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SERVICE MANUAL

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1. 118 Ignition timing DOC 1 1 1 goldespedchek _ fp ff 22 Throttle operation teemme Eo d 25 Carbon cleaning for cylinder X head cylinder 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 roads or in the Heavily polluted environment 2 Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage Reference 2 2 This chapter Contents 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 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
2. 7 3 Clutch Driven Pulley 7 10 Reassembly of Kick Starter 7 4 Installation of the Left Crankcase Cover TO 7 4 This chapter Contents 7 V TYPE BELT DRIVE SYSTEM KICK STARTER SYM Maintenance Information Precautions in Operation The surfaces of drive belt and driven pulley must be free of grease Specification Standard value mm ID of movable driving pulley 20 035 20 085 OD of movable driving pulley boss 20 010 20 025 19 98 OD of weight roller 15 92 16 08 o 15400 ID of clutch outer 107 0 107 2 107 5 OD of driven pulley 33 965 33 985 3394 ID of movable driven pulley 34 000 34 025 3406 ID Inner Diameter OD Outer diameter Torque Values Special Service Tools Movable drive face 3 8kgf m Clutch spring compressor Driven pulley 5 5kgf m Bearing driver Clutch outer 3 8kgf m Clutch nut wrench 39x41 mm Bearing driver accessory 39x41 mm Universal holder Driver Trouble Shooting Engine can be started but motorcycle can Insufficient horsepower or poor high not be moved speed performance 1 Worn drive Belt 1 Worn drive belt 2 Worn ramp plate 2 Insufficient spring capacity of driven pulley 3 Worn or damaged clutch weight 3 Worn weight roller 4 Broken driven pulley spring 4 Driven pulley operation un smoothly Shudder or misfire when drive 1 Broken clutch weight 2 Worn clutch weight This chapter Contents
3. No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged Float valve clogged Lines in fuel tank evaporation system clogged Malfunction of fuel pump Loosen or damaged fuel pump vacuum hose Fuel filter clogged Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression parts Crankcase leakage for pre compression Malfunction of throttle valve operation Air sucked into intake manifold Incorrect ignition timing Fuel level in carburetor too high Malfunction of throttle valve operation Throttle valve opening too wide Malfunction of auto starter 1 11 This chapter Contents 1 GENERAL INFORMATION SYM B Engine run sluggish Speed does not pick up lack of power Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1 Air cl Engine speed can Engine speed can not be 2 increased increased 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged Check ignition timing Using ignition lamp Ignition timing correct Incorrect ignition timing 1 Malfunction of CDI 2 Malfunction of AC
4. SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Left Crankcase Cover Leit crankcase conei Left crankcase cover removal Remove left body side cover Remove air cleaner Remove kick start arm Remove left crankcase cover Kick start arm Return spring 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 Kick start arm Snap ring Thrust washer Starter spindle Driven gear D Thrust washer Friction spring This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER SYM Reassembly of Kick Starter Install bush return spring and starter spindle as diagram shown Install thrust washer and snap clip onto starter spindle Install Kick starter lever temporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Return spring Width tooth Installation of the Left Crankcase Cover Install the dowel pin and gasket Install the left crankcase cover Install kick start arm 7 4 This chapter Contents SYM 7 V TYPE BELT DRIVE SY
5. 0 1 7 1 7 14 8 1 8 6 9 1 9 6 0 1 10 10 11 1 11 6 zo V IN bb 12 1 12 12 V TYPE BELT DRIVING SYSTEM KICK STARTER FINAL DRIVING MECHANISM CRANKCASE CRANKSHAFT FUEL SYSTEM BRAKE SYSTEM BODY COVER 13 1 13 12 14 1 14 4 1 5 1 15 20 16 1 16 2 STEERING FRONT WHEEL SUSPENSION REAR WHEEL SUSPENSION ELECTRICAL EQUIPMENT ELECTRICAL DIAGRAM 1 PEPER on BUM ms SYM MODEL ILLUSTRATION FA05U Light Starter switch CNC Rear turn signal D a se 105 t lt D l on Front turn signal Rear turn signal LA N Helmet hook High amp Low beam Turn signal Horn switch Fuel tank cap Head light Frame number Storage box Seat lock Tail light Air cleaner Ignition switch Muffler Engine number SYM 1 GENERAL INFORMATION Symbols and Marks 1 1 Torque 1 6 General Safety 1 2 Cables and Harness Routing 1 8 Service Precautions 1 3 Troubleshooting 1 11 Specifications Lubrication Points 1 15 Symbols and Marks oymbols and marks are used in this manual to indicate what and where the special s
6. 12 2 This chapter Contents SYM Side Covers 1 Removal e Remove 2 screws front middle from two side covers Slide the side cover backward so that and remove the side cover 2 Installation e Install in reverse order of removal procedures Luggage Box 1 Removal e Lift up seat cushion e Remove luggage box bolts 4 bolts e Remove oil tank cap and oil guide rubber Hold the luggage box in both front and rear sides by two hands and then lift up the box to remove it 2 Installation e Install in reverse order of removal procedures 12 BODY COVER Screws Oil tank cap 12 3 This chapter Contents 12 BODY COVER Body Cover 1 Removal Remove 4 bolts from rear carrier and then remove rear carrier e Remove the luggage box e Remove 4 screws from the two side cover and then remove the side cover Screws e Remove 1 screw from the front side 12 4 SYM 12 BODY COVER Remove the seat catch cable Seat catch cable e Remove the tail light power line attachment e Remove the body cover 2 Installation e Install in reverse order of removal procedures 12 5 This chapter Contents 12 BODY COVER Front Cover 1 Removal e Remove 12 screws from the inner cover side Screws e Remove 1 screw from the front cover Push the front guard up and then remove it 2 Installation e Install in reverse order of removal
7. Remove rear brake lever mounting nut and bolt Remove brake lever and cable Remove front and rear brake lever bracket mounting bolt Remove left handle switch left handle grip and rear brake lever bracket 13 4 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Remove handle holder bolt plug Remove handle holder 4 bolts then remove handle holder Remove handle and front brake lever bracket Installation Install handle and align with bolt hole Install bolt and then tighten it Torque value 1 8 2 5kgf m Apply with grease onto throttle cable and the sliding surface of handle Align the lock pin of the handle outer tube with the hole on the handle and then install the handle Tighten the bolt Caution Align the lock pin with the hole on the handle and also install brake lever seat Then tighten the lever with clamp and bolt Conduct following adjustment e Oil pump control cable e Throttle operation Brake lever free play This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Front Wheel _ Front brake cable Removal 4 Remove speedometer cable 1 screw Remove front brake cable Remove right and left pivot arm covers 2 bolts Remove front wheel axle nut and then pull out the axle then remove the wheel 13 6 This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Inspection Place the axle onto a V block to m
8. SERVICE MANUAL SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SANGANG Fiddle 50 series scooter The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter Fiddle 50 series are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department Sanyang Industry Co LTD How to Use This Manual SYM This service manual describes basic information of different system parts and system inspection amp service for Sanyang Fiddle 50 scooters In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information Th third to the tenth nine chapters covers engine and driving systems The tenth to the fourteenth is contained the parts set of assembly body The fifteenth chapter is electrical equipment The sixteenth chapter is wiring diagram Please see index of content for quick having the special parts and system information All information illustration directions and specifications included in this manual are c
9. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side Remove final gear final shaft and counter gear counter shaft Remove the drive shaft from left crankcase A Caution The bearing must be replaced when removing the drive shaft Remove drive shaft oil seal and bearing from left crankcase Mounting bolts PS Final gear amp shaft Cil seal Cil filling hole __ Counter gear amp shaft This chapter Contents 8 FINAL DRIVING MECHANISM Inspection of Final Driving Mechanism Check if the drive shaft counter shaft and final gear shaft are worn or damage Check if the gear box cover bearing oil seal and the inner diameter of counter shaft are worn or damage Check if the left crankcase cover bearing oil seal and the inner diameter of countershaft are worn or damage Bearing Replacement A Caution e Never install used bearings Once bearing removed it has to be replaced with new one Remove gear box bearing from left crankcase and gear box cover using following tools Special tool Inner type bearing puller Re Assembly of Final Driving Mechanism Re assemble the gearbox cover and left crankcase with special tools Special tool Gear Box Cover Final shaft bearing Bearing driver 6203 6004UZ SYM 9620000 Bearing driver 6201 SYM 9610001 Final shaft oil seal installer SYM 9125500 Left Crankcase Drive shaft bearin
10. This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Piston Ring Inspection Measure the end gap of each piston ring Service limit 0 40 mm A Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end and then check its clearance Measure the ID of connecting rod small end Service limit 17 025mm Piston Cylinder Installation Install the expanding ring into the groove of 2 ring Align the ring end with the lock pin in the ring groove Install the top ring and the 2 ring onto the ring groove respective A Caution c The top ring and the 2 ring can be L changeable each other 1T top ring 2T 2 ring 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 can not be replaced one ring only It should use same brand name piston ring in an engine and can not mix with other one 5 7 This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM 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 pis
