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Track Runner 200 SERVICE MANUAL

1. 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 To this chapter contents 1 GENERAL INFORMATION SYM When separating a connector it locker has to Insert the terminal completely be unlocked firstly Then conduct the service Check if the terminal is covered by the boot operation Do not let boot open facing up s DRM E miin l uy n x 1 Secure wires wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated or wires Hold the connector body locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses O X X Make sure if the connector pins are bent extruded or loosen Wire band and wire harness have to be clamped secured properly e Insert the connector completely If there are two lockers on two connector sides make sure the lockers are locked in properly Check if any wire loose Do not squeeze wires against the weld or its x ema Check if the connector is covered by the twin connector boot completely and secured properly mp Before terminal connection check if the boot 15 crack or the terminal is loose To this chapter content
2. E J L L FR E E 54 i I a T Ym ps a ER r ER jc E L ters 1 ES vs Uli E Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction Do you know how to set the instrument to its measurement position and the insert locations of its two probes 1 8 To this chapter contents SYM 1 GENERAL INFORMATION Specifications wacn umens Overall Length 1765 mm Suspension Front Unit Swing System Overall Height 1135 mm Front AT21x7 10 off road Tire Specifications Wheel Base 1115 mm Rear AT22x10 10 off road 102kg Curb Weight Rear 97 kg Front Disk u 175mm Brake System Total 199 kg Rear Disk y 190mm Passengers Weight Two 150 kg Max Speed Above 70 km hr Performance Front 132 kg Climb Ability Below 20 Primary Total Weight CHR Reduction sen oecondary Total 49 k ket imension D Weight 4 Stroke Engine Clutch Centrifugal dry type Installation and Vertical below center C V T auto speed Vu Transmission arrangement incline 80 change Fuel Used Unleaded opeedometer 0 90 km hr Cycle Cooling 4 stroke water cooled 93 112 dB A E ion amp Pul Exhaust Pipe Position and Hight side and Stroke beum 9 Direction Backward Number Arranqe Forced circul
3. 30mm Place the detent section of the bush remover toward the bush and drive both the pressing ring and bolt in to press the bush out Pressing In Place the flat section of the remover toward the bush and then drive the bush pressing ring and bolt in to install the bush SYM Mechanism 6 1 Precautions in Operation 6 2 Troubleshooting 6 3 Cylinder Head 6 4 Cylinder Head Disassembly 6 6 Cylinder Head Inspection 6 7 Mechanism Diagram 0 8 1 2kgf m 2 0 2 4kgf m Z Z 6 CYLINDER HEAD VALVE Valve Stem Replacement 6 8 Valve Seat Inspection and Service 6 9 Cylinder Head Reassembly 6 11 Cylinder Head Installation 6 12 Valve Clearance Adjustment 6 14 6 1 To this chapter contents 6 CYLINDER HEAD VALVE SYM Precautions in Operation General Information e This chapter is contained maintenance and service for cylinder head valve and camshaft as well as rocker arm e Cylinder head service can be carried out when engine is in frame Specification Compression prese mwm o Camshaft Height of cam lobe Intake 30 800 30 920 3 075 Guide seat 5 000 5 012 5 030 Free length of valve spring 35 000 31 500 Valve seat width 1 000 Torque Value Cylinder head bol
4. Fixed rear wheel or rear brake 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 the driven pulley Remove driven pulley Do not remove driving belt Remove the driving belt from the groove of driven pulley Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Service Limit 17 5 mm Replace the belt if exceeds the service limit L Caution Using the genuine parts for replacement The surfaces of driving belt or pulley must be free of grease Clean up all grease or dirt before installation Belt tooth To this chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER Installation Caution e Pull out driven face to avoid it closing e Cannot oppress friction plate comp in order to avoid creates the distortion or the damage Install driving belt onto driven pulley Install the driven pulley that has installed the belt onto drive shaft On the drive belt another end to the movable drive face Install the clutch outer with universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face with universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m 8 6 Drive belt Driven face To this chapter contents
5. Probable causes Check and adjustment Fault condition Check ignition timing using ignition lamp Normal Abnormal Adjust the air screw of carburetor Good Poor Air sucked through carburetor gasket No air sucked Air sucked Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground 222 d A Good spark Poor D Engine runs sluggish High speed Check and adjustment Fault condition Check ignition timing Check for fuel supplying system in automatic fuel cup Check if carburetor clogged No clogged Clogged Incorrect ignition timing malfunction of CDI or AC alternator Rich mixture loosen the screw Lean mixture tighten the screw Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch Probable causes Malfunction of CDI Malfunction of AC alternator Insufficient fuel in fuel tank Fuel filter clogged Hestricted fuel tank vent Cleaning 1 16 To this chapter contents SYM 1 GENERAL INFORMATION E Clutch driving and driving pulley V FAULT CONDITIONS Engine can be started but motorcycle can not be moved Engine running and misfire as motorcycle initial forward moving or jumping s
6. tHE 1119 D T 8 11050 14103 Hi T TA Hu EE ren arde III T IT Xu HH X O gt Z Z T JJ C m T x gt gt 3 gt F1 5 lui u xx umaku 2 zt 24 E t ES e AX Le FL INR AER HH HH ME T HIIT3M 18 ELECTRICAL DIAGRAM SYM Notes 18 2
7. SYM 8 V BELT DRIVING SYSTEM KICK STARTER Drive Face Removal Remove left crankcase cover Hold drive face with universal holder and then remove drive face nut Remove drive face Remove driving belt and movable drive face comp from crankshaft Crankshaft Remove ramp plate Ramp plate Remove weight rollers from movable drive face Movable drive face Weight roller chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER SYM Inspection The weight rollers are to press movable drive face by means of centrifuge force Thus if weight rollers are worn out or damaged the centrifuge force will be affected Check if rollers are worn or damaged Replace it if necessary Measure each roller s outer diameter Replace it if exceed the service limit Service limit 19 50 mm Weight 14 5g Weight roller Movable drive face Check if drive face boss is worn or damaged and replace it if necessary 4 Measure the outer diameter of movable drive face ff SR Drive face boss and replace it if it exceed service limit Service limit 26 94 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 27 06 mm Reassembly installation Install weight rollers A Caution The weight roller two end surfaces are not certainly same In order to lengthen the roller life and prevented exceptionally wears the occurrence Please end sur
8. To this chapter contents 3 LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear Refer to chapter 10 Remove snap ring and take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pump as illustration shown Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit 0 25 mm To this chapter contents SYM 3 LUBRICATION SYSTEM Check clearance between inner and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install fixing pin Install the oil pump cover and fixing pin properly 1 Screw MEE this chapter contents 3 LUBRICATION SYSTEM Oil Pump Installation Install the oil pump and then tighten bolts Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump driving chain and sprocket and then install snap ring onto oil pump shaft Install starting gear and generator Refer to chapter 10 To this chapter contents SYM 3 LUBRICATION SYSTEM Gear Oil Wf Gear oil Inspection window Oil leve
9. value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes s Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 14 13 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Notes 14 14 SYM Mechanism Diagram 15 STEERING SUSPENSION Steering Tie Rod Knuckle Operational Precautions Trouble Diagnosis Steering Handle Steering Shaft Mechanism Diagram F 2 4kgf m a m ji 5 8 4 0kgf m eT Q F 3 4kgf 3 6kgf m z am e L E 5 0kgf m 7 a uL A d L l 4 6kgf m 4 e N 5 0kgf m FT e qo s EU 4 7 5 0kgf m e a M i 5 0kgf m 15 1 To this chapter contents 15 STEERING SUSPENSION SYM Operational Precautions Torque Values Handlebar upper holder bolt 2 4kgf m Handlebar under holder nut 4 0kgf m Steering shaft holder bolt 3 4kgf m Steering shaft nut 5 0kgf m Steering tie rod nut 5 0kgf m Knuckle nut 5 0kgf m Tie rod lock nut 3 6kgf m Suspension arm nut 5 0kgf m Front cushion mounting bolt 4 6kgf m Trouble Diagnosis Hard to steer Front suspension noise Faulty tire Loose front suspension fasteners Steering shaft holder too tig
10. Measure the inner diameter of connecting rod small end Service Limit 15 06 mm Measure the inner diameter of piston pin hole Service Limit 15 04 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter A Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 60 90 mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 CYLINDER PISTON 7 5 To this chapter contents 7 CYLINDER PISTON SYM Piston Ring Installation Clean up piston top ring groove and piston surface Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown A 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 274 ring Cil ring Cil groove us 7 6 To this chapter contents SYM 7 CYLINDER PISTON Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to intake valve Install new piston pin snap ring A Caution Do not let the opening of piston pin snap ring align with the opening piston ring e Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling i
11. Poor main switch e Secondary winding circuit Poor ignition coil Poor spark plug Poor ignition coil cable Current leakage in the spark plug Incorrect ignition timing Poor AC G Improper installation of the pulse sensor Poor C D I Weak starter motor Poor charging system e The battery is not fully charged Poor connection in the windings e The motor gear is jammed by foreign material Starter motor is working but engine does not crank Poor starter motor pinion e The starter motor run in reverse direction Poor battery 17 3 To this chapter contents 17 ELECTRICAL SYSTEM SYM Battery Removal Remove the seat and then you can see the battery Disconnect the negative cable terminal first then the positive cable terminal Remove the battery clamp and then remove battery Voltage Check Use the digital voltmeter to check the voltage of the battery Voltage Fully charged 13 0 13 2 V at 20 C Undercharged Below 12 3 V at 20 C Charging Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Charging current Warning Keep flames away while recharging e Charging is completely controlled by the ON OFF switch on the charger not by battery cables A Caution Never rapid charge the battery unless in emergency Verify the battery is recha
12. Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding Standard resistance With no cap 3 60 10 With cap 7 3 11 KO Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if necessary Inspection of Pulse Generator Disconnect the coupler of the pulse generator and measure the resistance between the terminals of green white and blue yellow Standard resistance 50 1700 A wt r Pulse generator coupler 17 9 To this chapter contents 17 ELECTRICAL SYSTEM SYM Starting System Starting circuit diagram Main fuse 20A Battery iiri pipi Main switch Black Red Fuse 15A White Black Shift gear control unit Green Red i Neutral a Starter relay Green Starter motor PEZ Yellow Red IE switch Starter switch Green Yellow 9 Green Inspection on starter relay Open the main switch Press the brake Push down the starter switch If a sound of Looh Loob is heard it indicates the relay function normally Remove the seat Disconnect the negative cable terminal of the battery Disconnect the cable positive terminal from the relay Disconnect the positive cable of the starter motor Disconnect the coupler of the relay Connect an ohmmeter to the large terminal end Connect the yellow red cable to the battery positive terminal and the yellow black cable to the battery negative te
