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SERVICE MANUAL S50/R50/SR50

1. Model illustration SERVICE MANUAL S50 R50 SR50 O SYM Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Jet Sport X S50 R50 SR50 series scooters 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 scooters Jet Sport X S50 R50 SR50 series are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department Sanyang Industry Co LTD How to Use This Manual D SYM This service manual describes basic information of different system parts and system inspection amp service for SANYANG Jet Sport X S50 R50 SR50 series scooters In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information The 3rd to the 10th chapters covers engine and driving systems The 11th to the 14th chapters is contained the parts set of frame body The 15th chapter is electrical equipment The 16th chapter is wiring diagram Please see index of content for quick having the special parts and
2. Brake shoe Do not use an air hose or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid dust flying A Caution Inhaling dust may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep the brake fluid beyond reach of children Q SYM Service Precautions Always use with SANYANG genuine parts and recommended oils Using non designed parts for SANYANG scooter may damage the scooter Special tools are designed for remove and install of components without damaging the parts being worked on Using wrong tools may result in parts damaged When servicing this scooter use only metric tools Metric bolts nuts and screws are not interchangeable with the English system using wrong tools and fasteners may damage this vehicle Clean the outside of the parts or the cover before removing it from the scooter Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause damage Wash and clean parts with high ignition point solvent and blow dry with compressed air Pay special attention to O rings or oil seals because most cleaning agents have an adverse effect on them Never bend or twist a control
3. B Measure the secondary coil resistance Resistance 8 2 9 3KQ A D A C B D 15 8 This chapter Contents D SYM 15 Electrical Equipment Remove the plug cap and measure its negative terminal for the secondary coil resistance Resistance 3 1 3 2KO A C A C B D Electrical System Circuit Inspection Pulse Generator Remove luggage box Disconnect pulse generator coil coupler Resistance Measurement 20 C Pulse generator coil blue yellow ground 50 2000 Pulse generator coil couple CDI Electrical System Circuit Inspection Remove luggage box and body cover Disconnect the CDI unit coupler and check its circuit to diagnosis related ignition components per gr i i 7 Green Black RE a A S f K K L N Ji L E s 2 v 3 La ib D de c s G see n N om E n een Esa 4 ua fe Ps f x em I i E k C H i y Pi Val 1 mr SI Blue yellow Black yellow ui O L S S E Baiar ak y bh y _ Continuity battery voltage as main Main Switch Black Green switch ON Pulse Generator Blue Yellow Green 50 2000 Black yellow Green 0 19 0 23Q Ignition Coil Green high voltage cable w o Cap 3 5KO secondary Green high voltage cable w Cap 8 2 9 3KQO e If above checks are in normal but spark plug is still no spark Then it probable causes from CDI set or high voltage coll If abnormal circuits are found in above checks at first check all i
4. D SYM 15 Electrical Equipment Bulb Replacement Headlight position light Remove front cover Remove the headlight bulb set coupler Headlight coupler Turn the set in counter clockwise direction and then remove the bulb Replace with new bulb if necessary Specification Headlight bulb 12V 35W H8 Turn the position light set and then remove the position light bulb seat Replace with new bulb if necessary Specification Position light bulb 12V 5W This chapter Contents 15 Electrical Equipment Front winker light Remove 9 screws and then remove handle front cover refer to chapter 11 Turn the front winker light set in counter clockwise direction and then remove the front winker light bulb seat Push and turn the bulb in counter clockwise direction and then remove the bulb Replace with new bulb if necessary Specification Winker light bulb 12V 10W Rear winker light Remove rear winker lens 1 screw Remove rear winker inner lens 1 screw Push and turn the bulb in counter clockwise direction and then remove the bulb Replace with new bulb if necessary Specification Winker light bulb 12V 10W 15 20 This chapter Contents D SYM 15 Electrical Equipment Tail light Brake light Remove taillight coupler Remove body cover rear carrier rear fender and taillight assembly Refer chapter 11 Remove 1 screw from taillight upper side Remove 4 screws
5. Install the main switch coupler and cap Right handle switch Remove the front cover Disconnect the coupler of right handle switch Check the continuity between two points as indicated in the table below Engine Stop Switch Blue Yellow Blue Yellow Starter Motor Switch Yellow Red e _ 15 16 Right handle gi switch coupler This chapter Contents O SYM Left handle switch Remove the front cover Disconnect the coupler of left handle switch Check the continuity between two points as indicated in the table below Turn signal light switch 5 ee FROM R N PUSH OFF prow RI ni i A eT Horn Switch Sp aS High Low Beam switch ogg A i J Passing Switch FREE E L Front Rear Brake Light Switch If the switch is in continuity as braking it is in normal The switch is non adjustable Horn If the horn gives out sound as connecting to 12V battery it means that it is in normal 15 Electrical Equipment Passing switch n High low beam switch Turn signal switch Horn switch Left handle switch coupler 15 17 This chapter Contents 15 Electrical Equipment D SYM Lights Tail amp stop light Headlight Hi beam Headlight beam switch Main switch 16 Headlight Lo beam Winker relay Left winker light Battery 15 18 This chapter Contents
6. TING Expanding ring EX mark 2 S j a P R J Sf L L V tu Piston pin snap ring SYM 6 Cylinder Head Cylinder Piston 6 9 This chapter Contents 6 Cylinder Head Cylinder Piston D SYM Lubricate cylinder and piston with two stroke engine oil Hold the piston and then install it into cylinder A Caution To avoid to damaging the piston and the cylinder sliding surface Install the cylinder head Tighten torque 1 6 2 0kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut Tighten torque 1 0 1 4kgf m Tighten exhaust pipe mounting bolt Tighten torque 3 0 3 6kgf m Install the removed parts in the reverse order of removal procedures Inspect following item after installation Test engine compression pressure Check for engine noise 6 10 This chapter Contents D SYM 6 Cylinder Head Cylinder Piston Note D SYM 7 A C Generator Maintenance Information 7 2 Generator Installation 7 4 Generator Removal 7 3 3 5 4 5kgf m 1 1 Z This chapter Contents 7 A C Generator D SYM Maintenance Information Precautions in Operation e The maintenance service of A C generator can be carried out directly on the scooter e Please refer to Chapter 15 for the relative A C generator inspection Torque value Flywheel 3 5 4 5kgf m Sp
7. 12V 10W S lE E G1 a S o 5 S ne 5 gt ra Ta m mi _ g 38 ma 5 gt a SE 55 a amp Sca I Epa a sna IGNITION COIL WINKER RELAY S p SS O SPARK PLUG AUTO THERMO L HANDLESW RR STOPSW RESISTOR HORN EARTH STARTERMOTOR ACG BY STARTER SW CDI UNIT L HANDLE SW R HANDLE SW COMB SW gt Ho pat B wr tt Hi B BLACK BR BROWN Ty YELLOW 0 T ORANGE L BLUE SB SKYBLUE GREEN LG LIGHT GREEN PNK GRAY aloo T rep loo Passi 010 FREE gt 079 bart OTO pascal f T N pusHoF JFROMR O O o oto ES RI BD w WHITE GR GRAY 12V 10W 16 1 16 Electrical Diagram D SYM Notes 16 2
8. A Caution Do not let foreign materials enter into the cylinder s The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a Set Remove the leads of brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder 12 10 This chapter Contents D SYM Remove the rubber pad Remove the cir clip 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 12 750 mm Rear brake 11 050 mm Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit Front brake 12 654 mm Rear brake 10 654 mm Master Cylinder Assembly Caution e lt 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 s
9. Remove 2 bolts for separation starter motor and gasket Remove 2 bolts for disassembly the starter motor Armature Inspection Check the armature for discoloration or other damage It may be short circuiting if dark surface on the shifter found A Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces It can be in continuity among the shifter surfaces but both the shifter surface and the shaft cannot be in continuity Starter Motor Re Assembly Installation Re assemble and install the starter motor in reverse order of removal procedures Starter motor 12 bolts Armature Spring Motor housing Carbon bracket 15 12 This chapter Contents O SYM 15 Electrical Equipment Oil Level Switch Troubleshooting s If the oil level in oil tank is in specified level but the oil level indicator still goes on 1 Remove luggage box 2 Disconnect oil level switch wire and turn the main switch to ON position Indicator light up Indicator not light up Short circuit between Malfunction of oil indicator and oil level level switch switch e If there is no oil in oil tank or low oil level but the oil level indicator still not goes on 3 Remove body cover 4 Disconnect oil level switch wire and connect a jump wire among coupler and then turn the main switch to ON position Indicator not light up Indicator
10. Start engine and check its ignition timing 7 4 D SYM 8 V Type Belt Drive System Kick Starter Maintenance Information 8 3 Drive Belts seene 8 6 Trouble Shooting 8 3 Movable Driven Pulley 8 7 Left Crankcase Cover 8 4 Clutch Driven Pulley 8 11 Reassembly Of Kick Starter 8 5 Installation Of The Left Crankcase Cover 3 5 4 5kgf m 5 5 6 5kgf m 8 1 8 V Type Belt Drive System Kick Starter D SYM 8 2 This chapter Contents SYM Maintenance Information Precautions In Operation The surfaces of drive belt and driven pulley must be free of grease Specification Item Drive belt width ID of movable drive face OD of movable drive face boss OD of weight roller ID of clutch outer Thickness of clutch weight Free length of driven pulley spring OD of driven pulley ID of movable driven face ID Inner Diameter OD Outer diameter Torque Values Movable drive face 5 5 6 5kgf m Driven pulley plate 5 0 6 0kgf m Clutch outer 3 5 4 5kgf m Trouble Shooting Engine can be started but motorcycle cannot be moved 1 Worn drive Belt 2 Worn ramp plate 3 Worn or damaged clutch weight 4 Broken driven pulley spring Shudder or misfire when drive 1 Broken clutch weight 2 Worn clutch weight 8 V Type Belt Drive System Kick Starter 20 035 20 085 23 964 23 985 15 9
11. left rear side covers center cover rear carrier body covers rear fender and rear inner fender Refer to chapter 11 Remove the battery and battery case 1 bolt Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil level switch wire coupler of the oil indicator Remove the mounting bolt on the oil tank upper side and then remove the oil tank Installation Install in the reverse order of removal The oil tubes air bleeding after installation 3 Lubrication System This chapter Contents 3 Lubrication System D SYM Notes 3 6 Home page Q SYM Maintenance Information 4 2 Troubleshooting 4 2 Throttle Valve 0 0 4 3 Carburetor Remove 4 4 Auto By Starter 4 4 4 Fuel System Flaot Level Inspection ER RRs 4 7 Carburetor Installation 4 7 Peedi libano 4 7 Fuel Pump 4 8 Ar sa PT O 4 9 Float Float Valve dJet 4 6 fo x Throttle valve cable Fuel output tube Vacuum tube E di a va 5 SS a S VR XD Carburetor Fuel inlet tube Saison dii Fuel pump Fuel filter Re Fuel cap Fuel unit Fuel tank 4 1 _ This chapter Contents 4 Fuel System O SYM Maintenance Information Precautions in Operations A Warning Gasoline
12. D SYM E CLUTCH DRIVING AND DRIVING PULLEY V Engine can be started but motorcycle can not be driving Engine running and misfire as motorcycle initial forward moving or jumping sudden rear wheel rotating as engine in running Poor initial driving Poor climbing performance FAULT CONDITION 1 General Information PROBABLE CAUSES PEDENN Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch ling broken Driving slide shaft gear groove broken Transmission gear damage Transmission gear worn out or burned Clutch ling spring broken 2 Clutch outer cover stuck with clutch balance weights Connection parts in clutch and shaft worn out or burned Driving belt worn out or deformation Balance weight roller worn out Driving sliding gear shaft worn out Driving disk spring deformation Driving sliding gear shaft worn out Greased in driving belt and sliding gear 1 19 1 General Information D SYM Lubrication Points Throttle cable Front amp rear brake lever pivot _ a l Seat catch a Speedometer gear Side stand shaft Main stand shaft Rear wheel bearing front wheel bearing EH 1 20 SYM 1 General Information Note 1 21 SYM General Information 2 1 Periodical Maintenance Schedule 2 2 Ar P cenieni 2 3 Fuel Lila 2 3 D Eillafuunrare nni 2 4 En
13. Mashgbeltrpnege sean Barbasta a oss ee a a sos O Boorse de ss Lalal a a asse Voperbatiorsseczonio 30 ssd ee 0 e as L orti v co usa D SYM Cables and Harness Routing Note the following when routing cables and wire harnesses e A loose wire cable or harness may cause safety hazard After clamping check each wire to make sure it is Secured e Do not squeeze wires against the weld or its clamp 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 e Route harnesses so that they neither pull too tight nor have excessive slack e Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner e Route wire harnesses to avoid sharp edges or corners e Avoid the projected ends of bolts and screws e Keep wire harnesses far away from the exhaust pipes and other hot parts e Be sure grommets are seated in their groves properly e After clamping check each harness to be certain that it is not interfered with any moving or sliding parts e After routing check that the wire harnesses are not twisted or kink 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 posit
14. Remove the crankcase bolts Crankcase Install the crankcase puller onto the right disassemble tool crankcase with two 2 bolts 6mm as the diagram shown Disassemble the right crankcase Special Tools Crankcase disassemble tool SYM 1120100 G5 gt Crankcase Crankshaft Removal Ie Xe disassemble tool As the diagram show with 2 special bolts to install ila the specified service tool onto the left crankcase Remove the crankshaft A Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with bearing puller Remove the right and left side oil seals A Caution Replace the oil seal with new one as removing the crankshaft 10 3 This chapter Contents 10 Crankcase Crankshaft Crankshaft Inspection Measure the clearance of connecting rod big end Service limit 0 60 mm Measure the radial clearance of connecting rod big end at X Y directions as diagram show Service limit 0 04 mm Place the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Service limit A 0 10 mm B 0 10 mm Check the crankshaft bearing by means of turning Clearance it with hand If any noise and bigger clearance ll are detected replace the bearing with new one S Clearance Lateral Radial 10 4 This chapter Contents D SYM 10 Crankcase Crankshaft Crankcase Installation Clean the crankshaft with solvent and blow it with a A i e