11. check the shaft on bearing Damage may result if the tool is which the oil seal is to be installed for pressed against only one race either inner race smoothness and for burrs that may damage the or outer race In this case the bearing should oil seal be replaced To avoid damaging the bearing use equal force on both races __ Manufacturer s e Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage Both of these examples can result in bearing damage e Lubricate the rotation face as assembling Check if positions and operation for installed parts is in correct and properly This chapter Contents SYM 1 GENERAL INFORMATION Specifications SANYANG FA05 Series 1680 mm TELESCOPIC 750 mm System UNIT SWING 1070 mm Tire 3 00 10 42J T L 1170 mm 3 00 10 42J T L 33 kg Overall Length Overall Width Overall Height DIMENSION gt z UJ D O a Brake Front DRUM y 110mm 9 System 83 kg DRUM y 95mm Two 110 kg Max Speed 48 km hr Below WEIGHT 55 kg 138 kg Climb Ability 20 Below Primary Reduction BELT C g O 193 Secondary Gasoline Centrifugal dry type Vertical below center cline Transmission C V T Unleaded 92 95 Speedometer 0 90 km hr 2 stroke forced air H rn 93 112 dB A cooled 39 mm Muffler Expansion amp Pulse Type 41 4 mm Exhaust Pipe
12. 9 Apply liquid gasket 9 1 This chapter Contents 9 CRANKCASE CRANKSHAFT SYM Maintenance Information e This chapter concerns disassembly of the crankcase for repair purpose Before disassembling crankcase except removing engine firstly following components must be removed too e Carburetor chapter 10 e Oil pump chapter 3 e Reed valve chapter 10 Driving belt chapter 7 Alternator chapter 6 e Cylinder head cylinder piston chapter 5 e Except above components are needed be removed when disassembling L crankcase following components must be removed too e Final driving mechanism chapter 8 e 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 Limit mm Lateral clearance of the big end of the connecting rod 0 60 Radial clearance of the big end of the connecting rod 0 04 Crankshaft run out point A 0 10 Crankshaft run out point B 0 10 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 1 130020 L Crank shaft puller SYM 1130000 L L
13. Crank shaft install bush SYM 1130010 20 32 6 Oil seal driver SYM 9120200 Bearing driver 6204 SYM 91 10400 Troubleshooting Engine noise 1 Worn bearing of connecting rod bog end 2 Bend connecting rod 3 Worn crankshaft bearing ic chapter Contents 9 CRANKCASE CRANKSHAFT SYM Crankcase Disassembly Remove the crankcase bolts Install the crankcase puller onto the right crankcase with two 2 bolts 6mm as the diagram shown Disassemble the right crankcase Crankshaft Removal As the diagram show with 3 special bolts to install the crankcase puller onto the left crankcase Remove the crankcase Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with outer bearing puller Remove the right and left side oil seals Caution Replace the oil seal with new one as removing the crankshaft n 908 Special bolts Shaft protection collar 9 3 This chapter Contents 9 CRANKCASE CRANKSHAFT SYM 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 it with hand If any n
14. This chapter Contents SYM 12 BODY COVER Under cover 1 Removal e Remove right left side covers e Remove under cover right left side 4 bolts e Remove the under cover 4 bolts 2 Installation e Install in reverse order of removal procedures Rear fender Removal e Remove right left side cover e Remove rear carrier e Remove luggage box e Remove body cover e Remove ignition coil e Remove 2 nuts from after rear fender e Remove 1 bolt from front rear fender then remove the rear fender 2 Installation e Install in reverse order of removal procedures 12 BODY COVER SYM Note 12 12 SYM 13 STEERING FRONT WHEEL SUSPENSION Maintenance Information Front Wheel Troubleshooting Front Cushion Steering Handle Front Fork B el a 0 25kgf m gt gt 8 2 5kgf m f ry 4 0 5 0kgf m gt i P if Pi 2 4 3 0kgf m i aii y y c ES E ta 2 4 3 0kgf m ee 4 CUTEM is N N The _ 13 1 _ This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION Maintenance Information Specification SYM Sandra vai om Uni Rim wobbling 0 2 0 01 in 2 0 0 08 in Torque Value ard o Steering handle post nut 4 0 5 0kgf m Front fork pivot arm nut 2 4 3 0kgf m Front wheel axle nut 5 0 7 0kgf m Steering stem lock nut 1 5kgf m Fron
15. Warm up the engine and adjust idle speed ZO Remove fuel hose from carburetor and then wait for 5 minutes Measure the output of fuel pump Its output time is 10 seconds Output quantity Min 20 c c If the output quantity is lower than 20 c c check fuel hose vacuum hose and fuel filter Removal Installation Remove floor plate Remove fuel inlet outlet and vacuum hoses Remove 2 bolts and fuel pump Fuel inlet V T Install the fuel pump in the reverse order of hose removal procedures 10 8 This chapter Contents SYM 10 FUEL SYSTEM Air Cleaner Removal Installation Remove the EEC hose from the air cleaner set Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner set Install in the reverse order of removal procedures b Install the air cleaner outer case oun screws X 5 10 9 10 FUEL SYSTEM SYM Notes 10 10 SYM 11 BRAKE SYSTEM Front Drum Brake System Troubleshooting Rear Drum Brake System Drum Brake Maintenance Information Front Drum Brake System 11 1 11 BRAKE SYSTEM SYM Rear Drum Brake System 11 0kgf m 2 9kgf m 0 55kgf m This chapter Contents SYM 11 BRAKE SYSTEM Maintenance Information Precautions in Operation 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
16. 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 7 041 kg cm Probable causes for low 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 SERVICE MAINTENANCE INFORMATION Pilot screw Idle speed adjustment screw Adjust the idling after warn up engine for 10 minutes 1 Connect tachometer 2 Adjust the idle speed screw to let engine speed in 2000 100 rpm 3 Insert the sampling pipe of the CO HC meter to the test hole on the front end of exhaust pipe Adjust the idling emission value to standard range CO 1 8 2 6 4 Slightly accelerate the throttle valve and release it Repeat this operation for 1 2 times 5 Read the engine idle speed and the emission value after engine speed in stable Repeat the operation on step No 2 No 4 until these value within standard range Compression pressure gauge 2 11 This chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Headlight Adjustment Loosen headlight mounting bolt Move the headlight for adjustment its light beam Tighten the headlight mounting bolt af
17. chapter Contents 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 Dirty brake lining 4 Brake seized caused from dirty brake drum 5 Seized brake cable Worn brake cam 7 Improper brake lining installation CO SYM 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 This chapter Contents SYM 11 BRAKE SYSTEM 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 be reduced by grease on brake lining Remove wheel and brake drum Inspection Check brake drum for damage or wear out and replace it if necessary Measure the inner
18. diameter of brake drum and record the max value Allowable limit Front 110 5mm Rear 95 5mm Caution Clean the rust onto the brake drum with 120 sand paper Measure the inner diameter of brake drum with micrometer Measure the thickness of brake lining at three points both ends and center If the thickness is less than specified value or if it is contaminated by oil or grease replace as a set Service limit Rear 2 0 mm Removal Caution Brake linings must be replaced as a shoes Remove the brake linings from brake panel 11 5 This chapter Contents 11 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 Rear brake arm Brake efficiency will be reduced if brake linings is contaminated by oil or grease Install the brake cam and arm after aligning it with the punched point Tighten the bolts and nuts to specified torque Torque value 0 5kgf m Brake arm big indent Wear indicator plate Brake arm Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated Caution Brake efficiency will be reduced if brake linings is contaminated by oil or grease Install spring onto the brake shoes Install the brake shoes to the brake
19. generator Check cylinder compression pressure using compression pressure gauge 1 Cylinder amp piston ring worn out 2 Cylinder gasket leaked 3 Sand hole in compression parts 4 Valve deterioration 5 Crankcase leakage for Check if carburetor is pre compression clogged Remove spark plug No foul or discoloration Fouled and discoloration 1 Remove dirt 2 Incorrect spark plug heat range Check if engine over heat Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber B odi Continually drive in 5 Ignition timing too advanced acceleration or high speed 1 Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality 4 Lean mixture oN 1 12 This chapter Contents SYM 1 GENERAL INFORMATION C Engine runs sluggish especially in low speed and idling Check and adjustment Probable causes Fault condition Check ignition timing using ignition lamp Adjust the air screw of carburetor 1 Incorrect ignition timing malfunction of CDI or AC generator Rich mixture loosen the screw Lean mixture tighten the screw Air sucked through carburetor gasket leads 6 Malfunction of main switch 1 Poor heat insulation gasket 3 Poor intake gasket Remove spark plug install 4 Poor carburetor O ring spark plug into spark plug cap and perform spark test against engin
20. one of the problems takes place 1 The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction 2 The charging voltage and current are too much higher than the standard values The following problems are not related to the charging system correct it if any by following steps indicate in the checking list 1 The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rom Bulbs used exceed their rate and consume too much power replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not replacement battery is aged and does not have enough capacity Battery used do not have enough electricity or is over charged fuse of the ammeter is blown ammeter is improperly connected 3 The charging current is normal but the voltage is not fuse of the voltmeter is blown This chapter Contents SYM Headlight Voltage Inspection Do not disconnect the headlight harness coupler after engine started Turn the headlight ON and to high beam position Measure the voltage between the blue wire and green wire while the headlight harness is still in connection Measure alternating current voltage with a voltmeter Gradually increase engine speed and read the voltage in each specif