13. Remove the tank cover 2 bolts Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove the vacuum tube Remove 2 bolts and then remove fuel tank Installation Install the tank in the reverse order of removal 4 10 To this chapter contents SYM Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor and then remove the vapor hose Remove the air cleaner 2 bolts Installation Install the tank in the reverse order of removal Cleaning air cleaner element Loosen the clamp strip of left crankcase cover and then remove the left crankcase cover vapor hose Loosen the clamp strip of air cleaner and then remove the air cleaner vapor hose Remove the air cleaner cover 3 screws Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry A Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover 4 FUEL SYSTEM _3 screws __ P m B 4 11 To this chapter contents 4 FUEL SYSTEM SYM Notes SYM 5 ENGINE REMOVAL Precautions in Operation Engine Installation Removal of Engine Removal of Engine Hanger Bush Precautions in Opera
14. Track Runner 200 SERVICE MANUAL SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG Track Runner 180 ATV The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV Track Runner 180 are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department SANYANG INDUSTRY CO LTD HOW TO USE THIS MANUAL SYM This service manual describes basic information of different system parts and system inspection amp service for SANYANG Track Runner 180 ATV In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information and special tools manual The third to the 11th chapters cover engine and driving systems The 12th chapter is cooling system The 13th to the 16th chapter is contained the parts set of assembly frame body The 17th chapter is electrical equipment The 18th chapter is wiring diagram Please see index of content for quick having the special parts and system information There are 4 buttons Forwa
15. FRONT BRAKE AND FRONT WHEEL 15 1 15 12 U STEERING FRONT SUSPENSION 16 1 16 18 REAR BRAKE REAR WHEEL REAR CUSHION 1G 17 1 17 22 ELECTRICAL EQUIPMENT 1 7 18 1 18 2 ELECTRICAL DIAGRAM 1 8 SERIAL NUMBER SYM Frame number Engine number SYM 1 GENERAL INFORMATION Symbols and Marks Specifications General Safety Torque Values Service Precautions Troubles Diagnosis Specifications Parts to Be Greased Specifications Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using the symbols or marks N TE Means that serious injury or even death may result if procedures are not arnin 9 followed N Caution Means that equipment damages may result if procedures are not followed Limits to use SAE 10W 30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil p p oil KING MATE G 3 oil Grease 0 King Mate G 3 is recommended King Mate gear oil serials are recommended Bramax HYPOID GEAR OIL Gear oil 140 as Apply sealant medium strength sealant should be used unless otherwise Ta Locking sealant specified eRe Indicates where the bolt installation direction means that bolt cross through the compone
16. a A T A Valve guide driver caet AY mm W 1 Iw m with reamer Valve guide reamer 5 0 mm 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 Tool Valve guide reamer 5 0 mm 6 8 To this chapter contents SYM 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 4 Caution Do not let emery enter into between valve stem and valve guide Clean up the emery after corrected and apply with engine oil onto contact faces of valve and valve seat Remove the valve and check its contact face Caution Replace the valve with new one if valve seal is roughness wear out or incomplete contacted with valve seat nra a f Valve seat width Valve seat inspection N s If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat cutter Use 45 valve seat
17. and then remove the ducts 5 3 To this chapter contents 5 ENGINE REMOVAL Remove gear change lever 1 bolt Remove coolant drain bolt and drain out coolant Remove water hoses from water pump Remove the thermo sensor wire and coolant by pass pipe Loosen speedometer cable mounting nut and then remove the cable Mounting nut 5 4 To this chapter contents SYM 5 ENGINE REMOVAL Remove the drive chain retaining clip and master link and then remove the drive chain Remove the rear side engine hanger mounting nuts and bolts Remove the front side engine hanger mounting nut and bolt then remove engine Engine Installation Check if the bush of engine hanger parts for damage Install engine in the reverse procedures of removal Caution e Pay attention of foot amp hand safety as engine Installation to avoid hurting Do not bend or twist wires Cables wires have to be routed in accordance with normal layout Engine hanger Bolt Torque value 4 0 5 0kgf m 5 5 To this chapter contents 5 ENGINE REMOVAL SYM Removal of Engine Hanger Bush Check if engine hanger bush for damage Remove the engine hanger bush must be disassemble crankcase and transmission cover first Pressing out If engine hanger and the rear cushion rubber bush damaged Then with the bush remover presser Q 30mm to press the bush out and replace it with new one Engine hanger bush
18. puts on the left crank case Install R L crank case disassemble install tool on Clutch nut the left crank case wrench Again turns on crank shaft puller on the bearing driver spiral tooth Gradually tightens the crank shaft puller upper cap muU M nut presses in the bearing to locate puller After the bearing presses in to locate opens the H L crank case disassemble install tool takes down the bearing driver Installs crank to the left crank case Direct the crank shaft bearing fixing socket to crank shaft sJ Crank shaft bearing fixing socket 11 6 To this chapter contents SYM Install R L crank case disassemble install tool on the left crank case Again turns on crank shaft puller on the crankshaft Spiral tooth Caution Crank shaft puller lock into on as far as possible the crank spiral tooth prevented pulls the bad crank spiral tooth Gradually tightens the crank shaft puller upper cap nut drags into the crank to locate Install 2 new dowel pin and new gasket Install the right crankcase onto the left crankcase Tighten 2 bolts on the crankcase Torque value 0 8 1 2kgf m 11 CRANKCASE CRANK Crank shaft puller gt i Crank case disassemble install tool 11 7 To this chapter contents 11 CRANKCASE CRANK SYM Tighten 7 bolts on the crankcase Torque value 0 8 1 2kgf m Clean the crankshaft Apply a layer of grease on the lip of
19. until measured value within standard Emission standard CO below 2 5 3 5 HC below 2000ppm 2 MAINTENANCE INFORMATION Ignition cable 2 5 To this chapter contents 2 MAINTENANCE INFORMATION SYM Ignition System A Caution e C D I ignition system is set by manufacturer so it can not be adjusted Ignition timing check procedure is for checking whether CDI function is in normal or not Connect tachometer and ignition light Start engine As engine in idle speed 1600 rpm aim at the mark F with the ignition light Then it is means that ignition timing is correct Increase engine speed to 6000 rpm to check ignition advance degree If indent is located within the ignition advance degrees it is means that the ignition advance degree is in normal If ignition timing is incorrect check CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found Cylinder Compression Pressure Warm up engine Turn off the engine Remove the trunk Remove the central cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of starter motor 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 12 2 Kg cm Check following items if the pressure is too low e Inc
20. 2 14 SYM 3 LUBRICATION SYSTEM Mechanism Diagram 3 1 Engine Oil Strainer Clean 3 3 Precautions in Operation 3 2 Oil 3 4 Troubleshooting HR 3 2 T TL TT I TT 3 7 Engine 3 3 Mechanism Diagram Valve Rocker Arm Cam Shaft Oil Route Con Rod Spray Lubrication Press In Lubrication Oil Route Cil through Oil Pump 3 1 To this chapter contents 3 LUBRICATION SYSTEM SYM Precautions in Operation General Information e This chapter contains maintenance operation for the engine oil pump and gear oil Mac LI pu Specifications SAE 20W 40 Engine oil quantity Disassembly 1000 c c Change 800 SAE TOW 40 Oil viscosity SAE 10W 30 Recommended F E King serial oils SAE 10W 30 Gear oil Disassembly 750 Change 650 Gear oil viscosity SAE 140 Recommended SYM Hypoid gear oils LJ mm Oil pump Clearance between outer rotor and body 0 15 0 20 Clearance between rotor side and body 0 04 0 09 Torque value Torque value oil strainer cap 1 5 3 0kgf m Engine oil drain bolt 1 9 2 5kgf m Gear oil drain bolt 1 0 1 5kgf m Gear oil join bolt 1
21. Abnormal Punctured tire e Faulty tire valve Normal Accelerate lightly engine speed can be increase 2 Fuel air mixture ratio too rich or lean Clogged in air cleaner Abnormal e Clogged in muffler Restricted fuel flow Clogged fuel tank cap breather hole Normal Check ignition timing Normal Abnormal Faulty pulse generator Faulty CDI unit Test cylinder compression Normal Abnormal e Leaking head gasket Worn cylinder and piston rings Check carburetor Normal Clogged Clean Check spark plug Normal Fouled or discolored Clean the spark plug Spark plug is incorrect heat range Check for engine overheating Excessive carbon deposited in combustion chamber Overheating Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel Normal Accelerate or run at high speed worn piston and cylinder Fuel air mixture ratio is lean Knocks Wrong type of fuel Ignition timing too advanced Excessive carbon deposited in combustion chamber Normal 18 To this chapter contents SYM 1 GENERAL INFORMATION Parts to Be Greased Front suspension front side And steering shaft E Rear swing arm 1 19 To this chapter contents 1 GENERAL INFORMATION lever pivot i Wheel bearing 4 2 O O 1 20 SYM 2 MAINTENANCE INFORMAT
22. chapter contents 17 ELECTRICAL SYSTEM SYM Maintenance Data Operational precaution 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 The model of the spark plug and the tightening torque The ignition timing Adjustment of headlight Removal and installation of AC generator The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water To recharge the battery remove the battery from rack without removing ventilation caps Unless in emergency never rapid charge the battery The voltage must be checked with the voltmeter while charging the battery As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignition timing light after replacement if necessary Technical Specification Charging system Description Specification Capacity 12V8Ah 0 9A 5 hours standard 4A 1 hour fast charging Charging current 1 2 A 2000rpm Control voltage in charging 14 5 0 5 V 2000rpm Ignition system Description Specification Model CR8E Recommended opark plug Gap 0 6 0 7mm Primary winding 0 17 1096 Battery Charging rate Without cap 3 1 10KQ resistance Secondary winding With cap 8 1 10KQ 13 TDC 1000rpm Ignition timing F
23. clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element ooap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover Spark Plug Recommended spark plug CR8E Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug 0 8 0 9 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Hold spark plug washer and install the spark plug by screwing it Tighten the plug by turning 1 2 turn more with plug Socket after installed Tighten torque 1 0 1 2kgf m 2 3 To this chapter contents 2 MAINTENANCE INFORMATION Valve Clearance Caution Checks and adjustment must be performed when the engine temperature is below 35 C Remove trunk Remove central cover Remove valve adjustment cap Remove cylinder head side cover Turn camshaft bolt in C W direction and let the mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke amp Caution Do not turn the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check
