Brake System 14 3 To this chapter contents 14 Brake System Disk Brake System Inspection Inspection Examine for leaking or damage visually Inspect brake tube seam with spanner to check if it becomes loose Checking if there is any interferes contacts between protected pipeline and other parts by turning the handle bar right or left pressing the cushion up and down Remove the front brake pad cap Check the brake wear from the brake caliper The brake pad must be replaced with new lining when it reaches the wear limit Park the motorcycle on an even ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 M Caution e Inclined or just stopped vehicles could not be measured oil level accurately For accuracy vehicles should stay in still position for 3 to minutes In order
114. left crankcase Remove the crankshaft and balancer shaft from the left crankcase Check the main bearing on the crankcase for any wear Replace the main bearing with special tool if necessary 11 4 http www motorcycle in th To this chapter contents SYM 11 Crankshaft Crankcase Crankshaft bearing replacement Align the main bearing remover with the main bearing Fix the remover with the universal holder and press out the main bearing Crankshaft bearing installation Use the crankshaft main bearing holder to fasten the upper and lower main bearing Align the oil path on the main bearing and the crankcase Press the main bearing into the crankcase Special tool main bearing installer remover SYM 9100310 L4A 11 5 http Awww motorcycle in th To this chapter contents 11 Crankshaft Crankcase Crankcase assembly Install the crankshaft and balancer shaft to the left crankcase Marks on the crankshaft and The marks on the crankshaft and balancer shaft balancer shaft must be aligned jn E Lp srar B C LT t g Assemble the right crankcase to the left crankcase Tighten the bolts on the right crankcase Install the oil pump drive sprocket driven sprocket and drive chain 11 6 http Awww motorcycle in th To this chapter contents D SYM 11 Crankshaft Crankcase Install the oil separator bolt x2 Tighten the bolts on the left crankcase bolt x 11
115. ley and drive belt onto drive shaft 8 14 http www motorcycle in th 9 Final Drive Mechanism Mechanism Diagram Final Drive Mechanism Inspection Precautions in Operation Bearing Replacement cces0 9 4 Troubleshooting Final Drive Mechanism Reassembly 9 6 Final Drive Mechanism Disassembly 9 3 Mechanism Diagram Radial ball bearing 6206 UU Jo P seal 45 65 10 Final shaft Counter gear Final gear Counter shaft Oil seal 25 40 7 Pe od Lar 7 a a Drive shaft Radial ball bearing CSB305C 2 4 3 0 kgf m F Needle bearing HKS 25 33 18 9 1 http www motorcycle in th To this chapter contents 9 Final Drive Mechanism Precautions in Operation Specification Application oil scooter gear oil Recommended oil KING MATE serial gear oils Oil quantity 110 c c 100 c c when replacing Torque value Gear box cover 1 0 1 4 kg m Tools Special tools Bearing 6203 6004UZ driver Bearing 6204 driver Bearing 6301 driver Oil seal 27 42 7 driver Oil seal 20 32 6 driver Inner bearing puller Outer bearing puller Troubleshooting Engine can be started but motorcycle can not be moved e Damaged driving gear e Burnt out driving gear Noise e Worn or burnt gear e Worn gear Gear oil leaks e Excessive gear oil e Worn or damage oil seal http www motorcycle in th SYM To this chapter contents 9 Final Drive
116. linder head http www motorcycle in th To this chapter contents 2 Maintenance Information Engine Oil Turn off engine and park the vehicle in a flat surface with main stand Check oil level with oil dipstick Do not screw the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Change T Caution e Drain oil as engine warmed up so that to make sure oil can be drained smoothly and completely Place an oil pan under the vehicle and remove oil drain bolt After draining make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Add oil to crankcase oil viscosity SAE 10W 40 Recommended using King serial oil Engine oil capacity Disassembly 2000c c Replacement oil filter replaced 1900c c Replacement 1800c c Install dipstick start the engine for running several minutes Turn off engine and check oil level again Check if engine oil leaks Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 3 1 7kgf m http www motorcycle in th To this chapter contents 2 Maintenance Information Gear Oil Oil level inspection Park the vehicle on a flat surface with main stand Turn off the engine Gear Oil Change Remove oil inspect
117. ltage output pin another one for a grounding pin e Its main component is a negative temperature coefficient resistance temperature rise smaller thermistor e Installed in the air cleaner on the intake temperature sensor within the resistance with the induction to the temperature change and converted into voltage signals sent to the ECU then calculated the temperature and in accordance with the ECU temperature and state amendments injection time and ignition angle Testing Procedures Resistance Value Measurement e Dismantled inlet temperature sensor connector e Use of the Ohmmeter Ohm stalls inspection sensor resistance Detection judge Resistance value and the temperature between relationships as follows Temperature C Resistance value KQ 18 8 2 4 1 136 0 1 0 1553 0 007 Treatment of abnormal phenomena e Temperature sensor damaged or connector poor contact e Check whether the abnormal wire harness lines e Temperature sensor anomaly the proposed replacement of the temperature sensor 4 17 http www motorcycle in th 4 Fuel Injection System D SYM Functional Description e Use ECU provided DC 5V power supply has the three pin coupler one for the power supply pin one for a voltage output pin one for a grounding pin e Its main component is a sophisticated type of variable resistor e Installed on the throttle body beside the throttle through the accelerator rotates the output of lin
118. motorcycle in th Oo To this chapter contents SYM 12 Cooling System 8 Open the radiator cap and turn on the engine Overflow is normal Continue adding water to radiator until equilibrant if the amount of water diminished 9 Maintain the liquid level in reserve tank between upper and lower limit 12 11 http www motorcycle in th To this chapter contents 12 Cooling System SYM NOTE 12 12 http www motorcycle in th 13 Body Cover Mechanism Diagram Bida Caer aaae Maintenance Rear Carrier cccccccctttsstesteesssssessssseneeas Handle Cover Luggage Box trsersrserrerrerrererrerrenrenennee Front Cover Rear Body Cover ss s ssisssssesiessen 13 14 Meter Panel Pinnr Panel reika Inner Box Front Fender ss ccccccscsscsseesessesseesssssas Mechanism Diagram Wind screen cover Wind screen Wind screen garnish FR upper cover FR inner box 13 1 http www motorcycle in th 13 Body Cover 9 SYM Mechanism Diagram i cover Upper ha i Double seat Rear back seat Right side cover Inner box lid LH RR grip 13 2 http www motorcycle in th 13 Body Cover Maintenance cover RR luggage box Under cover 13 3 http www motorcycle in th 13 Body Cover Maintenance Body covers disassemble sequence __ Be careful not to damage various covers in assembly or disassembly operation Never injure hooks m