21. 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 e Motorcycle s exhaust gas includes with CO which causes human to coma or death so perform this operation in well ventilation place e Run the engine in extreme low speed to avoid to damaging the engine caused from clogged oil tube 3 4 This chapter Contents SYM Oil Tank Removal Installation Remove the battery and oil tank cap Remove the luggage box and seat Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil level switch wire of the oil indicator Remove the mounting nut and bolt on the oil tank two side and then remove the oil tank Installation in the reverse order of removal Air bleeding the oil tubes after installed 3 LUBRICATION SYSTEM Cil tank cap This chapter Contents 3 LUBRICATION SYSTEM SYM Notes 3 6 SYM 4 ENGINE REMOVAL Maintenance Information 4 2 Engine installation 4 5 Engine aaa 4 3 3 3kgf m This chapter Contents 4 ENGINE REMOVAL SYM Maintenance Information There are parts that require removal of engine for maintenance e Crankshaft Relat
22. panel one after one and make sure the shoe springs are in correct position Install the wheel 11 6 SYM 12 BODY COVER Body Overview Front Spoiler Maintenance Information Floor Panel Side Covers Front Fender Luggage Box Front Inner Box Body Cover Under cover Front Cover Rear fender Body Overview Battery cover Luggage box Body cover garnish Right side cover MI i r fa ut 7 Left body cover gy y Pi E Handle up cover ws Front inner box s E L FR Cover molding R FR Cover d Left side cover Under cover ARIA orte j stripe CN UN Front fender B Floor panel mat Front fender A 12 1 12 BODY COVER SYM Maintenance Information Body covers disassemble sequence Left Right Side Cover Luggage Box Seat Left Right Side Cover Front Fender B Front Fender A Body Cover Front Under Spoiler Front Inner Cover Center Cover Left Right Side Cover Rear Fender Floor Panel e 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 e Align the buckles on the guards with slot on the covers e Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly
23. procedures 12 6 This chapter Contents SYM 12 BODY COVER Front Spoiler 1 Removal e Remove the front cover and right left side cover e Remove 2 screws from the front inner box e Remove the front spoiler 2 Installation e Install in reverse order of removal procedures 12 7 This chapter Contents 12 BODY COVER Floor Panel 1 Removal Remove the luggage box rear carrier right left side covers and body cover e Remove the floor panel mat e Remove the floor panel 4 bolts 2 Installation e Install in reverse order of removal procedures 12 8 This chapter Contents SYM 12 BODY COVER Front Fender 1 Removal e Remove right left side 4 screws of front fender diat Screws Downward pulls causes card tenon to be separated from front fender A e Remove the front fender e Remove the front fender 2 Installation e Install in reverse order of removal procedures This chapter Contents 12 BODY COVER Front Inner Box 1 Removal e Remove the front cover e Remove the front under spoiler e Remove 2 bolts from the floor panel e The counter clock revolves main switch cap and remove it Main switch cap e Remove fuel tank cap and rubber e Open the inner box lid Remove 1 nut e Remove winker relay e Remove the front inner box 2 Installation e Install in reverse order of removal procedures 12 10
24. rear shock absorber upper lower bolts Torque value Engine hanger bolt 5 0kgf m Rear shock absorber upper mounting bolts 4 0kgf m Rear shock absorber lower mounting bolts 2 7kgf m Exhaust pipe connection nut 1 2kgf m Muffle mounting bolt 3 3kgf m Perform the following inspection and adjustment after installation 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 Adjust rear brake 4 5 4 ENGINE REMOVAL Note This chapter Contents SYM SYM 5 CYLINDER HEAD CYLINDER PISTON Maintenance Information 5 2 Cylinder 27 5 3 Troubleshooting 5 2 Cylinder Piston sss 5 5 This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM Maintenance Information Precautions in Operation 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 Specifi
25. the element onto the element seat and then install the air cleaner cover Limit to use SAE 20 JASO FC class engine oil otherwise SYM is no responsible for the warranty e Recommended engine oil MAX 2 serial oils Squeeze oil out Fuel Lines Remove the body cover Check fuel lines and replace damaged lines if found Install the body cover Squeeze out remaining oil Fuel line 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 Check the engine oil line and replace damaged Engine oH pipe parts Oil pump Remove the filling pipe from the oil pump and drain oil into a cleaning container Loosen the clamp under the engine oil tank and then remove the oil pipe Bleed the air inside the oil pump and oil pipe if air found Install the body cover 2 4 This chapter Contents 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 body cover Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump body T the adjustment nut of the oil pu
26. upper part Removal Remove 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 Throttle valve spring Sealed cap r Needle clamp Throttle valve cable Fuel needle clip Fuel needle Carburetor upper part Washer Throttle valve Installation Place the fuel needle onto the throttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Install carburetor protector Adjust the free play of throttle valve cable 10 3 10 FUEL SYSTEM SYM Carburetor Remove Remove the luggage box and body cover Disconnect the auto by starter connector Auto by starter Loosen draining screw and then drain out fuel Carburetor inside the carburetor M KL 7 Upper part Loosen carburetor upper part and remove Tig 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 th
27. Movable drive face Weight roller This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Install movable drive face assembly onto Drive face boss Movable drive face crankshaft Drive Face Installation Press drive belt into pulley groove and then pull the belt on to crank shaft Drive belt Press down Install drive face washer and nut A 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 Qe i a Flywheel di M Tighten nut to specified torque Torque value 3 8kgf m Install left crankcase cover This chapter Contents 7 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 A Caution Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven pulley and then remove O ring amp oil seal seat from sliding pulley Sliding pulley Inspection Clutch outer Measure the inner diameter of c
28. PENSION Maintenance Information Specification Rear wheel rim run out pw 2 0 0 08 in Torque Value 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 Rear wheel hub 2 3 2 7kgf 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 gt Io 14 2 This chapter Contents SYM 14 REAR WHEEL SUSPENSION Rear Wheel Remove Remove AICV system hose Remove exhaust pipe nuts 2 nuts Remove exhaust muffler bolt 2 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Shaft nut Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Brake Hub Replacement Hub nut Remove 4 nuts of cover and wheel rim and then remove the wheel hub Install the wheel hub and tighten the nuts Tighten torque 2 3 2 7kgf m 14 3 This chapter Contents 14 REAR WHEEL SUSPENSION Installation Shaft nut Install the rear wheel and tighten the nut T
29. Position Right side and Backward and Direction Single Cylinder Lubrication System Separated lubrication 49 4 cc CO Below 1 2 g km 7 1 1 2 1 kw 6750 rpm Below 1 0 g km Electrical amp kick Catalytic reaction control System PERFORMANCE Installation and arrangement Fuel Used Cycle Cooling Bore Stroke Cylinder Number Arrang ement ENGINE lon Displacement Compression Ratio Max HP Max Torque gt 2 C x O c O Ignition Starting System 1 This chapter Contents 1 GENERAL INFORMATION SYM Torque values Standard Torque Values for Reference 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 Crankcase bolts 1 6 This chapter Contents _ SYM 1 GENERAL INFORMATION Frame Thread Dia Torque Value Item Remarks mm Kgf m Mounting screws for exhaust pipe connection Brake hose bolts wm res _ Brake cushion guide bolts eme pa fe o __ s oo o a AA Le ___ ____ ___ _ ce ____ 25 ____ 1 7 This chapter Contents 1 GENERAL INFORMATION Cables and Harness Routing Note the following when routing cables and wire harnesses A loose wire cable or harness may ca
30. Remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and side electrode should have Center electrode constant thickness Replace the spark plug if there is apparent wear or if the insulator is cracked and or chipped If the spark plug deposits can be removed by sandpaper the spark plug can be reused Measure the spark plug gap with feeler gauge Spark plug gap 0 6 0 7mm 0 024 0 028in Adjust the gap by careful bending the side electrode 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 9 This chapter Contents 2 SERVICE MAINTENANCE INFORMATION Control Cable Lubrication Remove the throttle control and the brake cables periodically and lubricate the moving parts of the Tooth face 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 l ignition timing can not be adjusted If the ignition timing is incorrect check the C D I device and the alternator and replace damaged components Check ignition timing with standard instrument Hemowve the right sid
31. STEM KICK STARTER Drive Belt Removal Remove left crankcase cover Hold clutch outer with universal holder and remove nut and clutch outer A 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 A Caution e Using the genuine parts for replacement The surfaces of drive belt or pulley must be free of grease e Clean up all grease or dirt before installation Installation A Caution e Pull out driven pulley to avoid it closing Install drive belt onto driven pulley i Universal holder Clutch drive belt Belt tooth This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Install the driven pulley that has installed the belt Drive face onto drive shaft Install the clutch with universal holder and then tighten nut to specified torque value Torque value 3 8kgf m Movable Drive Face Removal Remove left crankcase cover Hold gener
32. a Clutch spring 2700 compressor SYM 8 FINAL DRIVING MECHANISM Maintenance Information 8 2 Inspection of Final Driving Mechanism Troubleshooting 8 4 Disassembly of Final Driving Mechanism Bearing Replacement 8 4 8 3 Re Assembly of Final Driving Mechanism 8 4 6 1 This chapter Contents 8 FINAL DRIVING MECHANISM Maintenance Information Limited usage of gear oil gear oil 140 Recommended Bramax serial oil Oil quantity 100 c c 90 c c as replacement Special tools Inner type bearing puller SYM 6204020 Outer type bearing puller SYM 6204010 Final shaft oil seal installer SYM 9125500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6204 SYM 9110400 Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 L crank puller SYM 1130000 L L crank shaft install bush SYM 1130010 Troubleshooting Trouble Diagnosis Engine can be started but scooter can not be moved 1 Damaged drive gear 2 Burnt out or seized drive gear Noise 1 Seized worn or damage gear 2 Worn or loose bearing Gear oil leaks 1 Excessive gear oil 2 Worn or damage oil seal SYM This chapter Contents SYM 8 FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove driven pulley Drain gear oil out from gearbox Remove rear wheel