24. cushion Press down the front cushion for several times to check it operation Check if it is damage Replace relative parts if damage found Tighten all nuts and bolts Rear Cushion Press down the rear cushion for several times to check it operation Check if it is damage Replace relative parts if damage found 2 10 Clutch weight Drive plate To this chapter contents SYM 2 MAINTENANCE INFORMATION Steering Handle A Caution Check all wires and cables if they are interfered with the rotation of steering handle bar Lift the front wheel out of ground Turn handle from right to left alternative and check if turning is smoothly If handle turning is uneven and bending or the handle can be operated in vertical direction then check the handle top bearing Wheel Tire A Caution Tire pressure check should be done as cold engine Check if tire surface is ticked with nails stones or other materials Appointed tire pressure Tire pressure as cold 0 8 kg cm 12psi Check if front and rear tires pressure is in normal Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm Nuts Bolts Tightness Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check all fixing p
25. lever nut 1 00kgf m Air bleed valve 0 50kgf m Front wheel nut 2 40kgf m Front axle castle nut 5 00kgf m 14 2 To this chapter contents SYM Trouble Diagnosis Soft brake lever Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining disk Low brake fluid Blocked brake hose Warp bent brake disk Bent brake lever O O1 QO IN gt Hard operation of brake lever Blocked brake system Poor brake caliper Blocked brake pipe Q N Bent brake lever Uneven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Seized worn master cylinder piston 14 FRONT BRAKE amp FRONT WHEEL Hard steering 1 Faulty tire 2 Insufficient tire pressure Front wheel wobbling 1 Faulty tire 2 Worn front brake drum bearing 3 Bent rim 4 Axle nut not tightened properly Steers to one side 1 Bent tie rods 2 Wheel installed incorrectly 3 Unequal tire pressure 4 Incorrect wheel alignment 14 3 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Front
26. may get scalded Remove the front cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilling system with coolant and bleeding the air ue Run the engine and remove by pass pipe e Check by pass hole whether has the air bubble to emit f emits without the air bubble only has the coolant to flow out then backflow pipe joint on engine flameout e Remove radiator filler cap e Starts the engine inspects does not have the air bubble in the radiator coolant also the coolant liquid level is stable Stop the engine Add coolant to proper level if necessary Screw and tighten up the radiator filler cap A Caution In order to avoid the water tank rusting please do not use the unclear trade mark refrigerant Coolant recommended SYM Bramax radiator agent Concentration 50 To this chapter contents 12 COOLING SYSTEM Check reserve tank Remove the front cover and then remove reserve tank filler cap Check the liquid level in the front fender right side Add coolant to proper level if too low Reinstall the reserve tank filler cap A Caution The reserve tank liquid level coca too is not high after avoids the water temperature elevating in the cooling system the refrigerant backflow floods Radiator Check Remove the front cover front under cover and front fender refer chap
27. performed more often if the ATV is frequently operated in high speed and after the ATV has accumulated a higher mileage 3 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 To this chapter contents SYM 2 MAINTENANCE INFORMATION Fuel Lines H th t Fuel tank 1 Fase 2 and 2 bolts al Remove the tank cover Check all lines and replace it when they are deterioration damage or leaking Warninc Fuel hose Gasoline is a low ignition material so any kind of 5 Fuel filter FI at e L 2 a fire is strictly prohibited as dealing it Acceleration Operation Have a wide open of throttle valve as handle in any position and release it to let back original full closed position Check handle if its operation is smooth Check acceleration cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure the throttle lever free play in its flange part Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment screw Tighten the fixing nut and check acceleration operation condition Free play 5 10 mm Air Cleaner Remove 3 screws from the air cleaner cover and then remove the cover Loosen the
28. repair Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the water thermometer Technical Specification Pressure to open filler cap 0 75 1 05 kg cm Capacity of coolant Engine radiator 780c c Reservoir upper 420 c c Begins to activate at 71 80 C Stroke 3 5 4 5 mm 80 C Thermostat Not pressure 107 7 C Bolling polnt Pressurized 125 6 C Torque Value For water pump rotor 1 0 1 4kgf m Tools Requirement Special tools Water pump bearing driver 6901 SYM 9100100 Water pump oil seal driver Inner SYM 9120500 H9A Water pump mechanical seal driver SYM 1721700 H9A Inner bearing puller SYM 6204020 Trouble Diagnosis The engine temperature is too high The engine temperature is too low The water thermometer and the temperature The water thermometer and the temperature sensor do not work properly sensor malfunction e The thermostat is stuck to close e The thermostat is stuck to open e Insufficient coolant The water hose and jacket are clogged Coolant is leaking Fan motor malfunction The water pump mechanical seal does not The filler cap of the radiator malfunction function properly The O ring is deteriorated The water hose is broken or aged 12 2 To this chapter contents SYM 12 COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high Y A Stop and waiting for the engin
29. starter amp Foot Catalytic reaction control system Displacement 171 2 cc Compression Ratio 10 8 1 c c C x O O m 1 10 To this chapter contents SYM 1 GENERAL INFORMATION Specifications wacn Overall Length 1765 mm Suspension Front Unit Swing System Overall Height 1135 mm Front AT21x7 10 off road Tire Specifications Wheel Base 1115 mm Rear AT22x10 10 off road 102kg Curb Weight Rear 97 kg Front Disk u 175mm Brake System Total 199 kg Rear Disk y 190mm Passengers Weight Two 150 kg Max Speed Above 70 km hr Performance Front 132 kg Climb Ability Below 20 Primary Total Weight CHR Reduction sen oecondary Total 49 k ket imension D Weight 4 Stroke Engine Clutch Centrifugal dry type Installation and Vertical below center C V T auto speed Vu Transmission arrangement incline 80 change Fuel Used Unleaded opeedometer 0 90 km hr Cycle Cooling 4 stroke water cooled 93 112 dB A E ion amp Pul Exhaust Pipe Position and Hight side and Stroke beum 9 Direction Backward Number Arranqe Forced circulation amp 9 Single Cylinder Lubrication System ment splashing Below 7 0 g km Below 1 5g km Below 0 4g km Catalytic reaction control system Cylinder Engine ps o 8 C x O O n To this chapter contents 1 G
30. the disk at several places Replace the disk if it has exceeded the service limit Allowable limit 2 5 mm Remove the brake disk from rear wheel axle Check the disk for deformation and bend Allowable limit 0 30 mm N Caution The dirty brake lining or disk will reduce the brake performance Brake lining includes the asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Rear Brake Master Cylinder Master Cylinder Removal 1 Brake lever bolt N Caution Do not let foreign materials enter into the cylinder N Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set I Handle left side rear brake master cylinder rake lever nut Remove brake light switch coupler Drain out the brake fluid Remove the brake hose Remove the brake lever from the brake master cylinder Remove the master cylinder socket bolts and the master cylinder 2 socket bolts 16 13 To this chapter contents 16 BRAKE amp REAR WHEEL amp REAR CUSHION Right footrest side rear brake master cylinder B Place a container under the brake master cylinder remove fluid hose clamp and drain out the brake fluid Loosen the brake hose bolt and finally remove the brake hose Remove E type clip and remove brake push rod pin Remove the m
31. 0 1 5kgf m Oil pump connection bolt 0 8 1 2kgf m Troubleshooting Low engine oil level Dirty oil Oil leaking No oil change in periodical Valve guide or seat worn out e Cylinder head gasket damage e Piston ring worn out e Piston ring worn out Low oil pressure Low engine oil level Clogged in oil strainer circuits or pipes Oil pump damage To this chapter contents SYM 3 LUBRICATION SYSTEM Engine Oil Turn off engine and park the ATV in flat surface with main stand Check oil level with oil dipstick So not screw the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Change A Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely Place a oil pan under the ATV and remove oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Oil strainer cap Torque value 1 5 3 0kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Engine oil capacity 0 8L when replacing Install dipstick start the engine for running several minutes Turn off engine and check oil level again Check if engine oil leaks
32. 3 checks Remove thermostat from holder then heats it by N Replace thermostat water directly to check its operation Refill with coolant then check again For bleed the air bubbles completely open radiator cap Notice the water hose and start engine while engine can t any unsuitable is cool then press water hose bend or twist and softly by hand to bleeding bleed the air bubbles Turn the throttle repeatedly completely until the coolant surface becomes stable 12 4 To this chapter contents SYM 12 COOLING SYSTEM System Test Test on the filler cap Hermetically seal the filler cap apply water and pressure to the filler cap Replace it with new one if found failing to maintain the specified pressure within a given time limit or the opening pressure is too high or too low The specified pressure shall be maintained at least for 6 seconds in the test Relief pressure for the filler cap 0 75 1 05 kg cm Pressure tester Apply pressure to the radiator engine and water Filler cap hose to check for any leakage A Caution Pressure which is too high may damage the radiator Never use pressure which exceeds Reserve tank cap 1 05 kg cm If the system fails to maintain the specified pressure for at least 6 seconds repair or replace parts Change of coolant A Warning Never attempt to carry out service work on the cooling system unless the engine is completely cooled down otherwise you
33. 4kgf m Front axle castle nuts 5 0kgf m 14 1 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Maintenance Description Operational precautions A Caution Inhaling asbestos may cause disorders of respiration system or cancer therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead The brake caliper can be removed without removing the hydraulic system After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system e While refilling brake fluid care should be taken not to let the foreign material entering into the brake system Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage Check the operation of the brake system before riding Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Specifications Standard Limit mm The thickness of front and rear brake disk 4 000 2 500 Front and rear brake disk eccentricity lt 0 100 0 300 Master cylinder inner diameter 11 000 11 043 11 055 Master cylinder outer diameter 10 957 10 984 10 945 Diameter of front disk 175 000 Thickness of front brake lining 5 100 2 000 Tire pressure as cold 0 8 kg cm 12psi Torque values Brake hose bolts 3 50kgf m Bolt for brake caliper 3 25kgf m Bolts for the brake disk 4 25kgf m Brake
34. AKE amp FRONT WHEEL SYM Assembly Bearing driver Install brake disk _ Install new inner side bearing and seal into front wheel hub Install front wheel hub bearing inner spacer Install new out side bearing and seal into front wheel hub Special tool Bearing driver 6203 Oil seal drive 24x35x7 Installation Install the front brake disk to the wheel hub Install brake caliper mounting seat on to knuckle N Caution Align the brake caliper mounting seat groove with the stopper flange Install wheel hub and brake disk on to knuckle Wheel hub nut 77 7 Install wheel hub washer and tighten the wheel eo hub nut s Torque 5 0kgf m Install cotter pin 14 6 To this chapter contents SYM 14 FRONT BRAKE amp FRONT WHEEL Disk Brake System Inspection Inspection By visual examination whether divulges or the damage with spanner inspection brake tube seam whether becomes less crowded and the inspection handle bar turn right or turn left or pressure the cushion whether besides the pipeline protection department whether there is interferes contacts other parts of Check the brake from behind the brake caliper The brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk A Caution e Check the front brake lining must be removed front wheel first Brake linings wear limit Park the ATV on a level ground and check if fluid leve