15. and also check the system for leaking Brake Fluid Check brake fluid level in the brake fluid reservoir If the level is lower than the LOWER limit add brake fluid DOT 3 to UPPER limit Also check brake system for leaking if low brake level found A Caution e In order to maintain brake fluid in the reservoir in horizontal position do not remove the cap until handle bar stop e Do not operate the brake lever after the cap had been removed Otherwise the brake fluid will soread out if operated the lever e Do not mix non compatible brake fluid together Brake Lining Wear Rear Drum Brake Type Replace the brake lining if the wear limit mark 4 on the brake arm aligning with the indicator of brake drum Brake lining replacements refer to chapter 12 Brake pad Wear Disc Brake Type The arrow mark on brake pad is the wear limitation Replace the brake pad if the wear limit mark closed to the edge of brake disc A Caution In order to maintain brake power balance the brake lining must be replaced with one set Brake pad replacements refer to chapter 12 Lower level Wear limit mark Brake pad Brake caliper Brake disc 2 1 This chapter Contents 2 Service Maintenance Information Loosen the guide pin bolts Remove the front wheel shaft bolt Take out the front wheel Remove brake caliper mounting bolt and then remove the brake caliper A Caution Do not operate the brake
16. and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal A Caution s In the current leakage test set the current range at larger scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit 15 4 Positive terminal Battery terminal _ This chapter Contents D SYM Charging Voltage Inspection Digital voltmeter Fuse connector A Caution s Before conducting the inspection be sure that the battery is fully charged If undercharged the current changes dramatically Use a fully charged battery having a voltage larger than 13 0 V While starting the engine the starter motor draws large amount of current from the battery After the engine is warmed up replace original battery with a fully charged battery Connecta digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse A Caution When the probe is reversibly connected use an ammeter having an indication that shows both positive and negative direction
17. correct it if any by following steps indicate in the checking list 1 The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rom Bulbs used exceed their rate and consume too much power The replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not The replacement battery is aged and does not have enough capacity Battery used 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 15 5 This chapter Contents 15 Electrical Equipment D SYM Charging System Fuse 15A REG REC R B G Y P LO Fuse 15A P S O D C oc G B Y Battery To other electric equipment Auto by starter AC Generator uto oy Regulator rectifier Inspection Check the each pins of coupler on the regulator rectifier g _ i Regulator rectifier Inspection Probable cause Check voltage between battery terminal red and ground Blown fuse green Check voltage between main switch terminal black and Blown fuse or poor main switch contact ground green main switch ON Check continuity between ground green and frame Check charging coil yellow to pink if its resistance is within Open circuit i
18. e Adjust rear brake Collar Engine hanger bracket B 5 6 D SYM 6 Cylinder Head Cylinder Piston Maintenance Information 6 2 Cylinder T Ta TTT 6 3 Troubleshooting tai 6 2 Cylinder Piston aaa 6 5 6 1 This chapter Contents I 6 Cylinder Head Cylinder Piston SYM Maintenance Information Precautions in Operation e The inspection and maintenance of the cylinder head cylinder and piston can be carried as engine mounted on the body It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal Remove all washes from the interfaces of cylinder head cylinder and crankcase Be careful do not damage cylinder head cylinder and piston when removing Inspect the removed amp cleaned parts thoroughly and apply with oil onto the rotation surfaces before installation Specification a a PistonOD SS 99 090 39 045 38 935 e ae Piston pin hole Piston pin OD 11 994 12 000 11 970 Clearance between piston and piston pin 0 002 0 014 Piston ring end gap 0 100 0 250 0 400 ID of rod small end 17 05 17 015 17 025 39 000 39 015 Cylinder S n ID inner diameter OD outer diameter Tighten torque value Cylinder head 1 6 2 Spark plug 1 1 1 Exhaust pipe connection nut 1 0 1 4kgf m Exhaust muffler mounting bolt 3 0 3 Troubleshooting Compression Pressure Too Low Difficult Piston Noise To Start Rough Idling 1 Cylinder and piston
19. gail pulley Oil seal Install guide pin and guide pin roller Guide pin Or Guide pin roller Install socket Socket Install driven pulley spring and clutch into clutch spring compressor and press down the assembly Mounting nut Clutch nut wrench by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Special tool Clutch spring compressor SYM 2301000 Clutch nut wrench SYM 9020200 Remove the clutch spring compressor S K Torque value 5 0 6 0kgf m ae 2 Clutch spring Install clutch driven pulley and drive belt onto compressor drive shaft 8 15 8 V Type Belt Drive System Kick Starter D SYM 8 16 D SYM 9 Final Driving Mechanism Maintenance Information 9 2 Inspection of Final Driving Mechanism Troubleshooting nee a sonora 9 6 Disassembly of Final Driving Mechanism Bearing Replacement 9 7 weer rrr rr rr rr rrr rr rrr rr rr re 9 3 Re Assembly of Final Driving Mechanism lai 9 8 Bearing 6004UU VA seal 27x42x7 Bearing 6201 A T j OLANE 1 0 1 5kgf m wie T I ait RA OS nb my XD za A T n S LU s jF 4 if 1 g gt i sg 1 0 1 5kgf m 9 1 This chapter Contents 9 Final Driving Mechanism Maintenance Information Limited usage of gear oil gear oil 140 Recommended oil
20. and then remove taillight assembly Taillight bulb is LED if necessary to replacement you must replacement assembly Taillight coupler T A 1 screw 4 Screws 15 21 This chapter Contents 15 Electrical Equipment Meter indicator light Remove steering handle front cover Remove winker and hi beam indicator light rubber Turn the bulb seat in counter clockwise direction and then remove and then take out the bulb seat from the bottom of instrument panel Hi beam indicator light bulb Replace with new bulb if necessary Specification Meter indicator light bulb 12V 3 4W Install the all removed parts 15 22 Contents d O G d G T 16 Electrical Diagram D SYM Jet Sport X 50 Series Electrical Diagram Open fire 12V 6AH FUEL OILLEVEL THERMO POWERFILTER SP SENSOR R HANDLE SW FR STOPSW COMB SW START RELAY BATTERY REG REC UNIT SW SW UNIT UNITASS Y Das ped S 1 zo 52 50 25 5 u 0 wa BBs m 3 L m 5 gt gt m 5 2 RU ER WINKER 12V 10W E Her SB RICO M Jj Il G1 G1 G1 G1 HEAD LIGHT Hi BEAM 12V 35W H8 HEAD LIGHT Lo BEAM a 12V 35W H8 BIY G4 YIW G3 r POSITION LIGHT 12V 5W ELEC METERASS Y R4 KF R4 LICENSE LIGHT BR G1 T 3 il Q SB TAIL STOP LIGHT LED 18 GIR G3 Q 9 POSITION LIGHT LH RR WINKER Gus f BR AL 12V 10W ms LH FR WINKER 9 E 2
21. bearing should be replaced To avoid damaging the bearing use equal force on both races Both of these examples can result in bearing damage e Lubricate the rotation face as assembling Check if positions and operation for installed parts is in correct and properly SYM 1 General Information 1 5 1 General Information D SYM Specifications 1840 mm Suspension Telescopic Fork AL Unit Swing Tire 120 70 12 Wheel Base 1275 mm Specifications 130 70 12 4210 Disk 190mm 56 kg Brake System Disk 160mm Rear 98 kg DRUM 110mm One 75 kg Max Speed 48 km hr Below Front 64 kg Climb Ability 22 Below Primary Reduction BELT Secondary Reduction GEAR Gasoline Clutch Centrifugal dry type Horizontal below center ur incline Unleaded 92 95 Speedometer 0 80 km hr 2 stroke forced air cooled 93 112 dB A 39 mm Muffler Expansion amp Pulse Type Exhaust Pipe Position and Right side and 41 4 mm are Direction Backward Single Cylinder Lubrication System Separated lubrication 49 4 cc CO 1 0 g km 4 2 6 kw 6000 rp a J Electrical amp kick Catalytic reaction control system qj D UD O gt d v D D U Overall Length Overall Width 690 mm Overall Height 1120 mm Dimension Front Curb Weight Total Passengers Neigh Weight al D 109 kg Total Weight o v g 173 kg Forman Perce Type Installation and arrangement Fuel Used Cy
22. damage e Check the operation of the brake system before you go Specifications Front brake master cylinder inner 42 700 12 743 42 750 diameter Front brake master cylinder piston 42 657 12 684 12 654 outer diameter Rear brake master cylinder inner 11 000 11 043 44 050 diameter Rear brake master cylinder piston 40 657 10 684 10 654 outer diameter ID of rear brake drum 110 0 110 5 Torque values Brake hose bolt 3 3 3 7kgf m Bolt for brake caliper 3 1 3 5kgf m Bolts for the lining guide pin 1 5 2 0kgf m Air bleed valve 0 8 1 0kgf m Bolts for the brake disc 4 0 4 5kgf m Nuts for the front wheel axle 5 0 7 0kgf m Nuts for the rear wheel 10 0 12 0kgf m Bolt for rear brake arm 0 8 1 2kgf m Rear brake lever nuts 0 8 1 2kgf m Brake master cylinder mounting bolts 1 0 1 4kgf m 12 3 12 Brake System D SYM 12 4 D SYM Troubleshooting Disc Brake Soft 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 disc 7 Low brake fluid 8 Blocked brake pipe 9 Warp bent brake disc 10 Bent brake lever Drum Brake Poor brake performance Improper brake adjustment Worn brake lining Worn brake drum Worn brake cam Improper brake lining installation Seized brake cable Dirty brake lining Dirty brake drum Brake pad worn in brake cam area 10 Poor contact between brake arm and camsh
23. flame or spark should be allowed in the work place or where gasoline is being stored A Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verified We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off 1 2 SYM Battery A Caution Battery emits explosive gases flame is strictly prohibited Keeps the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water and then go to hospital to see an ophthalmologist If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor Keep electrolyte beyond reach of children
24. is a highly flammable material and may explosive under circumstance Thus always work in a well ventilated place and strictly prohibit flame when working with gasoline Care must be taken when dealing with gasoline and always work in a well ventilated place and Strictly prohibit flame When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly It has to conduct air bleeding operation as removed the oil tube Idle speed adjustment Specification Fuel level 8 8 1 0mm Air screw opener 13 8 Idle speed 2000 100 rpm Troubleshooting Engine cannot be started Lean Mixture 1 No fuelin fuel tank 1 Clogged carburetor jet 2 Fuel can not reach to carburetor 2 Clogged hose from carburetor to canister 3 Too much fuel in cylinder 3 Bend squeezed or clogged fuel lines 4 Clogged air cleaner 4 Clogged fuel filter 5 Malfunction of float valve 6 Low fuel level in float chamber 7 Clogged vent pipe Stall after started 8 Malfunction of fuel pump 5 Incorrect idle soeed adjustment 6 No spark on the spark plug 7 Low compression pressure 8 Rich mixture Rich Mixture 9 Lean mixture 13 Malfunction of float valve 10 Clogged air cleaner 14 Low fuel level in float chamber 11 Inlet pipe leaking 15 Clogged carburetor air injector 12 Polluted fuel 4 2 This chapter Contents SYM ________ _ o o o amp o 4 Fuel System Throttle Valve Carburetor upper part i Removal Remo
25. it is a correct bolt Bolts for the same assembly should have the same length e Tighten assemblies with different dimension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated Bolts and fasteners should be kept clean and dry Do not apply oil to the threads e When oil seal is installed fill the groove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal A Manufacturer s name e Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage AX 1 4 D SYM 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 J 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
26. light up Poor wire Malfunction of oil connection level switch 5 Disconnect oil level switch coupler and check voltage between wire and ground No age Voltage e Open circuit between e Malfunction of oil level oil level switch and switch indicator s Poor connection of oil Blown bulb level switch Removal Installation Remove luggage box Drain out oil from oil outlet tube Pull up oil level switch and then remove oll level switch from the oil tank Install the oil level switch in reverse order of removal procedures Main switch Fuse T O_ __T L Indicator Oil level switch Oil level switch Oil level switch This chapter Contents 15 Electrical Equipment D SYM Carburetor Heater Power filter Thermo switch To REG REC Y W Y Carburetor heater G Battery i _ AC Generator Removal Installation Remove luggage box rear carrier and body cover Remove carburetor heater wire pins Remove carburetor heater Inspection Carburetor heater resistance 7 10 Q Remove power filter coupler and thermo switch coupler and then remove power filter and thermo switch 15 14 This chapter Contents D SYM 15 Electrical Equipment Fuel Unit Removal Installation Remove 4 bolts and floor panel Remove floor plate 2 nuts Remove fuel tank heat guard Disconnect fuel unit coupler from front wheel side Turns the fuel unit retain
27. plate in counter clockwise direction and then remove the fuel unit retain plate Remove the fuel unit A Caution Do not bend the float arm Install in reverse order of removal procedures Remark Aligning the slot of fuel unit with the retain plate of fuel tank as installation and then turn the retain plate in clockwise direction until matching to the arrow Inspection 1 Connect the fuel unit coupler Turn the main switch ON Move the float in up and down and make sure that the fuel indicator can be reached to F Full and E Empty positions Conduct the step 2 if the needle on the fuel indicator is not moved 2 Measure the coupler resistance while the float in up and down positions Up full 3 10Q Down empty 90 1000 Check the fuel indicator if the resistance is in normal Replace the fuel gauge if the resistance is abnormal 15 19 This chapter Contents 15 Electrical Equipment Switch Horn Remove handle covers and front cover Check continuity on each switch The connected circles with a line are that they should be in continuity Main Switch Wire color Black Re lock or ON e Replacement of main switch Turns the main switch cap in counter clockwise direction and then remove the main switch cap Disconnect the coupler of the main switch and loosen the mounting bolts 2 bolts Remove the main switch Install the new main switch and tighten the mounting bolts