33. ad Removal 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 it 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 This chapter Contents 5 CYLINDER HEAD CYLINDER PISTON SYM Cylinder Head Inspection Use a straight edge 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 0kgf m Install spark plug Tighten torque 1 4kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut Tighten torque 1 2kgf m Tighten exhaust pipe mounting bolt Tighten torque 3 3kgf m Install the removed parts in the reverse order of removal procedures Inspect following item after installation Compression pressure test Check for engine noise 5 4 This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Cylinder Piston Cylinder Removal Be careful to pull the cylinder up and prevent piston from damage A Caution Do not have pry out operation between cylind
34. age replace it with new one e Gear journal for wear out or damage gt replace it with new one Check the pinion for sliding in axial direction smoothly The pinion sliding in axial direction not in smooth replace it with new one 15 12 Starter relay Starter motor pinion This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Starter Motor Removal Disassembly Remove body cover Remove bolt and oil pump control cable Disconnect starter motor harness coupler Remove 2 bolts for separation starter motor and gasket Remove 2 bolts for disassembly the starter motor Armature Motor housing Spring Carbon bracket Front bracket Armature Inspection Check the armature for discoloration or other damage It may be short circuit if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces t can be in continuity among the shifter surfaces but both the shifter surface and the shaft can not be in continuity Starter Motor Re Assembly Installation Re assemble and install the starter motor in reverse order of removal procedures 15 13 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Oil Level Switch Troubleshooting Main switch Fuse fthe oil level in oil tank is in specified level TR f but the oil level indi
35. area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verified We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off 1 2 SYM Battery Caution Battery emits explosive gases flame is Strictly prohibited Keep the place well ventilated when charging the battery e 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 flus
36. arter motor Poor charging system The battery is not fully charged Poor connection in the windings The motor gear is jammed by foreign material Starter motor is working but engine does not crank Poor starter motor pinion e he starter motor run in reverse direction Poor battery 15 3 This chapter Contents 15 ELECTRICAL EQUIPMENT Battery Negative terminal Battery Removal Installation Turn off main switch Open seat Remove screw 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 Voltage Check Open seat and battery cover Remove wires from battery Check battery voltage Voltage Fully charged 13 0 13 2V Undercharged 12 V Charging Remove the battery Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard charging current time 0 4A 5 hrs Fast charging current hrs 4A 0 5 hr Caution Strictly keep flames and sparks away while recharging to avoid to explosion causing by hydrogen Stop charging battery when electrolyte temperature is over 45 C 117 F Caution Fast charging the battery is for in emergency only Battery should be charged in standard 15 4 SYM Positive te
37. as installation and then turn the snap ring in CW 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 Float position Resistance value Up full 3 100 Down empty 90 1000 Check the fuel indicator if the resistance is in normal Replace the fuel gauge if the resistance is abnormal 15 ELECTRICAL EQUIPMENT Fuel unit Fuel unit plastic 15 15 This chapter Contents 15 ELECTRICAL EQUIPMENT Switch Horn Remove front cover Check continuity on each switch The connected circles with a line are that they should be in continuity Main Switch Wire Black dor Green Rea ete OFF _ Main switch coupler Left Handle Switch light switch High low beam switch Winker light Horn switch Light green Horn switch High Low beam switch This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Right Handle Switch salt La Headlight switch Wire color OFF Starter switch Starter Switch PUSH _ Front Rear Brake Light Switch If the switch is in continui
38. ator Speedometer cable Front brake cable Throttle cable Front brake cable Rear brake cable Speedometer cable This chapter Contents 1 GENERAL INFORMATION SYM CDI unit Ignition coil Thermo switch unit Power filter unit ASS Y Air injection cut valve ACG amp Start relay connector Thermo switch connector Thermo switch 1 10 This chapter Contents SYM 1 GENERAL INFORMATION Troubleshooting A Engine hard to start or can not be started Loosen carburetor drain bolt Check and adjustment Fault condition Probable causes to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to 3 carburetor sufficient carburetor 4 Remove spark plug install it into spark plug cap and perform a spark test against engine ground Week sparks or no spark Check if sparks at all Perform cylinder compression pressure test 1 2 cylinder compression pressure normal Low compression pressure or no pressure 3 4 Re start by following the starting procedures 6 mM There are some signs of 1 No ignition ignition but engine can 2 not be started 3 Remove the spark plug again and check it Dry spark plug Wet spark plug 2 3 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 N pr ode m YS
39. ator flywheel with universal holder and then remove drive face nut Remove drive face 7 6 Drive belt Drive shaft This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Removal Drive face boss Movable drive face Remove movable drive face set and drive belt from crankshaft Remove ramp plate Remove weight rollers from movable face Movable drive face Weight roller Inspection The weight roller is to press movable driven face Weight roller by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wear out or damage Replace it if necessary Measure each roller s outer diameter Replace it if exceed the service limit Service limit 15 40 mm This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Check if movable drive face boss is worn or damage and replace it if necessary Measure the outer diameter of drive face boss and replace it if it exceed service limit 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 Ramp plate Apply with grease 4 5g to inside of movable Dilve face drive face and install drive face boss A Caution e The drive face has to be free of grease Clean it with cleaning solvent 7 8 SYM
40. brake oil can also damage the structural integration of plastic or rubber parts 1 3 This chapter Contents 1 GENERAL INFORMATION SYM e The length of bolts and screws for assemblies The ends of rubber hoses for fuel vacuum or cover plates or boxes is different from one coolant should be pushed as far as they can go another be sure they are correctly installed In to their connections so that there is enough case of confusion Insert the bolt into the hole to room below the enlarged ends for tightening the compare its length with other bolts if its length clamps out side the hole is the same with other bolts it is a correct bolt Bolts for the same assembly should have the same length e Rubber and plastic boots should be properly reinstalled to the original correct positions as designed 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 e he tool should be pressed against two inner grease install the oil seal with the name of the and outer bearing races when removing a ball manufacturer facing outside
41. buretor Installation u Carburetor Caution JOD 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 Draining screw Connect the automatic by starter connector Install air cleaner cap Conduct following operations Adjustment of throttle valve cable Adjustment of oil pump e Adjustment of idle speed Reed Valve Removal Remove the body cover Remove the carburetor Remove carburetor insulator Remove inlet pipe Remove the reed valve 10 7 chapter Contents 10 FUEL SYSTEM Inspection Check the reed valve for damage and its reed strength Check the reed valve seat for crack damage and the clearance between the seat and the valve Replace reed valve if necessary Caution Do not bend the reed valve stopper Otherwise it will cause its strength insufficient and rough engine running If the reed valve or its seat is damaged replace with a set Reed valve Reed valve seat Installation Install in the reverse order of removal procedures Check for leaking after installed H NE s F gt p fy V Inlet pipe E Fuel Pump Carburetor Inspection Remove the body cover a5 connector
42. cation Standard value mm Limit mm 39 030 39 045 0 040 0 050 12 002 12 008 11 994 12 000 Pj i 11 970 Clearance between piston and piston pin 0 002 0 014 iston ring end gap 0 100 0 250 D of connecting rod small end 17 05 17 015 0 400 17 025 Cylinder D 5 89 000 39 015 39050 Deformation 1 o 2 A 9010 ID inner diameter OD outer diameter Tighten torque value Cylinder head 1 0kgf m Exhaust pipe connection nut 1 2kgf m opark plug 1 4kgf m Exhaust muffler mounting bolt 3 3kgf m Troubleshooting Compression Pressure Too Low Difficult Piston Noise To Start Rough Idling 1 cylinder and piston worn out 1 Cylinder head gasket leaking 2 piston pin or piston pin hole worn out 2 Spark plug not tighten enough 3 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 This chapter Contents SYM 5 CYLINDER HEAD CYLINDER PISTON Cylinder Head Tightening bolt Cylinder Removal Removal body covers Remove spark plug cap Remove fan cover Remove engine shield Remove two connection nuts of the exhaust pipe Remove exhaust muffle mounting bolt and then remove the exhaust pipe Cylinder He
