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SYM Fiddle II 50 Service Manual

1. 0 15 A Caution e Check if new valve guide is deformation after pressed it in e When pressing in the new valve guide cylinder head still must be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer A Caution e Using cutting oil when correcting valve guide with a reamer Turn the reamer in same direction when it be inserted or rotated Correct valve seat and clean up all metal residues from cylinder head Special tool Valve guide reamer 5 mm 6 CYLINDER HEAD VALVE VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves Apply with emery slightly onto valve contact face Grind valve seat with a rubber hose or other manual grinding tool Caution Do not let emery enter into between valve stem and valve guide e Clean up the emery after corrected and apply with red paint onto contact faces of valve and valve seat Remove the valve and check its contact face Caution Replace the valve with new one if valve seat is roughness wear out or incomplete contacted with valve seat If the valve and the valve seat still can not be matched sealing after grinded replace it with new one
2. Battery inspection HE IEEE 3 9 Sterighandecheck 1 i f LI y Every 5 screw tightening check eC 14 xGearoilchange Replacement for every 5000km 5 months ___ re E E x gnon timing ie Emission checkin gt EE p n eer dee ote lt lt 723 Lignselectica equipmenimulmeters 1 1 I EE 3 F ppes SSS xx Valve clearance vapor control System xx Crankcase blow by over flow pipe Replacement for every 2000km a2 vapor contro system Code Inspection cleaning and adjustment R Replacement Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 These marks gt in the schedule are emission control items According to EPA regulations these items must be perform normally periodical maintenance following the use r manual instructions The
3. 12 BODY COVER Hemove the mounting screws 2 screws between the rear handle cover and the frame Hemove the speedometer cable Hemove the mounting screws 4 screws between the rear handle cover and meter Hemove the left right handle switch connectors Hemove the rear handle cover Installation Install according to the reverse procedure of removal FRONT COVER Removal Remove the 1 mounting bolt of front cover from the frame Remove the mounting screws 3X 2 screws between the front cover and inner box 6 screws 12 4 SYM 12 BODY COVER Remove the front turn left right signal light alday wire connectors Remove the front cover Installation Install according to the reverse procedure of removal UNDER COVER Removal Remove the 1x 2 mounting screws between the left right side cover and the floor panel Remove the 1x 2 mounting screws between the left right side cover and the frame 1x 2 Screw Remove the 2x 2 mounting bolts between the under cover and the frame Remove the under cover Installation Install according to the reverse procedure of removal 12 BODY COVER SYM FRONT INNER BOX Removal Remove the front cover Remove the 6 mounting screws of front cover from the inner box Remove the 1 2 mounting screws of front spoiler from the inner box 2 screws p 2 screws Remove the 1 2 mounting screws of front spoiler fro
4. Make sure service safety each other when conducting by two persons Before battery removal operation it has to remove the battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secured Battery positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables Make sure that the battery post caps are located in properly after the battery posts had been serviced If fuse burned it has to find out the cause and solved it And then replace with specified capacity fuse F capacity L3 1 5 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM e When separating a connector it locker has to Before terminal connection check if the boot be unlocked firstly Then conduct the is crack or the terminal is loose service operation e Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up 2 5 Do not pull the wires as removing CAS connector or wires Hold the connector m bogy in om a am e Secure wires wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the Make sure if the conn
5. Valve seat inspection If the valve seat is too width narrow or rough Correct it Valve seat width Service limit 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be grinded with valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat Caution After valve guide had been replaced it has to be grinded with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper part out 6 10 Roughness Old valve seat width SYM SYM Use 60 cutter to cut a quarter lower part out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width A Caution Make sure that all roughness and uneven faces had been grinded Grind valve seat again if necessary Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface A Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the va
6. AWTS a Bolt of engine suspension frame left side Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame Engine suspension frame nut Torque Value 4 5 5 5 kgf m 5 7 5 REMOVAL OF ENGINE INSTALLATION OF ENGINE Check if the bushings of engine suspension frame and shock absorber for damaged If so replace with new ones Install the engine according to the reversing order of removal A Caution Engine suspension 1 iii _ 11 b Notice both feet and hands safety for squeezing as engine installation Do not bent or squeeze each wires or hose Route all cables and wires in accordance with the routine layout Engine suspension nut Torque Value 4 5 5 5kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5kgf m lower 2 4 3 0kgf m Rear wheel axle nut Torque Value 11 0 13 0kgf m Rear wheel axle nut d SYM 6 CYLINDER HEAD VALVE CYLINDER HEAD INSPECTION VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLATION VALVE CLEARANCE ADJUSTMENT 6 14 MECHANISM DIAGRAM N 0 8 1 2 kgf m 1 0 1 4 kgf m 1 0 1 4 kgf m 0 8 1 2 kgf m 6 1 6 CYLINDER HEAD VALVE SYM PRECAUTIONS IN OPERATION General Information
7. Speedometer cable screw Speedometer cable locking screw 1 5 04503 E NN NR bolts mme 9 o connection bolt sem connection bolt Front brake air bleeding valve 0 8 1 0 Front brake disc mounting bolts 4 0 4 5 Front brake clipper mounting bolts 3 13 5 Drum brake arm bolts front rear 0 8 1 2 1 O suspension bracket bolts On frame side The torque values listed in above table are for more important tighten torque values Please see standard values for not listed in the table Standard Torque Values for Reference TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE 5mm bolt nut 0 45 0 60kgf m 0 05 0 08kgf m 6mm bolt nut 0 80 1 20kgf m 0 10 0 15kgf m 8mm bolt nut 1 80 2 50kgf m 0 35 0 50kgf m 10mm bolt nut 3 00 4 00kgf m 6mm screw SH nut 0 70 1 10kgf m 12mm bolt nut 5 00 6 00kgf m 6mm bolt nut 1 007 1 40kgf m rnin bt nu 2 40 3 00kgf m Eo 350 450kgkm 1 11 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM TROUBLES DIAGNOSIS A Engine hard to start or can not be started Check and Check and adjustment Fault condition condition Probablecauses Probablecauses Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to carburetor sufficient carburetor Remove spark plug install it into spark plug cap and perform a spark test ag
8. y aw LET c rr FUEL METER a E 2 maio ET S V ice ut HIGH BEAM 121 mE HL T1 1 an G B Y BY 00 WV y LY G B Y HEAD LIGHT wt LH DI e ii G FR POSITION HEAD LIGHT Q I CORD COLOR FULL NAME LIST TERT 1 LL LL CEE ZEN E B BA REG REC CDI UNIT TGN COIL ENG STOP SI AUTO B S Lm _ 1 i RED AC GEN ASS Y Cie 27 ORANGE CAY BR BROW o s YELLOW BLUE B R BLACK RED WINKER RELAY e BLACK YRLLON M HORN ASS Y ud LY R YELLOW RED sy LY V YELLOW WRITE HORN SV WIMKER SW DINMER SV BLUE WHITE BROWN WHITE LB _GREEN BLACK
9. SYM 5 REMOVAL OF ENGINE Remove the rear brake cable nut Brake cable nut Remove the rear brake cable i Remove the rear shock absorber lower bolt Rear shock absorber bolt Loose the strap screw of engine left guide and then remove the engine left guide Remove the engine suspension nut and bolt engine side and then remove the engine Caution e With a bracket to support the engine to prevent from it damage by falling down as removing the engine Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so 5 REMOVAL OF ENGINE REMOVAL OF ENGINE SUSPENSION BUSHING If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged Then with the bushing remover presser 28mm 20mm to press the bushing out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pressing ring and bolt in to press the bushing out Pressing In Place the flat section of the remover toward the bushing and then drive the bushing pressing ring and bolt in to install the bushing 5 6 SYM 5 REMOVAL OF ENGINE ENGINE SUSPENSION FRAME Removal Remove the right side bolt of engine suspension frame left side bolt of engine p 7x UE EI suspension frame ja
10. The crankshaft can not be rotated in counter clockwise to prevent from damage so that valve clearance can not be measured SYM 2 VALVE CLEARANCE INSPECTION AND ADJUSTMENT Check amp adjust valve clearance with feeler gauge Valve clearance IN EX 0 06x0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution It has to make sure that valve rocker arm is be adjusted to standard level when adjusting it and re check the valve clearance after tightened the fixing nut CARBURETOR IDLE SPEED ADJUSTMENT Caution Inspection amp adjustment for idle speed have to be performed after all other parts in engine that needed adjustment have been adjusted Idle speed check and adjustment have to be done after engine is being warm up around 10 minutes Park the motorcycle with main stand and warn up engine Open the carburetor cover from the luggage box Turn the throttle valve stopper screw to specified idle speed Specified idle speed 2100 100 rpm Emission adjustment in Idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the idle speed adjustment screw and let engine runs in 2100x100 rpm 3 Insert the exhaust sampling muffler of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerat
11. e a compress spring SYM Hemove fuel needle seat spring and injector needle Check if the vacuum piston for wear out crack or other damage Check if the diaphragm for damage or crack Cautions Do not damage vacuum diaphragm Installation Install injector needle spring and fuel needle seat to vacuum piston Cautions Note direction as installing the piston set because wrong direction of the piston cab not be installed e Align the indent of vacuum diaphragm with the carburetor body Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws 4 FUEL SYSTEM fuel needle seat fuel needle __ i spring injector gt needle f Piston spring Vacuum Chamber cover 4 FUEL SYSTEM SYM ACCELERATE PUMP Removal Loosen the fixing screws from carburetor Remove the accelerate pump drive arm from Accelerate pump the carburetor drive arm Hemove 3 mounting screws and remove the float chamber cover Hemove 3 mounting screws and remove the float chamber cover Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation direction 4 6 SYM AUTO BY STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling Check resistance across the two terminals of the auto by starter Resistance valu
12. his chapter is contained maintenance and service for cylinder head valve and camshaft as well as valve rocker arm e Cylinder head service cannot be carried out when engine is frame Specification unit mm Compression pressure 12 kg cm MERE Camshaft Height of cam lobe Rocker ID of valve rocker arm 10 000 10 015 am OD of valve rocker arm shaft 9 972 9 987 99100 OD of valve stem ID of Guide 5 000 5 015 50300 Clearance between Intake 0 010 0 037 0 080 valve stem and guide 0 030 0 057 0 100 Valve Torque Value Cylinder head cover bolt 0 8 1 2kgf m Cylinder head bolt LH 0 8 1 2kgf m Bolt of timing chain auto adjuster 0 8 1 2kgf m Spark plug 1 0 1 4kgf m Cam holder nut 1 0 1 4kgf m Valve adjustment fixing nuts 1 0 1 4kgf m TOOLS Special service tools Valve reamer 5 0mm Valve guide driver 5 0mm Valve spring compressor SYM 6 CYLINDER HEAD VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated Rough Idle Low compression pressure Low compression pressure 1 Valve Improper valve adjustment e Burnt or bended valve Improper valve timing Valve spring damaged Valve carbon Poor sealing on valve seat Improper spark plug installation 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack c
13. short circuited Between alternator and C D I Between CDI and ignition coil Between CDI and main switch Poor main switch Poor C D I alternator is out of work Engine does not crank smoothly Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch Secondary coil circuit Poor ignition coil Poor spark plug Poor high tension cable Current leakage in the spark plug cap Incorrect ignition timing Poor alternator Improper installation of the pulse sensor Poor C D I Weak starter motor Poor charging system 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 Poor starter clutch The starter motor run in reverse direction Poor battery SYM 16 ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram white alternator REG REC 12V 6AH LL green black Auto 55w by starter gt Current Leakage Inspection Turn the main switch to OFF position and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal as shown on left diagram Caution e the current leakage test set the current range at larger scale then gradually decrease to
14. LM OD of piston 38 970 38 990 OD of piston pin 12 994 13 000 TROUBLE DIAGNOSIS Low Or Unstable Compression Pressure Smoking in Exhaust Pipe e Cylinder or piston ring worn out e Piston or piston ring worn out e Compress pressure to high e Piston ring installation improperly e much carbon deposited in e Cylinder or piston damage combustion chamber and piston Knock or Noise Engine Overheat e Cylinder or piston ring worn out e Carbon deposits on cylinder head top e Carbon deposits on cylinder head side top side e Piston pin hole and piston pin wear out 7 2 SYM 7 CYLINDER PISTON CYLINDER REMOVAL Cylinder Remove cylinder head refer to chapter 6 Hemove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase 7 CYLINDER PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution To soap the residues into solvent so that the residues can be removed more easily INSPECTION Check if the inner diameter of cylinder is worn out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y direction values respective in the cylinder Service limit 39 047mm Calcula
15. SYM 11 CBANKCASE CRANKSHAFT MECHANISM DIAGRAM DISASSEMBLY OF CRANKCASE 11 3 OPERATIONAL PRECAUTIONS 11 2 CRANKSHAFT INSPECTION 11 5 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 0 7 1 1 kgf m 1 5 2 0 kgf m 11 CBANKCASE CRANKSHAFT SYM OPERATIONAL PRECAUTIONS General Information e This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced e Complete following operations before disassembling crankcase Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 V belt Drive pulley Chapter 8 AC generator Starting Clutch Chapter 10 If the crankshaft bearing or timing sprocket need be replaced then the crankshaft set have to replaced Specification Unit mm Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Below 0 090 Torque value Bolts for crankcase 0 8 1 2 kgf m Bolts for cylinder cylinder head 0 8 1 2 kgf m Engine oil draining plug 3 5 4 5 kgf m Bolts for cam chain tensioner 0 8 1 2 kgf m Special Service Tools Crankcase remover set Crankshaft installation puller Inner type bearing puller Outer type bearing puller Bearing pressing tools Oil seal pressing tools TROUBLE DIAGNOSIS Engine noise e Loose crankshaft bearing e Loose crankshaft pin bearing e Wear piston pin or piston pin hole
16. medium strength sealant should be used unless otherwise lt Renew Replace with a new part before installation Brake fluid Use recommended brake fluid DOT3 WELLRUN brake fluid sto Special service tools O corect Meaning correct installation X wrong wrong installation Indication Indication of components Directions Indicates position and operation directions al Components assembly directions each other QVE oil seal Apply with lubricant Indicates where the bolt installation direction means that bolt cross through the component invisibility 1 GENERAL INFORMATION TROUBLE DIAGNOSIS GENERAL SAFETY Carbon monoxide If you must run your engine ensure the place is well ventilated Never run your engine in a closed area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor A Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored C 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 no