28. plug can be reused Measure the spark plug gap with feeler gauge Spark plug gap 0 6 0 7mm 0 024 0 028in Adjust the gap by careful bending the side electrode e Install the spark plug by screwing it with hands after installed the spark plug washer so that can prevent the plug from out of thread Then tighten the spark plug with a spark plug wrench e Install the spark plug cap Side electrode 2 10 This chapter Contents D SYM 2 Service Maintenance Information Control Cable Lubrication Remove the throttle control and the brake cables periodically and lubricate the moving parts of the cables thoroughly Driver Belt e Remove left crankcase cover e Check if the belt is crack or worn out Replace the belt if necessary e Measure the driving belt width Allowable limit 16 5mm Ignition Timing Caution e C D I ignition timing cannot be adjusted If the ignition timing is incorrect check the C D I device and the alternator and replace damaged components e Check ignition timing with standard instrument Remove the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is correct Throttle Valve Operation Check if each steering positions are operated in smooth and handle bar if its operation is smooth as the throttle valve wide opening or fully closed Ch
29. starter Resistance value Max 10Q at cold engine Caution If the resistance value exceeds the standard a little bit the auto by starter may still in normal However it is necessary to check other relative components for damage Carburetor upper part K PO A F I L Z Draining screw Connection hose A Fuel hose Auto by starter This chapter Contents Q SYM Remove carburetor and allow it to cool off for 30 minutes Connect fuel rich circuit with a hose and pump compressed air to the hose Air should flow into fuel rich circuit Replace the auto by starter if the circuit clogged Connect battery to starter s connectors and wait for several minutes Pump compressed air into the fuel rich circuit Air should not flow into the circuit If air flow through the circuit then replace the auto by starter Check resistor to make sure that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor is in short circuit current higher than specification will flow into the PTC Then it will cause the fuel rich circuit close rapidly and difficult to start the scooter Resistance value 10 20 Auto by starter i Auto By Starter Removal Installation Remove the cover of the auto by starter Remove screw and mounting plate Remove the auto by
30. starter from carburetor Install in the reverse order of removal procedures 4 Fuel System ay Mounting plate This chapter Contents 4 Fuel System Float Float Valve Jet Removal Remove the float from carburetor body Remove the float pin and then remove float and float valve Check the valve seat for worn out or damage Check float for bend and if fuel inside the float Before removing both the throttle valve stopper and air screws record their original turns for close to their original set up position as installation Caution Do not tighten the screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Installation Install the idle jet the needle jet seat and main jet Then install the throttle valve stopper and air screws to their original position according to the marks as removal Adjust the screws if replace with new ones Air inlet for idle speed Se Float valve se Float Throttle valve stopper screw b Needle jet Float pin Idle jet __ f Needle jet seat Main jet Screw Draining screw This chapter Contents SYM Float Level Inspection Measures float fuel level to have the upper end of float just contact with the float Float fuel level 8 8 mm Carefully bend the float arm for adjustment Check the float operation and the install it Carburetor I
31. the bushing if looseness found Check the shock absorber for damage Tighten all nuts and bolts Nuts Bolts Tightness Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule Check all split pins snap rings hose clamps and wire holders for security This chapter Contents 2 Service Maintenance Information Transmission Oil Leak Check if the transmission is leak Check A Caution Park the scooter on flat ground with its main stand Remove the oil level check bolt and check if the oil level is placed on the hole of check bolt Replacement Remove the oil level check bolt Remove the oil draining bolt and then drain oil out Install the oil draining bolt Tighten torque 1 3kgf m A Caution Check if oil seal and washer is in good condition Replacement Quantity 0 09 L 90 cc Recommended oil King Bramax HYPOID GEAR OIL 140 Spark Plug Recommended plug NGK BR8HSA Remove the luggage box Remove the spark plug cap Clean any dirt on the spark plug seat Remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square Center electrode edges and side electrode should have a constant thickness Replace the spark plug if there is apparent wear or if the insulator is cracked and or chipped If the spark plug deposits can be removed by sandpaper the spark
32. tube Oil pump ma N X e A IZ 4 A A Y T Q DI SME TH 3 5 Oil lever switch 3 1 This chapter Contents 3 Lubrication System D SYM Precautions in Operation Be careful not let dirt enters into engine or oil hoses when removing or installing the oil pump If air is found in the oil tube from oil tank to oil pump or oil tube is removed the oil pump should be conducted air bleeding operation It should bleed the oil output tube from oil pump to carburetor as hose removed The adjustments of oil pump control cable Lubricant Appointed to apply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage Recommended oil MAX 2 oil Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pumps adjustment too much oil 2 Poor quality oil 3 Applying with poor quality oil Over heat 1 Improperly oil pumps adjustment insufficient oil 2 Poor quality oil 3 Applying with poor quality oil Piston seized 1 No oil in oil tank or clogged hose 2 Improperly oil pumps adjustment insufficient oil 3 Air in oil hose 4 Malfunction of oil pump Oil did not flow out the oil tank 1 Clogged breath hole on the oil tank cover This chapter Contents D SYM 3 Lubrication System Oil Pump Removal Caution Before removing the oil pump clean the oil pump and crankcase Remov
33. tube air enters oil tube due to oil leak out without added oil There is why the oil tube and oil pump have to conduct air bleeding operation Oil Tube Oil Pump lt has to add some oil into the oil tank Place a piece of dry cloth around the oil pump Disconnect the oil tube Fill out oil to oil pump connection section by means of the oil pot so that the oil pump body is full with oil Fill out oil to oil tube connection section so that the oil tube is full with oil Then install the tube onto oil pump Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted air bleeding operation too Oil Tube Air Bleeding Remove the oil output tube and plug its input connector Bend the oil tube into U shape and fill out new oil into the output tube Connect the oil output tube to the oil pump connection part Start engine and run it in idling as the oil control lever in wide open position Make sure oil flows out from the oil output tube Caution Motorcycle s exhaust gas includes with CO which causes human to coma or death so perform this operation in well ventilation place Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube This chapter Contents Q SYM Oil Tank Removal Remove the luggage box and seat Remove the right left side covers right
34. 2 Malfunction of throttle valve operation 3 Throttle valve opening too wide Remove carburetor after 30 minutes and connect a hose onto fuel supplement circuit Then blow the hose with air Blowing in normal Blowing clogged 1 Malfunction of auto starter 1 13 1 General Information SYM D SYM 1 General Information B Engine run sluggish Speed does not pick up lack of power Check and adjustment Try gradual acceleration and check engine speed Engine speed can be increased Check ignition timing Using ignition lamp Ignition timing correct Check cylinder compression pressure using compression pressure gauge Compression pressure No compression correct pressure Check if carburetor is clogged Engine speed can not be increased Remove spark plug No foul or discoloration Fouled and discoloration 1 _2 Check if engine over heat Engine overheat Continually drive in acceleration or high speed G E GM Fault condition Probable causes Air cleaner clogged Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Incorrect ignition timing 1 2 Malfunction of AC generator Malfunction of CDI Cylinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Crankcase leakage for pre compression Remove dirt Remove dirt Incorrect spark pl
35. 2 16 08 107 0 107 2 33 965 33 985 Special Service Tools Clutch spring compressor Clutch nut wrench Universal holder Inner bearing puller Clutch bearing driver Clutch seal driver SYM 2301000 SYM 9020200 SYM 2210100 SYM 6204020 Insufficient horsepower or poor high speed performance 1 Worn drive belt 2 Insufficient spring capacity of driven pulley 3 Worn weight roller 4 Driven pulley operation un smoothly This chapter Contents 8 V Type Belt Drive System Kick Starter Left Crankcase Cover Left crankcase cover removal Remove rear left body side cover Remove air cleaner 2 bolts Remove kick start arm 1 bolt Remove left crankcase cover 9 bolts Disassembly of Kick Starter Remove snap clip and thrust washer from left crankcase cover Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection of kick Starter Check if starter spindle driven gear for wear or damage Driven gear Starter spindle Friction spring fo Starter spindle Snap ring Thrust washer This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Reassembly of Kick Starter Install bush return spring and starter spindle as diagram shown Install thrust washer and snap clip onto starter spindle Install kick starter lever temporary S
36. Bramax serial oil Oil quantity 120 c c 110 c c as replacement Torque Values Mission cover bolt 2 4 3 0kgf m Mission oil drain bolt 1 0 1 5kgf m Mission oil check bolt 1 0 1 5kgf m Special tools Inner type bearing puller SYM 6204020 Outer type bearing puller SYM 6204010 Final shaft oil seal installer SYM 9125500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 R Crank shaft puller SYM 1130000 R L Crank shaft install bush SYM 1130010 Extension bush SYM 1130031 long Extension bush SYM 1130032 short Troubleshooting Trouble Diagnosis Engine can be started but scooter cannot be moved 1 Damaged drive gear 2 Burnt out or seized drive gear Noise 1 Seized worn or damage gear 2 Worn or loose bearing Gear oil leaks 1 Excessive gear oil 2 Worn or damage oil seal D SYM This chapter Contents D SYM 9 Final Driving Mechanism Disassembly of Final Driving Mechanism Remove driven pulley Remove oil drain bolt and filling bolt Drain gear oil out from gearbox Remove muffler and rear wheel Remove gearbox cover mounting bolts from the clutch side 7 bolts Remove the cover from the rear wheel side This chapter Contents 9 Final Driving Mechanism Remove final gear final shaft and counter gear counter shaft Final shaft Remove the drive shaft from left crankcase A Caution The bearing must b
37. Cover Front Fender Speedometer cable Removal Ramoval 1 bolt from left front cushion and then remove speedometer cable clamp and front brake hose clamp Ramoval 4 screws form front fender right and left side Ramoval front fender Installation Install in reverse order of removal procedures Rear Fender Removal Ramoval luggage box rear carrier and body covers Ramoval 3 screws and then removal rear fender Installation Install in reverse order of removal procedures Each side 1 screw 11 12 This chapter Contents SYM 11 Body Cover Rear Inner Fender Removal Ramoval luggage box rear carrier body covers and rear fender Ramoval 2 screws from rear inner fender upper Pull out rear fender front hanger with frame and then removal rear inner fender Installation Install in reverse order of removal procedures Rear Mudguard Removal Ramoval rear mudguard left side screw with air cleaner Ramoval muffler 2 nuts amp 3 bolts pull out muffler with rear mudguard right side hanger 1 Screw Ramoval rear mudguard right side bolt and then remove rear wheel Ramoval bolts form rear mudguard left side and then remove rear mudguard Installation Install in reverse order of removal procedures 11 Body Cover Under Cover Removal Remove right and left side cover Remove 1 bolt and 1 nut from the under cover right side Remove 1 bolt and 1 nut from the und
38. M 12 Brake System Disc Brake Air Bleed Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve A Caution e Do not release the brake lever before the drain valve is closed e Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enters into the system Slowly release the brake lever and wait for a few seconds until it reaches its top position Repeat the steps 1 and 2 until there is no air bubble at the end of the hose Tightly close the drain valve Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary Cover the cap Air bubble Front brake Drain valve Drain hose Drain valve a TR a Drain valve 12 7 This chapter Contents 12 Brake System Disc Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hoses A Caution Do not spill brake fluid on painted surfaces Remove two caliper bolts and the caliper Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 1 3 5kgf m Wo Sb bolt Caution ye NS s Use M8 x 35 mm flange bolt only lt lt eno s Long bolt will impair the operation of brake disc L B Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 3 3 7kg
39. NamelR Crankshaft install bush Name Extension bush 7 SYM 1130031 long No SYM 1130010 No SYM 1130020 i reas eee oe om 28mm 220mm ai Crankcase bush puller Name Crankcase bush puller Name ACG Flywheel puller No SYM 1120310 No SYM 1120320 No SYM 3110A01 25 37 6 20 32 6 2 42 7 Nam la Nam loi seal driver Nameloi seal driver Name 0i seal driver 2 14 SYM 2 Service Maintenance Information 2 15 This chapter Contents 2 Service Maintenance Information D SYM 6204 Bearing driver 017mm Bearing driver 6204 No SYM 9620000 No SYM 9110400 Bearing driver 6301 SYM 9610000 il jaa _ LULU I Inner bearing puller Name Inner bearing puller Name Outer bearing puller SYM 6204020 No SYM 6204022 No SYM 6204001 Name Clutch nut wrench Name Clutch spring compressor Name Universal holder No SYM 9020200 No SYM 2301000 No SYM 2210100 Multi meter SYM HE07007 01 2 16 SYM Lubrication System Diagram 3 1 Precautions In Operation 3 2 En O 3 2 Trouble Shooting 3 2 3 Lubrication System Oil Pump Removal 3 3 Oil Pump Installation 3 3 Oil Pump Oil Tube Air Bleeding 3 4 Lubrication System Diagram C Oil tank A N TT Oil tube Oil output