119. n reverse order of removal A Caution Always use a new oil ring and apply a coat of grease on it before installation Refill the specified coolant as necessary Steps to fill coolant after engine service iF Open the radiator cap 2 Remove the hose from engine and drain out the coolant 3 Pump in high pressure air from the water hole in order to vent out the water from the pipe 12 7 http www motorcycle in th To this chapter contents 12 Cooling System 4 Remove the engine circulation pipe and pump in high pressure air to the pipe 5 Based on the above steps coolant could be drained out Steps to fill coolant 1 Remove the tube connecting to thermostat 19320 cover 12 8 http www motorcycle in th To this chapter contents SYM 12 Cooling System 2 Close the fuel tube 95001 08550 loop 3 Fill up the coolant from filler neck 19039 without interruption 12 9 http Awww motorcycle in th To this chapter contents 12 Cooling System 4 Check the air exhausted through the thermostat tube head until coolant come out 9 Check the air exhausted through the thermostat cover joint until coolant come out 6 Reconnect thermostat tube 19320 to thermostat cover joint 19315 i Loosen flange bolt 8X12 on the water pump cover 19221 for exhausting air until coolant come out Tighten the flange bolt when finish 12 10 http Awww
120. n the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check amp adjust valve clearance with feeler gauge Valve clearance IN 0 10 0 02 mm Valve clearance EX 0 15 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment A Caution e Re check the valve clearance after tightened the fixing nut Special tool Tappet adjuster SYM 9001200 08 SYM 9001200 09 SYM 9001200 10 Special tool Tappet adjuster wrench SYM 9001200 PN fon http www motorcycle in th To this chapter contents Spark Plug Recommended spark plug CR8E 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 6 0 7 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 Tighten torque 1 0 1 2kgf m Connect spark plug cap http www motorcycle in th 2 Maintenance Information To this chapter contents 2 Maintenance Information Cylinder Compression Pressure Warm up engine Turn off the engine Remove luggage box and central cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of st
121. nd dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase MA Caution e Soap the residues into solvent so that the residues can be removed more easily Inspection Check if the inner diameter of cylinder is wear out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y values respective in the cylinder Service limit LM25W5 71 100 mm LM30W 73 100 mm http Awww motorcycle in th To this chapter contents 7 Cylinder Piston Measure the cylinder upper surface for warpage Service limit 0 05 mm Measure the clearance between piston rings and ring grooves Service Limit Top ring 0 09 mm 2 ring 0 09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn MA Caution e Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Measure the piston ring end gap Service Limit Top ring 0 50 mm 2 ring 0 65 mm http www motorcycle in th To this chapter contents Measure the outer diameter of piston pin Service Limit 16 96 mm Measure the inner diameter of connecting rod small end Service Limit 17 064 mm Measure the inner diameter of piston pin hole Service Limit 17 02 mm Cal
122. nnector pins are bent extruded or loosen e Insert the connector completely If there are two lockers on two connector sides make sure the lockers are locked in properly Check if any wire loose rd S 7 e Check if the connector is covered by the twin connector boot completely and secured properly es e Before terminal connection check if the boot is crack or the terminal is loose SYM e Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up w Ee a i x e Ta a a A e Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses O X x e Wire band and wire harness have to be clamped secured properly e Do not squeeze wires against the weld or its clamp http www motorcycle in th To this chapter contents 9 SYM 1 General Information e Do not let the wire harness contact with rotating Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness corner Thoroughly clean the surface where tape is to be applied e Keep wire harnesses far away from the hot e Secure the rubber boot firmly as applying it on parts wire harness ae Never Touch PP a ae e Route wire harnesses to avoid
123. ntents 6 Cylinder Head Valve 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 MA Caution e Do not let emery enter into between valve stem and valve guide e Clean up the emery after corrected and apply with engine oil onto contact faces of valve and valve seat Remove the valve and check its contact face A Caution e Replace the valve with new one if valve seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat Roughness MA Caution e After valve guide had been replaced it has to be ground with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper parts out Old valve seat width 6 11 http www motorcycle in th To this chapter contents 6 Cylinder Head Valve Use 60 cutter to cut a quarter lower parts out Remove the cutter and check new valve seat
124. o correct it if any one of the problems occurs 1 The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction 2 The charging voltage and current are too much higher than the standard values The following problems are not related to the charging systems correct it if any by following steps indicated in the checking list 1 The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rpm Light bulbs used exceed their rate and consume too much power The replaced battery is aged and does not have enough capacity 2 The charging voltage is normal while the current is not The replaced battery is aged and does not have enough capacity Battery used does 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 http www motorcycle in th D SYM 17 Electrical System Light System Ca a Light Circult o T Ly 01 02 03 0 4 05 06 0 7 0 8091 01 1 1 21 341 41 5116 17 8 1 9202 1 22 2324 2 5262 7 28 29 0 3 1 3933 3435 36 01 pin R Y Drive components Power 03 pin L O Crankshaft position sensor positive 09 pin G Crankshaft position sensor negative 18 pin Y G Ignition coil 17 9 http www m
125. ock procedure 7 Lock torque for the component 90304 L4A 00 is between 650 700 Kgf cm pe aoe ee oe al a rie ES 2 AG 10g slates Jibi igi APPLY GREASE Deg 109 ALL AROUND S77 5 1 dA AST Te a Setar beta STEEL BALL LOW ASST i Sa E SOA OLAS TL NG STEM HUT WASHER r STEER ms BAT jdi yl ai i FORK TOP BRIDGE STRG STEM LOCK MU S m A0 MED OOF AST zs aaa z iu a ifr AST a STEC STEM WASHER a w wW 5 3220 HMA OO LAST Li aa STREG HEAD TAF THREAD COMP 1 HM ACY LAST STRO UP CONE RACE kas iu IS HWA Vi At STEEL BALL UP ASSY E EE INIBREL Eq 1 Og BPPLY GREASE C69 1 0q ALL AA LNG I Sn tni il cul aci a STRG UP BALL RACE i J ALON gA DOL AST FRAME BOG SET Fig 1 Steering system components 15 11 http www motorcycle in th SYM Mechanism Diagram Operational Precautions Troubleshooting Muffler Mechanism Diagram i ee fa p t a a T 2 i i z mm nit Te i pi er See i W n E E oa ite al C ae Ps f 5 T l pee Eja as ni i J oa PL E T i aa f i d i FT eg i j iy 2 8 3 2kgf m 8 ek Ae Se 3 5 4 5kgf m a ileal r SSS a E fur wort 2 9 3 5kgf m http www motorcycle in th Rear Wheel cccstttsstsscsseessssee Rear Fork ccccsssccesccnncce Rear Cushion 16 Rear Wheel Rear Fork Rear Cushion 3 5 4 5kgf m is 1 0 1 4kgf m 16