17. 5kgf m 4 5 5 5kgf m 5 1 5 REMOVAL OF ENGINE OPERATIONAL PRECAUTIONS General Information e Engine must be supported by a bracket or adjustable tool in height The following parts be serviced with the engine installed on the frame 1 Carburetor 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification SYM Engine Oil Capacity Gear Oil Capacity Torque Values Engine suspension bolt frame side Engine suspension nut engine side Bolt of rear shock absorber upper connection Bolt of rear shock absorber lower connection 0 2 4 5 5 5kgf m 4 5 5 5kgf m 3 5 4 5kgf m 2 4 3 0kgf m SYM 5 REMOVAL OF ENGINE ENGINE REMOVAL Open the seat Hemove the luggage box assembly 6 bolts Disconnect the engine start control switch connector Hemove the power connector of auto by start Remove the generator wire and pulse generator connector Remove the starter motor wire on the Starter magnetic switch Remove the spark plug Spark plug pulse generator connector Auto by start connector 5 REMOVAL OF ENGINE SYM Remove the fuel pipe vacuum hose and throttle valve cable from the carburetor Loose the strap screw of the air cleaner guide and then the air cleaner guide Remove the exhaust muffler Bolts x 2 Nuts x 2 Remove the rear wheel Nut 2 bolts Remove the air cleaner connection bolts 2 bolts
18. Connect the Charger positive to the battery positive terminal Connect the Charger negative to the battery negative terminal Standard Max A Warning Strictly keep flames away from a charging battery The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires Turn the charger s switch OFF at first before or after charging to prevent from sparks created on the connectors and explosion To charge a battery must be based on the battery s ampere hour showed on label Quick charge a battery should be used only in an emergency Make sure the current and charging time of above description The battery will be damaged by too much current or too rush charging When finishing charge it is necessary to measure voltage after 30 minutes After installing the battery coat the terminals with clean grease 16 ELECTRICAL EQUIPMENT 16 7 16 ELECTRICAL EQUIPMENT Charging Voltage Current Inspection A Caution Before conducting the inspection be sure that the battery is fully charged Use a fully charged battery having a voltage larger than 13 0 V If undercharged the current changes dramatically While starting the engine the starter motor draws large amount of current from the battery Thus do not start the engine with battery After the engine is warmed up replace original battery with a fully charged batte
19. Use SAE 5W 40 when outside temperature is below 0 C Engine oil quantity Replacement 750 c c 3 LUBRICATION SYSTEM Dipstick l Oil drain plug 3 LUBRICATION SYSTEM SYM OIL PUMP Oil Pump Removal Remove the alternator refer to chapter10 Hemove the engine right crankcase cover Make sure that the pump axle can be rotated freely Remove the oil pump driving gear nut pump driving gear nut Hemove oil pump body bolts 3 bolts Hemove the oil pump pin Remove the oil pump Remove the 2 O rings 3 4 SYM 3 LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit below 0 12 mm Check clearance between inner and outer rotors Limit below 0 12 mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly F Install inner and outer rotors into the pump s Oil pump body body E Align the indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw Drive shaft 3 LUBRICATION SYSTEM 2 O rings F Oil Pump Installation A Install the 2 O rings Install the oil pump pin Install the oil pump Install the oil pump body bolts 3 bolts Install the oil pump driving gear nut Install the alternator refer to chapter1 0 Install the engine right crankcase cover pump dr
20. balls into a parts container to avoid to missing or shortage Top cone race 14 8 SYM With a plastic hammer to tap the steering column slightly and then remove the top ball bearing seat Remove the lower end cone bearing seat on the frame with a punch Caution Do not damage the frame and the steering column li Installation Install a new top cone bearing seat onto the top of steering column And then push the lower cone bearing seat from bottom until to locking position Caution Do not let the ball bearing in title motion as installation Apply with some grease onto the top amp bottom bearing balls and then install the balls into bearing seat Press in a new lower cone race onto the steering column and lubricate it with grease Install the steering column Lubricate the top cone race with grease Drive the cone race into the steering column until contact with the top bearing seat no clearance Note return 1 2 turn and then tighten the top cone race to specified torque tighten the race around 1 4 3 8 turn more Torque value 0 2 0 3kgf m Caution Do not tighten the top cone race too tight to prevent from damage the ball bearing seat when tightening the top cone race Install the steering column nut and lock the top cone race Then tighten the nut Torque value 1 0 2 0kgf m Install the bearing seat according to the reverse procedure of removal Caution Check the steering
21. bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution The rear shock absorber has to be replaced with one set and can not be replaced by unauthorized persons Otherwise it might damage the rubber bushing and construction Torque values upper mount bolt Rear shock absorber lower mount bolt 2 4 3 0 kgf m Hear shock absorber upper mount bolt 3 5 4 5 kgf m 15 4 SYM 16 ELECTRICAL EQUIPMENT MECHANISM DIAGRAM PRECAUTIONS IN OPERATION SPECIFICATION LIGHTS BULBS TROUBLE DIAGNOSIS MAIN SWITCH HORN CHARGING SYSTEM FUEL UNIT IGNITION SYSTEM MECHANISM DIAGRAM High amp low beam passing turn signal light Horn Front Rear stop Main switch switch Battery fuse box Winker relay REG REC Horn Resistor Starting headlight switch Engine start control switch Spark plug Fuel unit Starter magnetic switch Auto by star Ignition coil Alternator 16 1 16 ELECTRICAL EQUIPMENT SYM PRECAUTIONS IN OPERATION Charging System When remove the battery the disconnection sequence of cable terminals shall be strictly observed First disconnect the negative cable terminal next the positive cable terminal MF Maintenance Free battery does not need to check add electrolyte or distilled water Battery must be taken out from scooter when charging the battery But do not open the battery
22. caps Do not quick charge the battery unless in emergency A voltmeter must be used when checking battery charging condition Battery can be charged or discharged alternately To set a discharged battery idle for a prolonged period will shorten its service life and reduce its capacity Usually battery s capacity will reduce after 1 2 years After low capacity battery was charged its voltage will increase If it connects to an additional load the voltage will reduce suddenly and then go up again Over charged battery Usually the over charged battery can be seen externally If a short circuit occurred inside the battery there will be no voltage on the terminals of battery if voltage regulator does not operate Then the battery s voltage will be too high that may reduce battery s life The battery will be self discharged if it was set idle for a long time An idle battery must be charged about every 2months A new battery filled with electrolyte will generate a voltage after filled out electrolyte The voltage should be in 12 5V or more after 10 minutes When electrolyte is not enough the battery must be filled with electrolyte and then charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage cur
23. column if it can be turned freely and no clearance in vertical motion 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER Lower all bearing sea Balls 5 Lower cone 9 n to 1 4 3 8 turn Top cone race Top cone race 14 9 SYM 15 REAR WHEEL REAR SHOCK ABSORBER MECHANISM DIAGRAM EXHAUST MUFFLER PRECAUTIONS IN OPERATION HEAR WHEEL TROUBLE DIAGNOSIS SHOCK ABSORBER MECHANISM DIAGRAM 3 5 4 5kgf m 3 0 3 6kgf m 11 0 13 0kgf m 15 1 15 REAR WHEEL REAR SHOCK ABSORBER SYM PRECAUTIONS IN OPERATION General Information As for the wheel removal service and installation procedures please refer to the service manual of high speed tire Specification Unit mm Standard Wheel wobbling ha Torque values Rear axle nut 11 0 13 0kgf m Rear shock absorber upper mount bolt 3 5 4 5kgf m Rear shock absorber lower mount bolt 2 4 3 0kgf m Exhaust muffler connection nut 1 0 1 4kgf m Exhaust muffler connection bolt 3 0 3 6kgf m TROUBLE DIAGNOSIS Rear wheel wobbling Braking Noise Poor brake performance bend wheel rim worn brake lining Poor brake adjustment poor tire brake drum deformation contaminated brake loosen wheel shaft improperly brake panel lining installation worn brake lining Shock absorber too soft unparalleled brake drum greased brake drum insufficient shock or wheel unparallel contaminated and ab
24. equipment Fuel unit installation Install the gauge in the reverse order of removal Cautions Do not forget to install the gasket of fuel unit or damage it FUEL TANK REMOVAL Open the seat Remove the luggage box assembly 6 bolts Disconnect the engine start control switch connector Disconnect the fuel unit connector Remove the fuel pipe fuel filter Remove the fuel tank 2 bolts Fuel Tank Installation Install the tank in the reverse order of removal 4 10 SYM 4 FUEL SYSTEM AIR CLEANER 1 m air filter strap Removal Remove the seat Hemove the luggage box assembly 4 bolts Loosen the clamp strip of air cleaner Hemove evaporative return hose Remove the air cleaner body bolts 2 bolts Remove the air cleaner Installation p za bolts x 2 Install the air cleaner in the reverse order of i removal Air Cleaner Element Cleaning Remove the air cleaner cover 7 screws ENS UM screwsx Remove the air cleaner element 2 screws With compressed air to clean dirty around the element Replace it if it is too dirty to clean A Cautions The air cleaner element is made of paper so do not soap it into water or wash it with water Air cleaner element 4 11 SYM 5 REMOVAL OF ENGINE MECHANISM DIAGRAM REMOVAL OF ENGINE SUSPENSION BUSHING 5 6 OPERATIONAL PRECAUTIONS ENGINE SUSPENSION FRAME ENGINE REMOVAL INSTALLATION OF ENGINE MECHANISM DIAGRAM 3 5 4
25. fingers The bearing should be turn smoothly Also check if the outer collar is tightly connected to the wheel hub If the bearing do not turn smoothly or if they are too loose in the races or damaged then remove and replace the bearings with new ones A Caution The bearing must be replaced in pair Installation Install the bearing according to the reverse procedure of removal Apply some grease into the bearing seat of the wheel hub Install the left bearing onto the seat Install the bearing spacer and then install the right bearing onto the seat A Caution Do not install used bearing and replace the bearing once it has been removed Do not the bearing in tile motion when installing Tool C type compressor or bearing compressor Apply with some grease inside of the dust bearing AT Install the dust seal and the front wheel side yii Bearing spacer collar S eU Bearing Apply with some grease on both side of the erp speedometer gear oil seal and then install the seal Bearing Dust seal Wheel side collar 14 6 SYM 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER Installation Align the flange part on the speedometer gear with the slot of wheel hub and then install the brake disc or speedometer gear A Caution Contaminated brake lining will reduce brake performance so the brake lining brake disc must be free of grease Stopper Place the front wheel
26. inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Recommended to use the KING MATE G 3 Install the snap ring and hold the bearing Sealing end Install a new inner bearing Sealing end Caution ts sealing end should be forwarded to outside as bearing installation Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Align oil seal lip with bearing and then install the new oil seal if necessary 8 12 SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH 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 Sliding pulley Install sliding pulley onto driven pulley Oil seal Install guide pin and guide pin roller Guide pin roller Install oil socket Install driving belt spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with special nut wrench Remove the clutch spring compressor Torque value 5 0 6 0 kg m Install clutch driven pulley and driving belt onto driving shaft Clutch spring compressor 8 13 SYM MECHANISM DIAGRAM OPERATIONAL P
27. nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring amp oil seal seat from sliding pulley INSPECTION Clutch outer Measure the inner diameter of clutch outer friction face Replace the clutch outer if exceed service limit Service limit 107 5 mm Ema Special nut wrench 179 Clutch spring compressor seal Guide pin Guide pin roller Clutch outer 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM Clutch lining Measure each clutch lining thickness Replace it if exceeds service limit Service limit 2 0mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 93 2mm Driven pulley Check following items e f both surfaces are damage or wear f guide pin groove is damage or wear Heplace damaged or worn components Measure the outer diameter of driven surface and the inner diameter of driven pulley Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Heplace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing
28. or pipes A CAUTION Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system and conduct the air bleeding job for the system 13 10 SYM 13 BRAKE DRUM BRAKE DRUM Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the dust Caution nhaling dust may cause respiration system disorder even cancer Never use an air hose or a dry brush as to clean the brake parts Grease on brake pad will reduce braking efficiency Remove wheel Remove brake drum from wheel hub Inspection Check the brake drum for wear and damage replace wheel hub if necessary Measure the ID of hub at several points and record the largest value Service limit 131 0 mm 4 Caution e Remove the rust by using 120 sand paper An inside micrometer must be used when measuring ID of brake drum because the brake drum has a friction back plate BRAKE PAD Inspection Measure the thickness of the brake pad at three points both ends and center If the thickness is less than specified or if it is contaminated by oil or grease replace as a set Service limit Front 2 0 mm Rear 2 0mm 13 11 13 BRAKE front brake cam lt gt Caution er hn 7 Brake pads must be replaced as a set dit E Remove brake shoes from the brake panel by AY MS SU ad TT pulling out the brake pa
29. pin snap ring align with the opening piston ring Place a piece of cleaning cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation CYLINDER INSTALLATION Clean up all residues and foreign materials on the matching surface of crankcase Pay attention to not let these residues and foreign materials fall into crankcase 4 Caution To soap the residues into solvent so that the residues can be removed more easily Install 2 lock pins and new gasket Coat engine oil to inside of cylinder piston and piston rings Care to be taken when installing piston into cylinder Press piston rings in one by one as installation 4 Caution Do not push piston into cylinder forcefully because this will cause the piston and the piston rings to be damaged Install the cam chain plate the cylinder gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto adjuster 2 bolts camshaft chain adjuster SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH MECHANISM DIAGRAM KICK STARTER ARM MAINTENANCE DESCRIPTION DRIVING BELT TROUBLE DIAGNOSIS SLIDING PULLEY LEFT CRANKCASE COVER CLUTCH DRIVEN PULLEY MECHANISM DIAGRAM 5 0 6 0kgf m 8 1 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM MAINTENANCE DESCRIPTION PRECAUTIONS IN OPERATION GENERAL INFORMATION Driving pulley clutch and