43. cator still goes on 1 Remove body cover 2 Disconnect oil gauge wire and turn the Indicator main switch to ON position Indicator light up Indicator not light up level Wh Short circuit between Malfunction of oil indicator and oil gauge gauge Main switch lf there is no oil in oil tank or low oil level but the oil level indicator still not goes on 1 Remove body cover 2 Disconnect oil gauge wire and connect a jump wire among coupler and then turn the main switch to ON position Indicator not light up Indicator light up Indicator Poor wire connection Malfunction of oil gauge 3 Disconnect oil gauge coupler and check voltage between wire and ground No voltage Voltage Open circuit between e Malfunction of oil oil gauge and gauge Oil level switch Poor connection of oil gauge indicator Blown bulb Removal Installation Remove oil tank Remove oil level switch from the oil tank Install the oil level switch in reverse order of removal procedures 15 14 This chapter Contents SYM Fuel Unit Removal Installation Remove 4 bolts and floor panel Disconnect fuel unit coupler Remove the fuel unit plastic cap Turn the snap ring in CCW direction and then remove the fuel unit Caution Do not bend the float arm Install in reverse order of removal procedures Remark Aligning the slot of fuel unit with the ring of oil tank
44. clip and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its seal end should be forwarded to outside Apply with specified grease Install new inner bearing A Caution Inner bearing Seal 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 7 13 This chapter Contents 7 TYPE BELT DRIVE SYSTEM KICK STARTER Installation of Clutch Driven Pulley Assembly Install new oil seal and O ring onto sliding pulley Apply with specified grease to lubricate the inside of sliding pulley Install sliding pulley onto driven pulley Install guide pin and guide pin roller Install socket Install driven pulley spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch driven pulley and drive belt onto drive shaft 7 14 Specified grease Oil seal Guide pin Socket Clutch nut E wrench M e o
45. der Compression Pressure Test 9 11 Steering System suus 2 8 Headlight Adjustment 2 12 General Information Specification Front 3 00 10 42 Rear 3 00 10 42J Front 1 5kg cm Tire pressure at Only rider Rear 2 25 kg cm Front brake lever free play 10 20 mm Rear brake lever free play 10 20 mm Type HYPOID GEAR OIL Transmission oil Recommendation Oil SAE 140 Quantity 0 1 L EET T Standard 18 0mm Driving belt width Allowable limit replace it if below 16 5mm Cylinder compression pressure This chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Periodical Maintenance Schedule Maintenance 300KM Every Every Every Every kilometer 1000KM 3000KM 6000KM 12000KM Check item Maintenance New 1 month month 6 month 1 year interval t 1 _ R ___ erg toe Engine oilfitercleaning 4 Oil pump linkage operation ees S Trepessue J l 6 Battery inspection 1 11 8 Steering handle check L B Cushion operation check 10 Every screw tightening check Fit Gear of eheck orleaing Ib 12 Sparkplugcheckorchange 1 13 Gear oil cnange Replacement for every 5000km 14 Frame lubrication J S e _____ 15 Exhaustpipe _____ 1 _ 16 Carburetor 1 _
46. e careful not to let it touch to eyes skin or clothes If touched by accident flush them with clean water immediately However if the electrolyte sprays to eyes medical care should be done quickly 2 6 This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Rear Brake Free Play Drum Brake Type Measure the free play of the rear brake lever at the end of the lever Free play 10 20 mm 3 8 3 4 in Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked 10 20mm 3 8 3 4 in Decreasing free play Increasing play 2 This chapter Contents 2 SERVICE MAINTENANCE INFORMATION SYM Steering System Caution The control cables can not interfere with the rotation of steering handle Lift the front wheel out of ground and check if the steering handle turning is smoothly If handle turning is uneven and bending stuck or the handle can be operated in vertical direction then adjust the handle top bearing by adjusting the steering nut Suspension Warning Do not ride the scooter with poor suspension Looseness wear or damage suspension system will make poor stability and drive ability Front Shock Absorber Press down the front shock absorber for several times to check it operat
47. e cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is correct Throttle Valve Operation Check if each steering positions are operated in smooth and handle bar if its operation is smooth as the throttle valve wide opening or fully closed Check throttle cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure throttle valve handle free play Free play 2 6 mm 1 8 1 4 in Loosen the mounting nut and turn the free play adjustment nut of the throttle valve handle for adjustment Replace the cable if it can not be adjusted 2 10 SYM p Belt width 7 This chapter Contents SYM Carburetor Idle Speed Adjustment Caution e Inspection amp adjustment for idle soeed 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 warn 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 20002100 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
48. e ground 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator Good spark o Poor 4 Malfunction of ignition coil 5 Open or short circuit in spark plug 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 Check if carburetor clogged 1 Insufficient fuel in fuel tank Fuel filter clogged Restricted fuel tank vent 1 13 This chapter Contents 1 GENERAL INFORMATION SYM E CLUTCH DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1 Driving belt worn out or deformation 2 Driving disk damaged 3 Driving pulley spring broken Engine can be started but motorcycle can not be driving 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damage 7 Transmission gear worn out or burned Engine running and misfire as 1 Clutch ling spring broken motorcycle initial forward moving or jumping sudden rear wheel 2 Clutch outer cover stuck with clutch balance weights rotating as engine in running 3 Connection parts in clutch and shaft worn out or burned 1 Driving belt worn out or deformation Poor initial driving Poor climbing 2 Balance weight roller worn out performance 3 Driving sliding gear shaft worn out 4 Driving disk spring deformation 5 Driving sliding gear shaft worn out 6 Greased in drivin
49. e order of removal Caution Inspection and adjustment following items as installed The adjustment operation of control cable Air bleeding operation of oil pump Air bleeding operation of oil tube Check each section for leaking E Adjustment nut Mounting bolt This chapter Contents 3 LUBRICATION SYSTEM Oil Pump Oil Tube Air Bleeding Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage Caution After disconnect the oil tube air enters oil tube due to oil leak out without added oil There is why the oil tube and oil pump have to conduct air bleeding operation Oil Tube Oil Pump e t has to add some oil into the oil tank e Place a piece of dry cloth around the oil pump e Disconnect the oil tube e Fill out oil to oil pump connection section by means of the oil pot so that the oil pump body is full with oil e Fill out oil to oil tube connection section so that the oil tube is full with oil Then install the tube onto oil pump e 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
50. e resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the auto by starter Resistance value Max 100 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 10 4 This chapter Contents SYM 10 FUEL SYSTEM 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 at Nhe starter a Battery 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 Automatic By Starter Removal Installation Remove the cover of the auto by starter Remove scre
51. eal Install the dust seal and side collar Place the front wheel between the front shock absorbers Caution Align the brake panel groove with the stopper flange Speedometer cable Insert the wheel axle into the wheel and the install the wheel axle nut Tighten the nut to specified torque Torque value 5 0 7 0kgf m Connect the speedometer cable to the speedometer gear Speedometer cable 13 9 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION Front Cushion Removal Remove front fender Remove front cushion under bolt and nut Remove front cushion upper bolt then remove front cushion Installation Install the removed components in reverse order of removal procedures Torque value 2 4 3 0kgf m 13 10 Front cushion Bolt and nut This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Front Fork Removal Remove the handle pipe Remove the handle post cover Remove front wheel Remove front cushion and pilot arm Remove the steering stem lock nut Remove top cone race and front fork Caution Place the steel ball onto a parts container to prevent from missing Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats Remove bottom cone race body with a punch Caution Do not damage the steering stem Installation Install a new bottom cone race onto the steering stem Push the cone race unt
52. easure 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 it bearing free play Ifthe bearing is noisy or its free play is too much replace it Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and measure its rim wobbling value with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Free play Wheel axle 13 7 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION Remove wheel hub from wheel rim after 4 nut DRUM TYPE removed Dust seal Bearing Remove dust seal bearing and side collar Special tools Inner bearing puller SYM 6204020 Installation Fill out the block of bearing by grease Drive the left bearing and install the dist collar Install the right bearing Caution Carefully install the bearing in correct and evenly Bearing outer face should be faced up as bearing installation 13 8 SYM This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Lubricate the soeedometer gear with grease and install the gear into the wheel hub Align the flange part on the speedometer gear with the slot of wheel hub Caution Contaminated brake lining will reduce brake performance so the brake lining brake drum and disc must be free of grease Apply with grease onto the dust s
53. ed bolts tightening torque for removal of engine Engine hanger bolt 5 0kgf m Engine bracket bolt 6 0kgf m Rear shock absorber upper mounting bolts 4 0kgf m Rear shock absorber lower mounting bolts 2 7kgf m Exhaust pipe connection nut 1 2kgf m Muffle mounting bolt 3 3kgf m 4 2 This chapter Contents SYM 4 ENGINE REMOVAL Engine removal zi Spark plug cap Remove body cover Remove the spark plug cap from the spark plug section Remove the fuel output and the vacuum tubes from fuel pump Remove the oil control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire connectors of auto by starter and AC G Remove the upper parts and cable of the carburetor from its upper side Remove the vapor emission vacuum tube from carburetor intake manifold This chapter Contents 4 ENGINE REMOVAL Remove rear brake cable from engine rear lower side Remove air cleaner mounting bolts 2 bolts Support the engine and then remove shock absorber lower mounting bolt Remove two exhaust pipe connection nuts Remove two bolts beside fan cover and exhaust pipe he i i am m Uu Pe Mounting bolt Shock absorber lower mounting bolt Exhaust pipe Bolt This chapter Contents SYM 4 ENGINE REMOVAL Remove engine mounting nut and bolt Engine installation Install in the reverse order of removal procedures Tighten the engine mounting and