126. ode ENTER contin UF prev page DOVIA nex EAT Exi ENTER Gontinm UP tray page CHJWN next http www motorcycle in th To this chapte 4 Fuel Injection System 5 ERASE TB CODE In the directory functions used A Y button select ERASE TB CODE project press the ENTER key to the implementation Conditions The main switch ON or in the engine running state the fault code can be removed SYM KEIHIN 44 gt ECU ID 2 DATA STREAM 3 FREEZED DATA 4 TROUBLE CODE CENTER confirm lt UP DOWN EXIT Exit LEFT RIGGAT Fault code removed namely showing the ERASE TB SUCC Press the EXIT button the function can return to the directory screen ERASE TB SUCC I Enter leave 4 55 http Awww motorcycle in th FAs Fi 4 Y 4 Fuel Injection System F ki 6 CO ADAPTION In the directory functions used A Y button select CO ADAPTION project press the ENTER button into the CO adjustment screen i SYN KEIHIN 7 4tux LECU ID 2 DATA STREAM J FREEZED DATA 4 IRC S UBLE CODE S ERASE TB TODE ENTER confirm UP DOWN EMITS Exit LEFT gt RIGHT t 1 Use lt left and right gt or A W button CO value can be adjusted CO ADAPT CO adjusted value CO Read CO read back value Press the EXIT button the function can return to the directory screen CO ADAPT CU REJO UP gt 0 5 DOWN 0 5 RIGHT 2 5 LEFT 2 5 Enter fun
127. of starting clutch gear 20 026 20 045 20 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 5 0 6 0 kgf m Starting clutch hexagon bolt 1 0 1 4 kgf m with adhesive 8 mm bolts 0 8 1 2 kgf m 12 mm bolts 1 0 1 4 kgf m Tools Special tools A C G flywheel puller Universal holder 10 2 http www motorcycle in th To this chapter contents D SYM 10 AC Generator Starting Clutch Right Crankcase Cover Removal Remove 12 bolts from the right crankcase cover Remove the right crankcase cover Remove dowel pin and gasket 12 bolts A C G Set Removal Remove 2 screws from pulse generator and then remove it Remove 3 bolts from right crankcase cover and A C G set Flywheel Removal Remove the flywheel nut Install the shaft protector to the crankshaft Pull out flywheel with A C G flywheel puller Tool A C G Flywheel puller http Awww motorcycle in th To this chapter contents 10 AC Generator Starting Clutch Flywheel Installation Insert the pin onto crankshaft Align the key 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 kg m Tool Flywheel holder A C G Set Installation Install the A C G set onto right crankcase cover 3 bolts Install pulse generator 2 screws Tie the wire harness securely onto the indent of crankcase M Caution
128. oil oil viscosity SEA 10W 40 Recommended using King serial oil Install dipstick start the engine for running several minutes Turn off engine and check oil level again Check if engine oil leaks Engine Oil Strainer Clean Drain engine oil Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 3 1 7 Kgf m Add oil to crankcase oil viscosity SAE 10W 40 Recommended using King serial oil http www motorcycle in th To this chapter contents D SYM Oil Pump Removal Remove generator and starting gear Remove the oil separator bolt x 2 3 Lubrication System Remove snap ring and take out oil pump driving chain and sprocket Torque value 0 8 1 2 Kg m Make sure that pump shaft can be rotated freely Remove 3 bolts on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pump as illustration shown http www motorcycle in th To this chapter contents 3 Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit 0 25 mm Check clearance between inner and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Reassembly Install inner and outer rotors into the pump body Align the indent on driving shaft
129. olded on the body covers Align the buckles on the guards with slot on the covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly 13 4 http www motorcycle in th To this chapter contents 9 SYM 13 Body Cover Handle Cover Remove Loosen the 2 screws from handle upper cover front end Loosen the 2 screws from handle upper cover rear end Remove right and left handle side cover o ai w i 2 screws Pe m f Installation Install in reverse order of removal procedures 13 5 http Awww motorcycle in th To this chapter contents 13 Body Cover Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish Loosen 6 screws from the wind screen and remove the wind screen Loosen 4 screws from the meter visor and remove the meter visor Loosen 4 screws 2 screws on each side from the inner box Each side 2 screws 13 6 http Awww motorcycle in th To this chapter contents SYM 13 Body Cover Loosen 2 bolts from the front cover under side 4 bolts Loosen 2 screws and 2 bolts from the front cover upper side ul fi a Each side 1 screw Disconnect the headlight foggy light and winker Headlight coupler light couplers Remove the front cover Installation Install in reverse order of removal procedures 13 7
130. on ISC will be slightly vibration or da da A phase measurement of the continuous sound resistance value Treatment of abnormal phenomena e Idle air control valve damage or poor coupler contact e Check whether the abnormal wire harness lines e Idle Air Control Valve anomaly the proposed replacement of the Idle Air Control Valve further inspection of its actuator B phase measurement of the resistance value 4 24 http www motorcycle in th Confirmed working voltage To this chapter contents 4 Fuel Injection System Functional Description e Powered by DC 8 16V and has four pin socket on the pump e The two terminals are connected to power source and ground respective The ECU is to control and manage the operation of fuel pump through electrical power e ts major component is a driving fan pump that equipped with a low electrical consuming DC motor Powered by 12V voltage and keep fuel pressure inside the fuel pump in 294 6kpa about 3 kg cm e The fuel pump is located inside of the fuel tank and installed a filter in front of its inlet so that can prevent from foreign materials sucking into the fuel pump to damage it and the fuel injector Testing Procedures 1 Fuel pump working voltage confirmed e Fuel pump coupler to properly using the probe tool or can be removed coupler working voltage measurements direct measurement e Open the main switch but not to start engine e
131. on view injection system information a the any screen press the EXIT button the function can return to the directory screen 91 03 Data stream x 02 03 Date stream HAL Intake Ali A and AIR VALVE INEGI HS lo EN N ANGLE 13 DTEP Ma vie aaa STABLE RANI SHAFT 245 5 N lidie CW iaai l Me Cir EN BERDE M Idle 1550 1780 T E oma 20 BERN Above 12V W idle ON i I i a i i po ldie 32 30kpa o 5 03 03 Data sirean LEAR RED olEF 4 49 http Awww motorcycle in th _Tothis chapter contents 4 Fuel Injection System D SYM Data stream 1 3 01 03 Data stream Engine SPO BEERIRPM Idla 1550 1750 FAULT NO fl 0f No maal 120 BATI vVOLT E AE j ve 12v F IN Idle ON o ogee Nidie i2 Jakpa TPS position ke icile PS p pii on R Gay Idle 0 54 0 62 Oo SENSOR e CE die 50 200mv Oe MEATER T F i asp fom aN Aa oo stoble 85 95 Ie DOWN nadi Ent fixed Fa waveform EFT iat glp RI SH Par Fi Help The screen showed the ECU captured by the engine of the state reser an The following data for the benchmark idling state e Engine SPD RPM Idle 1550 1750 Engine idle speed e FAULT NO Normal 0 Fault code number e BATT VOLT V Above 12V Battery voltage e FUEL PUMP Idle ON Fuel pump actuator state e MAP kPa Idle 32 38kPa Manifold pressure e PS