30. the big end at the vertical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 11 5 11 CRANKCASE CRANKSHAFT SYM ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase and then split out the cam chain Caution Do not damage the cam chain as installing the crankshaft Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket Install the right crankcase and tighten the crankcase bolts 1 bolts Torque value 0 8 1 2 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution e The O ring must be installed into the bolt s groove 11 6 SYM 11 CRANKCASE CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x37x6 Special service tools the oil seal installer 25x37x6 11 7 SYM 12 BODY COVER MAINTENANCE INFORMA
31. thin cost of grease between the oil seals on the brake cam shaft Install the brake cam Align the mark on the brake arm with the inner gear of the brake cam Tighten the bolts and nuts to specified torque Hook on the return spring Torque 0 8 1 2 kgf m Return spring Brake arm 13 13 SYM 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER MECHANISM DIAGRAM FRONT WHEEL PRECAUTIONS IN OPERATION FRONT SHOCK ABSORBER TROUBLE DIAGNOSIS FRONT FORK STEERING COLUMN 14 8 STEERING HANDLE MECHANISM DIAGRAM v 3 1 3 5kgf m 11 0 13 0kgf m 14 1 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER SYM PRECAUTIONS IN OPERATION General Information Before remove front wheel use a jack to lift the body until front wheel free of ground and take care not to rotate body in reverse Be careful not to allow oil or grease get on brake drum or linings Torque values Front wheel axle oteering handlebar nut oteering column top cone sliding ring oteering column lock nut opeedometer cable nut Front shock absorber Upper nut Tools Special service tools oteering column wrench Bearing remover Inner type bearing remover Attachment 32 35 mm Attachment 42 x47 mm Steering column nut wrench oteering column top cone ring nut wrench TROUBLE DIAGNOSIS Hard steering stem Over tightening of steering stem lock nut Broken steering stem steel ball and cone bearing seat Insufficient tire press
32. tool Inner type bearing puller If the driving shaft is pulled out with its bearing then remove the bearing with bearing puller and bearing protector Tool Multi functional bearing puller Bearing protector Install a new driving shaft bearing onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer final driving shaft bearing Install a new final driving shaft bearing onto crankcase Specified tool Press the bearing in with C type hydraulic presser or the bearing installer Apply with some grease onto the lip section of oil seal and then install the seal 9 FINAL DRIVING MECHANISM SYM RE ASSEMBLY OF FINAL DRIVING MECHANISM Install final driving shaft and final driving gear countershaft and countershaft gear Install the setting pins 2 pins and new gasket Apply with grease onto the oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 6 3 0 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover Install the rear wheel Filling bolt 74 la Add gear oil Recommended usage gear oil SAE 85W 140 110 cc standard capacity 100 cc when replacement E 9 6 SYM 10 A C GENERATOR PRECAUTIONS IN OPERATION RIGHT CRANKCASE COVER A C GENERATOR REMOVAL INSTALLATION RIGHT CRA
33. with fingers to check if the bearing rotation is in smooth and silent 6 10 Clutch lining Free length Driven pulley u Guide pin Sliding disc groove Outer ball bearing SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH Clutch Block Replacement Remove snap and washer and the remove clutch block and spring from driving plate Check if spring is damage or insufficient elasticity Snap ring Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location 4 Caution e Grease or lubricant will damage the clutch block and effect the block s connection capacity Clutch block Install the spring snap into groove with pliers Spring 8 11 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM Install snap ring and mounting plate onto setting pin REPLACEMENT OF DRIVEN PULLEY BEARING Hemove inner bearing Outer bearing Caution f the inner bearing equipped with oil seal on one side in the driven pulley then remove the oil seal firstly f the pulley equipped with ball bearing it has to remove snap ring and then the bearing Inner needle bearing Remove snap ring and then push bearing forward to other side of
34. 11 2 SYM 11 CBANKCASE CRANKSHAFT DISASSEMBLY OF CRANKCASE Hemove the 1 bolt from the right crankcase Remove the cam chain tensioner hex socket bolt from the left side of crankcase Place the left side of crankcase upward and then install the crankcase remover set onto the crankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Hemove the cam chain Caution Never pry out the connection surfaces of crankcases as separating Otherwise the connection surfaces could be damaged and cause oil leaking e t have to separate the cam chain and the drive gear before pressing out the both left and right crankcases Special Service Tools Crankcase remover set 11 CRANKCASE CRANKSHAFT SYM Remove the crankshaft from the right crankcase Caution The left and right bearings of crankshaft is to press fit onto the crankshaft Hemove gasket and dowel pins 2 ocrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the crankcase Soap the gasket residues into solvent and the residues will be removed easily Hemowve oil seal from the left crankcase 11 4 SYM 11 CBANKCASE CRANKSHAFT CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end Service limit Replace when it is more than 0 55 mm Measure the radical clearance of
35. ARK PLUG 2 8 PERIODICAL MAINTENANCE CYLINDER COMPRESSION PRESSURE 2 9 SCHEDULE DRIVING SYSTEM LUBRICATION SYSTEM STEERING SYSTEM FUEL SYSTEM SUSPENSION SYSTEM AIR CLEANER FRONT DISK BRAKE SYSTEM THROTTLE VALVE OPERATION DRUM BRAKE SYSTEM VALVE CLEARANCE INSPECTION WHEEL TIRE amp ADJUSTMENT BATTERY CARBURETOR IDLING SPEED HEADLIGHT ADJUSTMENT ADJUSTMENT NUTS BOLTS TIGHTEN PRECAUTIONS IN OPERATION Specification 5000 c c Fuel Tank Capacity auxiliary 150000 o 1500 c c n 800 c c Engine Oil 750 c c i 110 Transmission Gear oil 100 c c Clearance of throttle valve Spark plug TORCH A7RC Gap 0 6 0 7 mm F Mark in idling speed Before TDC 13 2200 rpm Full timing advanced Before TDC 26 8000 rpm Idling speed 2100x100 rpm Cylinder compression pressure 11 8 0 4 1 kg cm Valve clearance IN EX 0 06 0 02 mm 110 70 12 47J 120 70 12 51J single Front 1 75 kg cm rear 2 00 kg cm Tire pressure cold Front 1 75 kg cm rear 2 25 kg cm Battery Capacity YTX A BS 12V6Ah battery Play of drum brake lever 10 20 mm 2 MAINTENANCE INFORMATION SYM PERIODICAL MAINTENANCE SCHEDULE 1 year Item Initial 300KM Every1000KM Every3000KM Every6000KM Fev 129008 EAr deaner 2nd air jet leaner oo 15 1 C 3 R Oil filter 1 l e xx Engine oil change amp esum
36. CTRICAL EQUIPMENT Specification Charging System Capacity 12V YTX7A BS 12V 6AH SITD 0 6A 5 10hrs emergency charging Baier Charging rate GA 0 5hrs 200 Resistance 20 C 5W50 Resistor Resistance 20 C 30W7 5Q Ignition System Ignition coil resistance Starting System Starting motor capacity 05 KW 16 3 16 ELECTRICAL EQUIPMENT TROUBLE DIAGNOSIS Charging System No power supply Dead battery Disconnect battery cable Fuse burned out Faulty ignition switch Low voltage Weak battery Loose battery connection Charging system failure Voltage current regulator failure Intermittent power supply Loosen wire connector in charging system Loose battery cables Loose charging system connection Loose connection in lighting system Charging system failure burn Fuse Loose broken or shorted wire or wire connection Faulty voltage current regulator Faulty alternator Starting System Starter motor does not work The fuse is blown The battery is not fully charge Poor main switch Poor starter switch The front and rear brake switches do not operate correctly Starter magnetic switch is out of work The ignition coil is poorly connected open or short circuited The starter motor is out of work 16 4 SYM Ignition System spark produced by spark plug The spark plug is out of work The cable is poorly connected open or
37. DRUM BRAKE TYPE Measure the free play of the front brake lever at the end of the lever Free play 10 20 mm p Adjust the free play by turning the front brake E adjustment nut if necessary f i7 I K 7 Decreasing Ve free play Increasing free play BRAKE CONFIRAMTION Caution After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked Pull the brake lever and make sure that the wear limit marks of brake ling on the both front amp rear brake arm are closer and touch to the A marks If so replace the brake ling with new one 2 MAINTENANCE INFORMATION BRAKE LIGHT SWITCH The brake light switch is to lit up brake light as brake applied Make sure that electrical starter can be operated only under brake applying WHEEL TIRE Check if both front and rear tire pressure are within specification A Caution Tire pressure check should be done as cold tire pressure as cold tire gt Kg em persons Appointed Tire Front Rear wheel 110 70 12 47J 120 70 12 51J Check if tire surface is ticked with nails stones or other materials Check if tire surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspection or depth gauge e Replace the tire if tire tread dent or unusual wearing out e The tire should be replaced if the wear limit mark A is in vi
38. Insufficient fuel in fuel tank 3 Restricted fuel tank vent Check if carburetor clogged No clogged Clogged 1 Cleaning 1 14 SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS E CLUTCH DRIVING AND DRIVING PULLEY V FAULT CONDITIONS PROBABLE CAUSES Engine can be started but motorcycle can not be moved E Engine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance 1 2 3 4 5 6 N Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch ling broken Driving slide shaft gear groove broken Transmission gear damaged Clutch ling spring broken Clutch outer stick with clutch balance weights Connection parts in clutch and shaft worn out or burned Driving belt worn out or deformation Balance weight roller worn out Driving sliding gear shaft worn out Driving disk spring deformation Driving sliding gear shaft worn out Greased in driving belt and sliding gear 1 15 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM LUBRICATION POINTS Acceleration cable Front amp rear brake lever pivot Steering shaft bearing Speedometer gear Side stand shaft Main stand shaft Rear wheel bearing Front wheel bearing SYM 2 MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION IGNITION SYSTEM SP
39. NKCASE COVER MOUNTED COIL SET REMOVAL INSTALLATION FLY WHEEL INSTALLATION PRECAUTIONS IN OPERATION General information Refer to chapter 5 Engine removal and installation Refer to chapter 1 The troubleshooting and inspection of A C generator Torque value Flywheel nut 3 574 5kgf m Exhaust muffler bolt 8 mm 3 0 3 6kgf m Oil screen cover 1 0 2 0kgf m Special service tools Flywheel puller Universal fixture 10 1 10 GENERATOR STARTING CLUTCH SYM A C GENERATOR REMOVAL Pulse generator Cooling fan shroud Drain out the engine oll Hemove the exhaust muffler 2 bolts 2 nuts Remove the fan shroud 4 bolts Remove the fan 4 bolts Hold the flywheel with the universal fixture Hemove the 10mm nut on the flywheel Universal fixture Special Service Tools ay RE Universal Fixture you 474 10 2 SYM Remove the flywheel with the flywheel puller Special service tools Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller Remove the connectors of the A C generator and pulse generator Remove the 6 bolts for the pulse generator the A C generator coil and cable guide Then remove the A C generator assembly Caution Do not damage the alternator coil RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 8 bolts Remove setti
40. OL ITEM OUTER BEARING PULLER SYM 6204010 PURPOSE REMOVE THE BEARING ITEM LOCK NUT PULLER NO SYM 9020100 PURPOSE REMOVE THE LOCK NUT ITEM CLUTCHSPRING COMPRESSOR NO SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH SYM ITEM ACG FLYWHEEL PULLER NO SYM 3110A00 PURPOSE REMOVE ACG FLYWHEEL ITEM UNIVERSAL HOLDER NO SYM 2210100 PURPOSE HOLD THE MDF CLUTCH OUTER ITEM CLUTCH NUT WRENCH NO SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT SYM SPECIAL TOOL ITEM GY6 STARTER GEAR PULLER SYM 2822100 GY6 PURPOSE REMOVE THE STARTER GEAR SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYMBOLS AND MARKS TORQUE VALUES ENGINE GENERAL SAFETY TORQUE VALUES FRAME SERVICE PRECAUTIONS TROUBLES DIAGNOSIS SPECIFICATIONS LUBRICATION POINTS SYMBOLS AND MARKS oymbols and marks are used in this manual to indicate what and where the special service are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using the symbols or marks Means that serious injury or even death may result if procedures are not Warning followed Caution Means that equipment damages may result if procedures are not followed Limits to use SAE 10W 30 SH CD class oil Warranty will not cover the Engine oil damage that caused by not apply with the limited engine oil et crease Mate G 3 is recommended Em Apply sealant
41. RECAUTIONS TROUBLE DIAGNOSIS DISASSEMBLY OF FINAL DRIVING MECHANISM MECHANISM DIAGRAM 2 6 3 0 kgf m 2 6 3 0 kgf m 9 FINAL DRIVING MECHANISM INSPECTION OF FINAL DRIVING MECHANISM BEARING REPLACEMENT RE ASSEMBLY OF FINAL DRIVING MECHANISM E GX Pa META a LOC n mee T m ey el Hl i ir L1 5 Tome AM At PT in ae Ghee Y i i 4l EA Em 1 i 5 F v i i x 2 A 9 1 9 FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Application gear oil 4 stroke lubricant Recommended gear oil 85W 140 Oil quantity 110 c c 100 c c when replacing Tools Special service tools Inner type bearing puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved Damaged driving gear Burnt out driving gear Broken driving belt Noise Worn or burnt gear Worn gear Torque value Gear box cover 2 6 Gear oil drain plug 1 0 Gear oil filling bolt 1 0 Gear oil leaks Excessive gear oil Worn or damage oil seal SYM SYM 9 FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING MECHANISM Remove the rear wheel refer to chapter 15 Remove the clutch Drain gear oil out from gear box Hemove gear box cover bolts 7bolts and then remove the gear box cover and the final driving
42. SERVICE MANUAL Fiddle II 50 ye x SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle The manual is shown with illustrations and focused on Service Procedures Operation Key Points Inspection Adjustment so that provides technician with service guidelines If the style and construction of the motorcycle are different from that of the photos pictures shown in this manual the actual vehicle shall prevail opecifications are subject to change without notice This manual that contains all data illustration indication and specifications is based on current production information SYM reserves the right to make changes at any time without notice and without incurring any obligation whatever No part of this manual can be duplicated by any means without written permission of SANYANG SERVICE DEPARTMENT SAN YANG 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 SYM series motorcycles n 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 second chapter covers service maintenance The third to the eleventh chapters cover engine and driving systems The twelfth to fifte
43. TANK science satan 4 10 AIR CUT OFF VALVE AIR CLEANER uci e eec und eec ds 4 11 MECHANISM ILLUSTRATION Carburetor 4 1 4 FUEL SYSTEM SYM PRECAUTIONS IN OPERATION General Information Warning Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline A Cautions Do not bend or twist throttle valve cable Damaged cable will make unstable driveability When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is drain screw in the float chamber for draining residual gasoline Do not disassemble automatic by starter and air cut off valve arbitrarily Specification Idle speed 2100 100 rpm Vae AM Level in float chamber Throttle handle free play Torque value Fuel valve tightening nut 1 52 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level gauge 4 2 SYM TROUBLE DIAGNOSIS Poor engine start No fuel in fuel tank Clogged fuel tube Too much fuel in cylinder No spark from spark plug malfunction of ignition system Clogged air cleaner Malfunction of automatic by starter Malfunction of throttle valve operation Stall after started Malfunction of automatic by starter Incorrect ignition timing Malfunction of carburetor Dirty engine oil Air existing in intake system Incorrect idl