40. Poor charging system e The battery is not fully charged e Poor connection in the windings The motor gear is jammed by foreign material Starter motor is working but engine does not crank e Poor starter motor pinion s The starter motor run in reverse direction Poor battery 15 3 This chapter Contents 15 Electrical Equipment Battery Battery Removal Installation Turn off main switch Open seat remove 2 screws and then open battery cover Disconnect the negative cable terminal first then the positive cable terminal Remove the battery from the scooter Install the battery in reverse order of removal Negative terminal Voltage Check Open seat and battery cover Remove wires from battery Check battery voltage Voltage Fully charged 13 0 13 2V Undercharged 12 V Charging Remove the battery Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard charging current time 0 7A 5 10 hrs Fast charging current hrs 3A 1 hr A Caution e Strictly keep flames and sparks away while recharging to avoid to explosion causing by hydrogen Stop charging battery when electrolyte temperature is over 45 C 117 F e Fast charging the battery is for in emergency only Battery should be charged in standard Current Leakage Inspection Turn the main switch to OFF position
41. ads or in the Heavily polluted environment 2 Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage 2 2 This chapter Contents D SYM 2 Service Maintenance Information Air Cleaner e Remove the mounting screw from the air cleaner cover e Remove the air cleaner cover Remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry A Caution Never use gasoline or acid organized solvent to clean the element soap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover e Limit to use SAE 20 JASO FC class engine oil otherwise SYM is no responsible for the warranty e Recommended engine oil MAX 2 serial oils Fuel Lines Remove the luggage box Check fuel lines and replace damaged lines if found Install the luggage box i i Squeeze oil out Fuel pump 5 screws Air cleaner element Carburetor Fuel line 2 3 This chapter Contents 2 Service Maintenance Information Fuel Filter Remove the luggage box Remove the fuel line from the fuel filter Replace the fuel filter with new one Install the fuel filter The arrow indicates the fuel flowing direction Check the fuel line for leaking Engine Oil Line Remove the body cover Ch
42. aft indent Sii A ES ONO This chapter Contents I Hard operation of brake lever 1 Blocked brake system 2 Poor brake caliper 3 Blocked brake pipe 4 Seized worn master cylinder piston 5 Bent brake lever Uneven brake 1 Dirty brake lining disc 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disc 5 Restricted brake hose and fittings Tight operation or low return speed of brake lever 1 Worn broken crack return spring 2 Worn drum 3 Dirty brake lining 4 Brake seized caused from dirty brake drum Seized brake cable Worn brake cam Improper brake lining installation l 12 Brake System Tight brake 1 Dirty brake lining disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel Brake noise 1 Worn brake lining 2 Worn drum 3 Dirty brake lining 4 Dirty brake drum 12 5 This chapter Contents 12 Brake System Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake Replace the brake fluid Before the brake fluid reservoir is removed turn the handle so that the brake fluid reservoir becomes horizontal and then remove the brake fluid reservoir Cover the painted surfaces plastic or rubber components with a rag when servicing brake system A Caution Spilled brake fluid on painted sur
43. aring driver 6204 compressed air Then check for damage or other foreign materials attached Install new bearing into right crankcase Caution All rotation and sliding surfaces have to be applied with clean engine oil e Remove all gaskets onto the crankcase interfaces and flat it with special tool Install new bearing into left crankcase Special Tools Bearing driver6204 SYM 9110400 S TOOL Bearing driver 6204 Install crankshaft onto the left crankcase Install left crankshaft puller and install bush onto crankshaft Screw the left crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil Special Tools L Crank shaft puller SYM 1130000 L L Crank shaft install bush SYM 1130010 Extension bush SYM 1130031 long Apply liquid gasket and dowel pin onto the interface of left crankcase 10 5 This chapter Contents 10 Crankcase Crankshaft Assemble the right crankcase with assembly tools R Crank shaft puller Install right crankcase onto the crankshaft sy Install right crankshaft puller and install bush onto ERI crankshaft 7 0 Screw the right crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil Special Tools R Crank sha
44. ation D SYM Periodical Maintenance Schedule Maintenance 300KM Every Every Every Every kilometer 1000KM 3000KM 6000KM 12000KM Mai i Reference ae e II i G a H H D 4 Oil pump linkage operation suas eee ie ai 7 Brake amp freeplaycheck 1 140 _ _ __ R Steeringhandlecheck 1 9 Cushion operationcheck 1 E __ fo Every sorewtighteningcheck 1 AG O M1 Gear oil check for leaking 1 AG ORI x I2 Sparkplug check orchange 1 f R 13 Gear oil change R Replacement tor every 5000km ta Frame tubrication J oO oo o T _ SS _ re Exhaustpipe a a S DOCE B check T DT heoo TI TTT rs re emission check 4 TT EEE tft O I I H i2t Fuellines e o a _ E E O O O i Ga pen engine sot nen 1 SIT TT fa engine sento TT TTI 25 Carbon cleaning for cylinder C head cylinder and piston head and exhaust system Have your scooter checked adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition Code Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 Clean or replace the air cleaner element more often for pro long engine life span when the scooter is operated on dusty ro
45. be reduced by grease on brake lining Rear brake drum Remove wheel and brake drum Inspection Check brake drum for damage or wear out and replace it if necessary Measure the inner diameter of brake drum and record the max value Allowable limit rear 110 5mm Caution Clean the rust onto the brake drum with 120 sandpaper Measure the inner diameter of brake drum with micrometer Measure the thickness of brake lining at three points both ends and center If the thickness is less than specified value or if it is contaminated by oil or grease replace as a Set Service limit Rear 2 0 mm Removal A Caution Brake linings must be replaced as a shoe Remove the brake shoes from brake panel 12 14 This chapter Contents D SYM 12 Brake System Installation Apply with a thin coat of grease to the brake cam and the anchor pin Install brake cam Never allow brake linings to be contaminated by oil or grease Wipe off the excessive grease from brake cam and the anchor pin Caution Brake efficiency will be reduced if brake shoe is contaminated by oil or grease Install the brake cam and arm after aligning it with the punched point Tighten the bolts and nuts to specified torque Torque value 0 8 1 2kgf m Brake shoes Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated VE OG A Caution Dk y R U y Brake efficie
46. between the front cushions A Caution Align the front cushion groove with the speedometer gear box stopper flange Insert the wheel axle into the wheel and then install the wheel axle nut Tighten the nut to specified torque Torque value 5 0 7 0kgf m Connect the soeedometer cable to the speedometer gear box 13 8 Stopper This chapter Contents D SYM 13 Steering Front Wheel Front Cushion Front Cushion Removal Remove front cover front fender and front wheel Remove the caliper mounting bolt and the caliper Take out the hose from hose clamp Brake caliper Remove the front cushion upper bolts and the front cushion Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Torque value 2 4 3 0kgf m Install the removed components in reverse order of removal procedures 13 9 This chapter Contents 13 Steering Front Wheel Front Cushion D SYM Steering Stem Steering stem Removal mounting nut Remove steering handle front wheel and front cushion Remove the steering stem mounting nut Remove top cone race and front fork A Caution Place the steel ball onto a parts container to prevent from missing Top cone race 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 Install a
47. cable to prevent stiff control and premature worn out 1 General Information Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary 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 A Caution In addition to damaging paint finish brake oil can also damage the structural integration of plastic or rubber parts 1 3 1 General Information e The length of bolts and screws for assemblies cover plates or boxes is different from one another be sure they are correctly installed In case of confusion Insert the bolt into the hole to compare its length with other bolts if its length out side the hole is the same with other bolts
48. cle Cooling Bore Stroke Cylinder Number Arrang ement Engine lon Displacement Compression Ratio 7 2 1 skd oe Cc C x O W C O O Max HP Max Torque Ignition Starting System SYM 1 General Information Torque values Standard Torque Values for Reference 5 mm Bolt nut 0 45 0 6kgf m 0 35 0 5kgf m l 6 mm Screw flange bolt R l 6 mm Bolt nut 0 8 1 2kgf m SH Type 0 7 1 1kgf m 8 mm Bolt nut 1 8 2 5kgf m 8 mm Flange bolt nut 1 0 1 4kgf m 10 mm Bolt nut 3 0 4 0kgf m 8 mm Flange bolt nut 2 4 3 0kgf m 12 mm Bolt nut 5 0 6 0kgf m 10 mm Flange bolt nut 3 5 4 5kgf m The torque values listed in below table are for more important tighten torque values Please see above standard values for not listed in the table Engine mm kgf m Cylinder head bolt oa z aeo When engine cooled e rae E e CC E raa Pol fees EE e I ooo maa TT seas enaa teas anan a 8 ness n 8 sese ae e 6 ness ane EI e O E Seri o e E eane e e wee Tear 6 sese f oo omm e tee 1 7 1 General Information O SYM Frame Qt Thread Dia Torque Value y mm kgf m Mounting nut for handle 0 ssa Se eee dee eee aa ss Laa e e ss ee ee ee ss Lal a da ee Ce Tn __ sea Moac E w_ E Brea saper naonin potis sist Moiediogiesta a mee reigi a e ses Sotetnionte lu e ssa
49. connect the negative 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 the motorcycle 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 C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignition timing light after replacement if necessary e The starter motor can be removed after the engine is removed Specification Charging System Battery 0 7A 5 10 hours standard 3A 1 hour fast charging Charging current 1 2 A 5000 rpm T Control voltage in charging 14 0 15 0 V 5000 rpm Ignition System NGK BR8HSA Recommended Spark plug Ignition coil and resistance Secondary coil 2 8 3 4 KQ Ignition timing F mark 17 BTDC 1800 rom 15 2 This chapter Contents D SYM Troubleshooting No voltage Battery discharged e The cable disconnected e The fuse is blown e Improper operation of the main switch Low voltage e The battery is not fully charged e Poor contact Poor charging system s Poor regulat
50. current The measurement would be at zero if the ammeter is one direction only A Caution Do not use short circuit cable It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal however while the starter motor is activated the surge current of the motor draws from the battery may damage the ammeter Use the kick starter to start the engine 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 15 Electrical Equipment Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 5000 rpm Control Charging Voltage 14 0 15 0 V 5000 rpm Caution To replace the old battery use a new battery The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any one of the problems takes place 1 The charging voltage cannot exceed the voltage between two battery terminals and the charging current is in the discharging direction 2 The charging voltage and current are too much higher than the standard values The following problems are not related to the charging system
51. e Rear cushion upper mounting bolt 3 5 4 5kgf m Rear cushion lower mounting bolt 2 4 3 0kgf m Rear wheel nut 10 0 12 0kgf m Bolts for the brake disc 4 0 4 5kgf m Exhaust muffler nut 1 0 1 4kgf m Exhaust muffler bolt 3 0 3 6kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft Cushion too soft 1 Insufficient cushion spring force Poor brake performance Poor brake adjustment Contaminated brake lining Worn brake lining cam Worn brake cam lever Worn brake drum Improper installation of brake arm gear set oo Si 14 2 This chapter Contents SYM 14 Rear Wheel Rear Cushion Rear Wheel Remove Remove exhaust pipe nut 2 connection nuts Remove exhaust muffler bolt 3 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Connection nuts T to Shaft nut 14 3 This chapter Contents 14 Rear Wheel Rear Cushion Brake disc removal install Remove 4 bolts and then remove brake disc Check item refer chapter 12 Install by reverse order of removal procedures Installation Install the rear wheel and tighten the nut Tighten torque 10 0 12 0kgf m Install exhaust pipe amp muffler Tighten torque bolt 3 0 3 6kgf m Tighten torqu
52. e nut 1 0 1 4kgf m 14 4 This chapter Contents D SYM 14 Rear Wheel Rear Cushion Rear Cushion Removal Remove luggage box Remove air cleaner Remove rear cushion upper amp lower bolts Remove rear cushion Installation Install the rear cushion Tighten the upper amp lower mounting bolts to specified torque Torque value Upper mounting bolt 3 5 4 5kgf m Lower mounting bolt 2 4 3 0kgf m Press down the tail of the scooter for several times to check cushion operation Install all components in reverse order of removal procedures Lower mounting bolt This chapter Contents 14 Rear Wheel Rear Cushion D SYM Note 14 6 D SYM 15 Electrical Equipment Maintenance Information Starting System Troubleshooting R THAR TE Fe Es Battery Oil Level Switch Charging System Fuel Unit Ignition System sit Switch Horn ie RERE Bulb Replacement Resistor Comp Winker Relay Reg Rec Comp Horn Main Switch Horn Winker Dimmer Switch Start ENG Stop Switch Fuel Unit Spark Plug IG Coil AC Generator Carburetor heater Oil Level Switch Fuse Battery Thermo Switch Start Relay CDI Unit Power filter 15 1 This chapter Contents 15 Electrical Equipment SYM Maintenance Information Precautions in Operation e When remove the battery the disconnection sequence of cable terminals shall be strictly observed First dis