132. ontents 4 Fuel Injection System D SYM EFi System Diagnosis Methods When the motorcycle injection system in the wrong signal causing abnormal functioning of the engine or can not start engine warning light at the meter will be lighting to inform drivers to carry out maintenance Overhaul the diagnosis tool can be used for troubleshooting refer to diagnosis tool use guide or manually by the meter warning light inspection revealed that the fault codes refer to checking signal fault codes discriminate method the two methods for maintenance If the fault has been ruled out or repaired after the inspection light will be extinguished but ECU fault code will be recorded so the need to get rid of fault codes If a fault exists this system has two kinds of methods to eliminate fault codes respectively in the diagnosis tool removal and manual removal Using diagnostic tool for overhaul Diagnosis tool will connect to the motorcycle for coupler diagnosis according to the use of diagnostic tool testing methods when belong fuel injection system fault or parts fault according to the diagnosis tool of the fault code display messages do describe parts of the inspection testing maintenance and replacement parts When after the maintenance the need to get rid of fault codes Please refer to detailed steps diagnosis tool of instructions or fault code will always be stored in the ECU Manual inspection Use of cross wiring wire or paper clips e
133. oor contact e Check whether the abnormal wire harness lines e O Sensor anomaly the proposed replacement of the O2 Sensor and measurements again 4 22 http www motorcycle in th D SYM Roll over sensor To this chapter contents 4 Fuel Injection System Functional Description Control power of the power relay coil has the three pin socket When vehicles tilt angle greater than 65 degrees roll over sensor will be the implementation of ECU system power off At this point once again to restart the engine the need to re open a main switch This as a safety device when the dumping of vehicles be cut off power supply of ECU and engine stop Testing Procedures Because of the roll over sensor for the electronic control agencies not against removed after a single measurement Normal state after power is turned on the main switch measurement of ECU power relays red yellow line to the Green Line ground the power supply voltage measurement can determine whether it is normal for the roll over sensor Detection judge Voltage Supply voltage Battery voltage Treatment of abnormal phenomena Vehicle state vertical power relays or ECU without electricity supply Roll over sensor internal short circuit or open circuit or coupler bad contact Check whether the abnormal wire harness lines Roll over sensor anomaly the proposed replacement of the roll over sensor 4 23 http www motorcycle in th
134. open up 4 Main switch ON 5 Described above the No 3 with the No 4 movements continued liberalization of 5 seconds later about 5 seconds after inspections at carnivals flash twice to complete the removal of fault code 6 Then remove the cross wiring Cross access Not to cross access UOIIMS SO Full throttle Full throttle closed pzoy L At least 5 seconds ON OF OF UYO IMS ule Lighting Lighting 2nd inspection lights flash Not lit __Not lt yy6 I y0949 4 41 http www motorcycle in th To this chapter contents 4 Fuel Injection System Fault Code and Sensors Table C Throttle Throttle position sensor fault sensor fault TP TPSensorandwire and wire aa meane arora EDEIS eee Sees ee inara EICI eee eae ae eens oem eee eee ejom ia atte ectorancwre ESL JO eee eee eee Be a a See herent 13 1410 Exhaust 2 air control solenoid valve fault a ee re Ch e ee T 0 e ee 4 42 http www motorcycle in th To this chapter contents 4 Fuel Injection System Fault Code and Check Light Flashing Lighting Identification Table neu Fault Description Check i Hashing Parts Inspection codes light state 1 oao Throttle position sensor fault Lighting long 0 short 6 Throttle position sensor and wire Fault detection procedures Please refer to the EFI System components description throttle position sensor TPS chapter 2 oos Manifold A
135. oses or l iy pipes Brake light Y switch Caution Still none Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 14 11 http www motorcycle in th To this chapter contents 14 Brake System NOTE 14 12 http www motorcycle in th Home page Mechanism Diagram Pront When Re eee Precautions in Operation Front Cushion errs Troubleshooting Steering Stems screenees Steering Handle Mechanism Diagram K a ae 2 9 3 5kgf m d j Fa E 6 0 8 Okgf m ites as y H 2 4 3 oa E A E 6 0 8 0kgf m 2 4 3 0kgf m 2 4 3 0kgf m i 5 0 7 0kgf m g 15 1 http www motorcycle in th To this chapter contents SYM Precautions in Operation General Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Torque Values Nut for the front wheel axle Nut for the steering handle Lock nut for the steering handle stem Top crown for the steering handle stem Locating screw for the speedometer cable Front cushion upper lock bolt Front brake disk Special Tools Steering handle top thread wrench SYM 5320000 Inner bearing puller SYM 6204020 Steering nut wrench SYM 6204010 Driver 32 35mm Driver 42 47mm Troubleshooting Hard to steer e The steering handle stem nut is too tight e The ball and the top crown of the steering handle stem are dama
136. otorcycle in th To this chapter contents 17 Electrical System Inspection on ignition coil Remove the right floor garnish Disengage the connector of the ignition coil Measure the resistance between the terminals of the primary winding Standard resistance 2 80415 20 C Replacement of ignition coil Remove the cap from the spark plug Loosen 2 bolts and replace the ignition coil if necessary Inspection of crank position sensor Remove luggage box bolt 6 Disconnect the coupler of the crank position sensor and measure the resistance between the terminals of green white and blue yellow Standard resistance 80 1600 A Caution It is not necessary to remove the coil from the engine during this process Please refer to the section 11 for disassembly of coil 17 10 http www motorcycle in th To this chapter contents D SYM 17 Electrical System Starting System Starting System Fuma k i Em emr FI Fuse Hi ka een a4 ay R Red B Black L Blue G Green SB Sky blue Y Yellow O Orange Inspection of starter relay Open the main switch Press the brake Push the starter switch If a sound of Looh Looh is heard it indicates the relay is working properly Open the inner box lid and remove battery cover Disconnect the negative cable terminal of the battery Remove the luggage box Disconnect the cable positive terminal from the start relay 17 11
137. ottle fully opened 4 18 http www motorcycle in th Throttle output signal measurement To this chapter contents 4 Fuel Injection System Also can be used for diagnosis tool confirm to the throttle output signal 1 Connected to the diagnosis tool and open the main switch but not to start engine 2 Diagnosis tool screen switches to a data analysis 01 03 screen 3 Rotations throttle and check voltages Treatment of abnormal phenomena e Throttle sensor damage or connector poor contact e Check whether the abnormal wire harness lines e Throttle sensor anomaly the proposed replacement of the throttle sensor to measure the voltage A Warning e Throttle sensor prohibited removed from the throttle body to do any testing 4 19 http www motorcycle in th To this chapter contents 4 Fuel Injection System TW Sensor Functional Description e Powered by 5V DC from ECU It has the two pin socket on the sensor One terminal is for power output and 1 terminal are for ground e Its main component is a negative temperature coefficient resistance temperature rise smaller thermistor e Installed in the cylinder head the engine temperature sensor resistance with the induction to the temperature change and converted into voltage signals sent to the ECU was calculated engine temperature ECU accordance with the engine warm up to amendment the injection time and ignition angle