44. TION BODY COVER REAR FENDER HANDLE COVER FRONT CENTER COVER FRONT COVER LUGGAGE BOX UNDER COVER FLOOR PANEL FRONT INNER BOX Rear carrier Fuel tank Front handle cover cover Frame number Luggage box I cover Rear inner fender Front fender Right side cover 12 1 12 BODY COVER SYM MAINTENANCE INFORMATION Body covers disassemble sequence Front handle cover Luggage box amp Seat Rear handle cover Front fender Left right body cover Rear inner fender Front spoiler Left right side cover Battery cover Floor panel Under cover Be careful not to damage various covers in disassembly or re assembly operation Never injure hooks molded on the body covers in disassembly or re assembly operation Align the buckles on the guards with slot on the covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly 12 2 SYM 12 BODY COVER HANDLE COVER Removal Remove the left right back mirror Hemove 2 lower mounting screws between the front handle cover and the rear handle cover mounting screwx 2 Remove the mounting screws 4 screws between the front handle cover and the rear handle cover Remove the headlight connector Remove the front handle cover Remove the front handle cover Installation Install according to the reverse procedure of removal
45. a result fuel flooding A worn out or dirty float needle valve must be replaced with a new one Remove main jet slow jet fuel amount adjustment screw A Cautions Take care not to damage jets and adjust screw Before removing adjustment screw turn it all the way down and note the number of turns Do not turn adjustment screw forcefully to avoid damaging valve seat face Clean jets with cleaning fluid Then use compressed air to blow dirt off Blow carburetor body passages with compressed air 4 8 float needle valve float pin slow jet fuel adjustment screw 1 SYM Installation Install main jet slow jet and fuel amount adjustment screw Cautions Set the adjustment screw in according to number of turns noted before it was removed Install the float needle valve float and float pin Checking Fuel Level Cautions Check again to ensure float valve float for proper installation To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 3 5 1 mm INSTALLATION OF CARBURETOR Install carburetor in the reverse order of removal Following adjustments must be made after installation e Throttle valve cable clearance adjustment speed adjustment IDLE SPEED ADJUSTMENT Caution Fuel amount adjust screw was set at factory so no adjustment is needed Note t
46. ainst engine ground Check if sparks Weak sparks no spark at all perform cylinder compression pressure test cylinder compression Low compression pressure normal pressure or no pressure 3 There are some signs of Re start by following the Starting procedures ignition nut engine can not be started Remove the spark plug again and check it Dry spark plug Wet spark plug Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing clogged 1 12 No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator lgnition coil is in open or short circuit 6 Ignition coil leads open or short circuit Malfunction of main switch 1 Piston ring seized 2 Malfunction of cylinder valves Worn cylinder and piston ring 4 Cylinder gasket leak 5 Sand hole in compression parts Malfunction of throttle valve operation Air sucked into intake manifold Incorrect ignition timing Fuel level in carburetor too high 2 Malfunction of throttle valve operation Thro
47. ake hose bolt and finally remove the brake hoses CAUTION Do not spill brake fluid on painted surfaces Remove two caliper bolts and the caliper Make sure the brake pad condition Replace the pad if the brake pad wear limitation groove close to the brake disk Brake Pad Replacement Compress the caliper and let the brake pad out of the caliper mounting plate Compress the brake pad locking spring Remove the inner brake pad firstly and then remove the outer brake pad Compress the brake caliper at first as installation Install the inner brake pad firstly and then install the outer brake pad INSTALLATION Install the brake caliper and tighten the attaching bolts securely Torque 3 3 kgf m CAUTION Use M8 x 35 mm flange bolt only Long bolt will impair the operation of brake disc Tighten the pad guide bolt Torque 1 8 kgf m Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5 kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding 13 BRAKE PF L a P i hose bolt brake pad wear limitation groove 13 7 13 BRAKE BRAKE DISK Inspection Visually check the brake disk for wear or break Measure the thickness of the disk at several places Replace the disk if it has exceeded the service limit Allowable limit 2 0 mm Remove the brake disk from wheel Check the disk for deformation and bend Allowab
48. and washer Inspection Check if starter shaft driving gear for wear or damage Replace it with new one if necessary Check the return spring for spring force or damaged Replace it with one if poor parts found Reassembly Apply with some specified grease on the gear shaft Install the friction spring of driving gear onto convex part of the case cover Install return spring and starter shaft as diagram shown Install kick starter arm temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install thrust washer and socket onto starter shaft Installation of the left crankcase cover Install the left crankcase cover 8 bolts Install front vent tube of left cover and tighten the strap Install kick starter arm 1 bolt Tighten the air cleaner 2 bolts Kick starter arm shaft Return spring 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM DRIVING BELT Removal Remove left crankcase cover Hold the sliding pulley with a universal fixture and then remove the nut and sliding pulley Hold driving pulley with universal fixture and remove nut and clutch outer A Caution Using special service tools for tightening or loosening the nut Fixed rear wheel or rear brake only will damage reduction gear system Push the driving belt into belt groove as diagram shown so that the belt can be loosened and then remove Driving belt and clutch at same tim
49. ar oil filling bolt 1 0 1 Oil pump fixing screws 0 8 1 TROUBLE DIAGNOSIS Low engine oil level Dirty oil e leaking e oil change in periodical e Valve guide or seat worn out e Cylinder head gasket damage e Piston ring worn out e Piston ring worn out Low Oil Pressure e Low engine oil level e Clogged in oil strainer circuits or pipes e Oil pump damage SYM ENGINE OIL Turn off engine and park the motorcycle in flat ground with main stand Check oil level with oil dipstick after 3 5 minutes Do not rotate the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Replacement Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely Place an oil pan under the motorcycle and remove oil strainer cap Make sure if the aluminum washer of the draining bolt is damaged so replace it with new one Install the drain bolt and tighten it Torque value 1 0 1 5 kgf m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it Torque value 1 0 2 0 kgf m Fill out oil to the oil filler Oil viscosity SAE 10W 30
50. be removed without removing the hydraulic system e After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system e While refilling brake fluid care should be taken not to let the foreign material entering into the brake system e Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage e Check the operation of the brake system before you go Specifications Unit mm disk As brake ling mark 2mm or As brake ling mark 2mm or As brake ling mark Thickness of front disk brake pad Thickness of front drum brake pad Thickness of rear brake pad Torque values Bolt for front brake arm 0 8 1 2kgf m Bolt for rear brake arm 0 8 1 2kgf m Brake hose bolt 3 3 3 7kgf m Bolt for brake caliper 3 1 3 5kgf m Air bleed valve 0 8 1 0kgf m 13 3 13 BRAKE oYM _ gt 1 TROUBLE DIAGNOSIS DISK BRAKE Soft brake lever Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake pad disk Low brake fluid Blocked brake pipe Warp bent brake disk Bent brake lever Hard operation of brake lever Blocked brake system Poor brake caliper Blocked brake pipe oeized worn master cylinder piston Bent brake lever DRUM BRAKE Poor brake performance Improper brake adjustment Worn brake pad Worn brake drum Worn brake cam Improper brake pad i
51. between the front shock absorbers Align the flange part on the speedometer gear with the slot of shock absorber stopper Install the front wheel axle from right shock absorber side Install the wheel axle nut and tighten it to specified torque value Torque value 11 0 13 0kgf m Connect the speedometer cable to the speedometer gear box Wheel axle nut Speedometer cable 14 7 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER SYM FRONT SHOCK ABSORBER Removal Remove the front fender front lower spoiler front guard and front wheel as well as front brake components Remove the brake fluid hose clipper or cable guide on the left shock absorber bolt x 1 As for disc brake remove the cable guide on the right shock absorber bolt x 1 Brake fluid hose clipper Remove the top connection bolt of the right shock absorber bolt x 4 Remove the shock absorber from the front fork Installation Install the shock absorbers according to the reverse procedure of removal Align the shock absorber top edge with the top end level of the front fork when installing the front shock absorber onto the front fork Then tighten the nut Torque value 2 4 3 0kgf m FRONT FORK STEERING COLUMN Removal Firstly remove the handlebar front wheel front brake set and front shock absorbers Remove the steering column nut Remove the top cone ring and then remove the steering column Caution Place the steering column bearing
52. ce the whole set comprising piston spring piston cup circlip piston a p brake lamp rubbers ina switch and circlip washer e Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master Install the circlip CAUTION Never install cup lip in the opposite direction e Make sure the circlip is seated securely in the groove Install the rubber pad into groove properly 13 9 13 BRAKE INSTALLATION Place the master cylinder onto handlebar and install the split ring and bolts The UP mark on the split ring should face upward Align the split ring on the master cylinder seat with the alignment point on the i n handlebar wr EC e Tighten the upper bolt of the seat to A 9 bolts 2 specified torque value and then tighten enlit ring F lower bolt to the same specified torque AL JP mark value Install the brake lever and connect leads to brake lamp switch Connect brake hoses with 2 new washes Tighten the brake hose bolt to the specified torque value Torque value 3 5 kgf m Make sure the hose is installed correctly CAUTION 7 brake hos Improper routing may damage leads hoses
53. connect terminal to green A side and to black yellow side high voltage shun Min voltage Above 95 V L Caution Do not touch metal parts on the test probe ith fingers to avoid electric shock Primary coil chec Disconnect the primary coil connector and check the resistance between primary coil terminals Standard 0 210 410 Q at 20 C Primary coil is good if resistance within standard Primary coil is broken if resistance is infinite Replace the coil 16 12 SYM 16 ELECTRICAL EQUIPMENT Secondary coil Attached the spark plug cap measure the resistance between plug cap side and green terminal Standard value 7 12 20 Remove the spark plug cap measure the resistance between plug cap side and green terminal Standard value 3 5 20 Secondary coil is good if resistance within standard oecondary coil is broken if resistance is infinite If the spark plug cap attached and the measured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution Checking pulse generator can be done on engine But the spark plug must be installed onto the cylinder head and cylinder compression pressure must be in normal condition Check Remove body cover Remove the pulse generator connector Measure the resistance between blue yellow terminal on engi
54. driven pulley can be serviced on the motorcycle Driving belt and driving pulley surface must be free of grease Specification Unit mm OD of driven pulley 33 965 33 985 ID of sliding pulley 34 000 34 025 ID Inner Diameter OD Outer diameter Free length of drive pulley 97 20 Torque value Sliding pulley nut 5 0 6 0kgf m Special Service Tools Clutch outer nut 5 0 6 0kgf m Clutch spring compressor driving pulley nut 3 5 4 5kgf m Bearing puller inner type Clutch mounting nut wrench Universal fixture TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved 1 Worn driving Belt 2 Worn tilt plate 3 Worn or damaged clutch lining 4 Broken driven pulley Insufficient horsepower or poor high speed performance 1 Worn driving belt 2 Insufficient spring capacity of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly Shudder or misfire when driving 1 Broken clutch lining 2 Worn clutch lining 8 2 SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH LEFT CRANKCASE COVER kick starter arm air cleaner lock nut Left crankcase cover removal Hemove air cleaner 2 bolts Remove kick starter arm 1 bolt Loosen vent strap on the front left side of cover and then remove the vent Hemove engine left side cover 8 bolts Friction spring Starter shaft KICK STARTER ARM Disassembly Remove the return spring starter shaft Remove driving gear friction spring
55. ds with two hands PAD gt pra 027 Installation TERNO Apply a thin coat of grease to the brake cam anchor pin p M j y brake shoes and the anchor pin Hook the brake spring onto the brake cam Pull out the brake pads and install them onto the brake panel Wipe off the excessive grease from the brake cam and the anchor pin after installation olightly grind the brake pad surfaces with sand paper to clean the surfaces Caution Braking efficiency will be reduced if brake pad is contaminated by oil or grease BRAKE PANEL Removal Hemove the brake arm bolt and then remove the brake arm wear indicator brake return spring and brake cam as well as the oil seal from the brake panel i i a 7 E Wear indicator 12 Or P Return spring 13 12 SYM 13 BRAKE Installation iB e Return spring FRONT BRAKE PANEL N Wear Apply a thin cost of grease onto the brake 5 J gt cam shaft Install the brake cam Apply a thin cost of grease onto the oil seal lip and then install the oil seal onto the brake cam shaft Finally install it on the brake panel Align the end part of the brake return spring with the hole of brake panel Align both the inner gear of wear indicator and the mark on the brake arm with the indent gear of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2 kgf m REAR BRAKE PANEL Apply a
56. e Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited specification Service Limit 16 80mm Caution Using the genuine parts for replacement The surfaces of driving belt or pulley must be free of grease e Clean up all grease or dirt before installation SYM Installation Pull out the driving pulley and then insert the driving pulley A Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily Install the starter gear Install the clutch set with driving belt onto the driving shaft Install the sliding pulley on the other end of belt Install clutch outer Install the clutch with universal fixture and then tighten nut to specified torque value Torque value 3 5 4 5 kgf m A Caution When install the driving belt if there is a arrow mark then the arrow mark must point to rotation motion If not the letters on the belt must be forwarded to assembly direction 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH Sliding driven 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM SLIDING PULLEY REMOVAL Remove left crankcase cover Hold driving pulley with universal fixture and then remove driving pulley nut Remo
57. e Max 100 Measured after engine stopped for more than 10 minutes Replace the auto by starter with a new one if resistance value exceeds standard Hemove the carburetor allow it to cool off for 30 minutes Connect a hose to fuel richment circuit Pump compressed air to the circuit Replace the auto by starter if the circuit clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter Removal Hemove fixing plate screw and then remove the plate and auto by starter from carburetor Valve inspection Check if auto by starter and valve needle for damage or wear out fixing plate Installation Install auto by starter to the carburetor body Install fixing plate to the upper groove of auto by starter and install its flat surface to carburetor Install screw and tighten it Cautions Align the round point of the starter with the screw hole of air intake side fixing plate 4 FUEL SYSTEM valve needle 4 FUEL SYSTEM FLOAT CHAMBER Disassembly Hemove 3 mounting screws and remove the float chamber cover Hemove the float pin and float valve Checking Check float needle valve and valve seat for drop difference damage wear out dirty or clogged a Cautions In case of worn out or dirt the float needle valve and valve seat will not tightly close causing fuel level to increase and as