35. Caution Take care not to damage jets and adjust screw e Before removing adjustment screw turn it all the way down and note the number of turns e Do not turn adjust screw forcefully to avoid damaging valve seat face Clean jets with cleaning fluid Then use compressed air to blow the dirt off Blow carburetor body passages with compressed air Assembly Install main jet needle jet holder needle jet slow jet and air adjustment screw A Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking fuel level A Caution e Check again to ensure float valve float for proper installation e 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 14 8mm Installation of carburetor Install carburetor in the reverse order of removal Following adjustments must be made after installation Throttle cable adjustment Idle adjustment 4 8 SYM Needle jet holder Main jet Needle jet Slow jet Air adjustment screw AN Float gauge Throttle adjustment screw SXAA 4 FUEL SYSTEM Adjustment of Idle Speed Parking brake A Caution Air screw was set at factory so no adjustment is needed Note the number of turns it takes to screw it all the way in for ease of installation e parking brake must be used to st
36. Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right crankcase cover Install the cir clip to hold the inner bearing 12 10 To this chapter contents SYM Install the seal washer into the rotor A Caution Washer must be replaced together with the mechanical seal Install the rotor onto the water pump shaft and tighten Torque Value 1 0 1 4kgf m A Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil pump drive shaft flange install the right crank case 9 bolts Install the dowel pin and new gasket Install the water pump cover with 4 bolts 12 COOLING SYSTEM To this chapter contents 12 COOLING SYSTEM Thermostat Please refer to chapter 17 for inspection of temperature sensor Removal Drain out the coolant Disconnect the cable of temperature sensor Disconnect the by pass pipe Remove the thermostat set 1 bolt Disassembly Remove the temperature sensor and O ring from the thermostat body Remove 2 bolts and separate the thermostat body from the cover Remove the thermostatl 12 12 To this chapter contents SYM 12 COOLING SYSTEM Inspection Visually inspect thermostat for any damage Place the thermostat into heated water to check its o
37. ENERAL INFORMATION SYM Torque Values 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 Tighten Torque Tighten Torque 5 mm bolt nut 0 45 0 6kgf m 5 mm screw 0 35 0 5kgf m 6 mm bolt nut 0 8 1 2kgf m 6 mm screw SH nut 0 7 1 1kgf m 8 mm nut 1 8 2 5kgf m 6 mm bolt nut 1 0 1 4kgf m 10 mm bolt nut 3 0 4 0kgf m 8 mm bolt nut 2 4 3 0kgf m 12 mm bolt nut 5 0 6 0kgf m 10 mm nut 3 5 4 5kgf m Engine Torque Values tem Thread Dia Torque Value kgt m Remarks Cylinder head nut 4 8 2 0 2 4 Cylinder head right bolt 2 8 2 0 2 4 Cylinder head stud bolt inlet pipe 2 6 0 7 1 1 Cylinder head stud bolt EX pipe 2 7 0 5 1 0 Tappet adjustment hole cap bolt 6 6 1 0 1 4 Tappet adjustment screw nut 4 5 0 7 1 1 Apply oil to thread Spark plug 1 10 1 0 1 2 Carburetor insulator bolt 2 6 0 7 1 1 Cylinder stud bolt 4 8 0 7 1 1 Engine left cover bolt 7 6 1 1 1 5 Engine oil draining bolt 1 12 1 1 1 5 Engine oil strainer cap 1 30 1 3 1 7 Mission draining bolt 1 12 1214129 Mission filling bolt 1 12 1 1 1 5 Clutch driving plate nut 1 28 5 0 6 0 Clutch outer nut 1 12 5 0 6 0 Drive face nut 1 12 5 0 6 0 Flywheel nut 1 12 5 0 6 0 Crankcase bolts 7 6 0 8 1 2 Mission case bolt 7 8 2 0 2 4 1 12 To this chapter contents SYM 1 GENERAL INFORMATION Fra
38. ION Brake fluid replacement Air bleed y guggAir leed valve Connect drain hose to air bleed valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brake fluid Connect one end of transparent hose to the drain valve and put the other end into a container Open the drain valve around 1 4 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 si 1 Tightly hold the brake lever and open the drain 5 L 7 Transparent hose valve around 1 4 turns and then close the valve Caution Do not release the brake lever before the drain valve is closed Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enters into the system 2 Slowly release the brake lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1 and 2 until there is no air bubble at the end of the hose 4 Tightly close the drain valve 5 Make sure the brake f
39. ION Precautions in Operation Drive Chain 2 7 Periodical Maintenance Schedule Brake System Disk 2 8 Fuel Lines Brake Light Switch Starting Inhibitor A Ite SEE 2 9 Headlight Beam Distance 2 10 Clutch Disc Wear 2 10 i e TTE 2 10 Steering Handle 2 11 SANI 2 11 Nuts Bolts Tightness 2 11 Special Tools List 2 12 Acceleration Operation Air Cleaner Spark Plug Valve Clearance Carburetor Idle Speed Adjustment Ignition System Cylinder Compression Pressure Drive Belt Precautions in Operation Specification Fuel Tank Capacity 8000 Capacity 1000 c c Engine Oil E Capacity Transmission Gear oil Reservoir upper NGK CR8E Spark plug F Mark in idling speed BTDC 13 1000 rom Full timing advanced BTDC 27 6000 rpm Idling speed 1600 100 rpm Cylinder compression pressure 12 0 2 kgf cm Valve clearance IN EX 0 12 0 02 mm Tire dimension Tire pressure cold 0 8 kgf cm 12psi Capacity of coolant To this chapter contents 2 MAINTENANCE INFORMATION SYM Periodical Maintenance Schedule 1 Month 3 6 1 year 15 month Code Item 300KM every every every every every 1 000KM 3 000KM 6000
40. KM 12 000KM 14 500KM ape po T TT R o0 ame ar bu L T 1 e oil change Replacement for every 1000 km paye j 7 orate a tee py ene E E E e semeren a foushion operation creck 11 fever screw tightening otek S a erta 01 LE 3 1 is joeroitane R Replacement Tor every 000Km L L Dot i eee c i sn egg a Throttle pa n a a CVT driving device belt e jenes o e Lights electrical CDU meters 2 Cam chain L5 Wess eo 27 lines amp connectionsincooing 11 o n fo 0 y 28 Cooantresevoir 0 1 jJ j 9 joo 11411 I R Code l Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Have your ATV checked adjusted and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the ATV 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 Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in the Heavily polluted environment 2 Maintenance should be
41. L amp REAR CUSHION Inspection Check bearings on rear wheel axle bearing seat 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 bearing seat 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 Disassembly A Caution e Never install used bearings Once bearing removed it has to be replaced with new one Remove bearing and seal from rear wheel axle bearing seat using following tools Special tool Inner bearing puller Remove bearing spacer Assembly Install new left side bearing and seal into rear wheel axle bearing seat Install rear wheel axle bearing inner spacer Install new out right bearing and seal into front wheel hub Apply with grease onto the oil seal lip of rear wheel axle Special tool Bearing driver 6007LLU Oil seal drive 43x62x12 Installation Install rear wheel axle and driven sprocket holder Driven sprocket holder 16 7 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Install rear brake disk bracket and disk Install rear wheel axle nuts rear axle nut fixed plate and tighten the nuts Torque 9 2kgf m Special tool Rear axle nut wrench 55mm Rear axle nut torque wrench Torque wrench After tightened the axle nut bend the rear axle
42. Remove the outside bearing by inner bearing puller Rotate the inner ring of bearing the bearing shall move smoothly and quietly If the bearing does not rotate smoothly or produces a noise replace it with new one Special tool Inner bearing puller 12 8 To this chapter contents SYM Check any wear and damage of the mechanical seal and inside seal A Caution The mechanical seal and inside seal must be replaced as a unit Replacement of Mechanical Seal Remove the inside bearing by inner bearing puller Drive the mechanical seal and inner seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new mechanical seal Install the mechanical seal onto the right crankcase Special tools Water pump mechanical seal driver 12 COOLING SYSTEM Mechanical seal 235 Water pump mechanical seal driver s 35 Water pump bearing driver 12 9 To this chapter contents 12 COOLING SYSTEM SYM Install the new inner seal onto the right crankcase Special tools Water pump oil seal driver inner 25 Water pump oil seal driver inner Install a new outside bearing to the right SS Water pump bearing crankcase cover driver 6901 Special tools Water pump bearing driver 6901 A Caution
43. Use a fully charged battery having a voltage larger than 13 0 V While starting the engine the starter motor draws large amount of current from the battery After the engine is warmed up replace original battery with a fully charged battery Connect a digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse A Caution When the probe is reversibly connected use 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 Does not use short circuit cable It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal however while the starter motor is activated the surge current the motor draws from the battery may damage the ammeter Use the kick starter to start the engine The main switch shall be turned to OFF position during the process of inspection Never tamper with the ammeter and the cable while there is current flowing through It may damage the ammeter 17 6 SYM Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 6000 rpm Control Charging Voltage 14 5 0 5 V 2000 rpm 4 Caution To replace
44. VING MECHANISM SYM Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the cover inner side Special tool Inner bearing puller Remove cir clip of final shat out side bearing Remove final shat out side bearing Special tool Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearings into gear box cover inner side Special tool Needle bearing driver 4905 Bearing driver 6302 Bearing driver 6204 Install new final shaft oil seal into gear box cover and then install new out side bearing Special tool Oil seal driver 30x40x5 Bearing driver 6205LU 9 9 To this chapter contents 9 FINAL DRIVING MECHANISM Re assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft Install final shaft and then install the washer and cir clip Install counter shaft and gear shift shaft onto gear box Install shift drum shift fork and fork shaft onto gear box 9 10 To this chapter contents SYM 9 FINAL DRIVING MECHANISM Align the position mark on the shift spindle sprocket with that of shift drum and then install shift spindle 10 bolts Install dowel pin and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Apply with grease onto new oil seal lip and then install the shift
45. Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame Remove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 2 4kgf m Front Wheel Hub Removal Remove brake caliper Remove cotter pin wheel hub nut and washer Remove wheel hub and brake disk Remove brake caliper mounting seat Inspection Check bearings on wheel hub 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 wheel hub 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 Brake disk Collar 14 4 To this chapter contents SYM 14 FRONT BRAKE amp FRONT WHEEL Disassembly Inner bearing puller A Caution e Never install used bearings Once bearing removed it has to be replaced with new one Remove out side bearing and seal from wheel hub using following tools Special tool Inner bearing puller Remove front wheel hub bearing inner spacer _ Inner spacer Remove inner side bearing and oil seal from wheel hub using following tools Special tool Inner bearing puller Remove 4 socket bolts and then remove the brake disk from wheel hub 4 bolts To this chapter contents 14 FRONT BR