138. per Thermostat Boiling point Torque Value For water pump rotor Tools Requirement Special tools Water pump bearing driver 6901 Water pump oil seal driver Inner Water pump mechanical seal driver Inner bearing puller 12 2 Refill the radiator with distilled water or specified additives The cooling system can be serviced on the motorcycle Avoiding spilling the coolant on the painted surface Test the cooling system for any leakage after the repair Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and 0 9 0 15 Kg cm Begins to activate at 82 92 C Stroke 0 05 3 0mm 80 C Not pressured 107 7 C Pressurized 125 6 C 1 0 1 4kgf m http www motorcycle in th SYM To this chapter contents SYM 12 Cooling System Troubleshooting The engine temperature is too high The water thermometer and the temperature sensor do not work properly The thermostat is stuck to close Insufficient coolant The water hose and jacket are clogged Fan motor malfunction The malfunction of the radiator filler cap The engine temperature is too low The malfunction of the water thermometer and the temperature sensor The thermostat is stuck to open Coolant is leaking The water pump mechanical seal does not function properly The Oring is deteriorated The water hose is broken or aged 12 3 http www motorcycle in th To this chapter contents
139. position Idle lt 1 5 Throttle opening e PS position V Idle 0 58 0 62 Throttle sensor voltage e O2 SENSOR mV Idle 50 200mV gt O sensor voltage e O HEATER Idle 3500rpm ON gt O heater actuator state e ENGINE TEMP C Stable 85 95 C Engine temperature cooling water temperature In the DATA STREAM of the screen use A W button to move the left side of the project symbol selected items press the ENTER button lock of the project and press the F4 button showed that the wave of projects Able to use lt left and right gt button can transform View wave numerical size 81 03 Dota siteam t Engine SPD 17 TORPM O080 Engine SPO ERWRPM idle 1550 1 7 50 maou No mall 01 BATI VOLT TM ERI Above 12V FUEL PUMI mas zo lee ON 0g i die KP sea IPS parition er h idis 18 TPS position O oE 580 62 O2 SENSOR ROmYV de 50 2600m O2 KEATER Ala 3500rpm ENGINE TENIP Stoble 85 75 1 We prey DOWN neni Entefixed CFA waveform EXP ealt LEFT Pol RIGHT Pon Fi Help L Reewith rane EXIT anil Numerical analysis of images 1 3 the waveform can be displayed as shown in the following items Engine SPD BATT VOLT MAP TPS position TPS position Voltage O SENSOR Voltage ENGINE TEMP 4 50 http Awww motorcycle in th EE 4 Fuel Injection System Data stream 2 3 02 03 Data stream s BARD oo
140. r ball bearing http www motorcycle in th Guide pin groove Needle bearing 8 11 To this chapter contents 8 V Belt Drive System Clutch weight Replacement Remove snap ring and washer and then remove Spring clutch weight and spring from driving plate Caution e Some of models are equipped with one mounting plate instead of 3 snap rings Check if spring is damage or insufficient elasticity Clutch weight Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block should not be greased If so replace it Caution e Grease or lubricant will damage the clutch weight and affect the block s connection Capacity Install the spring into groove with pliers 8 12 http www motorcycle in th To this chapter contents SYM Install snap ring and mounting plate onto setting pin Replacement of Driven Pulley Bearing Remove inner bearing Caution e If the inner bearing equipped with oil seal on side in the driven pulley then remove the oil seal firstly e If the 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
141. rcycle in th D SYM 8 V Belt Drive System With 4 5g grease spreads wipes drives in the movable drive face axis hole Install drive face boss Caution e The movable drive face surface has to be free of grease Clean it with cleaning solvent Install movable drive face comp onto crankshaft Drive face boss Driven pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut M Caution e Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold drives face with universal holder Tighten nut to specified torque Torque value 8 5 10 5kgf m Install left crankcase cover http www motorcycle in th To this chapter contents 8 V Belt Drive System Clutch Outer Driven Pulley tea Clutch nut wrench Disassembly Remove drive belt clutch outer and driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let the wrench be installed more easily Caution e Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with special service a SS i 3 TOL Clutch spring compressor tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller
142. res Resistance Confirmation e Removed coil first circuit plugs on the ignition coil Red Yellow amp Black Yellow e Use of the meter Ohm stalls Q measurement of the ignition coil resistance value Detection judge e Ignition coil primary circuit 2 80 15 20 C Treatment of abnormal phenomena 1 Ignition coil internal coil disconnection damaged or plugs bad contact 2 Ignition coil ignition is not abnormal proposes to replace the ignition coil Crankshaft position sensor Measurement resistance value 4 28 Functional Description e Do not need for an external power supply has two pin of signal plug e Constitutes a major change in its reluctance induction coil e The spacing of flywheel and sensor should be 0 7 to 1 1 mm e Magnetic induction sensor is the use of flywheel on the Gear 18 1 tooth rotary cutting induction coil changes in the magnetic field sensor with the inductive voltage signal for ECU judgment calculated at the engine speed and crankshaft position and with a most appropriate time of fuel injection and ignition control Testing Procedures Resistance Confirmation e Removed crankshaft position sensor coupler Blue Yellow amp Green White e Use of the meter Ohm stalls QO measurement of the crankshaft position sensor resistance value Detection judge e Resistance value 80 1600 20 C Treatment of abnormal phenomena 1 Sensor internal coil interrupted
143. s oil Warranty will not cover the e Engine oil damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil E Grease kro Mate G 3 is recommended Apply sealant medium strength sealant should be used unless otherwise E Locking sealant specified s Oil seal Apply with lubricant rere poo with a new part before installation Soe Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid EI Special tools Special tools O coret Meaning correct installation OX wong Meaning wrong installation Indication Indication of components Indicates position and operation directions Ema a Components assembly directions each other Indicates where the bolt installation direction means that bolt cross through the component invisibility http www motorcycle in th To this chapter contents 1 General Information General Safety Carbon Monoxide Before you start the engine make sure the place is well ventilated Never start the engine in an unventilated place If you have to start the engine in an unventilated place an exhaust fume extractor is needed Caution Exhaust fume contains toxic gas which may cause one to lose consciousness and even result in loss of life 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