54. ell 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 FIDDLE 50 Venturi diameter Fuel level 8 6 H 0mm 1 3 8 Idle speed Throttle handle free play PB2BE 20004100 rpm Main jet Fuel pump output 20 c c minimum Troubleshooting Engine can not be started 1 No fuel in fuel tank 2 Fuel can not reach to carburetor 3 Too much fuel in cylinder 4 Clogged air cleaner Stall after started Incorrect idle speed adjustment No spark on the spark plug Low compression pressure Rich mixture Lean mixture Clogged air cleaner Inlet pipe leaking Polluted fuel ot OF 10 2 Lean Mixture Clogged carburetor jet Clogged hose from carburetor to canister Bend squeezed or clogged fuel lines Clogged fuel filter Malfunction of float valve Low fuel level in float chamber Clogged vent pipe Malfunction of fuel pump eo eS SYS Rich Mixture 1 Malfunction of float valve 2 Low fuel level in float chamber 3 Clogged carburetor air injector This chapter Contents SYM 10 FUEL SYSTEM Carburetor Throttle Valve ef
55. enerator l d harness coupler 50 2000 EL eT Cri mm d 4 Exciting yellow ground 400 8000 eas Ap ot d ud M i i CDI Electrical System Circuit Inspection Remove body cover Disconnect the CDI set coupler and check its circuit to diagnosis related ignition components CDI Electrical System Circuit Inspection Main Switch Black white green Continuity as main switch OFF Exciter Coil Black Red Green 400 8000 PulseCot PulseCot Blue Yellow green 50 2000 Black yellow green 0 210 10 Ignition Coil Green high voltage cable w o Cap 3 5KO Secondary Green high voltage cable w Cap 7 12KQ If above checks are in normal but spark plug is still no spark Then it probable causes from CDI set or high voltage coil e f abnormal circuits are found in above checks at first check all items and then check each item one by one 15 11 This chapter Contents 15 ELECTRICAL EQUIPMENT Starting System Starter Relay Inspection Remove luggage box Connect both the green yellow and the yellow red pins to battery posts directly If the red and red white pins are also in continuity it means it is in normal Battery Starter Motor Pinion Removal Installation Remove left crankcase cover 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 dam
56. ent insufficient oil 2 Poor quality oil 3 Applying with poor quality oil Piston seized 1 No oil in oil tank or clogged hose 2 Improperly oil pump adjustment insufficient oil 3 Air in oil hose 4 Malfunction of oil pump Oil did not flow out the oil tank 1 Clogged breath hole on the oil tank cover This chapter Contents SYM 3 LUBRICATION SYSTEM Oil Pump Removal Oil output tube Caution Before removing the oil pump clean the oil pump and crankcase Remove the luggage box and seat Loosen the mounting nut of the oil pump control cable and remove the control cable Remove the oil tube and clip its end side to prevent oil from flowing out a Control cable Mounting nut 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 Caution The oil pump can not be disassembled Oil Pump Installation Install the oil pump onto the crankcase Caution e Apply with some grease onto oil pump O ring e The connection between both oil pump and crankcase has to be installed in position security Tighten the oil pump mounting bolt security Install the oil tube Installation in the revers
57. er 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 Check if cylinder and piston are 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 This chapter Contents 5 CYLINDER HEAD CYLINDER 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 max value to decide cylinder wear out condition Service limit 39 05mm Measure the OD of piston at the 7 mm from the bottom of the piston Service limit 38 935 mm Calculate the clearance between piston and cylinder Service limit 0 100 mm Measure the ID of piston pin hole Service limit 12 030 Measure the OD of piston pin Service limit 11 970 mm 5 6 The ID of piston pin hole gt SYM The OD of piston pin
58. ervice are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using the symbols or marks Means that serious injury or even death may result if procedures are not Warning followed Caution seme in equipment damages may result if procedures are not 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 King Mate G 3 is recommended King Mate gear oil serials are recommended Bramax HYPOID GEAR OIL 140 Locking Apply sealant medium strength sealant should be used unless otherwise YE sealant specified with lubricant Replace with a new part before installation Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid 25 pecia tools Special tools O Meaning correct installation OX Wes Meaning wrong installation gt Indication Indication of components pem Indicates position and operation directions m 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 lf you must run your engine ensure the place is well ventilated Never run your engine in a closed
59. g Bearing driver 6203 6004UZ SYM 9620000 Bearing driver 6201 SYM 9610001 L crank puller SYM 1130000 L L crank shaft install bush SYM 1130010 Drive shaft oil seal installer SYM 9120200 With the special service tools to install drive shaft by through the bearing Install a new drive shaft oil seal Install a new final shaft oil seal 8 4 SYM Final driven gear amp shaft 5 he Countershaft 7 6 Drive shaft Adapter This chapter Contents SYM 8 FINAL DRIVING MECHANISM Install countershaft final driven gear and thrust Final driven gear amp shaft washer Install new gasket and lock pin Cil filling hole Ur t E 9 b y E 1 E m i i z 4 Install gearbox cover Install clutch driven pulley assembly Install driven pulley drive belt and left crankcase side cover A draining hole Install body cover Install rear wheel Fill out specified oil quantity into gearbox 8 5 This chapter Contents 8 FINAL DRIVING MECHANISM SYM Notes 8 6 Contents ie 9 CRANKCASE CRANKSHAFT SYM I gt o E tc C c 0 ES O Maintenance Information Q Crankshaft Inspection 9 Troubleshooting Qe Crankcase Installation 9 Crankcase Disassembly
60. g belt and sliding gear 1 14 This chapter Contents SYM 1 GENERAL INFORMATION Lubrication Points Throttle cable Front amp rear brake lever pivot Engine suspension bushing Seat lock Steering shaft bearing Speedometer gear front Side stand shaft Main stand shaft wheel bearing This chapter Contents 1 GENERAL INFORMATION SYM Note SYM 2 SERVICE MAINTENANCE INFORMATION General Information 2 1 Suspension 2 8 Periodical Maintenance Schedule 2 2 Transmission Oill 2 9 Air Cleaner eee 2 3 Spark Plug eeeeee eese 2 9 Fuel Lines 2 3 Control Cable Lubrication 2 10 Fuel Filter ereeeeerr n 2 4 Driver Bellt eee 2 10 Engine 2 4 Ignition Timing 9 10 Oil Pump Control Cable 2 5 Throttle Valve Operation 2 10 EIL TT E I IT 2 6 Carburetor Idle Speed Adjustment 2 11 Battery M 2 6 Carbon Removing For Exhaust Pipe amp Rear Brake Free Play Drum Brake Type Muffle CT EC CCE P M M CCE CEE 2 11 2 7 Cylin
61. h 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 Brake shoe Do not use an air hose or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid dust flying Caution Inhaling dust may cause disorders and cancer of the breathing system Brake fluid Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep the brake fluid beyond reach of children This chapter Contents SYM Service Precautions e Always use with Sanyang genuine parts and recommended oils Using non designed parts for Sanyang motorcycle may damage the motorcycle 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 motorcycle use only metric tools Metric bolts nuts and screws are not interchangeable with the English system using wrong tools and fasteners may damage this vehicle Clean the outside of the parts or the c
62. ied rom Control voltage 12 0 14 0 V 5000 rpm Resistance Measurement of Resistor at 20 C Resistor 10 20 5W Green Black and Body ground 9 00 10 00 Resistor 5 90 5W Pink and Body ground 5 6 6 20 15 ELECTRICAL EQUIPMENT Headlight coupler rT Resistor 15 7 This chapter Contents 15 ELECTRICAL EQUIPMENT SYM Voltage Regulator Inspection Voltage regulator Check the each pins of coupler on the voltage regulator Voltage regulator Inspection Probable cause Check voltage between battery terminal red and ground Blown fuse or poor main switch green contact Check continuity between ground and frame Check charging coil white to ground if its resistance is within 0 2 1 00 Open circuit in alternator charging Check charging illumination coil yellow to ground if its coil or in illumination switch resistance is within 0 2 0 80 If wire circuit check is in normal and there is no loose in the pins of voltage regulator coupler then measure the resistance among pins on the couplers of voltage regulator Voltage Regulator White Yellow Red Green A Yellow L If the resistance values are abnormal among the pins replace the voltage regulator Caution If the probe is touched by finger then the resistance values will be incorrect It contains semi conductor in circuit so the measured resistance value will be in different if diffe
63. ighten torque 10 0 12 0kgf m Install exhaust pipe amp muffler Install AICV system hose Tighten torque bolt 3 0 3 6kgf m Tighten torque nut 1 0 1 4kgf m Rear Cushion Removal Remove body cover 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 Installation all components in reverse order of removal procedures Install air cleaner 14 4 15 ELECTRICAL EQUIPMENT Starting System Oil Level Switch Fuel Unit Switch Horn Bulb Replacement Resistor Comp Horn Reg Rec Comp Winker Relay Main Switch Left Handle Switch Right Handle Switch Fuel Unit AC Generator Spark Plug Power Filter Unit ASS Y Thermo Switch IGN Coil Fuse Box CDI Unit Start Relay Thermo Switch Unit Battery Oil Level Switch 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 disconnect the negative cable terminal next the positive cable terminal e The model of the spark plug and the tightening torque he ignit