58. e speed Rough idle Malfunction of ignition system Incorrect idle speed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing e Malfunction of ignition system Malfunction of carburetor 4 FUEL SYSTEM Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system Mixture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogged fuel tank cap vent Clogged fuel filter Obstructed fuel pipe Clogged air vent hose Air existing in intake system xture too rich Clogged air injector Malfunction of float valve Fuel level too high in float chamber Malfunction of automatic by starter Dirty air cleaner 4 3 4 FUEL SYSTEM CARBURETOR REMOVAL throttle valve cable Remove the luggage box Loosen the adjustment nut and fixing nut of throttle valve cable and release the cable from carburetor Hemove fuel pipe vacuum hose Disconnect auto by starter connectors Release the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress spring and vacuum piston i m LE a br _ vacuum hose
59. e start control switch wire connector Disconnect the fuel unit wire connector A Caution Do not damage or bend the float arm as removing The resistance values are listed below when the float arm in F and E positions Float arm position Resistance value E empty 97 5 107 5Q F full DOWN empty Connect the fuel unit to the main harness Turn the main switch position Move the float arm in UP amp DOWN and then check if the fuel unit indication needle is in correct position Caution Turn on the turn signal light to make sure battery is in good condition before this test Float arm position Indicator needle UP full E empty DOWN empty F full 16 22 AWOSW 6 WIRING DIAGRAM FR STOP SW RR STOP SN START SV START MAG FUEL UNIT LIGHT MAIN SWITCH FRAME BARTH olo olo D GAl BATTERY LL n i START MOTOR R g b Y R 6 1 YN G zc Y BRA B YAN 6 1 RH FR WINKER BNET 09 RR VINER G E ES 12 108 EL 6 6 E IL L 12V 1 LH FR WINKER on A TAIL STOP LIGHT 121 219 50 X HL dL Ll dll W om E 2 T ERE cr ie EXE FR POSITION aa A masimo IY ET END IB l a
60. e the engine start control switch wire connectors Installation Install the luggage box according to the reverse procedure of removal FLOOR PANEL Removal Remove the 4 bolts from the floor panel 12 BODY COVER 12 9 12 BODY COVER Remove the 4 screws from the battery i screws cover Cu n Remove the battery cover Remove the front center cover mounting screw 1 screw Remove the 1 2 screws between the body cover and the floor panel 1 2 screws Remove the 1 x 2 screws between the left right side cover and the floor panel Remove the floor panel Installation Install the floor panel according to the reverse procedure of removal 12 10 1 2 screws SYM 13 BRAKE MECHANISM DIAGRAM BRAKE CALIPER MAINTENANCE INFORMATION BRAKE DISK TROUBLE DIAGNOSIS BRAKE MASTER CYLINDER HYDRAULIC BRAKE SYSTEM DRUM BRAKE DRUM INSPECTION BRAKE LING BRAKE FLUID REPLACEMENT BRAKE PANEL AIR BLEED MECHANISM DIAGRAM Front Disk Brake System 3 3 3 kgf m 4 0 4 5 kgf m a 11 0 13 0 kgf m Oae 2 S 2 13 1 13 BRAKE Rear Drum Brake System 0 8 1 2 kgf m 13 2 SYM 13 BRAKE MAINTENANCE INFORMATION Precautions in Operation CX Caution Installing pad dusts may cause disorders of respiration system or cancer therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead e brake caliper
61. e the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value within standard Exhaust Emission CO 12 0g km HC 1 0g km MAINTENANCE INFORMATION Feeler gauge Ignition coil cable 2 MAINTENANCE INFORMATION SYM IGNITION SYSTEM Ignition timing Caution C D I ignition system is set by manufacturer so it can not be adjusted Ignition timing check procedure is for b Ignition light checking whether C D I function is in normal AP p or not 1 Remove ignition timing hole cap located on fi the cooling fan cap or remove the cooling fan cap Check ignition timing with ignition light Start engine and set engine idle speed in 2100 100 rpm and if the mark aligns with the F then it means that ignition timing is correct Increase engine speed to 8000 rpm to check ignition timing advance If the detent aligns with advance mark then it means ignition timing advance is in functional If not check CDI set pulse flywheel and pulse generator Replace these components if malfunction of these parts are found SPARK PLUG Appointed spark plug TORCH A7RC Remove luggage box Remove center cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap n Spark plug gap 0 6 0 7 mm Spark plug cap Car
62. eck clutch pad operation If the motorcycle moves with shaking then check its clutch pad for wearing Replace it if necessary 2 MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE 7i a E ME Spark plug cap Cylinder pressure gauge Gear teeth poc un a Clutch pad 2 MAINTENANCE INFORMATION STEERING SYSTEM Caution Check all wires and cables if they are interfered with the rotation of steering handle bar Lift the front wheel out of ground Turn handle from right to left and check if turning is smoothly If handle turning is uneven and bending or the handle can be operated in vertical direction then adjust the handle top bearing SUSPENSION SYSTEM Warning Do not ride the motorcycle with poor shock absorber Looseness wear or damage shock absorber will make poor stability and driveability Front shock absorber Hold front brake lever and press down the front shock absorber for several times to check its operation Hold front brake lever and push forward the front shock absorber for several times to check its locking status Check if it is scratched or leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scratched or leaking Replace damaged and non repairable components Park the motorcycle with main s
63. ector pins are bent wires or wire harnesses extruded or loosen Q e Insert the connector completely f there are Wire band and wire harness have to be two lockers on two connector sides make clamped secured properly sure the lockers are locked in properly Check if any wire loose CTD EAM 2 ern 88 e Check if the connector is covered by the twin Do not squeeze wires against the weld or its connector boot completely and secured clamp properly SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS Do not let the wire harness contact with rotating moving or vibrating components as routing the harness Keep wire harnesses far away from the hot parts sortie NA Do not touchit Route wire harness to avoid sharp edges or corners and also avoid the projected ends of bolts and screws Route harnesses so that they neither pull too tight nor have excessive slack Do not extend it too much Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied oecure the rubber boot firmly as applying it on wire harness O Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace them Never clamp or squeeze the wire harness as installing other components Please do not clip or squee
64. efully bend ground electrode of the plug to adjust the gap if necessary ocrew the park plug into the plug hole with Side electrode hands then tighten the plug with a wrench to prevent from damaging the spark plug s thread Torque value 1 0 1 4 kgf m Connect spark plug cap SYM Warn up engine and then turnoff the engine Remove the luggage box and the center cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of stepping the kick starting lever A Caution Rotate the engine until the reading in the gauge no more increasing Usually the highest pressure reading will be obtained in 4 7 seconds Compression pressure 11 8 0 4 1 kg cm7 Check following items if the pressure is too low incorrect valve clearance Valve leaking Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit above 18 5 mm Clutch pad Start the motorcycle and gradually increase throttle valve openness to ch
65. enth chapters are contained the parts set of assembly bogy The sixteenth chapter is electrical equipment The seventh chapter is for wiring diagram Please see index of content for quick having the special parts and system information SYM CONTENTS CONTENTS GENERAL INFORMATION TROUBLE DIAGNOSIS MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD VALVE CYLINDER PISTON V TYPE BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH FINAL DRIVING MECHANISM A C GENERATOR STARTING CLUTCH CRANKCASE CRANKSHAFT BODY COVER BRAKE SYSTEM STEERING FRONT WHEEL FRONT SHOCK ABSORBER REAR WHEEL SUSPENSION ELECTRICAL EQUIPMENT ELECTRICAL DIAGRAM MECHANISM ILLUSTRATIONS SYM Meter High amp Low beam Passing turn signal horn Start magnetic switch Head light Fuel tank Fuel unit Position light Frame number Rear brake lever Horn REG REC Tail light Front turn RR turning signal light signal light Air cleaner Gear oil filling bolt Gear oil draining Front disk brake bolt Engine number engine oil draining bolt Light starter switch Front brake lever Engine control switch Batlery Fuse CDI Ignition switch Winker relay Tail light Front turn signal light Rear turn signal light Exhaust muffler Ignition coil Oil level A C Generator SPECIAL TO
66. ervice Limit Top ring replace if over 0 50mm 2nd ring replace if over 0 650 7 CYLINDER PISTON SYM Measure the outer diameter of piston pin Service Limit 12 980mm Measure the inner diameter of connecting rod small end Service Limit 13 020mm Measure the inner diameter of piston pin hole Service Limit 13 000mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter A Caution measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 38 970 Compare measured value with service limit to calculate the clearance between piston and cylinder 7 6 SYM 7 CYLINDER PISTON PISTON RING INSTALLATION Clean up piston top ring groove and piston skirt Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rings can be rotated freely after installed Top ring And ring Side ring Spacer Cil ring Side ring Top groove 2nd groove groove 7 CYLINDER PISTON SYM PISTON INSTALLATION Install piston and piston pin and place the IN mark on the piston top side forward to intake valve Install new piston pin snap ring amp Caution Do not let the opening of piston
67. ffects motorcycle s performance i Especial tool LER M i c VALVE CLEARANCE ADJUSTMENT Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the adjustment nut Standard Value IN EX 0 06 0 02mm Turn the cam chain adjuster in clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Tighten the bolt cap of the adjuster adjustment hole Caution The O ring must be installed into glove Replace the O ring of the cylinder head with new one Install the cylinder head Tighten the cylinder head lock bolts Connect the blow by hose onto the cylinder head Tighten the 274 air injection Al nut Install the engine onto the engine frame Refer to Chapter 5 6 14 SYM 7 CYLINDER PISTON PISTON REMOVAL PISTON RING INSTALLATION PISTON INSTALLATION CYLINDER INSTALLATION 0 8 1 2kgf m 7 1 7 CYLINDER PISTON SYM PRECAUTIONS IN OPERATION General Information Both cylinder and piston service cannot be carried out when engine mounted on frame Specification unit mm 39 00 Bend wrap age D 0 050 Cylinder Cylindrical Clearance between 0 025 0 060 0 090 piston and rings 0 015 0 050 0 090 0200 0400 0 500 Piston Ring end gap 0 250 0 400 0 650 Piston ring
68. gf m A Caution Warm up the engine This will make the oil flow out easily Add oil to the specified capacity Oil Viscosity SAE 10W 30 recommended using King Mate serial oil Engine oil capacity Disassembly 850cc Change 750cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen wash it off with suitable solvent recommended using compressed air Check O ring for damage replace if necessary Reinstall strainer spring O ring and strainer cover Torque value 1 0 2 0 kgf m spring 2 MAINTENANCE INFORMATION SYM Gear Oil Inspection Check gear oil if leaking Park the motorcycle with main stand on flat level place Turn off engine and remove the gear oil draining plug Place a measurement cup under the draining hole Remove the oil drain plug and drain gear oil into a measurement cup Check gear oil if enough Replacement At first remove the gear oil refilling bolt and then remove the draining plug Install the draining plug after drained oil out Torque value 1 0 1 5 kgf m Caution Inspect if washer is in good condition Replace it with new one if it was deformed or damaged Fill out gear oil to specified quantity from the engine oil filling hole Install the oil filling bolt DU Tor
69. he number of turns it takes to screw it all the way in for ease of installation Never screw in forcedly to avoid damaging the screw seat The main stand must be used to support the motorcycle to perform the adjustments EN Throttle valve cable Use a tachometer when adjusting engine RPM adjustment nut Screw in adjustment screw gently then back up to standard turns Standard turns 1 1 2 3 4 turns Warm up engine adjust throttle valve stopper screw to standard RPM Idle speed rpm 2100x100 rpm Connect the sampling hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the air volume adjustment screw and read CO reading on the analyzer CO standard value 1 0 1 5 96 Accelerate in gradual increments make sure both and CO value are in standard values after engine running in stable If rpm and CO value fluctuated repeat the procedures described above for adjusting to standard value 4 FUEL SYSTEM fuel amount adjustment screw throttle valve 4 stopper screw air volume adjustment screw 4 9 4 FUEL SYSTEM SYM FUEL TANK Fuel unit removal Open the seat Hemove the luggage box 6 bolts Hemove the engine starter control switch wire connector Disconnect fuel unit connector Remove fuel unit Cautions Do not bend the float arm of fuel unit Do not fill out too much gasoline to fuel tank Fuel unit inspection Refer to chapter 16 electrical
70. he diode and check the continuity between main wire terminals according to following method Main wire circuit inspection Item wire color Judgment Check voltage between Battery voltage battery terminal red and ground green Check continuity between ontinuity ground green and frame Check illumination wire yellow to ground disconnect the connector of Continuity amp the resistor s pin and resistance automatic by starter pin Illumination switch is in OFF Check charging coil white to Continuity amp ground resistance If the measured value is abnormal check the abnormal wire circuit If components are good it could be a poor wire circuit If all items are in good condition then replace the voltage regulator If main wire circuit check is in normal and there is no loose in the pins of voltage regulator connector then measure the resistance between the connector of voltage regulator Voltage Regulator Check Unit O Red White Yellow p R I Y NRI 160 180 160 180 If the e i values are abnormal among the pins replace the voltage regulator Caution Do not touch the probe of multi meter by fingers then the resistance values will be incorrect because there is some resistance existence in human body use the multi meter recommended by SYM Otherwise the measured resistance might be different 16 ELECTRICAL EQUIPMENT SYM Alternator charging co
71. he small fasteners first If the bigger ones are loosen first small fasteners may receive too much stress otore 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 1 3 1 GENERAL INFORMATION TROUBLE DIAGNOSIS The length of bolts and screws for assemblies cover plates or boxes is different from one another be sure they are correctly installed In case of confusion Insert the bolt into the hole to compare its length with other bolts if its length out side the hole is the same with other bolts it is a correct bolt Bolts for the same assembly should have the same length Tighten assemblies with different dimension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated Bolts and fasteners should be kept clean and dry Do not apply oil to the threads When oil seal is installed fill the g