46. amp adjust valve clearance with feeler gauge Valve clearance IN EX 0 12 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution Re check the valve clearance after tightened the fixing nut To this chapter contents SYM Carburetor Idle Speed Adjustment Caution Inspection amp adjustment for idle speed have to be performed atter all parts in engine that needed adjustment have been adjusted Idle speed check and adjustment have to be done after engine is being warm up It is enough that operates engine from stop to running for 10 minutes Park the ATV with main stand and warm up engine Connect tachometer the wire clamp of tachometer is connected to the high tension cable Turn the throttle valve stopper screw to specified idle speed Specified idle soeed 1600 100 rom 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 throttle valve stopper screw and let engine runs in 1600 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures
47. and 2 until there is no air bubble at the end of the hose 4 Tightly close the drain valve 5 Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary 6 Cover the cap Air bleed valve Air bleed valve Transparent hose 14 9 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL Front Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hose s Caution Do not spill brake fluid on painted surfaces Remove two caliper bolts and the caliper Inspection Make sure the brake linings condition Replace the linings if the brake linings wear limitation groove close to the brake disk Brake lining replacement Remove two guide pins Compress caliper mounting plate and then remove brake linings Install new linings and tighten the guide pins Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 20 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding 14 10 To this chapter contents SYM 14 FRONT BRAKE amp FRONT WHEEL Brake Disk Brake disk yp f Inspectio
48. arburetor Insulator Remove Air Injection system Al pipe mounting bolt Remove 1 bolt of thermostat and then remove the thermostat Remove hole cap for the adjustment bolt of cam chain tensioner and then loosen the tensioner by turning a flat driver in C W direction Remove the side cover mounting blots of cylinder head and then take out the side cover Remove cam sprocket bolts and then remove the sprocket by prying chain out 6 4 To this chapter contents SYM 6 CYLINDER HEAD VALVE Remove the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side Remove the cylinder head Remove 2 bolts of carburetor insulator and then take the insulator out Carburetor insulator Remove cylinder head gasket and 2 dowel pins Remove chain guide Clean up residues from the matching surfaces of cylinder and cylinder head Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Chain guide To this chapter contents 6 CYLINDER HEAD VALVE Cylinder Head Disassembly Remove the hole cap of intake amp exhaust valve clearance adjustment There are 6 bolts Then remove the cap Remove the rocker arm pin stopper plate and then screw a 5mm bolt into the rocker arm pin Finally remove the pin and the rocker arm screw a 6 m
49. ary Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent 1 Check if the bearing outer parts are closed and fixed Replace it if necessary Outer ball bearing 8 11 To this chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER Clutch weight Replacement Remove snap ring and washer and then remove clutch weight and spring from driving plate A Caution Some of models are equipped with one mounting plate instead of 3 snap rings Check if spring is damage or insufficient elasticity Clutch weight Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block should not be greased If so replace it A Caution Grease or lubricant will damage the clutch weight and affect the block s connection capacity Install the spring into groove with pliers Spring 8 12 Driving plate Snap ring ma Setting pin To this chapter contents SYM 8 V BELT DRIVING SYSTEM KICK STARTER Install snap ring and mounting plate onto setting pin Replacement of Driven Pulley Bearing Remove inner bearing Caution f the inner bearing equipped with oil seal on side in the driven pulley then remove the oil seal firstly If th
50. aster cylinder socket bolts and the master cylinder Disassembly Remove the rubber boot Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master Cylinder Inspection Check the master cylinder for damage or scratch Replace it if necessary Measure the cylinder inner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit Allowable limit 12 550 mm 16 14 SYM E type clip Cm Cir clip eA Rubber boot Piston Spring 4 eu IMS ER 7 To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit 12 654 mm Master Cylinder Assembly amp Caution 115 necessary to replace the whole set comprising piston spring piston cup and cir clip 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 Cir clip Install the larger end of the spring onto the master aC cylinder Rubber boot The master cup s cavity should be face inside of Piston BS master cylinder when installing the master cup Install the cir clip 91 Piston cup Caution Never install cup lip in the opposite
51. ation amp 9 Single Cylinder Lubrication System ment splashing Below 7 0 g km Below 1 5g km Below 0 4g km Catalytic reaction control system Cylinder Engine ps o 8 C x O O n 1 cO To this chapter contents 1 GENERAL INFORMATION SYM Specifications maker SANYANG MODEL UA18A1 6 Overall Length 1765 mm Suspension Front Unit Swing Overall Width 1040mm System Unit Swing Overall Height 1135 mm EM AT21x7 10 on road Tire Specifications Wheel Base 1115 mm AT22x10 10 on road Dimension 102 Curb Weight Rear 97 kg Front Disk u 175mm Brake System Total 199 kg Hear Disk y 190mm Passengers Weight Two 150 kg Max Speed Above 70 km hr Performance Climb Ability Below 20 Primary Belt m oecondary Reduction Gear Sprocket Heduction 4 Stroke Engine Clutch Centrifugal dry type Installation and Vertical below center C V T auto speed Transmission arrangement incline 80 change Fuel Used Unleaded Speedometer 0 90 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A E Pul Type Stroke TETN Exhaust PDE POSION and Right side and Direction Backward Number A Forced circulation amp Single Cylinder Lubrication System I ment splashing Engine Cylinder Below 7 0 g km Max HP 10 3kw 7000rpm Below 1 5g km 15 2Nm 5500rpm Below 0 40 km C D Electrical
52. brake performance to be reduced or totally lost 14 8 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Brake fluid replacement Air bleed Connect drain hose to air bleed valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brake fluid Air bleed must from pressure control valve fist Connect one end of transparent hose to the air bleed 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 A Caution e Do not release the brake lever before the drain valve is closed Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enters into the system 2 Slowly release the brake lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1
53. chamfer cutter to cut any rough or uneven surface from valve seat A Caution After valve guide had been replaced it has to be ground with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper parts out Old valve seat width 6 9 To this chapter contents 6 CYLINDER HEAD VALVE Use 60 cutter to cut a quarter lower parts out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width A Caution Make sure that all roughness and uneven faces had been ground Grind valve seat again if necessary Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface A Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat to specified width SYM Old valve seat width Contact surface too high E te pagg PPE ED valve seat width lt z Ou Contact surface too low Old valve seat width n al To this chapter contents SYM After the valve seat grou
54. cushion under bolt cotter pin and remove the bolt Remove front cushion upper bolt cotter pin and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value 4 6kgf m After tightened the bolts install the cotter pins 15 9 To this chapter contents 15 STEERING SUSPENSION Suspension Arm Remove Remove front wheel wheel hub and brake caliper brake caliper mounting seat tie rod and front cushion Loosen suspension arm front side nuts remove swing arm bolts Loosen suspension arm rear side nuts remove swing arm bolts Remove suspension arm spacer and seal covers Inspection Inspect the suspension arm spacer bush and seal cover for damage or bending Installation Install in reverse order of removal procedures Torque value Suspension arm nut 5 0kgf m Lubricate with grease into suspension arm 15 10 To this chapter contents 15 STEERING SUSPENSION SYM Toe In When repair or disassemble steering system parts must to adjustment the toe in Keep the vehicle on level ground and the front wheels facing straight ahead Mark the centers of the tires to indicate the axle center height Measure the distance between the marks Carefully to move the vehicle back let the wheels turn 180 degree so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the fron
55. cuum or coolant should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps Groove e Rubber and plastic boots should be properly reinstalled to the original correct positions as designed 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 To this chapter contents SYM 1 GENERAL INFORMATION e Lubricate the rotation face with specified After service completed make sure all lubricant on the lubrication points before connection points is secured assembling Battery positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables e Check if positions and operation for installed parts is in correct and properly Make sure that the battery post caps are located in properly after the battery posts had been serviced Make sure service safety each other when conducting by two persons f fuse burned it has to find out the cause and solved it And then replace with specified Capacity fuse Capacity a verification
56. d final shaft Remove shift spindle shift drum shift fork shaft and fork Remove gear shift shaft gear and washer Remove counter shaft and gear Remove gasket and dowel pin Gear shif 9 4 To this chapter contents SYM 9 FINAL DRIVING MECHANISM Remove the drive shaft In order to avoid damaging the crankcase in the cover place a rag between the case and table Check drive shaft and gear for wear or damage Special tool Shaft protector Oil seal Bearing A Caution f non essential do not remove the drive shaft from the case upper side If remove the drive shaft from the gear box then its bearing and oil seal has to be replaced Remove the final shaft cir clip and washer Remove the final shaft To this chapter contents 9 FINAL DRIVING MECHANISM SYM Inspection of Mission Mechanism Check if the shift spindle is wear or damage Check if the shift drum is wear or damage Check if the shift fork and shaft is wear or damage Check if the gear shift shaft is wear or damage To this chapter contents SYM 9 FINAL DRIVING MECHANISM Check if the counter shaft is wear or damage Check if the final shaft and gear are burn wear or damage Check bearings on gear box and 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 tightly If bearing r
57. diameter of valve stem is the clearance between the valve stem and valve guide Service Limit 0 08 mm EX 0 10 mm To this chapter contents 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 has to correct valve seat when replacing valve guide Valve Stem Replacement Heat up cylinder head to 100 150 C with heated plate or toaster A Caution Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating it e Wear on a pair of glove to protect your hands when operating Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 5 0 mm A Caution e Check if new valve guide is deformation after pressed it in When pressing in the new valve guide cylinder head still have to be kept in 100 150 C Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide Valve guide driver