53. e replaced when removing the drive shaft Drive shaft is pulled out with its bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller SYM 6204001 Shaft protector SYM 6204010 Remove drive shaft oil seal and bearing from left crankcase 9 4 This chapter Contents D SYM 9 Final Driving Mechanism Remove final gear final shaft and counter gear counter shaft Final shaft Remove the drive shaft from left crankcase A Caution The bearing must be replaced when removing the drive shaft Drive shaft is pulled out with its bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller SYM 6204001 Shaft protector SYM 6204010 Remove drive shaft oil seal and bearing from left crankcase To this chapter contents 9 Final Driving Mechanism D SYM Inspection of Final Driving Mechanism Check if the drive shaft are burn wear or damage and replace it if necessary Caution f remove the drive shaft from the gear box upper side then its bearing has to be replaced Check if the countershaft is wear or damage and replace it if necessary Check if the final shaft and gear are burn wear or damage and replace it If necessary Check bearings on gearbox cover Oil seal Rotate each bearing s inner ring with f
54. e the luggage box and seat Loosen the mounting nut of the oil pump control cable and remove the control cable Remove the oil tube and clip its end side to prevent oil from flowing out Remove the oil output tube form intake manifold Remove the oil pump mounting bolt and then take out the oil pump Inspection Inspect the following items on the removed oil pump Check if O ring is damaged or softening Check if crankcase interface is damaged Check if pump body is damaged Check if pump gear is damaged Check for oil leaking A Caution The oil pump cannot be disassembled Oil Pump Installation Install the oil pump onto the crankcase A Caution Apply with some grease onto oil pump O ring The connection between both oil pump and crankcase has to be installed in position security Tighten the oil pump mounting bolt security Install the oil tube Install in the reverse order of removal A Caution Inspection and adjustment following items as installed The adjustment operation of control cable Air bleeding operation of oil pump Air bleeding operation of oil tube Check each section for leaking This chapter Contents 3 Lubrication System Oil Pump Oil Tube Air Bleeding Control cable Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that causes serious engine damage A Caution After disconnect the oil
55. ear cushion lower mounting bolts Exhaust pipe connection nut Muffle mounting bolt 5 5 6 5kgf m 4 5 5 5kgf m 3 5 4 5kgf m 2 4 3 0kgf m 1 0 1 4kgf m 3 0 3 5kgf m D SYM This chapter Contents D SYM 5 Engine Removal Engine removal Fuel output tube Remove body cover i ar Remove the spark plug cap from the spark plug Remove the fuel output and the vacuum tubes from fuel pump Remove the oil control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire couplers of auto by starter and ACG Carburetor Remove the upper parts of the carburetor from its upper parts upper side Remove the carburetor heater electric wire This chapter Contents 5 Engine Removal Drum type rear brake Remove rear brake cable from engine rear lower side Remove brake cable from cable clamp Disc type rear brake Remove rear brake caliper 2 bolts from engine rear upper side Remove brake hose from hose clamp Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Y NI 7 TTT RR II III FIANO Lon ua A K fee ium uae SOI ERE A w Mey J 7 9 BI ies This chapter Contents D SYM 5 Engine Removal Remove two exhaust pipe connection nuts Remove two bolts beside fan cover and exhaust pipe Support the engine and then remove cushion i Rear cushion lower lower mountin
56. ecial Service Tools Flywheel puller SYM 3110A01 Universal holder SYM 2210100 Coil resistance value for the A C generator AC generator This chapter Contents D SYM 7 A C Generator Generator Removal Remove the luggage box and rear side cover Remove 3 bolts and then take out cooling fan cover Remove 4 bolts and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel Special tool Universal holder SYM 2210100 Remove the flywheel with flywheel puller Special tool Flywheel puller SYM 3110A01 This chapter Contents 7 A C Generator Disconnect generator wire coupler and pulse coil Generator coupler coupler Remove the pulse coil and generator coil bolts 4 bolts and then take out the generator assembly Caution Care to be taken for not damaging the generator coil Generator Installation Install the generator assembly Connect the generator coupler Caution Connect the generator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove A Caution e Clean dirt and metal pieces inside the flywheel e Make sure that there is no foreign material inside the flywheel Install the flywheel Tighten the flywheel 10 mm nut Torque value 3 5 4 5kgf m Install the removed parts in reverse order of removal procedures
57. eck the engine oil line and replace damaged parts Engine oil pipe Remove the filling pipe from the oil pump and Rone drain oil into a cleaning container Loosen the clamp under the engine oil tank and then remove the oil pipe Bleed the air inside the oil pump and oil pipe if air found Install the body cover 2 4 This chapter Contents D SYM 2 Service Maintenance Information Oil Pump Control Cable Caution To adjust the oil pump control cable after adjusted the throttle grip play Remove the luggage box Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump body Loosen the adjustment nut of the oil pump control cable Turn the adjustment nut and align with the point then tighten the mounting nut Battery Open the seat Loosen two screws of battery cover and then remove the cover Check if the battery terminals are loosened Remove the battery if its terminals are corroded obviously Battery Removal 1 Remove the Negative battery cable at first 2 Then remove the Positive battery cable 3 Remove the battery Clean the rust with steel brush Install the battery in reverse order of removal and apply with grease onto two terminals A Caution The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes skin or clothes If touched by accident flush them with clean water immediately Howev
58. eck throttle cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure throttle valve handle free play Free play 2 6 mm 1 8 1 4 in Loosen the mounting nut and turn the free play adjustment nut of the throttle valve handle for adjustment Replace the cable if it can not be adjusted Tooth face ni Belt width n 2 11 This chapter Contents 2 Service Maintenance Information Carburetor Idle Speed Adjustment A Caution e Inspection amp adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification e Idle speed check and adjustment have to be done after engine is being warned up It around operates engine from stop to running for 10 minutes Remove the body cover Park the scooter with main stand after warned up engine According to the required idling and air screw to adjust to specified idle speed Idle speed 2000 100 rpm Carbon Removing For Exhaust Pipe amp Muffle Remove the body cover Remove the exhaust pipe amp muffler Clean the carbon deposits on the muffler amp cylinder exhaust edge Cylinder Compression Pressure Test Remove the left body cover and warn up engine Stop the engine and remove the spark plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 0 1 kg cm Probable causes for l
59. emoval Q Cylinder Head Cylinder Piston N 7 1 7 14 A C Generator A 8 1 8 6 VT Type Belt Driving System Kick Starter Final Driving Mechanism 0 Crankcase Crankshaft d Body Cover E Ne Brake System Steering Front Wheel Shock absorber Rear Wheel Shock absorber a Electrical Equipment fa Ogu Electrical Diagram D SYM Model illustration Jet Sport X S50 R50 SR50 Series N ENG Stop Starter switch Fuel tank cap r_ _ lt i fa _ KR L ty sale ae J Rear turn signal AZ Lh f r gt x WS Di a D bi Taillight A Rear turn signal Front turn signal gaiii Helmet hook High amp Low beam Passing Turn signal Horn switch Battery Fuses C D I R Ka came number Eng Oil tank cap Za LA AU GFR 7 4 eat loc Headlight STA Luggage box Z A Air cleaner a a i a Home page BP Contents _ SYM 1 General Information Symbols and Marks Torque values General Safety Cables and Harness Routing Service Precautions Troubleshooting Specifications Lubrication Points Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using
60. er if the electrolyte sprays to eyes medical care should be done quickly Mounting nut This chapter Contents 2 Service Maintenance Information D SYM Tire Caution Tire pressure should be checked when cold Check tire for cracks damage nail or other object stuck in tread Recommended tire and tire pressure 120 90 10 130 90 10 cold kg cm Check if the tire tread and wall rubber for crack or damage and replace if necessary Check if foreign materials such as nail metal pieces and stones stuck on tire The thread depth can be checked by visual inspection or by a depth gauge e f the tread bend too much replace the tire e lf tire wear exceeds limitation replace the tire and check it for un even wear A Caution Wear indicator 4 is distributed on average Wear indicator along the wall rubber for check Rear Drum Brake Free Play Measure the free play of the rear brake lever at Panas the end of the lever 3 8 3 4in Free play 10 20 mm 3 8 3 4 in Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked Decreasing free play Increasing free play This chapter Contents Vv SYM 2 Service Maintenance Information Disc Brake System Hose Make sure that the brake hose is corrosion or damage
61. er cover left side and then remove under cover Installation Install in reverse order of removal procedures 11 14 Q SYM Disc Brake System 12 Brake System Disc Brake Caliper Rear Drum Brake System Brake pad replacement Maintenance Information Brake Disc Troubleshooting Disc Brake Master Cylinder Hydraulic Disc Brake Rear Drum Brake Disc Brake Air Bleed Disc Brake System SELL hh yall 3 3 3 kgf m ee Le S Ay 3 3 3 kgf m ASR L J Be 3 1 3 5kgf m a WN 3 1 3 5kgf m N l X pra J f 4 0 4 5kgf m 4 0 4 5kgf m 12 1 This chapter Contents 12 Brake System D SYM Rear Drum Brake System 10 0 12 0kgf m 0 8 1 2kgf m 12 2 This chapter Contents SYM 1 Brake System Maintenance Information Precautions in Operation A Caution Inhaling brake lining ashes may cause disorders of respiration system therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead e The brake caliper can be removed without removing the hydraulic system After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system e While refilling brake fluid care should be taken not to let the foreign material entering into the brake system s Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid
62. er screws Disconnect each switch connectors Remove speedometer electric cord coupler Remove handle rear cover Installation Install in reverse order of removal procedures Caution Push the front connection part of rear handle cover at first when removing front cover so that the buckles are out of the cover Never push it forcefully to cause buckles broken or cover damaged Speedometer coupler 11 4 This chapter Contents D SYM 11 Body Cover Front Cover Removal Remove 10 screws from the front inner box and front cover Remove 1 screw from the front cover Remove electric cord coupler from the headlight Remove the front cover Installation Install in reverse order of removal procedures f Each side 5 screws 11 5 This chapter Contents 11 Body Cover Luggage Box Removal Lift up seat cushion Remove oil tank cap and oil guide rubber Remove luggage box mounting nuts and bolt 2 nuts amp 1 bolt Hold the luggage box in both front and rear sides by two hands and then lift up the box to remove it Installation Install in reverse order of removal procedures Battery Cover Removal Installation Remove 2 screws and then remove battery cover Install in reverse order of removal procedures 11 6 i D SYM 11 Body Cover Removal Remove 2 screws under side cover front end Remove 2 screws and then slide the side cover backward so tha
63. f m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Front brake Loosen the 2 pad guide pin bolts Remove brake caliper Remove the brake pad guide pin bolts and then remove brake pads 12 8 This chapter Contents D SYM 12 Brake System Install the new brake pads onto brake caliper Install the brake pad guide pin bolts Install the brake caliper and tighten the mounting bolts Torque 3 3 3 7kgf m Tighten the lining guide pin bolts Torque 1 5 2 0kgf m Rear brake Loosen the 1 lining guide pin bolt Remove brake caliper Remove the brake pad guide pin bolt and locking spring and then remove brake pads Install the new brake pads onto brake caliper Install the brake pad guide pin bolt and Install the brake caliper and tighten the mounting bolts Torque 3 3 3 7kgf m Tighten the lining guide pin bolt Torque 1 5 2 0kgf m Locking spring Locking spring 12 9 This chapter Contents 12 Brake System Brake Disc Brake disc Inspection Visually check the brake disc for wear or break Measure the thickness of the disc at several places Replace the disc if it has exceeded the service limit Allowable limit Front brake disc 3 5mm Rear brake disc 3 0mm Remove the brake disc from wheel Check the disc for deformation and bend Allowable limit 0 30 mm Disc Brake Master Cylinder Master Cylinder Removal
64. faces plastic or rubber components may result in their damages Remove the master cylinder cap and diaphragm Use brake fluid to clean the dirty brake disc Caution The dirty brake lining or disc will reduce the brake performance Refill up same grade brake fluid into the reservoir Caution To mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing brake performance to be reduced or totally lost Connect drain hose to drain valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brakes fluid Caution To reuse the spent brake fluid will affect brake performance Connect one end of transparent hose to the drain valve and put the other end into a container Open the drain valve around 1 4 turns and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever Close the drain valve when finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 12 6 Cap Diaphragm Upper level Air bubble Drain hose This chapter Contents D SY
65. from the front upper part of the front spoiler and the front inner box Ts lt lt ae MULO gt A Pull up the front inner spoiler from holder hook and then remove the front inner spoiler and right left under spoiler assembly Each side 5 screws Disassembly Remove 10 screws and then remove right left under spoiler Installation Install in reverse order of removal procedures 11 9 This chapter Contents 11 Body Cover Floor Panel Removal Remove luggage box rear carrier center cover right amp left side cover and body covers Remove 4 rubber caps Remove the floor panel 4 bolts Disassembly Remove 2 screws from right left center cover and floor panel Remove 2 screws from right left center cover and floor panel other side Remove right left center cover Installation Install in reverse order of removal procedures 11 10 This chapter Contents D SYM 11 Body Cover Front Inner Box Removal Remove the front cover Remove luggage box rear carrier center cover right amp left side cover body covers and floor panel Remove main switch cover Remove 1 bolt and hook PIO or Remove 2 screws from the under spoiler and front inner box ie Remove 6 screws from the front inner box and under spoiler Remove the front inner box Installation Install in reverse order of removal procedures This chapter Contents 11 Body