144. s to adhere to the traditional way 10 0230 Fuel pump fault lighting long 4 short 1 Fuel pump and wire Fault detection procedures Please refer to the EFI System components description fuel pump chapter ors O2 sensor heater fault lighting long 4 short 5 O2 Sensorand wire Fault detection procedures Please refer to the EFI System components description O2 Sensor chapter 12 1505 ISC motor fault lighting long 4 short 9 Step motor and wire Fault detection procedures Please refer to the EFI System components description idle speed control valve ISC chapter 1 mo Exhaust 2 air solenoid valve fault lighting long 5 short 4 2 air eau valve and wire Fault detection procedures Please refer to the EFI System components description 2 air solenoid valve chapter 4 ons Crankshaft position sensor fault lighting long 6 short 6 Crankshaft position sensor and wire Fault detection procedures Please refer to the EFI System components description Crankshaft position sensor chapter Se Manifold absolute pressure sensor as PM wire fault lighting long6 short 8 Fault detection procedures Please refer to the EFI System components description Manifold absolute pressure sensor MAP chapter 16 0603 EEPROM fault Not lit long short EEPROM This fault Please direct replacement ECU 4 43 http www motorcycle in th 4 Fuel Injection System D SYM EFi System Diagnostic Tool V
145. sharp edges or e Never use wires or harnesses which insulation corners and also avoid the projected ends of has been broken Wrap electrical tape around bolts and screws e Route harnesses so that they neither pull too e Never clamp or squeeze the wire harness as tight nor have excessive slack installing other components Never clamp or squeeze the wire harness http www motorcycle in th To this chapter contents 1 General Information D SYM e Do not let the wire harness been twisted as e With sand paper to clean rust on connector installation pins terminals if found And then conduct O x connection operation later 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 http www motorcycle in th To this chapter contents D SYM 1 General Information Specifications MAKER SANYANG MODEL LX40A1 6 F Overall Length 2270 mm Front TELESCOPIC FORK Suspension System Overall Width Rear UNIT SWING Overall Height Front 120 70 15 56S Tire Specifications c O
146. sk for deformation and bend Allowable limit 0 30 mm A Caution The dirty brake lining or disk will reduce the brake performance Brake lining includes the asbestos ingredient cannot use the air gun to clean it The operator should wear a mask and glove and use vacuum cleaner clean it Master Cylinder Fe Master Cylinder Removal B A Caution Do not let other substance enter into the cylinder A Caution The whole set of master cylinder piston spring diaphragm and circlip should be replaced as a set Remove the handlebar covers Remove the leads of brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder bolts and the master cylinder http www motorcycle in th To this chapter contents 14 Brake System Remove the rubber pad Remove the circlip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master Cylinder Inspection Check the master cylinder for damage or scratch Replace it if necessary 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 Front brake 11 055 mm Rear brake 14 055 mm Measure the outer diameter of the piston Replace the piston if the measured value exceeds allowable limit Allowable limit Front brake
147. special parts and system information 3 tt 7 tt There are 4 buttons Foreword Contents How to Use This Manual and Mechanism Illustration in the PDF version and can be access to these items by clicking on the buttons lf user wants to look for the content of each chapter selecting the words of each chapter on the contents can reach to each chapter There are two buttons Homepage and contents on the top line of first page of the each chapter Thus if the user needs to check other chapters he can click the top buttons to back the homepage or contents The content of each chapter can be selected too Therefore when needs to checking the content inside of the chapter click the content words of the chapter so that can back to the initial section of the content In addition there is a To this Chapter Contents button at the second page of each content so that clicking the button can back to the contents of this chapter http www motorcycle in th D SYM Contents Page 1 General Information Maintenance Information Maintenance Information B ATW 4 1 4 58 7 1 7 8 8 1 8 14 0 Lubrication System Fuel Injection System OI Engine Removal Cylinder Head Valve N Cylinder Piston 0 V Belt Drive System 9 1 9 8 13 1 13 16 17 1 17 22 wry ey eyes ey ee eye ee Oo Boe ECI ol D ol AS 18 1 18 2 Final Drive Mechanism
148. specifications e Diagnosis tool display voltage required to achieve more than 10 V The sensor detection methods and specifications please refer to repair manual Pressure fuel specifications Open the main switch three seconds after but not start engine more than 250 kPa Idle gt 294 6kPa Injector resistance specifications 11 740 60 Spark plug specifications NGK CR8E To this chapter contents 4 Fuel Injection System Continued from previous page YES Closed loop e Observation O2 e O2 sensor e O2 sensor fault e O2 sensor systems for senslor voltage voltage is e ECU fault voltage beating mobility changes Standed maintained in a specifications motorcycle so that long time within 100 900 mV engine speed a certain range from the two refueling between beating groups within 4500 to 5500 rpm the interactive beating YES Engine e Use diagnosis Diagnosis tool e Valve clearance is Manifold vacuum tool to detect of manifold not normal pressure the manifold pressure for e Intake system leak Specifications pressure compliance with 32 38 kPa specifications YES Normal starting Can not starting or starting difficulties Finish In traditional engine overhaul way to maintenance 4 37 http www motorcycle in th To this chapter contents 4 Fuel Injection System Remove fuel pump fuel unit Remove side cover Remove rear carrier Remove rear body cover Remove floor p
149. sure sensor first pin Yellow Black 5 Confirmed plains output voltage values e Voltage meter negative access to the inlet pressure sensor third pin Green Red e Voltage meter positive access to the inlet pressure sensor second pin Black Red A Cautions e Attentions to the tools required close to the probe wire waterproof i f he z Working voltage measurement apron penetrate skin and internal terminal before measurements to the correct value FEN Detection judge y e Working voltage value 5 0 0 1V e Plains output voltage values 2 87 0 03V Conditions In the plains 101 3 KPa Measurement AC A cautions z er y VY F AO ia E a Output voltage measurement Treatment of abnormal phenomena piang e Inlet pressure sensor damaged or poor contact couplers e Check whether the abnormal wire harness lines e Inlet pressure sensor anomaly the proposed replacement of the sensor to measure the output voltage e ECU anomaly the proposed replacement of the ECU to measure the working voltage e The higher the altitude the measurement value to the lower voltage e Sea level atmospheric pressure 1Atm 101 3kPa 760mmHg 1013mbar 4 16 http www motorcycle in th V SYM TA Sensor ae ae Resistance value measurement To this chapter contents 4 Fuel Injection System Functional Description e Use ECU DC 5V power supply provided has the two pin coupler a vo