58. direction Make sure the cir clip is seated securely in the groove Install the rubber boot into groove properly Master cylinder Master Cylinder Install Caution Improper routing may damage leads hoses or pipes N Caution Kink of brake leads hose or pipe may reduce brake performance Handle left side rear brake master cylinder Install the rubber pad into the groove correctly Place the master cylinder onto handlebar and Install the bolts Install the brake lever and connect coupler to brake light switch Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Add specified brake fluid and bleed the system Brake light switch coupler Brake lever nut 16 15 To this chapter contents 16 BRAKE amp REAR WHEEL amp REAR CUSHION Right footrest side rear brake master cylinder B Install the master cylinder socket bolts and the master cylinder Install brake push rod to the brake pedal and Install pin and E type clip N Caution To adjustment brake pedal you must be removed push rod pin fist Loosen lock nut and turn adjustment nut and push rod bracket to adjustment brake free play Install fluid hose and clamp Connect brake hoses with 2 new washers Tighten
59. e radiator Installation Install the removed parts in the reverse order of removal Install radiator in the reverse order of removal Upon completion check for any leakage 12 7 To this chapter contents 12 COOLING SYSTEM Water Pump Check water pump seal cooling system divulges inspection Disassembles the refrigerant drain bolt overflows little buckles the N actually fluid confirmed overflows the refrigerant whether has the greasy dirt Turns on lathe the engine oil gauge rule the inspection engine oil whether does have bleaches situation of the emulsified If has the above two kind of interior to divulge the phenomenon possibly for the water pump inner two seal damages the engine cooling system damages or the cylinder and the cylinder head gasket damages please first dismantles the right crank case to say Aconfirms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Drain bolt Removal of water pump Loosen the drain bolt to drain out the coolant Remove the water hose Loosen 4 bolts and remove the pump cover Loosen 9 bolts and remove the right cover Take off the gasket and dowel pin Turn pump rotor clockwise and remove A Caution The rotor is provided with left turn thread Remove the cir clip from the right crankcase cover Remove the water pump shaft and the inner bearing
60. e IS completely A1 Refill the radiator with Y cooled down open cap to coolant then check for any Water leaking problem check the capacity of leakage coolant in radiator B Turn on main switch and check the water B 1 Measure thermo unit to temperature indicator confirm voltage 6V T back to zero Replace thermo unit B 2 Inspect the circuits of water temperature have Short or earth handle short or earth Meter problem C Open radiator cap and C 1 Eng stop and remove softly throttle inspect water pump cover start Water pump repair coolant have circulated the motor to inspect pump its rotation Y Water hose clogged D Close radiator cap measure thermo unit to N confirm voltage reduced Replace thermo unit comply with temperature rise Y Next page 12 3 To this chapter contents 12 COOLING SYSTEM SYM Preceding page Measure thermal switch to confirm voltage be Replace thermal switch changed 12 0V E Keep eng 3000 4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks Y Connect cooling fan N F Confirm cooling was terminals with battery Replace cooling fan convulsion 12V directly to inspect Y its operation Meter unusual Y Keep eng 3000 4000 rpm and inspect coolant If circuit connects reverse flow into reserve tank cooling fan will forward after the temperature correct and check again gauge over
61. e pulley equipped with ball bearing it has to remove snap ring and then the bearing Inner needle bearing Snap ring Remove snap ring and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Outer bearing Install new inner bearing Bearing end N Caution Its sealing end should be forwarded to outside as bearing installation e Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Install snap ring into the groove of driving face Align oil seal lip with bearing and then install the Inner bearing new oil seal if necessary 8 13 To this chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER SYM Installation of Clutch OUTER Driven Pulley Assembly Install new oil seal and O ring onto movable driven face Apply with specified grease to lubricate the inside of movable driven face Install the movable driven face onto driven face Movable driven face Oil seal Guide pin Install the guide pin and guide pin roller Guide pin Guide pin roller Install the collar Install friction plate spring and clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed NT Hold the compressor by bench vise and tighten the mounting nut to spec
62. e the 3 5 minute In order to prevent has the chemical change please do not use counterfeiting or other unclear trade marks brake fluid Uses by all means must with the trade mark brake fluid guarantees the ghost vehicle efficiency 16 9 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Adding Brake Fluid Before the brake fluid reservoir is removed turn the handle so that the brake fluid reservoir becomes horizontal and then remove the brake fluid reservoir When maintenance brake system will be supposed to paint the surface or the rubber parts catches up by the rags 4 Caution Supplement brake fluid please do not surpass the upper limit spilled brake fluid on painted surfaces plastic or rubber components may result in their damages Remove the brake fluid cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in the master cylinder Clean the dirty brake disk Caution e The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing brake performance to be reduced or totally lost 16 10 Fluid cup Screw a Brake fluid cap Upper level ud rar 8 To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSH
63. eferably to replace crankshaft as a unit Specification Unit mm Connecting rod side clearance of the big end 0 100 0 400 0 600 Crankshaft ramen Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Run out 04100 Torque value Bolts for crankcase 0 Engine oil drain bolt 1 Tools Special tools R L crank disassemble install tool SYM 1300001 H9A L crank shaft bearing driver SYM 9100200 H9A Crank shaft bearing fixing socket SYM 9100210 H9A Crank shaft puller SYM 1130000 H9A L crank shaft oil seal driver 25 40 8 SYM 9121600 Outer bearing puller SYM 6204010 Inner bearing puller SYM 6204020 Clutch nut wrench SYM 9020200 Trouble diagnosis Engine noise Loose crankshaft bearing Loose crankshaft pin bearing Worn out piston pin and pin hole To this chapter contents SYM 11 CRANKCASE CRANK Disassembly of crankcase Tensioner gg 98 Remove the cam chain setting plate and then P remove chain Loosen the bolt and remove the tensioner Loosen 2 bolts on the right crankcase Loosen 7 bolts on the left crankcase Place right crankshaft case downward and left up crankcase Caution Care should be taken not to damage the contact surfaces gem R L crank disassemble install tool 11 3 Tothis chapter contents 11 CRANKCASE CRANK Remove crank by left crank shaft Refer to chapter 2 Special tools Special tool R L crank case disassemb
64. enter cover Front fender Right footrest Be careful not to damage various covers in assembly or disassembly operation Never injure hooks molded on the body covers e Align the buckles on the guards with slot on the covers e Make sure that each hook is properly installed during the assembly e Never compact forcefully or hammer the guard and the covers during assembly 13 2 To this chapter contents SYM Handle front cover Disassembly Loosen 3 screws from handle cover rear side and then remove handle cover Installation Install in reverse order of removal procedures Handle protect cover Loosen 2 screw from handle protect cover and then remove handle protect cover Installation Install in reverse order of removal procedures Front center cover Remove Loosen 2 screws from the front center cover Please disassemble first then push the cap upward 2 screws Remove position light coupler and then remove front center cover Installation Install in reverse order of removal procedures Position light c upl 13 BODY COVER 5 13 3 To this chapter contents 13 BODY COVER Rear center cover Remove Remove seat Remove fuel tank cap Remove 2 bolts and then remove rear center cover Installation Install in reverse order of removal procedures Rear carrier Remove Loosen 4 bolts from the rear carrier Remove the rear carrier Installation Install in rever
65. er clogged Remove spark plug install it into spark plug cap and perform a spark test against engine ground e Malfunction of spark plug Checkifspaks k if k Weak K k at Spark plug foul a Malfunction of CDI set e Malfunction of AC generator Ignition coil is in open or short circuit Perform cylinder compression Ignition coil leads open or short circuit pressure test Malfunction of main switch Cylinder compression Low compression Piston ring seized pressure normal pressure or no pressure Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Re start by following the starting Sand hole in compression parts procedures There are some signs of Malfunction of throttle valve operation ignition nut engine can Air sucked into intake manifold not be started e Incorrect ignition timing Remove the spark plug again and check it e Fuel level in carburetor too high Dry spark plug Wet spark plug e Malfunction of throttle valve operation Throttle valve opening too wide Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing clogged e Malfunction of automatic by starter N 1 14 SYM To this chapter contents 1 GENERAL INFORMATION B Engine run sluggish Speed does not pick up lack of power Check and adjustment Fault condition Probable caus
66. es N Try gradual acceleration and check engine speed Engine speed can be Increased Check ignition timing Using ignition lamp Ignition timing correct Check cylinder compression pressure using compression pressure qauqe Compression pressure correct Check if carburetor jet is clogged No clogged Remove spark plug No foul or discoloration Check if engine over heat Continually drive in acceleration or high speed N Engine speed can not be increased Incorrect ignition timing No compression pressure Clogged Fouled and discoloration Engine overheat Air cleaner clogged Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Fuel nozzle clogged in carburetor Fuel nozzle clogged in carburetor Malfunction of CDI Malfunction of AC alternator Cylinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring Remove foreign Remove dirt Incorrect spark plug heat range Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber Ignition timing too advanced Poor circuit on the cooling system Too much carbon deposited in combustion chamber Lean mixture Poor fuel quality Ignition timing too advanced 1 15 To this chapter contents 1 GENERAL INFORMATION SYM C Engine runs sluggish especially in low speed and idling
67. face of the closure surface counter clockwise assembles onto movable drive face Closure surface Install ramp plate Ramp plate 8 8 To this chapter contents SYM With 4 5g grease spreads wipes drives in the movable drive face axis hole Install drive face boss Caution The movable drive face surface has to be free of grease Clean it with cleaning solvent Install movable drive face comp onto crankshaft Driven pulley installation Press driving belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut A Caution Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold drives face with universal holder Tighten nut to specified torque Torque value 5 0 6 0kgf m Install left crankcase cover 8 V BELT DRIVING SYSTEM KICK STARTER Drive face boss Movable drive face Press down Drive face 8 9 KE TYT chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER SYM Clutch nut wrench E S Clutch Outer Driven Pulley Disassembly Remove drive belt clutch outer and driven pulley Install clutch spring compressor onto the pulley assembly and operate the compressor to let the wrench be installed more easily A Caution Do not press the compressor too much Hold the clutch spring compressor onto bench vise and then remove mounting nut with spec