66. ft puller SYM 1130000 R R Crank shaft install bush SYM 1130020 Install the bolts and tighten them Torque value 1 0 1 5kgf m Tiga R Crank shaft With right crankshaft install bush install new oil install bush seal into the right crankcase Its installation depth is 4mm as the diagram shown With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown Caution i p oe Oil seal driver Make sure that the crankshaft can be rotated q Install the following components Final driving mechanism chapter 9 Alternator chapter 7 Piston cylinder cylinder head chapter 6 Oil pump chapter 3 Reed valve and carburetor chapter 4 Engine remove chapter 5 10 6 amp SYM 11 Body Cover Body Overview Front under Spoiler Maintenance Information Floor Panel Steering Handle Cover Front Inner Box Front Cover Front Fender Luggage Box Rear Fender Side Covers Rear Inner Fender Center Cover Rear Mudguard Body Cover Under Cover Body Overview Seat attery cover Battery case Right rear grip Handle upper cover Left rear grip Handle rear cover Handle front cover LE 9 Left center IS cover Floor panel AAE Front cover Rear inner fender Front cover emblem Left rear side cover tear mudguard Front inner spoiler Left side cover Right front under A 74 Front inner nee Ne Under cove
67. g bolt mounting bolt Remove engine mounting nut and bolt Each side 1 bolt and 1 nut Remove the engine Engine mounting nut F 2 CIA UR d Wa z SN Fae gt gt EE oe L Engine mounting bolt This chapter Contents 5 Engine Removal Engine Hanger Bracket Removal Remove the frame side right and left side bolts of engine hanger bracket 1 bolt on each side Disassembly Remove the engine hanger bracket nut and bolt Disassembly engine hanger bracket A and engine hanger bracket B Check if the engine hanger rubber bushes hanger bushes and collar for damage If so replace with new ones Assembly Install hanger bushes and collar into engine hanger bracket B Install engine hanger bracket A and engine hanger bracket B and tighten the bolts and nuts of engine hanger bracket Torque Value 4 5 5 5kgf m Engine installation Install in the reverse order of removal procedures Tighten the engine mounting bolts and rear cushion upper lower bolts Torque value Engine hanger bolt 5 5 6 5kgf m Rear cushion upper mounting bolts 3 5 4 5kgf m Rear cushion lower mounting bolts 2 4 3 0kgf m Exhaust pipe connection nut 1 0 1 4kgf m Muffle mounting bolt 3 0 3 5kgf m Perform the following inspection and adjustment after installation e Check if control cable is correct e Check if throttle valve cable is correct e Check if oil pump control cable is correct e Oil input and output of the oil pump
68. ge and a feeler gauge to measure the cylinder head for warp Service limit 0 10 mm Cylinder Head Installation Replace the cylinder head gasket with new one and place the cylinder head onto cylinder Tighten the 4 bolts with diagonal direction and by 2 3 sequences Tighten torque 1 6 2 0kgf m Install spark plug Tighten torque 1 1 1 7kgf m 6 4 This chapter Contents D SYM 6 Cylinder Head Cylinder Piston Cylinder Piston Remove spark plug cap Remove fan cover Remove engine shield Remove two connection nuts of the exhaust pipe Remove exhaust muffle mounting bolt and then remove the exhaust muffler Cylinder Removal Remove cylinder head Be careful to pull the cylinder up and prevent piston from damage A Caution Do not have pry out operation between cylinder and crankcase Or let radiation fan be knocked seriously Piston Removal Place a clean rag onto crankshaft to cover the piston Remove piston pin clip one piece and then push piston pin out the piston A Caution Do not damage or scratch the piston Do not apply with lateral force to connecting rod Do not let piston pin snap ring falling into crankcase Piston Ring Removal A Caution Pry out the opening end of each piston ring and then remove the ring from piston 3 bolts Piston pin clip Connection nut This chapter Contents 6 Cylinder Head Cylinder Piston D SYM Check if cylinder and piston a
69. gine Oil Line ssssss sese ereer 2 4 Oil Pump Control Cable 2 5 T T 9 5 v ee eee 2 6 Rear Drum Brake Free Play 2 6 Disc Brake System Hose 2 7 Steering System ereer eee eee 2 9 2 Service Maintenance Information Transmission Oil 0 011 1 2 10 Spark Plug sss serere seer errer 2 10 Control Cable Lubrication 2 11 Driver Belt 0000 2 11 Ignition Timing eeren 2 11 Throttle Valve Operation 2 11 Carburetor Idle Speed Adjustment 2 12 Carbon Removing For Exhaust Pipe amp ocio 2 12 Cylinder Compression Pressure Test 2 12 Headlight Adjustment 2 13 Special Tool Manuali 2 14 SUSPENSION 1000001011 2 9 General Information Specification Tire dimension Front 120 70 12 Rear 130 70 12 Tire pressure at cold Only rider Front 1 75kg cm Rear 2 0 kg cm Rear brake lever free play Transmission oil H dati D Scommengaton lo SAE 140 Quantity 0 12 L Replacement 0 11L Spark plug Recommendation Type NGK BR8HAS Plug gap 0 6 0 7mm se l Standard 18 0mm Driving belt widt Allowable limit replace it if below 16 5mm Ignition timing F el h Acceleration operation Idle speed 2000 100 rpm ylinder compression pressure 7 1 kgf cm2 This chapter Contents 2 Service Maintenance Inform
70. hould be face inside of master cylinder when installing the master cup Install the cir clip A Caution e Never install cup lip in the opposite direction e Make sure the cir clip is seated securely in the groove 12 Brake System Install the rubber pad into groove properly 12 11 12 Brake System y Rubber pad a Piston Ce k Spring Master cylinder Cylinder gauge 12 12 Piston Rubber Sub cup bush gt Cir clip Piston Master cylinder This chapter Contents Vv SYM 12 Brake System Place the master cylinder onto handlebar and install the bolts Install the brake lever and connect leads to brake light switch Brake hose Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes A Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 12 13 This chapter Contents 12 Brake System Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts Caution e Inhaling brake lining ashes may cause disorders of respiration system therefore never use compressed air or dry brush to clean brake parts Brake performance will
71. ing groove Install the top ring and the 2 ring onto the ring groove respective A Caution The top ring and the 2 ring cannot be changeable each other Push the rings into ring groove and then check rings mating condition If ring could not be push in the ring groove it means that ring groove is dirty or wrong ring groove installation A Caution All rings should be installed with the marks facing up All rings should be replaced at same time and it cannot be replaced one ring only It should use same brand name piston ring in an engine and cannot mix with other one Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase Apply with two stroke engine oil onto needle bearing and piston pin and install needle bearing into connecting rod small end Install piston and place EX mark of the piston toward to exhaust side and then install the piston pin onto piston and connecting rod Install new piston pin snap ring Clean all gaskets onto the interfaces of cylinder and crankcase Place a new gasket onto the crankcase Make sure that the piston ring aligns with the lock pin in piston ring groove A Caution Make sure that all rings in the piston ring groove cannot be rotated around the lock pin to avoid to damaging the rings piston and cylinder Top ring ie d ring Piston ring mark a 1T top ring ond _ vee
72. ingers 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 gearbox bearing as the same way above and replace it if necessary 9 6 This chapter Contents D SYM 9 Final Driving Mechanism Bearing Replacement Remove gearbox bearing from left crankcase and gearbox cover using following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 A Caution Never install used bearings Once bearing removed it has to be replaced with new one Install new bearings into left crankcase Special tool Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 Install new bearings into gearbox cover Special tool Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 Oil seal driver amp Apply with grease onto final shaft oil seal TO Zz Install the oil seal into gearbox cover K L Special tool Oil seal driver 27x42x7 SYM 9125500 a Fe Oil seal To this chapter contents 9 Final Driving Mechanism Re Assembly of Final Driving Mechanism Install drive shaft With the special service tools to install drive shaft by through the bearing Special tool R Crank shaft puller SYM 1130000 R L Crank shaft install bush SYM 1130010 Ex
73. ions e Thoroughly clean the surface where tape is to be applied e Wrap electrical tape around the damaged parts or replace them 1 General Information O Correct 1 General Information D SYM Headlight Winker switch cwitrh Speedometer High low beam switch Starter switch 3 Horn switch S S WET A oe dunra Speedometer Front brake cabf gt le es Rear brake cable Headlight Ss R dl SE a a E N SS aes Kaan kr Paan ba i M W cf BOK iO a Throttle cabi A inn inker relay L gt Main switch___ _ Regulator Horn gt Resistor ront brake hose 1 10 D SYM 1 General Information Front brake hose Speedometer cable NI OX Throttle vent fa Winker relay Rear brake cable Cc Ete A DE S ane 2 CI RS SK 1 bh Ala tti o Q LL Din xe gt Fuel unit Rear brake cable hrottle cable Front brake Lana L Ud Fuel unit cord i Fuel pump NAN Front brake hose Fuel filter 1 General Information D SYM Battery Fuse Purge control valve amp lA Ka GS N N Oil control cable AZ TAI 2 C D I UNIT Fuel hose Fuel pump Fuel filter Oil lever switch 1 12 D SYM 1 General Information Troubleshooting A Engine hard to start or can not be started Check and adjustment and Check and adjustment Faultcondition condition Probablecau
74. lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat driver if lining is clipped Remove brake lining bolt Take out the lining Tighten Torque Mounting bolt 2 9 3 5kgf m Pin bolt 1 5 2 0kgf m Pin bolt cap 0 8 1 2kgf m The brake light switch is to light up brake light as brake applied Replace the switch if the light does not light up in properly A Caution The brake light switch is un adjustable This chapter Contents D SYM 2 Service Maintenance Information Steering System Caution The control cables cannot interfere with the rotation of steering handle Lift the front wheel out of ground and check if the steering handle turning is smoothly If handle turning is uneven and bending stuck or the handle can be operated in vertical direction then adjust the handle top bearing by adjusting the steering nut Suspension A Warning Do not ride the scooter with poor suspension Looseness wear or damage suspension system will make poor stability and drive ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be repaired Tighten all nuts and bolts Rear Shock Absorber Park the scooter with its main stand Shake the rear wheel side to side to check engine suspension bushing for wear Replace
75. lightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Installation of the Left Crankcase Cover Install the dowel pin and gasket Install the left crankcase cover Install kick start arm Driven gear This chapter Contents 8 V Type Belt Drive System Kick Starter Drive Belt Removal Remove left crankcase cover Hold clutch outer with universal holder and remove nut and clutch outer Special tool Universal holder SYM 2210100 Caution e Using special tools for tightening or loosening the nut Fixed rear wheel or rear brake will damage reduction gear system Push the drive belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 16 5 mm Replace the belt if exceeds the service limit Caution e Using the genuine parts for replacement e The surfaces of drive belt or pulley must be free of grease e Clean up all grease or dirt before installation Installation Caution Install drive belt onto driven pulley Clutch drive belt Belt tooth SON SESTA Mo
76. lternator chapter 6 Cylinder head cylinder piston chapter 5 Except above components are needed be removed when disassembling L crankcase following components must be removed too Final driving mechanism chapter 8 When assembling both crankcase and crankshaft it has press the inner ring edge of the crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service tools The old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil seal has to be replaced with new one after assembled the crankcase Standard Limit mm Lateral clearance of the big end of the connecting rod 4060 Radial clearance of the big end of the connecting rod 004 Crankshaft run out point A es do Crankshaft run out point B es do Special Tools Crankcase disassemble tool SYM 1120100 G5 Outer bearing puller SYM 6204010 R Crank shaft puller SYM 1130000 R R Crank shaft install bush SYM 1130020 L Crank shaft puller SYM 1130000 L L Crank shaft install bush SYM 1130010 Extension bush SYM 1130031 long 20x31x7 Oil seal driver SYM 9120200 Bearing driver6204 SYM 9110400 Torque Values Crankcase bolt 1 0 1 5kgf m Troubleshooting Engine noise 1 Worn bearing of connecting rod bog end 2 Bend connecting rod 3 Worn crankshaft bearing 10 2 This chapter Contents O SYM 10 Crankcase Crankshaft Crankcase Disassembly
77. m Inner diameter 34 06 mm Sliding pulley Guide pin groove 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 Caution e Some of models are equipped with two ball bearings 8 12 Outer ball bearing This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Clutch Block Replacement Spring Remove clip and washer and then remove clutch 7 Ed weight and spring from drive plate Seek i AER UR Caution T Oe 4 e SS e Some of models are equipped with one mounting plate instead of 3 snap clips Check if spring is damage or insufficient elasticity Snap clip Check if shock absorption rubber is damage or Shock absorption deformation Replace it if necessary rubber Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch weight should not be greased If so replace it Caution e Grease or lubricant will damage the clutch Shock absorption rubber weight and affect the weight s connection capacity Install the spring into groove with pliers 8 13 This chap