64. il to mounted position Caution Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 18 balls bottom race Steering stem lock nut 21 p i Steering vat 7 i up race fy Steering ball ES Steel balls Bottom cone race 13 11 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Lubricate the top cone race seat with grease Steering lock nut Screw the cone race in to top ball bearing seat till touching and then screw out the cane race 1 4 3 8 turns Torque value 0 25kgf m f iF amp Caution WS freely and no clearance in vertical direction 1 4 3 8 turns Install the steering stem lock nut and tighten the Top cone race d nut by means of holding the top cone race body Torque value 1 5kgf m Install handle post Torque value 4 0 5 0kgf m Install in reverse order of removal procedures Handle post 13 12 SYM 14 REAR WHEEL SUSPENSION Maintenance Information Troubleshooting Rear Wheel Rear Cushion i lt 3 fs nc f 1 a m f Fi 1 E Zu or ir f rens OM j 7 il SA X a X 10 0 12 0kgf m 17 P qc ah 3 0 3 6kgf m 14 1 This chapter Contents 14 REAR WHEEL SUS
65. instead e The brake caliper can be removed without removing the hydraulic system e After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system While refilling brake fluid care should be taken not to let the foreign material entering into the brake system Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage e Check the operation of the brake system before you go Specifications ID of front brake drum 110 0 110 5 ID of rear brake drum 95 0 95 5 Thickness of front brake lining Thickness of rear brake lining Torque values Nuts for the wheel rim 2 5kgf m Nuts for the front wheel 6 0kgf m Nuts for the rear wheel 11 0kgf m Bolt for rear brake arm 0 55kgf m 11 3 11 BRAKE SYSTEM Troubleshooting Disc Brake Soft brake lever 1 Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining disc Low brake fluid Blocked brake pipe Warp bent brake disc 0 Bent brake lever gn Drum Brake Poor brake performance 1 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 camshaft indent ML ox 11 4 This
66. ion Check if the shock absorber assembly is damage Replace it if damage found and can not be repaired Tighten all nuts and bolts Rear Shock Absorber Park the scooter with its main stand Shake the rear wheel side to side to check engine suspension bushing for wear Replace the bushing if looseness found Check the shock absorber for damage Tighten all nuts and bolts Nuts Bolts Tightness Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule Check all split pins snap rings hose clamps and wire holders for security 2 8 This chapter Contents SYM 2 SERVICE MAINTENANCE INFORMATION Transmission Oil TARN Y SARE Leak Oil level check bolt Check if the transmission is leak did uid a Check 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 3 kgf m Caution Check if oil seal and washer is in good condition Replacement Quantity 0 09 L 90 cc Recommended oil King Bramax HYPOID GEAR OIL 140 Spark Plug Recommended plug NGK BR8HSA e Remove the luggage box Remove the spark plug cap Clean any dirt on the spark plug seat
67. ion timing Adjustment of headlight e Removal and installation of AC generator e The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water recharge the battery remove the battery from the motorcycle without removing ventilation caps e Unless in emergency never rapid charge the battery e The voltage must be checked with the voltmeter while charging the battery e 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 he starter motor can be removed after the engine is removed Specification Charging System Capacity 12V3Ah Battery Charging rate 0 4A 5 hours standard 4A 0 5 hour fast charging Charging current 1 2 A 5000 rpm Control voltage in charging 14 0 15 0 V 5000 rpm Control voltage in headlight 12 6 13 6 V 5000 rpm Ignition System Spark plug Ignition coil and resistance Secondary coil 2 8 3 4 Ignition timing F mark 17 BTDC 1800 rpm 15 2 This chapter Contents SYM Troubleshooting No voltage Battery discharged The cable disconnected e he fuse is blown Improper operation of the main switch Low voltage The battery is not fully charged Poor contact Poor charging system Poor voltage regulator No spark produced by spar
68. k plug The spark plug is out of work he 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 Poor main switch Poor C D I e AC G is out of work Starter motor does not work e The fuse is blown e The battery is not fully charge e Poor main switch e Poor starter switch e The front and rear brake switches do not operate correctly Starter relay is out of work e The ignition coil is poorly connected open or short circuited The starter motor is out of work 15 ELECTRICAL EQUIPMENT Intermittent power supply The coupler of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection or short circuit of the power generation system Charging system does not operate properly Burnt fuse Poor contact open or short circuit Poor regulator Poor ACG Engine does not crank smoothly Primary coil circuit Poor ignition coil Poor connection of cable and couplers Poor main switch Secondary coil circuit Poor ignition coil Poor spark plug Poor ignition coil cable Current leakage in the spark plug cap Incorrect ignition timing Poor AC G Improper installation of the pulse sensor Poor C D I Weak st
69. lutch outer friction face Replace clutch outer if exceed service limit Service limit 107 5 mm diameter 7 10 Oil seal SYM Clutch nut TOH wrench C pM M ark Clutch spring Guide pin Guide pin roller Clutch outer This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER 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 92 7 mm Driven pulley Check following items f both surfaces are damage or wear e f guide pin groove is damage or wear Heplace damaged or worn components Measure the outer diameter of driven pulley and the inner diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage 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 A Caution e Some of models are equipped with two ball bearings Clutch weight Free length Drive
70. ly screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil x R Crank shaft puller Crank shaft install bush Install the bolts and tighten them Torque value 1 0kgf m With right crank shaft install bush install new oil AF Tex seal into the right crankcase Its installation depth i M UR Crank shaft install bush is 4mm as the diagram shown install bus 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 freely after tightening the bolts Install the following components Final driving mechanism chapter 8 Alternator chapter 6 Piston cylinder cylinder head chapter 7 Oil pump chapter 3 Reed valve and carburetor chapter 10 Engine chapter 4 9 6 SYM 10 FUEL SYSTEM Maintenance Information Flaot Level Inspection Troubleshooting Carburetor Installation Throttle Valve Reed Valve Carburetor Remove Fuel Pump Auto By Starter Air Cleaner Float Float Valve Jet Throttle valve cable Air hose Oil tube Vacuum hose Carburetor Fuel unit Vacuum tube Fuel filter Fuel tank 10 1 This chapter Contents _ 10 FUEL SYSTEM Maintenance Information Precautions in Operations Warning Gasoline is a highly flammable material and may explosive under circumstance Thus always work SYM in a w
71. mp control aul es 7 ed Turn the adjustment nut and align with the point then tighten the nut This chapter Contents 2 SERVICE MAINTENANCE INFORMATION 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 Front Rear 3 00 10 42J 3 00 10 42J 1 75 2 0 Tire pressure 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 tread bend too much replace the tire tire wear exceeds limitation replace the tire and check it for un even wear X Caution VEAUR Wear indicator A is distributed on average UN Wear indicator along the wall rubber for check Battery Open the seat Loosen two screws of battery cap and then remove the cap Check if the battery terminals loosen Remove the battery if its terminals are corroded obviously Battery Removal 1 Remove the Negative battery cable at first 2 Then remove the Positive battery cable 3 Remove the battery Clean the rust with steel brush Install the battery in reverse order of removal and apply with grease onto two terminals Caution The electrolyte is contained sulfuric acid so b
72. n pulley Sliding pulley Outer ball bearing Guide pin groove 7 11 This chapter Contents 7 V TYPE BELT DRIVE SYSTEM KICK STARTER SYM Clutch Block Replacement Remove clip and washer and then remove clutch weight and spring from drive plate A Caution e Some of models are equipped with one mounting plate instead of 3 snap clips Check if spring is damage or insufficient Snap clip elasticity Shock absorption Check if shock absorption rubber is damage or rubber deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch weight should not be greased If so replace it A Caution e Grease or lubricant will damage the clutch weight and affect the weight s connection capacity Clutch block Install the spring into groove with pliers 7 12 This chapter Contents SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Install snap clip and mounting plate onto lock pin Snap clip Replacement of Driven Pulley Bearing Remove inner bearing A Caution Outer bearing If the inner bearing equipped with oil seal on side in the driven pulley then remove the oil seal firstly If the pulley equipped with ball bearing it has to remove snap clip and then the bearing Remove snap
73. oise and bigger clearance are detected replace the bearing with Dee 1 Clearance new one 14 Lateral Radial This chapter Contents SYM 9 CRANKCASE CRANKSHAFT Crankcase Installation CE Clean the crankshaft with solvent and blow it with Bearing 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 Remove all gaskets onto the crankcase interfaces and flat it with special tool Install new bearing into left crankcase i TIEN Bearing driver 6204 Install crankshaft onto the left crankcase Ff Uma L Crank shaft puller Install left crankshaft puller and install bush onto U crankshaft Collar Screw the left crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil Apply liquid gasket and dowel pin onto the interface of left crankcase QUE guid gasket 4 TE 9 5 This chapter Contents 9 CRANKCASE CRANKSHAFT Assemble the right crankcase with assembly tools Install right crankcase onto the crankshaft Install right crankshaft puller and install bush onto crankshaft screw the right crankshaft puller onto crankshaft Turn the puller in C W direction and then complete