68. ght and left winker Power outlet couplers couplers Remove front fender Installation Install in reverse order of removal procedures ET Winker coupler 13 8 To this chapter contents SYM Footrest Remove Loosen the 6 screws which connect the front fender and footrest these 6 screws just be twin the front fender two side Loosen the 6 screws which connect the rear fender and footrest these 6 screws just be twin the rear fender two side Loosen the 4 bolts and then remove footrest bar and footrest These 4 bolts just are the right and left footrest Installation Install in reverse order of removal procedures 13 BODY COVER 13 9 13 BODY COVER SYM Note 13 10 SYM 14 FRONT BRAKE amp FRONT WHEEL Mechanism Diagram Adding Brake Fluid Maintenance Description Brake fluid replacement Air bleed 14 9 Trouble Diagnosis Front Brake Caliper Front Wheel Brake Disk Front Wheel Hub Front Brake Master Cylinder Disk Brake System Inspection Mechanism Diagram Front brake master cylinder i 1 Front pressure control valve E 4 hose bolts 3 5kgf m gee dile E 1 F d ie 2 m Ira vll E i m s z e 5 pressure control valve Brake caliper bolts 3 25kgf m 1 Brake disk bolts 4 25kgf m Bearing 6203LU P Front wheel nuts 2
69. haft nut 5 0kgf m Steering tie rod nut 5 0kgf m Oil rings TN oi liners 15 6 To this chapter contents SYM 15 STEERING SUSPENSION Steering Tie Rod Remove Remove cotter pin and tie rod nut from steering shaft side Remove cotter pin and tie rod nut from wheel side Inspection Inspect the tie rod for damage or bending Inspect the ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Ball joint Installation Install the ball joint with adjustment groove on the wheel side Install tie rod nuts and tighten the nuts Torque value 5 0kgf m After tightened the tie rod nut install the cotter pin Adjustment 15 7 To this chapter contents 15 STEERING SUSPENSION Knuckle Remove Remove front wheel front wheel hub and front brake caliper mounting seat Remove cotter pin and tie rod nut remove tie rod Remove cotter pin and flange pin hole bolt nut remove bolt sleeve seal cover and knuckle Inspection Inspect the kingpin and knuckle for damaging or cracking Installation Install in reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Knuckle nut 5 0kgf m After tightened the nuts install the cotter pins Lubricate with grease into knuckle 15 8 To this chapter contents SYM 15 STEERING SUSPENSION Front Cushion Remove Remove front
70. harness passes the condition Check Points Standard Value Main switch Battery voltage connection ON Battery R G Battery voltage Charging coil Y Y 0 17 0 80 connection If the readings measured are not normal check parts in the circuit If the parts are normal then trouble is in the wiring If there is nothing wrong with parts and wiring replace the regulator rectifier 17 ELECTRICAL SYSTEM 17 7 To this chapter contents 17 ELECTRICAL SYSTEM SYM Ignition System Ignition circuit diagram Shift gear control unit CDI Unit Green Black White Green Green White White Black Black Yellow Fuse 15 Ignition coil Black Blue Yellow Main fuse i 20A BUDE r7 a Ce Spark plug Battery E Main switch Pulse generator C D I unit Disconnect connectors of the C D I unit Check the following connectors as indicated in the table at the harness side Main switch turn to ON position Black white green Battery voltage Pulse generator Green White Blue yellow 50 1700 Black yellow green 0 17 10 0 Ignition coil Black yellow with no cap 3 6 10 0 Secondary circuit Black yellow with 7 3 11 17 8 To this chapter contents SYM 17 ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap Measure the resistance between the terminals of the primary winding Standard resistance 0 170 10
71. he fuel unit and the ohmmeter as shown Connect the fuel unit coupler to the wire harness Turn on the main switch Move the float arm to verify the proper position the fuel gauge needle indicates Up Full F Full Down Empty E Empty A Caution While conducting the test turn on the direction indication lamp to make sure that the battery is in serviceable condition 17 19 To this chapter contents 17 ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor In case that the fan motor fails to work disconnect the green and black blue leads and connect jump wires to the terminals then turn on the main switch the fan motor should operate If the fan motor still fails to run measure battery voltage between the green and black blue leads If there is no voltage check for blown fuse loose connection or short circuit If the fan motor runs check the thermo switch in the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperature increase the coolant temperature gradually The switch should have a continuity at 98 102 C A Caution e Keep the coolant at a constant temperature at least for three minutes Sudden increase the coolant temperature will cause the thermometer and the tester t
72. he reverse procedures of removal Dowel pins Kick tarter spindle Return spring Driven gear 8 3 To this chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER SYM Kick Starter Removal Remove left crankcase cover Disassembly of kick starter Remove 4 screws and remove the kick starter plate Remove snap clip and thrust washer from left crankcase cover Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection Check if starter spindle driven gear for wear or damage Reassembly of Kick Starter Install bush return spring and starter spindle as diagram shown Install thrust washer and snap clip onto starter spindle Install Kick starter lever temporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Install kick starter plate 8 4 To this chapter contents SYM 8 V BELT DRIVING SYSTEM KICK STARTER Drive Belt Removal Remove left crankcase cover Hold drive face with universal holder and remove nut and drive face Special Tool universal holder Tools number SYM 2210100 Hold clutch outer with universal holder and remove nut and clutch outer Caution Using special service tools for tightening or loosening the nut
73. ht e Binding suspension link Insufficient tire pressure e Faulty steering shaft bushing Damaged steering shaft bushing Hard suspension Faulty front swing arm bushings Improperly installed front swing arms Front wheel wobbling Bent front shock absorber swing rod Faulty tire Worn front brake drum bearing Bent Soft suspension Axle nut not tightened properly e Weak front shock absorber springs Worn or damage front swing arm bushings Steers to one side Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment 15 2 To this chapter contents SYM 15 STEERING SUSPENSION Steering Handle Removal Remove the handle cover handle protect cover and front fender Refer to chapter 13 Remove meter set and main switch couplers Remove speedometer cable Loosen 2 bolts to remove handle cover stay Loosen 4 bolts of the meter stay and then remove meter set and main switch Main switch coupler Meter set couplers 4 bolts meter stay 15 3 To this chapter contents 15 STEERING SUSPENSION Loosen the socket bolts for the front brake master Handle protect cover cylinder and remove front brake master cylinder brocket bolts Caution Do not let foreign materials enter into the cylinder Remove 2 screws and then remove throttle hosing holder and throttle hosing Loo
74. ial service tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable driven face and then remove O ring amp oil seal seat from movable driven face Guide pin Guide pin roller Guide pin Inspection Clutch outer Measure the inner diameter of clutch outer Replace the clutch outer if exceed service limit Service limit 130 5 mm Clutch outer 8 10 To this chapter contents SYM 8 V BELT DRIVING SYSTEM KICK STARTER Clutch lining Clutch lining Measure each clutch weight thickness Replace it if exceeds service limit 7 Service limit 2 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit 83 2 mm Free length Driven pulley Check following items e f both surfaces are damaged or worn If guide pin groove is damaged or worn Replace damaged or worn components Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Movable driven face Guide pin groove Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necess
75. ified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch outer driven pulley and driving belt onto driving shaft 8 14 Clutch nut wrench o Kum 28 Clutch spring compressor SYM 9 FINAL DRIVING MECHANISM Mechanism Diagram transmission cover Inspection of Mission 9 6 9 1 Mechanism Diagram transmission 9 2 Bearing Replacement 9 8 Re assembly of Final Driving Precautions in operation 9 3 Mechanism Trouble Diagnosis 9 3 Disassembly of Final Driving Mechanism 9 4 Mechanism Diagram transmission cover Boss Eng Hanger rubber bush Gasket Gear oil fill bolt Safety switch 1 1 1 5kgf m Transmission plate 2 Oil seal 14x28x7 Eng Hanger rubber bush 9 1 To this chapter contents 9 FINAL DRIVING MECHANISM SYM Mechanism Diagram transmission Shift spindle arm 7 e Shift spindle bracket enit Shift spindle Bearing 6204 g 6204 77 Q fo 7 p 7 Oil seal 30 40 5 k E F L E F 7 4 Needle bearing 4905 1 F e ur Sy 7 ir 9 1 e Bearing 6302 7 Fe Shift fork Final shaft Counter shaft Dr
76. imitation groove t is not necessary to remove brake hose when replacing the brake lining Brake Lining Replacement refer chapter 14 Make sure the brake lining condition Replace the lining if the brake lining wear limitation groove Brake lining wear close to the brake disc limitation groove A Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining e In order to maintain brake power balance the brake lining must be replaced with one set Brake Light Switch Starting Inhibitor Switch The brake light switch is to light up brake light as brake applied Make sure that electrical starter can be operated only under brake applying 2 9 To this chapter contents 2 MAINTENANCE INFORMATION Headlight Beam Distance Turn on main switch Headlight beam adjustment Turn the headlight adjustment screw to adjust headlight beam high Caution To adjust the headlight beam follows related regulations Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting Clutch Disc Wear Run the ATV and increase throttle valve opening gradually to check clutch operation If the ATV is in forward moving and shaking check clutch disc condition Replace it Cushion A Warning Do not ride the ATV with poor cushion e Looseness wear or damage cushion will make poor stability and drive ability Front
77. in Operation 7 2 Piston Ring Installation 7 6 Trouble 7 2 Piston Installation 7 7 Cylinder L asua 7 3 Cylinder Installation 7 7 Mechanism Diagram 7 1 To this chapter contents 7 CYLINDER PISTON SYM Precautions in Operation General Information e Both cylinder and piston service cannot be carried out when engine mounted on frame UA18A Specification Unit mm Cylinder Bed 99 Clearance between piston and cylinder ID of piston pin boss Clearance between piston and piston pin ID of connecting rod small end Trouble Diagnosis Low or Unstable Compression Pressure Smoking in Exhaust Pipe Oylinder or piston ring worn out e Piston or piston ring worn out e Piston ring installation improperly Oylinder or piston damage Knock or Noise Engine Overheat Cylinder or piston ring worn out Carbon deposits on cylinder head top side Carbon deposits on cylinder head top side Cooling pipe clogged or not enough in coolant e Piston pin hole and piston pin wear out flow 7 2 To this chapter contents SYM Cylinder Removal Remove cylinder head refer to chapter 6 Remove coolant hose from cylinder Remove cylinder Remove cylinder gasket and dowel pin Cover the holes of crankcase and cam chain with a piece of cloth C