78. n alternator charging coil 0 2 1 0Q If wire circuit check is in normal and there is no loose in the pins of regulator rectifier coupler then measure the resistance among pins on the couplers of regulator rectifier 15 6 This chapter Contents D SYM 15 Electrical Equipment Regulator rectifier Inspection Ble bile e l e emo 52210 15M0 G 27mo_ 52210 t5M0_ _1 5MO 29 2m0 29 200 300 Y 1 6MQ 26 3MQ If the resistance values are abnormal among the pins replace the regulator rectifier Caution e If the probe is touched by finger then the resistance values will be incorrect e lt contains semi conductor in circuit so the measured resistance value will be in different if different testers are used Thus these values cannot be judged with standards AC Generator Inspection Remove luggage box Disconnect the generator harness coupler Measure the resistance on charging coil the yellow to pink Resistance Measurement 20 C Charging coil yellow pink 0 2 1 0Q AC Generator harness coupler 15 7 This chapter Contents 15 Electrical Equipment D SYM Ignition System DC CDI Unit To tachometer Ignition Coil AC Generator Pulse Generator Spark plug ENG Stop switch Ignition Coil Inspection Remove lower side cover Remove ignition coil wire pins Measure the primary coil resistance Resistance 0 19 0 230 A
79. ncy will be reduced if brake lining S oy J gt is contaminated by oil or grease SH Install spring onto the brake shoes A L Install the brake shoes to the brake panel one AC after one and make sure the shoe springs are in Brake shoe spring correct position Install the wheel 12 15 This chapter Contents 12 Brake System D SYM Notes 12 16 D SYM 13 Steering Front Wheel Front Cushion Maintenance Information Front Wheel Troubleshooting Front Cushion Steering Handle Steering Stem dia 0 2 0 3kgf m 2 4 3 0kgf U 9KQI li 13 1 This chapter Contents 13 Steering Front Wheel Front Cushion D SYM Maintenance Information Specification Shaft bending 0 2 0 01 in rasa T_T 200066 Rim wobbling Torque Value 2 0 0 08 in Steering handle nut 4 0 4 5kgf m Brake master cylinder mounting bolts 1 0 1 4kgf m Front wheel axle 5 0 7 0kgf m Brake disc bolt 4 0 4 5kgf m Front cushion mounting nut 2 4 3 0kgf m Front brake caliper bolt 3 1 3 5kgf m Steering stem mounting nut 1 0 1 2kgf m Top cone race 0 2 0 3kgf m Special Tools Inner bearing puller SYM 6204022 Bearing driver 6201 Troubleshooting Hard To Steer The Front Wheel Wobbling 1 The steering shaft bolt is too tight 1 The rim is bent 2 The steering shaft bearing are damaged 2 The wheel axle nut is not tightened 3 The ball and the top cone of the steering improperly shaft are damaged 3 Bend
80. nd replace it If necessary Measure the outer diameter of drive face boss and replace it if it exceed service limit Service limit 19 98 mm Measure the inner diameter of drive face and replace it if It exceed service limit Service limit 20 120 mm Reassembly Installation Install weight rollers Install ramp plate Drive face Apply with some grease to inside of movable drive face and install drive face boss Caution e The drive face has to be free of grease Clean it with cleaning solvent Movable drive face This chapter Contents 8 V Type Belt Drive System Kick Starter D SYM Install movable drive face assembly onto Drive tace boss H crankshaft i lt Drive belt Drive Face Installation Press down Press drive belt into pulley groove and then pull the belt on to crankshaft Universal holder Install drive face washer and nut STOOL Caution e Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to specified torque Torque value 5 5 6 5kgf m Install left crankcase cover Drive face 8 10 This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Clutch Driven Pulley Disassembly Remove drive belt and clutch driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let nut be installed more easily S
81. new bottom cone race onto the steering i stem Top ball Push the cone race until to mounted position Sj bearing seat A Caution x Bottom ball bearing seat Do not tilt the ball bearing seats as installation Steel balls Apply with grease onto the ball bearing seats and install steel balls onto the seats Du Top 26 balls bottom 29 balls tom cone race i Steering lock nut Lubricate the top cone race seat with grease 3 Screw the cone race in to top ball bearing seat till touching and then screw out the cane race Return 1 2 turns 1 4 3 8 turns Torque value 0 2 0 3kgf m A Caution Check the steering stem that should be rotated freely and no clearance in vertical direction Locking to 1 4 3 8 turns Top cone race GO This chapter Contents D SYM 13 Steering Front Wheel Front Cushion Install the steering stem mounting nut and tighten Sisering stent mounting nut the nut by means of holding the top cone race body Torque value 1 0 1 2kgf m Install in reverse order of removal procedures Top cone race 13 11 D SYM 14 Rear Wheel Rear Cushion Maintenance Information Rear Wadi 14 3 Troubleshooting S Rear Cushion iii 14 5 mese SE 4 0 4 5kgf m 10 0 12 0kgf m 14 1 This chapter Contents 14 Rear Wheel Rear Cushion D SYM Maintenance Information Specification Rear wheel rim run out pe 2 0 0 08 in Torque Valu
82. nstall the right handle switch Tighten the screws 2 screws Align the lock pin of the left handle switch with the hole on the handle and then install the left handle switch Tighten the screws 2 screws Place master cylinder disc brake or brake lever bracket drum brake onto steering handle Align the lock pin on mounting holder with lock pin hole on the handle Tighten the upper part bolt and then tighten lower bolt Check hoses and cords dispose Install all components in reverse order of removal procedures Meter cord Conduct following adjustment Left handle e Oil pump control cable switch cord e Throttle operation Brake lever free play drum brake 13 4 Front brake hose Throttle cable Right handle switch cord This chapter Contents D SYM 13 Steering Front Wheel Front Cushion Front Wheel Removal Support body bottom and lift front wheel free of ground with a stand Remove speedometer cable from speedometer gear box 1 screw Remove front wheel axle nut and then pull out the axle and remove the wheel Axle nut Inspection Place the axle onto a V block to measure its run out with a dial gauge The dial gauge indicated 1 2 run out Service limit 0 20 mm Place the wheel on to a rotation seat and turn the wheel to check its bearing free play Ifthe bearing is noisy or its free play is too much replace it Wheel axle Free play 13 5 This chapte
83. nstallation Caution Do not let foreign materials into the carburetor Install the carburetor and insulator onto intake pipe with bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Connect the automatic by starter connector Install air cleaner cap Conduct following operations e Adjustment of throttle valve cable e Adjustment of oil pump e Adjustment of idle speed Reed Valve Removal Remove the luggage box Remove the carburetor Remove carburetor insulator Remove inlet pipe Remove the reed valve 4 Fuel System Fuel hose Carburetor i IN IT S upper part FAS LER e ag NI gt OI Draining screw l Connection hose clamp This chapter Contents 4 Fuel System Inspection Check the reed valve for damage and its reed strength Check the reed valve seat for crack damage and the clearance between the seat and the valve Replace reed valve if necessary Caution Do not bend the reed valve stopper Otherwise it will cause its strength insufficient and rough Reed valve engine running If the reed valve or its seat is damaged replace with a set Reed valve seat Installation Install in the reverse order of removal procedures Check for leaking after installed Carburetor Fuel Pump Inspection Remove the rear side cover Warm up the engine and adjust idle speed Remove fuel hose f
84. or rectifier No spark produced by spark plug e The spark plug is out of work e The cable is poorly connected open or short circuited Between AC G and C D I e Poor connection between C D I and ignition coil Poor connection between C D I and the main switch e Poor main switch e Poor C D I e AC G is out of work Starter motor does not work e The fuse is blown The battery is not fully charge Poor main switch Poor starter switch 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 Intermittent power supply e The coupler 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 15 Electrical Equipment Charging system does not operate properly s Burnt fuse e Poor contact open or short circuit Poor regulator e Poor AC G Engine does not crank smoothly e Primary coll circuit Poor ignition coll Poor connection of cable and couplers Poor main switch e Secondary coll circuit Poor ignition coll Poor spark plug Poor ignition coil cable Current leakage in the spark plug cap e Incorrect ignition timing Poor AC G Improper installation of the pulse sensor Poor C D I Weak starter motor
85. ow compression pressure e Damaged cylinder head gasket e Worn piston ring e Worn cylinder Probable causes for high compression pressure e Carbon on the combustion chamber or cylinder head 2 12 Pilot screw i a a b 2 Idle speed adjustment screw Adjust the idling after warn up engine for 10 minutes 4 Connect tachometer 5 Adjust the idle speed screw to let engine speed in 2000 100 rpm 6 Insert the sampling pipe of the CO HC meter to the test hole on the front end of exhaust pipe Adjust the idling emission value to standard range CO 1 8 2 6 7 Slightly accelerate the throttle valve and release it Repeat this operation for 1 2 times 8 Read the engine idle soeed and the emission value after engine speed in stable Repeat the operation on step No 2 No 4 until these value within standard range This chapter Contents D SYM 2 Service Maintenance Information Headlight Adjustment Turn the headlight adjustment bolt for adjustment its light beam Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance Headlight adjustment bolt 2 13 This chapter Contents 2 Service Maintenance Information Special Tool Manual Nameit Iaia CaseidiecssemBio R L Crank puller R Crank shaft puller No SYM 1 120100 G5 No SYM 1 130000 L No SYM 1 130000 R Nam Crankshaft install bush
86. pecial tool Clutch spring compressor SYM 2301000 Clutch nut wrench SYM 9020200 Caution s Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven Sliding pulley Oil seal pulley and then remove O ring amp oil seal seat from sliding pulley Inspection Clutch outer Measure the inner diameter of clutch outer friction face Replace clutch outer if exceed service limit Service limit 107 5 mm l diameter l Guide pin Or aaa co Clutch nut wrench Guide pin roller Clutch outer 8 11 This chapter Contents 8 V Type Belt Drive System Kick Starter D SYM Clutch weight Clutch weight Measure each clutch weight thickness Replace it if exceeds service limit Service limit 2 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 82 5 mm Free length wes Driven pulley Driven pulley Check following items If both surfaces are damage or wear e If guide pin groove is damage or wear Replace damaged or worn components Measure the outer diameter of driven pulley and the inner diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 m
87. r Front fender lt Q Left front under spoiler 11 1 This chapter Contents _ 11 Body Cover SYM Maintenance Information Body covers disassemble sequence Handle Front Cover Luggage Box Seat Handlebar Rear Cover Front Fender Front Inner Cover Left Right Side Cover Left Right Side Cover Front Inner Spoiler And Right Left Side Spoiler Assembly Left Right Rear Side Cover Under Cover Left Right Rear grip Front Fender Rear Mudguard Be careful not to damage various covers in disassembly or re assembly operation Never injure hooks molded on the body covers in disassembly or re assembly operation 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 This chapter Contents D SYM 11 Body Cover Steering Handle Cover TSE 4 screws Removal L P aS a Remove 4 screws from the handle rear cover upper Remove 2 screws from the handle rear cover under Each side 1 screws Remove 3 screws from the handle front cover under Remove front winker light electric cord couplers Remove handle front cover This chapter Contents 11 Body Cover Remove 1 screw from the handle rear cover inner tscrew Remove handle upper cover Remove 1 screw from rear by handle rear cover Remove 2 inn
88. r Contents 13 Steering Front Wheel Front Cushion 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 Bearings replacement Remove 3 bolts and brake disc Remove left side dust seal bearing and dist collar Special tools Inner bearing puller SYM 6204020 Installation Fill out the block of bearing by grease Drive the left bearing dust seal into wheel rim and install the dist collar Install the right bearing and dust seal A Caution e Carefully install the bearing in correct and evenly e Bearing outer face should be faced up as bearing installation 13 6 Bearing Dist collar Bearing Dust seal SYM 13 Steering Front Wheel Front Cushion 13 7 This chapter Contents 13 Steering Front Wheel Front Cushion Install the brake disc and then tighten the bolts disc brake Torque value 4 0 4 5kgf m ee ITEM gy x P Lubricate the soeedometer gear with grease and install the gear into the wheel hub Align the flange part on the soeedometer gear with the slot of wheel hub A Caution Contaminated brake lining will reduce brake performance so the brake lining brake drum and disc must be free of grease Apply with grease onto the left side dust seal Install the left side collar Place the front wheel
89. re worn or damaged and then clean carbon deposit on exhaust opening area as the diagram shown A Caution Do not scratch both the cylinder and the piston Use a straight edge and a feeler gauge to measure the cylinder head for warp Service limit 0 10 mm In X and Y direction measure the cylinder for worn out as the three levels shown in the figure With the maximal value to decide cylinder wear out condition Service limit 39 050mm ne 0 Measure the OD of piston at the 7 mm from the bottom of the piston Service limit 38 935 mm Calculate the clearance between piston and cylinder Service limit 0 100 mm This chapter Contents D SYM 6 Cylinder Head Cylinder Piston Measure the piston pinhole ID of piston Service limit 12 030mm The ID of piston pinhole Measure the OD of piston pin on The OD of piston pin Service limit 11 970 mm Piston Ring Inspection Measure the end gap of each piston ring Service limit 0 40 mm Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Measure the ID of connecting rod small end Service limit 17 025mm Install bearing and piston pin onto connecting rod small end and then check its clearance This chapter Contents 6 Cylinder Head Cylinder Piston Piston Cylinder Installation Install the expanding ring into the groove of 2 ring Align the ring end with the lock pin in the r