72. il Ignition light coil A Caution connecto B COnnector The check of alternator charging coil and illumination coil can be done when the Pulse generator alternator is mounted on engine connector Check Remove the 3P connector of the alternator Measure the resistance between the white wire on the alternator and frame ground with a multi meter Standard 0 6 0 10 20 C Replace the alternator charging coil if the measured value exceeds standard Alternator lighting coil Check Remove the 3P connector of the alternator Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 80 0 10 20 C Replace the alternator lighting coil if the measured value exceeds standard Resistor check Remove the front cover Measure the resistance between the resistor wire green black and frame ground Standard 50 5W 4 5 5 5 green black Standard 7 50 30W 7 0 8 0 pink 16 10 SYM 16 ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit Blue yellow Black yellow Pluser Engine start control switch spark plug Blue yellow 0 5 L Blue yellow green Black black yellow green C D I unit green Ignition coil CDI UNIT Removal Remove the right body cover then the C D I unit can be removed from the frame Check Disconnect the connector from the CDI unit Make the following inspection at each terminal of the har
73. ing EX Replacement when less than 25 12 mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Disassembly Of Camshaft Holder With a 5 mm bolt to screw in the cam rocker arm shaft so that take it out cam rocker arm 5mm bolt m TU D A r i i 7 i y rocker arm shaft Inspection Of Camshaft Holder Check if the camshaft holder cam rocker arm and rock arm shaft for wearing out or damage Caution Further check is necessary if any wear is found on the moveable surface of cam rocker arm Check if the camshaft bearing mounting surface for wear or damage Measure the 1 0 of the camshaft holder Service Limit Replace when it is above 10 10 mm rocker arm shaft 6 CYLINDER HEAD VALVE SYM Measure the valve rocker arm 1 0 Service Limit Replace when it is above 10 100 mm Measure the active O D of the valve rocker arm shaft Service Limit Replace when it is above 9 910 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD REMOVAL Hemove double seat luggage box and front center cover Remove the engine refer to Chapter 5 Hemove the cooling fan cover Remove the engine shroud L 2 bolts R 3 bolts Remove the camshaft 6 6 SYM 6 CYLINDER HEAD VALVE Hemove the 2 cylinder head mounting bolts dowel pin
74. ion The pulley surface has to be free of grease Clean it with cleaning solvent Install siding pulley assembly onto crankshaft Driving pulley install Press driving belt into pulley groove and then press down the up amp down sides of the driving belt to separate it away from the driving pulley hub Caution To press down the up amp down sides of the driving belt can avoid to pressing and damaging the belt when installing the driving pulley and also can make sure that the driving pulley can be tighten Install driving pulley washer and nut Caution Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold driving pulley with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover 8 8 Pulley bush Pulley surface Crankshaft Sliding pulley Pulley bush Limited speed MV 1 s 27 c m un oum Nim T t p SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH CLUTCH DRIVEN PULLEY DISASSEMBLY Remove driving belt and clutch driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let nut be installed more easily A Caution Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with special
75. it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play 2 6 mm Adjustment can be done in either ends oecondary adjustment is conducted from top side Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment nut Fixing nut Adjustment nut 2 MAINTENANCE INFORMATION SYM Primary adjustment is conducted from button side Loosen fixing nut and adjust by turning the adjustment nut Tighten the fixing nut and check acceleration operation condition Adjustment nut Fixing nut A Caution When always riding in rainy area or full throttle position maintenance period must be shorted The deposits can be seen in the transparent section of draining hose VALVE CLEARANCE ADJUSTMENT Caution Checks and adjustment must be performed hen engine is cold below 35 Remove luggage box and front center cover Remove the left body cover amp left side cover Remove cylinder head cap Remove the ignition timing check hole on the cooling fan cover With T type wrench turn crankshaft in clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TDC position in the compression stroke Caution
76. ity Too much carbon deposited in combustion chamber Ignition timing too advanced 6 Poor circuit on the cooling system Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality Ignition timing too advanced 1 13 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM C Engine runs sluggish especially in low speed and idling Check and adjustment Fault condition Probable causes Check ignition timing using ignition lamp 1 Incorrect ignition timing malfunction of CDI or AC alternator Adjust the air screw of carburetor 2 Lean mixture tighten the screw Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack con cap and perform spark test Spark plug fouled Malfunction of CDI against engine ground Malfunction of AC generator Good spark Malfunction of ignition coil Open or short circuit in spark plug a leads Malfunction of main switch D Engine runs sluggish High speed Check and adjustment and Check and adjustment Fault condition condition Probablecauses 000 Probablecauses 000 Check ignition timing 1 Malfunction of CDI 2 Malfunction of AC alternator Check for fuel supplying system in automatic fuel cup O 1
77. iving gear nut SYM 3 LUBRICATION SYSTEM Filling bolt GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand Turn off engine and remove both engine oil filling bolt and oil draining bolt rere li Draining bolt Remove gear oil filling hole bolt and place a h 05 er measurement cup under the draining plug Remove the oil draining plug and the pour gear oil into the measurement cup Measure the gear oil quantity if within standard value Add specified gear oil if the oil level too low otandard quantity 110cc Replacement 100 cc Gear Oil Replacement Remove the gear oil filling bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it with new one Torque Value 1 0 1 5 kgf m Add new gear oil 100 c c from the gear oil filling hole and then install the gear oil filling hole bolt after added oil And then tighten the bolt Torque Value 1 0 1 5 kgf m Recommended to apply with SAE 85W 140 Start engine and run it for 2 3 minutes Turn off engine and check if oil leaking SYM 4 FUEL SYSTEM MECHANISM ILLUSTRATION AUTO BY STARTER 4 7 PRECAUTIONS IN OPERATION FLOAT CHAMBER 4 8 TROUBLE DIAGNOSIS INSTALLATION OF CARBURETOR 4 9 CARBURETOR REMOVAL IDLE SPEED ADJUSTMENT 4 9 VACUUM CHAMBER
78. le limit 0 30 mm A CAUTION Do not let grease touch to the brake disc that will cause brake performance Do not clean the brake pad with air gun Operator should wear mask amp glove and use vacuum cleaner to clean the brake pad BRAKE MASTER CYLINDER Removal A CAUTION Do not let foreign materials enter into the cylinder A CAUTION The whole set of master cylinder piston spring diaphragm and circlip should be replaced after removal Remove the front and rear handlebar guards circlip Remove the leads of brake lamp switch rubber boot Drain out the brake fluid brake lamp Remove the brake lever from the brake switch master cylinder 2 Remove the brake hose Hemove the master cylinder seat and the master cylinder Remove the rubber pad Remove the circlip Remove the piston and the spring Clean the master cylinder with recommended brake fluid 13 8 SYM 13 BRAKE Inspection Check the master cylinder for damage or e master cylinder scratch Replace it if necessary Measure the cylinder inner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit Allowable limit 11 055 mm Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit 10 945 mm Piston a 1 1 bm x Micrometer Assembly CAUTION rubber boot e t is necessary to repla
79. lve do not release the brake lever transparent draining hose 2 11 2 MAINTENANCE INFORMATION ADDED BRAKE FLUID Brake fluid cap Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or DOTA WELL RUN brake fluid A Caution Low limit Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance BRAKE LINING WEAR The indent mark on brake lining is the wear limitation Replace the brake lining if the wear limit mark closed to the edge of brake disc A Caution It is not necessary to remove brake hose hen replacing the brake lining Remove the brake clipper bolt and take out the clipper Caution Brake 5 clipper bolts x 2 Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution In order to maintain brake power balance the brake lining must be replaced with one set 2 12 SYM 2 MAINTENANCE INFORMATION DRUM BRAKE SYSTEM Front Brake Free Play Drum brake Measure free play of rear brake level at the end of the lever Free play 10 20 mm Adjust the free play by turning the front brake adjustment nut if necessary Increasing free x BU F 2 play J SS E Adjustment nut Decreasing free play REAR BRAKE FREE PLAY
80. lve seat with 45 cutter to specified width 6 CYLINDER HEAD VALVE Old valve seat width Contact surface too high valve seat width Contact surface Old valve seat too low ___ width 6 11 6 CYLINDER HEAD VALVE After the valve seat grinded coat valve seat surface with emery and then slightly press the grinded surface Clean up all emery coated onto cylinder and valve after grinded CYLINDER HEAD REASSEMBLY Lubricate valve stem with engine oil and then insert the valve into valve guide Install new valve stem oil seal Install valve springs and retainers Caution The closed coils of valve spring should face down to combustion chamber Use valve spring compressor to press valve spring Install valve split locks and release the valve compressor Caution In order to avoid to loosing spring tension do not compress the spring too much length is based on the installation of latch opecial tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly A Caution Place and hold cylinder head on to working table so that can prevent from valve damaged 6 12 SYM Valve cotters um N 4 stem oil seal Valve sprin retainer Valve spring SYM CYLINDER HEAD INSTALLATION Install the lock pins and new cylinder head gasket onto the cylinder head Install the camshaft chain plate In
81. m the inner box Hemove the screw on the front inner box 12 6 SYM 12 BODY COVER Remove the screw on the main switch Remove the main switch cover Remove the front inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal BODY COVER REAR FENDER Removal Open the seat Hemove the luggage box 6 bolts Remove the rear carrier 3 bolts Hemove the 1 2 mounting screws between the body cover and frame 12 7 12 BODY COVER SYM Hemove the 2x 2 mounting screws between the body cover and the rear fender Remove the 1 2 mounting screws between 1X 2 screws the body cover and the floor panel Remove the 1 mounting screw between the body cover and front center cover 1 screw Hemove the 2 mounting bolts of the rear fender Remove the left right body cover Remove the rear fender Installation Install the body cover and rear fender according to the reverse procedure of removal 12 8 SYM FRONT CENTER COVER Removal Remove the 1 mounting screw between the body cover and the front center cover Hemove the 4 screws from the battery cover Remove the the battery cover Remove the front center cover Installation Install the cover according to the reverse procedure of removal LUGGAGE BOX Removal Open the seat Remove the 6 bolts from the luggage box Remove the luggage box and the double seat Remov
82. mended brake fluid WELLRUN DOT 3 brake fluid A CAUTION e The fluid level will not be correct if parking the motorcycle in title or just parking It has to waiting for around 3 5 minutes Never use faked brake fluid to prevent from chemical reaction e It has to apply with same brand brake fluid to sure the brake performance Brake Fluid Add Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or rubber components when conduct brake system maintenance CAUTION Do not over the upper level when adding brake fluid and avoid to spilling brake fluid on painted surfaces plastic or rubber components to result in their damages 13 BRAKE Hose connection 13 5 13 BRAKE A Remove the master cylinder cap and diaphragm Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder Clean dirty brake disk CAUTION The dirty brake pad or disc will reduce the brake performance The mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing brake performance to be reduced or totally lost BRAKE FLUID AIR BLEED Connect drain hose to drain valve Open the drain valve on the caliper and hold and release the brake lever alternatively until the old brake fluid is entirely drained out Clo
83. n condition of valve stem in valve guide and measure amp record the valve stem outer diameter Service Limit 4 900mm EX 4 900mm Valve guide Caution Before measuring the valve guide clean carbon deposits with reamer opecial Service Tool 5 0mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 030 The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide Service Limit 0 08 EX 0 10mm 6 8 SYM 6 CYLINDER HEAD VALVE A Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too A Caution It must correct valve seat when replacing valve guide Valve guide replacement Valve guide drivek Heat up cylinder head to 100 150 C with 5 0mm heated plate or toaster A Caution Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating it Wear on a pair of glove to protect your hands when operating Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 5 mm 13 mm
84. ne side and frame ground Standard 140 200 20 Replace the alternator if the measured value exceeds standard value 16 13 16 ELECTRICAL EQUIPMENT STARTING SYSTEM Starting Circuit red fusejisA lgnition switch a rear brake black switch start button start magnetic switch front brake switch Starter magnetic switch inspection Turn main switch to on and operate the brake lever Then press starting button to check if there a click sound It is normal if there is a click sound Remove the luggage box Disconnect the battery negative terminal Remove the battery positive connection and starting motor wires from the starter magnetic switch large pin Remove the power control connector of the Starter magnetic switch Connect a Ohmmeter between the Starter magnetic switch large pins Connect the green yellow wire to battery positive terminal and yellow red to battery negative terminal Check the continuity between the Starter magnetic switch large pins If it is not continuity then replace the starter magnetic switch 16 14 white green S M SYM 16 ELECTRICAL EQUIPMENT Starting Motor Removal Remove the right side cover screws x3 Firstly remove the battery negative terminal and then remove the positive terminal Remove the luggage box Remove the starting motor power wire Remove the starting motor mounting bol
85. ness side connector Pulse Generator Blue Yellow green 50 2000 i Ignition Black yellow green 0 210 10 Coil Green high voltage cable w o cap 3 5KQ Green high voltage cable w cap 7 12 16 11 16 ELECTRICAL EQUIPMENT Ignition coil Ignition coil Removal Loree Remove the luggage box center cover Remove spark plug cap 4 Remove the primary coil wire of ignition coil WELL Remove the fix bolts for the ignition coil and s remove the ignition coil Install the ignition coil in reverse order of removal A Caution Install primary coil with black yellow lead connected to black connector and green lead connected to green connector Spark plug confirmation Remove the spark plug and install a good plug into plug cap and then ground it to engine ground Make sure its spark condition If it is in not good or burnt spark plug replace the spark plug with new one 4 Caution Make sure each wire connection is correct and test as required Even the wire connection is in correct sometimes it might not be tested occurred Connect the high voltage shunt with a multi meter or input a resistor in the 10 0 100V of voltage meter Connect ignition coil wires and connect a shunt between primary terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection
86. ng pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase Caution Do not damage the connection surfaces 8 bolts 10 A C GENERATOR 10 GENERATOR STARTING CLUTCH SYM RIGHT CRANKCASE COVER INSTALLATION Install setting pin and new gasket on the crankcase Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip Install right crankcase cover onto the right crankcase 8 bolts Torque value 1 5 2 0kgf m MOUNTED COIL SET INSTALLATION Install the coil set onto right crankcase cover 2 bolts Install pulse generator 2 bolts Torque 0 8 1 2kgf m Tie the wire harness hose onto the indent of crankcase Install A C generator connector and pulse generator connector Pulse generator 1 uto by start connector connector FLYWHEEL INSTALLATION Make sure that there is no magnetic powder If so clean up it Align insert on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel with flywheel holder and tighten its nut Torque value 3 5 4 5kgf m Special service tool Universal fixture he LS 1 Universal fixture 10 4 SYM 10 A C GENERATOR Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Exhaust muffler 10 5
87. nstallation Seized brake cable Dirty brake pad Dirty brake drum Brake pad worn in brake cam area Poor contact between brake arm and camshaft indent 13 4 Uneven brake Dirty brake pad disk Poor wheel alignment e Clogged brake hose e Deformed or warped brake disk e Restricted brake hose and fittings Tight brake Dirty brake pad disk Poor wheel alignment e Deformed or warped brake disk Brake noise e Dirty pad e Deformed brake disk Poor brake caliper installation e Imbalance brake disk or wheel Tight operation or low return speed of brake lever e Worn broken crack return spring e Worn drum e Dirty brake pad Brake seized caused from dirty brake drum Seized brake cable Worn brake cam Improper brake pad installation Brake noise Worn brake pad Worn drum Dirty brake pad Dirty brake drum SYM HYDRAULIC BRAKE SYSTEM INSPECTION Inspection Visual inspect for brake fluid leaking or damage Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components Operate the brake system and check the brake pad Check the front brake from front side and replace the brake pad with new one when the brake pad wear limitation groove reaches to the brake disk Park the motorcycle on a flat ground and check its brake fluid level Hecom
88. que value 1 0 1 5 kgf m 2 um Quantity 90 Gear oil draining plug Recommended SAE 85W 140 Fuel System Fuel Pipe Remove luggage box rear center cover body cover and rear fender as well as front inner box Check all pipes and replace it when they are deterioration damage or leaking A Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing Fuel filter it Fuel filter Fier Remove the fuel tank Remove fuel pipe from the fuel filter 3 Replace the fuel filter with new one Install the fuel filter Caution The arrow on the fuel filter means the flow direction of fuel and check it if leaking after installation zi 2 MAINTENANCE INFORMATION un TE X AIR CLEANER Element Remove screws from the air cleaner cover Remove element of air cleaner 2 screws Check the element if dirt or damaged Replace it with new one if dirt or damaged ScrewsX 7 fg b UE A Caution Air cleaner element contains a paper made filter so do not try to clean it Make sure that the air cleaner cover had been installed properly after installation Air cleaner element THROTTLE VALVE OPERATION Have a wide open of throttle valve as handle bar in any position and release it to let back original full closed position Check handle bar if its operation is smooth Check throttle valve cable and replace
89. rake system Keep brake fluid beyond reach of children SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SERVICE PRECAUTIONS Always use with SANYANG genuine parts Never bend or twist a control cable to prevent 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 cover before removing it from the motorcycle Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause a damage 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 stiff control and premature worn out 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 t
90. re opecifi Curb Weight Brake System WEIGHT HEN Total Weight Total 209kg Deceleration equipment D Exhaust Pipe Position Right side and 2 O INumber Arran Single Cylinder Forced circulation amp gt gement horizontal y splashing 49 4 cc ET 12 0 g km atio 2 35KW 8500 rpm 1 2 g km 2 91N m 6500 rpm Air Filtration Paper filter Starting System Kick amp electrical starter m 23kg 1 9 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM TORQUE VALUES ENGINE THREAD DIA TORQUE Cylinder head bolts DA 0812 Cylinderheadnuts 8 18 22 Apply olto thread _ Cyinderiyinderheadiwo endsbols 4 7 07 1 Tighten ocrankcase Camhddrnt 7 014 Right crank case cover bolts 1 6 0 8 1 2 Pulse generator bolts 5 0 35 0 5 Valve adjustment fixing nuts 2 5 Applyolltothread _ Spark plug 0 1 0 1 4 a 1020 148 148 e G PINIS Camshaft chain adjuster bolts Cooling fan bolts 0 8 1 2 0 8 1 2 0 8 1 2 Hex socket bolt N 1 10 SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS TORQUE VALUES FRAME mme THREAD DIA TORQUE REMARKS mm VALUE Kg m Mounting bolt for steering 4 0 5 0 handlebar EMI Cone seatforsteoingrod 1 a wem
91. rent regulator will be damaged The ignition switch must be turned OFF before performing any work Please do not replace with traditional type battery as replacement Please refer to the removal instruction when removing the alternator and the pulse generator Ignition System Please follow the procedure of trouble diagnosis chart to check ignition system The ignition system equipped with a auto advanced timing device in CDI unit Thus ignition timing need not to be adjusted In case of incorrect ignition timing occurred check the CDI unit or alternator system It has to check the ignition timing with the ignition timing light if replaced these components Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by impact Therefore take care when disassembling Most of ignition system problems were resulted from poor connecting connector Please check the connectors first when servicing Make sure that the heat range of spark plug is suitable Improper spark plug is the main cause of poor engine operation or combustion Inspection procedures in this manual are based on Max voltage This manual also contains methods of how to check ignition coil resistance and component operation Please follow the continuity chart to check ignition switch Starting System Starting motor can be removed directly from engine Please refer to chapter 10 for starting clutch removal procedures 16 2 SYM 16 ELE
92. roove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal Manufacturer s 1 4 Connector 4 SYM Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps Groove ld Clamp ll 1 E esa uon dor Vra us vt tne eher nr Em I m F F igi i Rubber and plastic boots should be properly reinstalled to the original correct positions as designed Boots The tool should be pressed against two inner and outer bearing races when removing a ball bearing Damage may result if the tool is pressed against only one race either inner race or outer race In this case the bearing should be replaced To avoid damaging the bearing use equal force on both races Both of these examples can result in bearing damage SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS Lubricate the rotation face with specified lubricant on the lubrication points before assembling e Check if positions and operation for installed parts is in correct and properly T Jn 5 CD
93. ry Connect a digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse Caution When the probe is reversibly connected use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero ammeter at one direction only A Caution Do not use short circuit cable e it is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal however while the starter motor is activated the surge current of the motor draws from the battery may damage the ammeter Use the kick lever to start the engine The main switch shall be turned to OFF position during the process of inspection Never tamper with the ammeter and the cable while there is current flowing through It may damage the ammeter 16 8 SYM digital voltmeter Py 1 Tay f i 5 4 F F i F i a ammeter Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage current Specified Charging Current headlight OFF 0 6 or more 2500rpm 1 2 A or more 6000 rpm 0 4 A or more 2500rpm 1 0 A or more 6000 rpm Control Charging Voltage 14 0 0 5 V 2000 rpm A Caution To replace the old batte
94. ry use a new battery with the same current and voltage The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any one of the problems takes place 1 The charging voltage can not exceed the voltage between two battery terminals and the charging current is in 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 rpm Bulbs used exceed their rate and consume too much power e he replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not he replacement battery is aged and does not have enough capacity e Battery used do not have enough electricity or is over charged The fuse of the ammeter is blown e he ammeter is improperly connected 3 The charging current is normal but the voltage is not The fuse of the voltmeter is blown headlight ON SYM 16 ELECTRICAL EQUIPMENT VOLTAGE REGULATOR INSPECTION A eR Remove the front cover Remove the front cover mounting screw screws x 1 remove the headlight wiring connector Disconnect the 4P connector on t
95. s from cylinder head left side cover Hemove cylinder head gasket and 2 dowel pins Remove chain plate Clean up residues from the matching surfaces of cylinder and cylinder head A Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning CYLINDER HEAD DISASSEMBLY Use a valve compressor to press the valve spring valve cotters After removed valve cotters release the N compressor and then take out spring retainer valve spring and valves A Caution In order to avoid to loosing spring tension do not compress the spring too much Its length is based on the installation of latch Special Service Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface A Caution Do not damage the matching surface of cylinder head 6 CYLINDER HEAD VALVE CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack Measure cylinder head flat with a straightedge and flat feeler gauge Service limit below 0 05mm Valve spring free length Measure the free length of intake and exhaust valve springs Standard 35 250 mm The narrow pitch of the spring shall face to the combustion chamber Valve stem Check if valve stems are bend crack or burn Check the operatio
96. se the drain valve and add specified brake fluid into the brake master cylinder CAUTION To reuse the spent brake fluid will effect brake performance Connect one end of transparent hose to the drain valve and put the other end into a container Open the drain valve around 1 4 turns and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever Close the drain valve when finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve CAUTION B ON Do not release the brake lever before the transparent draining hose drain valve is closed Always check the brake fluid level when carrying out the air bleeding procedure to avoid air entering into the system 2 Slowly release the brake lever and wait for a few seconds until it reaches its top osition 3 Hepeat the steps 1 and 2 until there is no air bubble at the end of the hose Tightly close the drain valve 4 Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary 5 Cover the cap 13 6 SYM BRAKE CALIPER Removal Place a container under the brake caliper and loosen the br
97. shaft Hemove gasket and setting pin Hemove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft and the gear are wear or damage final driving shaft Check if the final driving shaft and gear are burn wear or damage final driving gear 9 FINAL DRIVING MECHANISM SYM Check bearings on the gear box cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on gear box amp cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT Caution Never install used bearings Once bearing removed it has to be replaced with new one Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Tool Press the bearing into cover with C type hydraulic presser or bearing installer 9 4 SYM Press out the driving shaft from the crankcase Remove oil seal from the crankcase Remove the driving shaft bearing from the gear box cover with the inner type bearing puller Caution Using the bearing protector as pressing out the driving shaft from the left crankcase Specified
98. sible Measure tire thread depth from tire center surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm Load for Caution The wear limit marks A are located around the tire wall even for inspection 2 14 Brake light switch Wear limit indictor mark SYM SYM 2 BATTERY Battery Removal Remove the 4 screws on the floor panel Remove battery cap 4 screws Battery cables removal 1 At first remove the negative cable 2 Then remove the positive cable 3 Remove the battery If there is some rust on battery posts clean it with steel brush Install the battery in the reverse procedures of removal Caution If there is rust on the posts very serious spray some hot water on the posts Then clean it with steel brush so that can remove rust for more easily Apply some grease on the posts after rust removed to prevent from rust again HEADLIGHT ADJUSTMENT Turn the headlight adjustment bolt And adjust the headlight beam height Then tighten the adjustment bolt after the beam height in proper position A Caution To adjust the headlight beam follows related regulations Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting NUTS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and n
99. sorber spring force seized brake cable improperly installation of brake cable 15 2 SYM 15 REAR WHEEL REAR SHOCK ABSORBER EXHAUST MUFFLER Exhaust muffler Removal Remove the front end nut of the exhaust muffler nuts x 2 Remove the bolts bolts x 2 Remove the exhaust muffler Installation Install the exhaust muffler according to the reverse procedure of removal Caution Replace the exhaust muffler gasket if it is broken or deformed Torque value Exhaust muffler connection bolt 3 0 3 6kgf m Exhaust muffler connection nut 1 0 1 4kgf m REAR WHEEL Inspection Measure wheel rim wobbling Service limit Radial 2 0mm Axial 2 0mm If the wheel rim wobbling out of the specification except resulted from the wheel rim deformation it might be loosen or worn final driving shaft bearing or bend deformed driving shaft Removal Remove the right cover screws x 4 Remove the battery bolts x 2 Remove the battery cover assembly bolts x2 nuts x 2 Remove the rear wheel wheel axle nut x1 15 3 15 REAR WHEEL REAR SHOCK ABSORBER SYM REAR SHOCK ABSORBER Removal Hemove the left amp right covers screws x 8 Remove the luggage box bolts x 4 nuts x 2 screw x 1 Remove the rear carrier bolts x 3 Remove the body cover bolts x2 Remove the air cleaner bolts bolts x2 Hemove the lower nut of the rear shock absorber bolt x 1 Hemove the upper nut of the rear shock absorber
100. stall the cylinder head CAMSHAFT INSTALLATION Assemble the camshaft holder Install the exhaust valve rocker arm set onto the camshaft holder showing EX mark Install intake valve rocker arm and rocker arm shaft Caution The tangent of rocker shaft of intake valve should match with the bolt hole of camshaft mounting seat With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other single hole of the cam sprocket is in upward Then install the cam chain onto the cam sprocket 6 CYLINDER HEAD VALVE Lock pins ylinder head gasket 5mm blot arm shaft Rocker arm l Pp Camshaft aw 6 13 6 CYLINDER HEAD VALVE SYM Install the lock pins Install the camshaft holder gasket and nut onto the cylinder head Tighten the cylinder head nuts 4 nuts At first tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head Torque value 1 8 2 2 kgf m Install the spark plug and tighten it Torque value 1 0 1 4 kgf m 4 Caution Apply with oil onto the thread of cylinder head bolts and tighten the bolts in diagonally for 2 3 sequences Do not over tightening the bolts to avoid the cylinder head deformation noise created or leaking so that e
101. t be verdict Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off 1 2 SYM Battery A Caution e Battery emits explosive gases flame is strictly prohibited Keep the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor Keep electrolyte beyond reach of children Brake shoe Do not use an compressed air or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid asbestos dust flying C Caution Inhaling asbestos dust may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the b