150. table condition sensor voltage variation Idle continued 5 minutes later to measurement Diagnosis tool of the fault code is it can be eliminated Start again the fault is it will happen again e Battery voltage 10V Above e Open main switch but do not start the engine of pressure 250kPa Stable value e Idle state pressure 294 6kPa Beating situation from top to bottom e rotation throttle moment pressure 294 6kPa Slightly beating e Specifications NGK CR8H e Ignition conditions With traditional engines found ways Manifold pressure 32 38kPa Not started injector not leaking fuel In started the injection state must show fan shape Idle stable condition O2 Sensor voltage 50 200mV Show from top to bottom beating phenomenon Without any residual Fault Code If residual Fault Code according to the Fault Code Maintenance Form implementation of troubleshooting Battery electricity Battery connector loose Harness circuit opening ECU coupler not connected properly Fuel not enough Security switch not disarm Fuel pump relay fault Fuel pump fault Injector fault ECU fault Spark plug fault Roll over sensor fault ECU No 5 pin fault Ignition coil fault Crankshaft position sensor fault Valve clearance abnormal Intake system leak Security unit is configured not disarm Fuel pump relay fault Fuel pump fault Injector fault ECU fault O2 Sensor fault ECU f
151. tance value becomes higher when the temperature falls Sensors provide the temperature of the engine coolant and intake air to ECU to determine the injection and ignition timing Manifold absolute pressure sensor Manifold absolute pressure sensor MAP Sensor uses the piezoresistive resistor composed of silicon diaphragm forming the Wheatstone bridge circuit to measure the atmospheric pressure and the intake manifold pressure which are both transmitted to ECU for reference of engine control Working voltage 5V oinssold a6eloA 1ndjnO Inlet pressure kPa http www motorcycle in th To this chapter contents 4 Fuel Injection System O2 Sensor Power relay pa r O2 Sensor O2 Sensor a 1 Ceramics tube aa A 2 Electrode 3 Emissions ae pl Ba TE nn ar nas WN it 4 Atmosphere a6eloa 1ndjno Rich 14 7 Lean Function O Sensor measures the proportion of oxygen in the exhaust gas sending signals to ECU which adjusts the air fuel ratio by changing the fuel injection time If the proportion of oxygen is too low it means the rich air fuel mixture with higher HC amp CO concentration in the exhaust gas If the proportion of oxygen is too high it means the lean air fuel mixture with higher temperature and higher NOx concentration 1 O2 Sensor outputs feedback signal to ECU which keeps the air fuel mixture near the stoichometric ratio approximately 14 6 and forms the
152. tc to cross Joints Test Switch for grounding in the meter of this check light are flashing it means that the injection system or parts of abnormal situations but not in the diagnosis tool can be for the detection inspection can enjoy for a long time flashing lights flashing and the short period of time to inform the cause of the malfunction refer to check light fault information fault code table Test switch coupler Diagnostic tool coupler Diagnostic tool coupler and test switch coupler plant 4 40 http www motorcycle in th To this chapter contents SYM 4 Fuel Injection System Check Light Fault Codes Differentiation Check light flashing mode If problem without diagnosis tool to be detected it can be cross access the test switch coupler the motorcycle from the CHK lights flashing signal interpretation and then the basis for the diagnosis of dynamic information tables on the priorities of light and prompts you to the motorcycle to the emergence of some warning or FLASH CODE is to determine what kind of fault and exclusion Unit second Fault code 22 Fault code 12 Continuous repeated Fault Code manual removal procedure When there is without diagnosis tool can be manually cleared Fault Code the implementation of the following steps 1 Main switch OFF 2 Cross access the test switch for interconnection access and without opening up cross access movement must indeed 3 Full throttle and do not
153. th hydraulic presser http www motorcycle in th To this chapter contents D SYM 9 Final Drive Mechanism Remove oil seal and then remove final shaft bearing from left crankcase Install new final shaft bearing Press the bearing in with hydraulic presser Tool Bearing 6203 6004UZ driver Oil seal 27 42 7 driver Press out the driving shaft from gear box cover Using bearing protector as operation Remove oil seal from gear box cover and discard the seal Use bearing puller to remove the final shaft bearing from the cover If the driving shaft is pulled out with its bearing then remove the bearing with bearing puller and bearing protector Tool Bearing 6204 driver or Multi functional bearing puller Bearing protector Install a new driving shaft bearing onto gear box cover Tool Bearing 6204 driver Press the bearing in with hydraulic presser http www motorcycle in th To this chapter contents 9 Final Drive Mechanism Install a new final shaft bearing onto gear box cover Tool Bearing 6203 6004UZ driver Press the bearing in with hydraulic presser Install the driving shaft onto gear box cover and then place it to proper position Apply with grease onto new oil seal lip and then install the oil seal Tool Oil seal 20 32 6 driver Final Drive Mechanism Reassembly Apply with grease onto the oil seal lip of final driving shaft Install countershaft final sh
154. to move the inner ring of each bearing it shall move smoothly and quietly Check the outer ring is securely attached on the wheel hub If the motion of the inner ring of the bearing is not smooth or noisy and loose when being moved replace with a new one M Caution e The bearing shall be replaced in pair Wheel Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and measure its rim wobbling value with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in E TOOL bearing puller Disassembly Remove brake disk 5 bolts Remove dust seal bearing and dist collar from left side Remove dust seal and bearing from right side Special tools Inner bearing puller SYM 6204020 http www motorcycle in th 15 6 To this chapter contents SYM Assembly Dust seal Dist collar Fill out the block of bearing by grease m Drive the left bearing dust seal and install the dist collar Install the right side bearing A Caution e Carefully install the bearing in correct and evenly e Bearing outer face should be faced up as bearing installation Install the brake disk and then tighten the bolts Torque value 4 0 4 5kgf m http www motorcycle in th 15 7 To this chapter contents SYM r eau a a ie Front Cushion Ga W a o5 bolts at both Remove _ iiit Remove front cover front under spoiler and front fender Remo