90. rom carburetor and then wait for 5 minutes Measure the output of fuel pump Its output time is 10 seconds Output quantity Min 20 c c If the output quantity is lower than 20c c check fuel hose vacuum hose and fuel filter Removal Installation Remove floor plate Remove fuel inlet outlet and vacuum hoses Remove 2 bolts and fuel pump Install the fuel pump in the reverse order of removal procedures 4 8 Ya E VEC ae E 7 i si d j H Fuel outlet This chapter Contents SYM Air Cleaner Removal Installation Remove air cleaner and rear inner fender mounting screw 4 Fuel System Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Install in the reverse order of removal procedures 4 9 This chapter Contents 4 Fuel System D SYM Notes 4 10 Contents d O G d E T 5 Engine Removal SYM 5 5 6 5kgf m 3 0kgf m ld L b Ag Engine installation c ecce c e eee 2 4 5 5kgf m 4 5 Maintenance Information Engine removal 3 1 This chapter Contents 5 Engine Removal Maintenance Information There are parts that require removal of engine for maintenance e Crankcase e Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt Engine hanger bracket bolt Rear cushion upper mounting bolts R
91. ses Probablecauses Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are s Fuel supplied tom No fuel is supplied to 3 Bae clogged carburetor sufficient carburetor 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose perform a spark test against 7 Fuel filter clogged engine ground Week sparks or no Spark at all Remove spark plug install it into spark plug cap and Malfunction of spark plug Spark plug foul 2 VAGGRILSpArS 3 Malfunction of CDI set 4 Malfunction of AC generator 5 Ignition coil is in open or short circuit 6 7 Perform cylinder compression pressure test 1 Piston ring seized Oylnder compression ne e r no pr r pe pressure normal pressure or no pressure 4 Cylinder gasket leak 5 6 Ignition coil leads open or short circuit Malfunction of main switch Sand hole in compression parts Crankcase leakage for pre compression Re start by following the 9 p E starting procedures There are some signs of Malfunction of throttle valve operation ignition but engine can Air sucked into intake manifold Remove the spark plug again and check it not be started Incorrect ignition timing Fuel level in carburetor too high Dry spark plug Wet spark plug Cee plug
92. system information All information illustration directions and specifications included in this manual are current as at the time of publication SANYANG reserves the rights to make changes at any time without prior notice and without incurring any obligation whatever Without written consent by SANYANG can not copy any part of this manual There are 4 buttons Forward How to use this manual Mechanism Illustrations and Contents on the CD R version and can be access to these items by click the mouse If user wants to look for the content of each chapter selecting the words of each chapter on the main contents can reach to each chapter There are two buttons Back to homepage and Main contents onto 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 main 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 o section of the content In addition there is a This chapter contents button at the top line of each page so that clicking the button can back to the contents of this chapter Contents Mi X Page General Information N Service Maintenance Information W Lubrication System Fuel System vi Engine R
93. t their hooks are out of slots Take out the side cover end part and then remove the cover Remove 2 screws from rear side cover Slide the rear side cover backward so that their hooks are out of slots Take out the rear side cover end part and then remove the cover Installation Install in reverse order of removal procedures A Caution The tail of each cover is held with buckles and slot never pull them with force or it would crack the buckles 11 7 This chapter Contents 11 Body Cover Center Cover Removal Remove 2 screws from center cover Slide the center cover frontward so that their hooks are out of slots Take out the center cover end part and then remove the cover Installation Install in reverse order of removal procedures Body Cover Removal Remove luggage box and center cover Remove 4 bolts from rear carrier and then remove rear carrier Remove 4 screws from right and left body cover Remove 2 bolts from the rear fender Slide the body covers and taillight backward so that their hooks are out of slots Take out the body covers and taillight end part and then remove the covers Installation Install in reverse order of removal procedures 11 8 This chapter Contents D SYM 11 Body Cover Front under Spoiler Removal Remove front cover and right left side covers Remove front wheel and front fender Remove 6 screws from the front inner box Remove 2 screws
94. tems and then check each item one by one 15 9 This chapter Contents 15 Electrical Equipment D SYM Starting System Brake light Main switch Starter relay Start switch G d Starter motor BE G Battery Starter Relay Inspection Remove battery box and then remove starter relay Connect both the green yellow and the yellow red pins to battery posts directly If the red and red white pins are also in continuity it means it is in normal Starter relay E Battery 15 10 This chapter Contents D SYM 15 Electrical Equipment Starter Motor Pinion Removal Installation Remove left crankcase cover and drive face Remove starter motor pinion holder and then remove starter motor pinion Install the starter motor pinion in reverse order of removal Starter Motor Pinion Inspection e Pinion reduction gear for wear out or damage replace it with new one e Gear journal for wear out or damage replace it with new one Check the pinion for sliding in axial direction smoothly e The pinion sliding in axial direction not in smooth replace it with new one Starter motor pinion holder z Er EI 1 5 E S E ori 5 15 11 This chapter Contents 15 Electrical Equipment Starter Motor Removal Disassembly Remove body cover Remove bolt and oil pump control cable Disconnect starter motor harness coupler
95. tension bush SYM 1130031 long Extension bush SYM 1130032 short Apply with grease onto drive shaft oil seal Install the oil seal to left crankcase Special tool Drive shaft socket amp oil seal driver 17x30x6 SYM 9120200 Install 2 dowel pins amp new gasket Install counter shaft counter shaft side washer and final shaft into the gearbox Install the gearbox cover and tighten the bolts 7 bolts Torque value 2 4 3 0kgf m Install driven pulley clutch outer belt Install movable drive face drive face and left crankcase cover Install rear wheel Add gear oil L Gear oil quantity 120c c Final shaft Counter shaft Side washer 9 8 SYM 9 Final Driving Mechanism 9 9 D SYM 10 Crankcase Crankshaft Maintenance Information Crankshaft Removal Troubleshooting Crankshaft Inspection Crankcase Disassembly Crankcase Installation Apply liquid gasket Dae AM 1 ed SLM A m gt a lt a ZA yj N s Airc Ea i YORE RS a ra lt gt IRA 10 1 This chapter Contents 10 Crankcase Crankshaft D SYM Maintenance Information This chapter concerns disassembly of the crankcase for repair purpose Before disassembling crankcase except removing engine firstly following components must be removed too Carburetor chapter 10 Oil pump chapter 3 Reed valve chapter 10 Driving belt chapter 7 A
96. ter Contents 8 V Type Belt Drive System Kick Starter D SYM Install snap clip and mounting plate onto lock pin Snap clip Replacement of Driven Pulley Bearing Remove inner bearing Outer bearing Caution f 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 clip and then the bearing Inner ball bearing Snap clip Remove snap clip and then push bearing forward Inner needle bearing to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Specified grease Outer bearing Sealing end Install new inner bearing r Inner bearin f Caution g Sealing end 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 or driver Install snap clip into the groove of drive face Align oil seal lip with bearing and then install the new oil seal if necessary 8 14 This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Installation of Clutch Driven Pulley Oil seal Assembly Install new oil seal and O ring onto sliding pulley Apply with specified grease to lubricate the inside of sliding pulley e Specified grease Install sliding pulley onto driven pulley
97. the symbols or marks Means that serious injury or even death may result if procedures are not followed Means that equipment damages may result if procedures are not followed Limits to use SAE 20 JASO FC class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil MAX 2 serial oils Grease King Mate G 3 is recommended King Mate gear oil serials are recommended Bramax HYPOID GEAR OIL 140 Gear oil Apply sealant medium strength sealant should be used unless otherwise Locking sealant a specified SED Oil seal Apply with lubricant 4 Nig ahad EE g ee O gt Indication Indication of components amie Directions Indicates position and operation directions Components assembly directions each other Indicates where the bolt installation direction means that bolt cross through the component invisibility 1 1 This chapter Contents 1 General Information General Safety Carbon monoxide If you must run your engine ensure the place is well ventilated Never run your engine in a closed area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor A Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no
98. ug heat range Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber Ignition timing too advanced Too much carbon deposited in Poor fuel quality Lean mixture combustion chamber Lean mixture 1 15 1 General Information SYM SYM 1 General Information C Engine runs sluggish especially in low speed and idling Check and adjustment Fault condition Probable causes Check ignition timing using ignition lamp 1 Incorrect ignition timing malfunction of CDI or AC generator Adjust the air screw of carburetor 2 Lean mixture tighten the screw Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground Good spark Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring E GO M Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch DIS DN D Engine runs sluggish High speed Check and adjustment Fault condition Probable causes Check ignition timing 2 Malfunction of AC generator Check for fuel supplying system in automatic fuel cup 1 Insufficient fuel in fuel tank 3 Restricted fuel tank vent Check if carburetor clogged 1 17 1 General Information SYM
99. vable driven ri 4 X HA pulley WAS ON x L c V j X na d NN LE A QY NA a N N This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Install the driven pulley that has installed the belt onto drive shaft Hold the clutch outer and then tighten nut to specified torque value Special tool Universal holder SYM 2210100 Torque value 3 5 4 5kgf m Movable Drive Face Removal Remove fan cover and fan Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Special tool Universal holder SYM 2210100 Remove drive face Drive face This chapter Contents 8 V Type Belt Drive System Kick Starter Removal Remove movable drive face set and drive belt from crankshaft Remove ramp plate Remove weight rollers from movable face Inspection The weight roller is to press movable driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wearing out or damage Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 40 mm 8 8 Drive face boss Movable drive face Weight roller Weight roller This chapter Contents D SYM 8 V Type Belt Drive System Kick Starter Check if movable drive face boss is worn or damage a
100. ve the body cover Remove the carburetor upper part throttle valve spring and sealed cap Remove the throttle valve cable from the throttle valve Remove needle clamp and fuel needle Inspection Sealed cap FI z e valve spring Needle clamp Ne Throttle valve cable Ker uel needle clip Fuel needle Carburetor upper ilan Washer i Throttle valve Installation Place the fuel needle onto the throttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve cable This chapter Contents d Fuel System Carburetor Remove Remove the rear side cover Disconnect the auto by starter coupler Loosen draining screw and then drain out fuel inside the carburetor Loosen carburetor upper part and remove carburetor upper part Remove fuel and oil hoses from carburetor Remove carburetor mounting bolt and carburetor Auto By Starter Inspection Connect resistor meter to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the auto by
101. wheel rim 4 Insufficient tire pressure 4 Side worn or poor tire 5 The bearing play of the wheel axle is too The Steering Handle Is Tilted large 1 Uneven arrangement of the front cushions 2 The front fork is bent Soft Cushion 3 The front wheel axle is bent 1 Weak front cushion spring Noise In Front Cushion 1 Cushion outer tube noise 2 The joint of the cushion gets loose 13 2 This chapter Contents D SYM 13 Steering Front Wheel Front Cushion Steering Handle Removal Remove handle cover and front cover refer to chapter 11 Remove front brake master cylinder disc brake after 2 bolts removed Remove throttle grip and right handle switch after right handle switch mounting screws removed 2 screws 2 screws Remove rear brake master cylinder disc brake after 4 bolts removed Remove rear brake lever bracket drum brake after mounting bolt removed Remove left handle switch after left handle switch mounting screws removed 2 screws 2 screws This chapter Contents 13 Steering Front Wheel Front Cushion Remove handle mounting bolt and nut and then remove the handle Installation Installs handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 4 5kgf m Apply with grease onto throttle cable and the Lock pin sliding surface of handle grip Align the lock pin of the right handle switch with the hole on the handle and then i
102. worn out 1 Cylinder head gasket leaking 2 Piston pin or piston pin hole worn out 2 Spark plug not tighten enough d Connecting rod small end bearing worn out 3 Worn seized or crack piston ring 4 Damaged worn cylinder or piston Piston Ring Noise 5 Poor reed 1 Worn seized or crack piston ring 2 Cylinder worn out or damaged Compression Pressure Too High Overheat Knock 1 Too much carbon deposit built up in combustion chamber 6 2 This chapter Contents D SYM 6 Cylinder Head Cylinder Piston Cylinder Head Cylinder Head Removal Removal luggage box body covers and center cover Remove fuel pump tubes Remove spark plug cap Remove fuel pump bracket 2 nuts Remove vacuum tube and oil pump control cable from engine shield Remove fan cover 3 bolts Remove engine shield mounting bolt 1 bolt Vacuum tube Fuel output tube Engine shield This chapter Contents 6 Cylinder Head Cylinder Piston Remove engine shield Cylinder Head Removal Remove spark plug Remove the 4 cylinder head bolts and then remove the cylinder head A Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging tt Cleaning Carbon in Combustion Chamber Clean carbon deposit in which built up in combustion chamber with shown chisel A Caution Do not scratch to the interfaces of combustion chamber and cylinder Chisel Cylinder Head Inspection Use a straight ed

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