102. tandard otart engine and let the rear wheel rotate after increased engine rpm Check engine for any parts loose or shaking Also check the engine suspension bushing for wear out Replace the bushing if worn out Tighten all nuts and bolts Rear Shock absorber 2 10 SYM 2 MAINTENANCE INFORMATION FRONT DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil and also check brake system for leaking BRAKE FLUID Check brake fluid level in the brake fluid reservoir If the level is lower than the LOWER limit add brake fluid to UPPER limit Also check brake system for leaking if low brake level found Caution In order to maintain brake fluid in the reservoir in horizontal position do not remove the cap until handle bar stop Do not operate the brake lever after the had been removed Otherwise the brake fluid will spread out if operated the lever Do not mix non compatible brake fluid together Brake fluid cap FILLING OUT BRAKE FLUID Low brake level Tighten the drain valve and add brake fluid Place the diaphragm in Operate the brake lever so that brake fluid contents inside the brake system hoses AIR BLEED OPERATION Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses A Caution Before closing the air bleed va
103. tch ON OFF to check if the bulb has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb headlight beam adjustment screw The headlight beam adjustment Loosen the adjustment bolt located under the front handle cover Caution This outer cover of headlight is a fixed type so that the light seat will be moved only when adjusting 16 17 16 ELECTRICAL EQUIPMENT Front Turn Signal Lamp Bulb Front turn Replacement f signa light 9 E Remove the front cover Remove the wire connector of the turn signal light the wire connector of Pull out the bulb and replace it with new one nihe turn signal light 12V 10W Installation Install the bulb in reverse order of removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the tail light assembly Replace the bulbs of the tail light brake light 12V 5W 21W Replace the bulbs of the turn signal light 12V 10W Installation Install the bulb in reverse order of removal 16 18 SYM 16 ELECTRICAL EQUIPMENT Main Switch Check Remove the headlight connector and the front Disconnect main switch leads connector Check connector terminals for continuity main switc bolts X2 Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the main switch Install a new main swi
104. tch and tighten the bolts bolts x2 16 19 16 ELECTRICAL EQUIPMENT Handle switch headlight switch Remove the front handle cover ED Disconnect the connector of the handle switch Check the continuity of follow pins listed below columns Headlight switch M ory starting switch headlight switch yellow yeu AA brown white Starting switch FREE switch o yellow red green a High Low b High Low beam switch passing LM TTE brown White g A uf white reen xt ist turn signal switch horn switch lt High Low beam Z switch seat open white brown white turn signal switch gray 5 Light green Horn switch SYM 16 ELECTRICAL EQUIPMENT Turn signal light switch Sky eo 80 i turn signal orange KEEN light switch Sky blu Brake light switch The circuit of black wire and the green yellow wire on the brake light switch should be in continuity when operating the brake lever If the switch damaged replace it with new one Horn Remove the front cover Connect the light blue wire on the horn to the battery positive terminal and the green wire to the battery negative terminal Then the horn should sound Replace it if necessary 16 21 16 ELECTRICAL EQUIPMENT FUEL UNIT A Ww Eust unit 9 Open the seat Remove the luggage box bolts x 6 Remove the engin
105. te both the real roundness the difference between X and Y motion values and the cylindrical roundness the bO Mas Bottom difference in the top center or bottom i positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Exhaust side Check Cylinder flat Service limit correct or replace as over 0 05 mm SYM Intake side SYM 7 CYLINDER PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling Hold another snap ring with pliers Push out the piston pin from the side that not removed the snap ring Remove piston rings Caution Pay attention to remove piston rings because they are fragile Disassemble the piston rings Check if the piston rings are damaged or its grooves are worn Cleaning the carbon in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Piston Take out the piston rings and place them respective into cylinder below 20mm of cylinder top Measure each piston ring gaps Caution Push the piston rings into cylinder with piston top end in parallel motion oy gt piston ring 3 S
106. the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse e Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit green 16 5 16 ELECTRICAL EQUIPMENT Battery Removal Remove the 4 screws on the battery cover Screws x 4 A CAUTION e Electrolyte diluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind In case of being spread flush with great quantity of water immediately and then send to hospital When clothes is spread by electrolyte it will contact with skin So it must flush with great quantity water to take off the clothes Remove the battery cover Disconnect the negative cable from the battery first then the positive cable Remove the battery Install the battery in reverse order of removal A CAUTION e To prevent form circuit short connect positive terminal at first and next negative terminal 16 6 SYM positive 77 SYM Voltage Check With a digital voltage meter or multi meter to measure battery voltage Voltage Fully charged 13 0 13 2V at 20 Undercharged Below 12 3 V at 20 C CHARGING
107. tion Install the handlebar according to the reverse procedure of removal Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat acceleration handlebar and acceleration cable FRONT WHEEL Removal Support body bottom and lift front wheel free of ground Remove the bolts and disconnect speedometer cable from the gear box Remove the wheel axle nut and pull out the axle Then remove the front wheel Caution Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder Wheel axle nut 14 4 SYM 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER Inspection Wheel axle Set the axle in V blocks and measure the run out Service limit 0 2 mm Wheel axle Wheel Rim Place the wheel onto a rotated bracket Turn the wheel with hand and measure its wobble value with a dial gauge Service limit Radial 2 0 mm Axial 2 0 mm Disassembly Hemove 3 hex socket bolts and brake disc Remove the left axle ring and dust seal Hemove the dust seal on the right side of speedometer gear Remove the bearing with the inner type bearing remover Take out the bearing spacer and then remove the other bearing Tool Inner type bearing remover Bearing spacer Bearing Dust seal Wheel side collar 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER SYM Bearing Inspection Turn the inner race of bearing with
108. ts and motor Starting Motor Installation Install the motor in reverse order of removal METER Removal Remove the front handle cover e 2 Remove the speedometer cable speedometer cable cw Remove the front cover Remove the power connector of the meter 16 ELECTRICAL EQUIPMENT Remove the rear handle cover Remove the meter mounting screws Take out the meter Speedometer High Beam Indicator Turn Left Signal Right Indicator Signal Indicator Odometer Fuel meter A Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components Installation Install the meter in reverse order of removal 16 16 SYM 16 ELECTRICAL EQUIPMENT LIGHT BULBS Headlight Bulb Replacement Remove the left right back mirror Remove the front handle cover Disconnect the headlight wire connector Press down the bulb spring locker and then remove the locker with turning it left motion Remove the bulb Replace the bulb with new one if necessary 12V 35W 35W A Caution Do not touch the bulb surface with fingers because the bulb will create hot spot so that let it be burnt It has to be package with cloth or wear glove as installing Wipe the bulb with cloth to prevent from damaged if the bulb be touched by hands Install the bulb in reverse order of removal Turn the main swi
109. ttle valve opening too wide Malfunction of automatic by starter SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS 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 cleaner clogged Engine speed can be Engine speed can not be 2 increased increased 3 4 5 Check ignition timing Using ignition lamp Ignition timing correct Incorrect ignition timing 1 2 Check cylinder compression pressure using compression pressure gauge Compression pressure correct Check if carburetor jet is clogged No clogged Remove spark plug No foul or discoloration Fouled and discoloration 1 2 No compression Clogged 1 Check if engine over heat Continually drive in acceleration or high speed C1 No knock N I Co Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Fuel level too low in carburetor Fuel nozzle clogged in narhiiratar Malfunction of CDI Malfunction of AC alternator Cylinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring Remove foreign Remove dirt Incorrect spark plug heat range Piston and cylinder worn out Lean mixture Poor fuel qual
110. ure Steering stem off center e Uneven left right cushion Bend fork Bent front wheel tire offset 14 2 5 07 7 0kgf m 4 0 5 0kgf m 0 2 0 3kgf m 1 0 2 0kgf m 0 15 0 3kgf m 2 4 3 0kgf m Front wheel wobbling Deformed rim Front wheel bearing loose e Faulty tire e Wheel axle nut tightened improperly Soft front suspension e Weak fork springs Oil leakage of the shock absorber seal Front suspension noise e Cushion cover friction noise e Cushion bolts loose SYM 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER STEERING HANDLE Acceleration 8 REMOVAL handlebar seat G gu Remove handle front amp rear covers and the S Y EN front cover refer to chapter 12 Brake lever at screw qe Remove the 2 bolts of the brake master cylinder and then take out the master cylinder and the split ring Caution Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder Remove acceleration handlebar screw and then remove the handlebar acceleration cable and handlebar cover amp seat Remove the rear brake lever nut and screw then take out the rear brake cable Remove the brake lever seat bolt and then remove the seat Brake cable 14 3 14 STEERING FRONT WHEEL FRONT SHOCK ABSORBER SYM With a wrench to hold the handlebar bolt and then remove the nut Take out the handlebar after removed the bolt Installa
111. uts on the frame are tightened securely Check all fixing pins snap rings hose pipe clamps and wire holders for security MAINTENANCE INFORMATION _ Battery cover screws h 43 17 k AN E J i L i E EI 1 444 4 E Headlight adjustment bolt 2 15 SYM 3 LUBRICATION SYSTEM MECHANISM DIAGRAM CLEANING ENGINE OIL STRAINER 3 3 OPERATIONAL PRECAUTIONS OIL PUMP TROUBLE DIAGNOSIS GEAR OIL ENGINE OIL MECHANISM DIAGRAM Valve rocker arm Forcedly lubrication Camshaft ocoop lubrication Inner passage Connecting rod Forcedly lubrication Crankshaft Oil strai il strainer Oil pump 3 1 3 LUBRICATION SYSTEM SYM OPERATIONAL PRECAUTIONS General Information e his chapter contains maintenance operations for the engine oil pump engine oil and gear oil Specifications Cil viscosity Engine oil quantity Disassembly 800 c c Replacement 750 c c OIN SAE ZU 40 Oil viscosity SAE 10W 30 or equivalent __ oem Use SAE 5W 40 when outside temperature is TAE 10W 30 below 0 C Gear Oil Disassembly 110 c c Replacement 100 c c Oil viscosity of gear oil SAE 85W 140 unit mm Innerrotorclearance rotor clearance 0 12 Clearance between outer Clearance between rotor Torque value Engine oil drain plug 1 071 Engine oil filter screen cap 1 072 Gear oil drain bolt 1 0 1 5kgf m Ge
112. ve driving pulley Remove the sliding pulley fixing nut and remove the driving belt from the sliding pulley Remove the driving belt from the sliding pulley Remove the limited speed bush Remove the bush and remove the sliding pulley from the crankshaft Limited speed Remove tilt plate Tilt plate 259 Remove weight rollers from sliding pulley Roller SYM 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force And then the speed is changed by the title plate rotation Thus if weight rollers are wear out or damage the centrifuge force will be effected Check if rollers are wear out or damage Heplace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 57 mm Sliding pulley Measure the inner diameter of the sliding pulley Service limit 34 06 mm Pulley hub Measure the inner diameter of the pulley bush Replace it if exceed the service limit Service limit 20 15 mm Assembly Installation Install the weight rollers Guide boot Install the title plate guide boot onto the title plate Install the title plate Tilt plate 8 V BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH SYM Apply with grease 4 5 g to inside of driving shaft hole and install driving pulley hub A Caut
113. y are prohibited to be adjusted or repaired by unauthorized people Otherwise SYM is no responsible for the charge 2 Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily polluted environment 3 Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage 4 Preventive maintenance a Ignition system Perform maintenance and check when continuous abnormal ignition misfire after burn overheating occur b Carbon deposit removal Remove carbon deposits in cylinder head piston heads exhaust system when power is obvious lower than ever c Replace worn out pistons cylinder head SYM 2 MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Caution The vehicle must be parked on a level ground when checking oil capacity Run the engine for 2 3 minutes then stop wait about 2 3 more minutes allowing engine oil to settle before checking the oil level Dipstick Remove dipstick to check the oil level If oil level is below the lower limit mark add oil to the specified upper limit mark Oil change Shut off the engine and remove dipstick Remove the oil drain plug on the bottom left of crankcase to drain oil After draining out oil clean oil plug and its gasket and reinstall Replace the gasket if it is damaged Torque value 1 0 1 5 k
114. ylinder surface 3 Piston Piston ring worn out High compression pressure much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Cam chain wear out or looseness Auto adjuster wear out or damage of cam chain Camshaft sprocket wear out Rocker arm or rocker arm shaft wear out White smoke Valve guide or valve stem wear out Valve stem seal wear out 6 CYLINDER HEAD VALVE SYM CAMSHAFT REMOVAL Hemove the shroud of the engine Hemove the crankcase blow by system hose from the cylinder head Remove the cylinder head bolts and then remove the cylinder head 4 bolts Loosen the bolt of camshaft chain adjuster in a counter clockwise motion for release adjuster camshaft chain adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at position Hemove camshaft holder nut and washer Caution Loosen the nuts diagonally by 2 3 sequences 6 4 SYM 6 CYLINDER HEAD VALVE Remove the camshaft holder and rocker arm set Remove the camshaft chain from the camshaft sprocket Remove the camshaft Camshaft Inspection Inspect cam lobe height for damaged Service Limit Camshaft IN Replacement when less than 25 29 mm bear
115. ze the wire 1 7 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SYM Do not let the wire harness been twisted as installation x e Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack be rubbed against or interfere with adjacent or surrounding parts in all steering positions Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction Do you know how to set the instrument to its measurement position and the insert locations of its two probes 1 8 e With sand paper to clean rust on connector pins terminals if found And then conduct connection operation later SYM 1 GENERAL INFORMATION TROUBLE DIAGNOSIS SPECIFICATIONS wake SANYANG MODEL Overall Length 1870mm Telescopic fork Overall Height 1140 mm Front 110 70 12 47J Wheel Base 1325mm 120 70 12 51J Total 99kg Hear DRUM e 110 mm Passengers Weight Two men 110 kg Max Speed 45km h EN Climb Abiy 26 Below Primary Reduction BELT Final Reduction GEAR Type 4 STROKE ENGINE Clutch Auto centrifugal clutch Installation and Vertical below center M Transmission C V T arrangement incline 80 FuelUsed Used Unleaded gasoline opeedometer 0 80 km hr Cycle Cooling Seite eral 75 112dB A cooled o 39 0 mm Muffler Expansion amp Pulse Type DIMENSION cations Ti

SYM Fiddle II 50 Service Manual

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