155. to prevent chemical change please do not use counterfeiting or other uncertified brake fluid Please use the same brand of brake fluid consistently for brake efficiency 14 4 Brake caliper Brake disk http www motorcycle in th To this chapter contents SYM Adding Brake Fluid Before the brake fluid reservoir is removed turn the handle so that the brake fluid reservoir becomes horizontal and then remove the brake fluid reservoir of Si ae Ve at In When maintain the brake system it is supposed T is HAH Ji to cover the surface of rubber parts by rags P A ag at for ad fe SI MA Caution ety Please do not refill the brake fluid over upper limit Overflow may result in damages on painted surface such as rubber or plastic parts 14 Brake System Front brake master cylinder Remove the master cylinder cap and diaphragm Fill high quality brake fluid with same brand into master cylinder Clean the dirty brake disk M Caution Master cylinder cap e Dirty brake lining or disk will reduce the brake performance e Mix incompatible brake fluid will reduce brake performance e Other substance will block the brake fluid system and lead to reduce the brake performance or lose brake ability completely 14 5 http www motorcycle in th To this chapter contents 14 Brake System Brake Fluid Replacement Air bleed ar FN X WAir bleed valve OPE SpA Connect
156. tom side p ERN nA Loosen fixing nut and adjust by turning the Sie adjustment nut PY Tighten the fixing nut and check acceleration operation condition 2 Maintenance Information Air Cleaner Air Cleaner Element Remove 6 screws from the air cleaner cover Remove the air cleaner element A Caution e The air cleaner element is made of paper so do not soap it into water or wash it with water http Awww motorcycle in th To this chapter contents 2 Maintenance Information P C V system Remove the plug from lower of the breather chamber hose Release the dry internal deposit Every 5 000 kilometers release oil Caution e In releases the breather chamber hose in the transparent section is worthy of looking at as any deposit In the multi rain or the accelerator in the situation rides must reduce the maintenance traveling schedule In releases the breather chamber hose in the transparent section is worthy of looking at as any deposit Valve Clearance e Checks and adjustment must be performed when the engine temperature is below 35 C Remove luggage box Remove cylinder head cover amp side cover Remove ignition timing hole cap located in front upper side of engine right cover Turn camshaft bolt in C W direction and let the T mark on the camshaft sprocket aligns with cylinder head mark so that piston is placed at TDC position in compression stroke Caution e Do not tur
157. uter 3 The fuel pressure regulator maintains a 294 6 kPa pressure difference between intake pipe and fuel pipe raising the accuracy of fuel injection 4 By measuring the air pressure of intake pipe this system gives the vehicle better accommodation to the environment 5 Idle air by pass system supplies fuel and air to stabilize the idle running and cold starting 6 O2 sensor feeds back the signal to minimize the exhaust pollution http www motorcycle in th To this chapter contents SYM 4 Fuel Injection System Fuel System Fuel pump relay Injector get i E Power relay System Description 1 After Key on the sensors signal to be sent to the ECU ECU controls the fuel pump relay to make the fuel pump operate If the engine is not started the fuel pump will be shut down within 2 to 3 seconds in order to save electricity Fuel pressure regulator maintains fuel pressure at 294 6kPa about 3 kg cm According to the operating conditions and environmental compensation coefficient appropriate fuel will be injected After Key off or engine stopped operating the fuel pump stops running 2 Fuel impurities filtered by the fuel filter should be cleaned regularly 3 When the engine can not be started do not keep start motor running continuously which may lead to lack of battery power less than 10 V and the fuel pump will not be able to operate The correct way is to use a new battery Inj
158. valves MA Caution e In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool Valve cotter remove amp assembly tool i tea Val tt 5 SYM 1471110 SY125 gt e A 6 6 http Awww motorcycle in th To this chapter contents O SYM 6 Cylinder Head Valve Remove valve cotters spring retainers springs Inlet valve Inner spring I Spring retainer and valves Exhaust valve Outer spring Cotter Remove valve stem seals Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution e Do not damage the matching surface of cylinder head http www motorcycle in th To this chapter contents 6 Cylinder Head Valve Cylinder Head Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 34 860mm EX Replacement when less than 34 725mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D and wear or damage oil hole clogged Service Limit Replace when it is less than 12 080 mm Rocker Arm Shaft Measure the active O D of the c
159. ve three bolts at both sides Remove front wheel Remove front brake caliper Remove speedometer cable 15 8 http www motorcycle in th To this chapter contents SYM Steering Stem Stem mounting nut f g Steering stem top thread Remove F wrench Remove handle front wheel and front cushion x Remove the steering stem mounting nut Remove top cone race and steering stem Caution e Place the steel ball onto a parts container to prevent from missing Special tools Steering stem top thread wrench SYM 5320010 Handle stand nut wrench SYM 5321100 Handle stand nut Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats Remove bottom cone race body with a punch A Caution Do not damage the steering stem Installation l Steering stem mounting nut Install a new bottom cone race onto the steering stem Push the cone race until to mounted position A Caution yop cone r J Top ball bearing sea e Do not tilt the ball bearing seats as Bottom ball installation Ass bearing seat P Ea Apply with grease onto the ball bearing seats and a AN RSE Stool bails install steel balls onto the seats Top 26 balls gt bottom 29 balls Bottom cone race 15 9 http www motorcycle in th To this chapter contents SYM Lubricate the top cone race seat with grease Screw the cone race into top ball bearing seat till touching and
160. ving chain of engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Service data Unit mm Pp tem Standadd Connecting rod side clearance of the big end 0 100 0 400 0 600 Grankshan clearance of the big end of the connecting 0 0 008 0 050 Run out 0 100 Torque value Bolts for crankcase 0 8 1 2kgf m Bolts for cam chain adjuster 1 2 1 6kgf m Tools Special tools R L crank disassemble install tool L crank shaft bearing driver Crank shaft bearing fixing socket Crank shaft puller Outer bearing puller Inner bearing puller Troubleshooting Engine noise e Loose crankshaft bearing e Loose crankshaft pin bearing e Worn out piston pin and pin hole 11 2 http www motorcycle in th To this chapter contents D SYM Crankcase Disassembly Remove the cam chain Loosen the bolt and remove the tensioner Remove the water pump shaft locknut Remove the oil separator bolt x 2 Remove the oil pump drive sprocket driven sprocket and drive chain Remove the right crankcase bolts bolt x 3 11 Crankshaft Crankcase Mr Tensioner Cam chain B Water pump shaft locknut boltsx2 fea Oil pump drive sprocket Bolt x 3 http Awww motorcycle in th To this chapter contents 11 Crankshaft Crankcase Remove the left crankcase bolts bolt x 11 SSS Bolt x 11 tt wi _ i 3 ar g i y F d Remove the right crankcase from the

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