74. oling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel 10mm flanged nut 7 Remove the flywheel with rotor puller Rotor puller This chapter Contents 6 ALTERNATOR SYM Disconnect alternator wire connector and pulse generator connector Wire harness connector Remove the pulse generator and alternator four 4 bolts and then take out the alternator assembly Caution Care to be taken for not damaging the alternator coil Alternator Installation Install the alternator assembly Connect the alternator connector Caution Connect the alternator wire harness properly and then clip the harness with clipper Es Install the woodruff key onto the crankshaft J 10mm flanged nut groove Caution Clean dirt and metal pieces inside the flywheel Make sure that there is no foreign material inside the flywheel Install the flywheel Tighten the flywheel 10 mm nut Torque value 3 8kgf m Install the removed parts in reverse order of removal procedures Start engine and check its ignition timing 6 4 SYM 7 V TYPE BELT DRIVE SYSTEM KICK STARTER Maintenance Information 7 2 218522577 7 7 757 75 2517 7 rrr rrr rrr rr 7 5 Trouble 7 2 Movable Driven 7 6 Left Crankcase Cover
75. over before removing it from the motorcycle Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause a damage 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 e Never bend or twist a control 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 Caution In addition to damaging paint finish
76. rent testers are used Thus these values cannot be judged with standards AC Generator Inspection Remove body cover NU Disconnect the generator harness coupler harness coupler Measure the resistance on both charging coil the white to ground and illumination coil the yellow to ground Resistance Measurement 20 C Charging coil white green 0 2 1 00 Illumination coil yellow green 0 1 0 80 15 8 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Ignition System AC Generator gt Green gt Black Yellow 3 F Fuse 7 Black White 1 4 5 5 o S is CDI z a Battery tid 15 9 This chapter Contents 15 ELECTRICAL EQUIPMENT Ignition Coil Inspection e Remove body cover Measure the primary coil resistance Resistance 0 19 0 23KQ B Measure the secondary coil resistance Resistance 8 2 9 3KO C D Remove the high voltage coil cap and measure its negative terminal for the secondary coil resistance Resistance 3 1 3 2KQ A D D 15 10 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Electrical System Circuit Inspection Pulse Generator Exciting Coil Remove body cover Disconnect alternator coupler Resistance Measurement 20 C Pulse generator coil blue yellow ground cU ELLE eer AC g
77. rminal This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Charging System White Red Battery Yellow REG REC o1 Pink rA Green UJ Q AC Generator Auto by starter Resistor 10 20 5W Resistor 5 90 30W Current Leakage Inspection Turn the main switch to OFF position and j remove the negative cable terminal from the a Battery terminal battery Connect an ammeter between the negative cable terminal and the battery negative terminal Caution Ammeter e 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 Ammeter If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit Fuse coupler 15 5 This chapter Contents 15 ELECTRICAL EQUIPMENT Charging Voltage Inspection Caution 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 f
78. rom 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 Caution When the probe is reversibly connected use an ammeter having an indication that shows both positive and negative direction current The measurement would be at zero if the ammeter is one direction only Caution 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 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 5 V 5000 rpm 15 6 SYM X Caution with the same current and voltage The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any
79. t cushion mounting bolt upper 2 4 3 0kgf m Top cone race Front cushion mounting nut under Special Tools Inner bearing puller Bearing driver Troubleshooting Hard To Steer 1 The steering stem nut is too tight 2 he steering stem bearing are damaged 3 The ball and the top cone of the steering stem are damaged 4 nsufficient tire pressure The Steering Handle Is Tilted 1 Uneven arrangement of the front cushion 2 The front fork is bent 3 The front wheel axle is bent 13 2 The Front Wheel Wobbling 1 The rim is bent The wheel axle nut is not tightened improperly Bend wheel rim oide worn or poor tire The bearing play of the wheel axle is too large D Soft Cushion 1 Weak front cushion spring Noise In Front Cushion 1 Front cushion outer tube noise 2 The joint of the cushion gets loose This chapter Contents SYM 13 STEERING FRONT WHEEL SUSPENSION Steering Handle Removal Remove the front cover Remove wire harness band and then remove the wire harness couplers The counter clock revolves speedometer cable cap nut Remove 2 cap nuts from meter ASS Y and then remove meter 55 Y Remove bolt nut from head light stay and then remove the head light Bolt nut 13 3 This chapter Contents 13 STEERING FRONT WHEEL SUSPENSION SYM Remove 2 screws from right handle switch under side Remove right handle switch Remove throttle grip and cable
80. ter adjusted Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance SYM 3 LUBRICATION SYSTEM Lubrication System Diagram 3 1 Oil Pump Removal 3 3 Precautions In Operation 3 2 Oil Pump Installation 3 3 e D LL DI LC I 3 2 Pump Oil Tube Air Bleeding 3 4 Trouble Shooting MT POETE 3 2 bb Hd hii 3 5 Lubrication System Diagram Oil lever switch Oil tank Oil tube Oil output tube Oil pump 3 1 This chapter Contents 3 LUBRICATION SYSTEM SYM Precautions in Operation e careful not let dirt enter into engine or oil hoses when removing or installing the oil pump e lf 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 e t should bleed the oil output tube from oil pump to carburetor as hose removed e he adjustment of oil pump control cable Lubricant e Appointed to apply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage e Recommended Oil MAX 2 oil e Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pump adjustment too much oil 2 Poor quality oil 3 Applying with poor quality oil Over heat 1 Improperly oil pump adjustm
81. ton pin and then install the piston pin onto connecting rod Install piston and place EX mark of the piston toward to exhaust side Install new piston pin snap ring Clean all gaskets onto the interfaces of cylinder and crankcase Place a new gasket onto the crankcase Make sure that the piston ring aligns with the lock pin in piston ring groove A Caution Make sure that all rings in the piston ring groove can not be rotated around the lock pin to avoid to damaging the rings piston and cylinder Lubricate cylinder and piston with two stroke engine oil Hold the piston and then install it into cylinder A Caution To avoid to damaging the piston and the cylinder sliding surface Install the cylinder head 5 8 SYM 6 ALTERNATOR Maintenance Information 6 2 Alternator Installation Alternator Removal 6 3 3 8kgf m 6 1 This chapter Contents 6 ALTERNATOR SYM Maintenance Information Precautions in Operation e The maintenance service of A C alternator can be carried out directly on the scooter Please refer to Chapter 15 for the relative alternator inspection Torque value Flywheel 3 8kgf m Tool General tool Rotor puller Universal holder Coil resistance value for the A C alternator Earth SYM 6 ALTERNATOR Alternator Removal Remove the body cover Remove two bolts and then take out cooling fan cover Remove four bolts and then take out the co
82. ty as braking it is in normal The switch is non adjustable Horn If the horn give out sound as connecting to 12V battery it means that it is in normal 15 17 This chapter Contents SYM Headlight corrects 15 ELECTRICAL EQUIPMENT Bulb Replacement Headlight Remove head light corrects Remove bulb seat and replace the bulb Install the all removed parts Front winker light Remove front winker light lens with driver 5 Ot screw 15 18 This chapter Contents SYM 15 ELECTRICAL EQUIPMENT Replace front winker light bulb Install the all removed parts Tail light Brake light Rear winker light Remove 2 screws and then remove tail light lens Replace tail light and brake light bulb Install the all removed parts 15 19 This chapter Contents 15 ELECTRICAL EQUIPMENT Remove front winker light lens with screw driver Replace rear winker light bulb Install the all removed parts 15 20 SYM 16 ELECTRICAL DIAGRAM Wvaovid 121410919 OS lt 4 16 1 16 ELECTRICAL DIAGRAM SYM Notes 16 2
83. urrent 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 section of the content 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 5 1 1 1 16 2 1 2 12 3 1 3 6 4 1 4 6 5 1 5 8 W 6 1 6 4 Content GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM ENGINE REMOVAL CYLINDER HEAD CYLINDER PISTON ALTERNATOR Index IS UI
84. use safety hazard After clamping check each wire to make sure it is secured Do not squeeze wires against the weld or its clamp Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses Route harnesses so that they neither pull too tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses far away from the exhaust pipes and other hot parts Be sure grommets are seated in their groves properly After clamping check each harness to be certain that it is not interfered with any moving or sliding parts After routing check that the wire harnesses are not twisted or kink Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack be rubbed against or interfere with adjacent or surrounding parts in all steering positions Thoroughly clean the surface where tape is to be applied Wrap electrical tape around the damaged parts or replace them 1 8 Correct Wrong This chapter Contents SYM 1 GENERAL INFORMATION Right handle switch Right handle switch Front brake cable Rear brake cable Throttle cable Horn Resistor Regul
85. w and mounting plate Remove the auto by starter from carburetor Install in the reverse order of removal procedures 10 5 10 FUEL SYSTEM SYM 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 X Caution damaging the valve seat Remove main jet needle jet seat and idle jet and H X A a clean them and each component with queen D circuit compressed air slants xir inlet for idle speed Install the idle jet the needle jet seat and main jet n Then install the throttle valve stopper and air screws to their original position according to the marks as removal Adjust the screws if replace with new ones Float valve yg Float n Float pin Throttle valve stopper screw Idle jet needle jet seat Main jet Screw i Draining screw 10 6 SYM 10 FUEL SYSTEM Float Level Inspection Measure float fuel level to have the upper end of float just contact with the float Float fuel level 8 8 mm Carefully bend the float arm for adjustment Check the float operation and the install it Car

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