78. ins snap rings hose clamp and wire holders for security 2 11 To this chapter contents 2 MAINTENANCE INFORMATION SYM Special Tools List SYM 1120000 H9A SYM 1130000 H9A SYM 9100200 H9A y 30mm CRANK SHAFT BRG FIXING SOCKET CRANK CASE BUSH PULLER CRANK CASE BUSH PULLER Val tt amp 22 adjusting wrench adjuster SYM 1471110 20 SYM 9001200 SYM 9001209 NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor NO SYM 2210100 NO SYM 9020200 NO SYM 2301000 2 12 To this chapter contents SYM 2 MAINTENANCE INFORMATION Inner bearing puller NAME jOuter bearing puller NAME AC G Flywheel puller SYM 6204002 No SYM 6204001 NO SYM 3110A00 1272075 6901 NAME Water pump oil seal driver NAME Water pump bearing driver NAME 2 mechanical 6301 6204 6203 6004UZ SYM 9610000 SYM 9110400 SYM 9620000 20 32 6 25 40 8 27 42 7 NAME Oil seal driver Oil seal driver Oil seal driver NO SYM 9120200 SYM 9121600 SYM 9125500 2 13 To this chapter contents 2 MAINTENANCE INFORMATION SYM NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush long NO SYM 1130000 L NO SYM 1130010 NO SYM 1130031 SYM 1130032 lt 07004 1 SYM 4230200 Rear axle nut wrench NO SYM HT06007 ww w wi
79. ive shaft Counter gear Bearing 6203 Bearing CSB204 s Oil seal x 20x32x6 Gear oil drain bolt 1 1 1 5kgf m 9 2 To this chapter contents SYM 9 FINAL DRIVING MECHANISM Precautions in operation Specification Application oil scooter gear oil Recommended oil KING MATE serial gear oils Oil quantity 750c c 650c c when replacing Torque value Gear box cover 1 0 1 4kgf m Gear oil drain bolt 1 1 1 5kgf m Gear oil fill bolt 1 1 1 5kgf m Tools Special tools Bearing 6203 6004UZ driver SYM 9620000 Bearing 6204 driver SYM 9110400 Bearing 6302 driver SYM 9610000 Oil seal 30 40 5 driver SYM 9125500 Oil seal 20 32 6 driver SYM 9120200 Inner bearing puller SYM 6204002 Drive shaft puller SYM 1130000 L Drive shaft install bush SYM 1130010 Extension bush long SYM 1130031 Extension bush short SYM 1130032 Trouble Diagnosis Engine can be started but motorcycle can not be moved e Damaged driving gear Burnt out driving gear Damaged gear shift system Noise Worn or burnt gear Worn gear Gear oil leaks Excessive gear oil Worn or damage oil seal To this chapter contents 9 FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove engine Remove driven pulley Drain gear oil out from gear box Remove drive sprocket Remove shift spindle bracket 10 bolts Remove gear box cover bolts 10 bolts and then remove the cover an
80. l Raise the rear wheels off the ground by placing a jack or other support under the frame Remove rear axle cover 4 screws Remove the rear wheel nuts and then remove rear wheels Installation Install the rear wheel and tighten the nuts Torque 2 4kgf m Rear Wheel Shaft Connecter Removal Remove cotter pin rear wheel shaft connecter nut and washer iJ Cotter pin Remove right and left rear wheel shaft connecter Installation Install the rear wheel shaft connecter Install wheel shaft connecter washer and tighten the wheel shaft connecter nut Torque 2 4kgf m Install cotter pin 16 4 To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Rear Wheel Axle Remove right and left rear wheel wheel connecter Remove 2 bolts and then remove rear brake Caliper Remove 3 bolts and remove drive chain cover Remove drive chain lock clip master link and then remove drive chain Remove 4 nuts and remove driven sprocket To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Bend out the rear axle nut fixed plate Fixed plate Remove rear wheel axle nuts Special tool Rear axle nut wrench 55mm Remove rear brake disk bracket and disk Brake disk bracket Remove rear wheel axle and driven sprocket holder Driven sprocket holder 16 6 To this chapter contents SYM 16 REAR BRAKE amp REAR WHEE
81. l inspection Park the ATV on flat surface Check gear oil inspection window gear oil level whether above scale division Gear lubrication oil quantity has to be measured with measure device If oil level is too low add gear oil Recommended using King series oils Install oil join bolt Gear Oil Change Remove oil join bolt Remove drain bolt and drain gear oil out Install the drain bolt after drained Torque value 1 0 1 5kgf m Make sure that the drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 1000 c c when replacing Make sure that the join bolt washer can be re used and install the bolt k Gear oil drain bolt Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is in correct level Make sure that no oil leaking 3 7 To this chapter contents 3 LUBRICATION SYSTEM SYM Notes SYM 4 FUEL SYSTEM Mechanism Diagram Throttle Valve Precautions in Operation Float Chamber Trouble Diagnosis Adjustment of Idle Speed Carburetor Remove Install Fuel Tank Air Cut Off Valve Air Cleaner Mechanism Diagram Fuel unit Fuel tank Auto fuel cock Fuel strainer Inlet pipe To this chapter contents 4 FUEL SYSTEM SYM Precautions in Operation General Information A Warning Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibi
82. l is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 4 Caution e The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minute In order to prevent has the chemical change please do not use counterfeiting or other unclear trade marks brake fluid Uses by all means must with the trade mark brake fluid guarantees the ghost vehicle efficiency 14 7 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Adding Brake Fluid Before the brake fluid reservoir is removed turn the handle so that the brake fluid reservoir becomes horizontal and then remove the brake fluid reservoir When maintenance brake system will be supposed to paint the surface or the rubber parts catches up by the rags Caution Supplement brake fluid please do not surpass the upper limit spilled brake fluid on painted surfaces plastic or rubber components may result in their damages Screw Remove the master cylinder cap and diaphragm Upper level Ee Master cylinder cap Increases the high quality brake fluid uses by all 3 means must with the trade mark brake fluid joins in the master cylinder Clean the dirty brake disk Caution e The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performance Foreign materials will block the system causing
83. le install tool SYM 1120000 H9A Remove crankshaft from right crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Check any damage in oil seal Replace with new one if damaged 11 4 SYM To this chapter contents SYM 11 CRANKCASE CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end Service limit 0 6 mm Measure point for the crank big end of the connecting rod Measure the clearance of the big end at the vertical directions Service limit 0 05 mm Place the crankshaft on a V block measure run out of the crankshaft Service limit 0 10 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If any roughness noise and loose linkage are detected replace the bearing with new one Caution The bearing shall be replaced in pair Special tool outer bearing puller Crank bearing 11 5 To this chapter contents 11 CRANKCASE CRANK Assembly of crankcase Special tool R L crank case disassemble install tool L crank shaft bearing driver Crank shaft bearing fixing socket Crank shaft puller Clutch nut wrench The new bearing and bearing driver
84. lean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase A Caution e Soap the residues into solvent so that the residues can be removed more easily Inspection Check if the inner diameter of cylinder is wear out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y values respective in the cylinder Service limit 61 016 mm Check cylinder if warp Service limit 0 05 mm 7 CYLINDER PISTON 7 3 To this chapter contents 7 CYLINDER PISTON SYM Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials 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 Inspection Measure clearance between piston rings and grooves Service Limit Top ring 0 09 mm 274 ring 0 09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn A Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Service Limit Top ring 0 50 mm 274 ring 0 65 mm 7 4 To this chapter contents SYM Measure the outer diameter of piston pin Service Limit 15 040 mm
85. luid is in the UPPER level of the master cylinder and refill the fluid if necessary 6 Cover the cap 16 11 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Rear Brake Caliper Brake hose bolt M Removal r Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hose s Caution Do not spill brake fluid on painted surfaces Remove two caliper bolts and the caliper Inspection Make sure the brake linings condition Replace the linings if the brake linings wear limitation groove close to the brake disk Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 20 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake lining replacement Remove two guide pins Guide pins Remove brake caliper cylinder and then remove brake linings Install new linings and brake caliper cylinder Tighten the guide pins Torque 1 8kgf m 16 12 To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Brake Disk Brake disk Inspection I SC Visually check the brake disk for wear or break Measure the thickness of
86. m bolt into cam sprocket mounting bolt hole and then pull the camshaft out Use a valve compressor to press the valve spring A Caution e In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool Valve spring remover SYM 1471110 Valve spring installer SYM 1471120 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 To this chapter contents 6 CYLINDER HEAD VALVE SYM Cylinder Head Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 5 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit 28 90 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure amp record the valve stem outer diameter Service Limit IN 4 90 mm EX 4 90 mm Valve guide Caution Before measuring the valve guide clean carbon deposits with reamer Tool 5 0 mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer
87. mark 2 TDC 6000rpm 17 2 To this chapter contents SYM Trouble Diagnosis No voltage Battery discharged The cable disconnected The fuse is blown Improper operation of the main switch Low voltage The battery is not fully charged Poor contact Poor charging system Poor voltage regulator o spark produced by spark plug The spark plug is out of work The cable is poorly connected open or short circuited Between AC G and C D I Poor connection between C D I and ignition coil Poor connection between C D I and the main switch Poor main switch Poor C D I AC G is out of work 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 relay is out of work The ignition coil is poorly connected open or short circuited The starter motor is out of work Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection or short circuit of the power generation system 17 ELECTRICAL SYSTEM Charging system does not operate propery Burnt fuse e Poor contact open or short circuit Poor regulator Poor ACG Engine does not crank smoothly e Primary winding circuit Poor ignition coil Poor connection of cable and connectors
88. me Torque Values Lem iy Tes Dia mm TorqueValutigtm Remarks _ Handlebar upper holder bolt 2 40 Steering shaft nut 1 5 00 Steering tie rod nut 4 10 5 00 Knuckle nut 2 10 5 00 Steering shaft holder bolt 2 8 3 40 Tie rod lock nut 4 10 3 60 Handlebar under holder nut 2 8 4 00 Front wheel nut 8 10 2 40 Front axle castle nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 10 4 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 6 Driven gear nut 4 10 4 6 Swing arm pivot bolt 1 14 9 20 Front suspension arm nut 4 10 5 00 Front Rear cushion mounting bolt 6 10 4 60 Brake lever nut 2 6 1 00 Brake hose bolt 13 10 3 50 Brake caliper bolt 6 6 3 25 Brake disk mounting bolt 11 8 4 25 Air bleed valve 3 5 0 50 Exhaust muffler mounting bolt 8 3 00 Exhaust muffler connection nut 2 7 1 20 1 13 To this chapter contents 1 GENERAL INFORMATION SYM Troubles Diagnosis A Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged Fuel led N No fuel led t Float valve clogged ke e Lines in fuel tank evaporation system carburetor sufficient carburetor clogged Malfunction of fuel pump Loosen or damaged fuel pump vacuum hose Fuel filt
89. n Install rocker arm pin mounting plate Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head Install chain guide Install 2 set pins and cylinder head gasket Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Loosen the tensioner by turning a flat driver in C W direction Install cylinder head 6 12 To this chapter contents SYM Tighten 4 nuts and washers on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of cylinder head side cover Torque value 2 0 2 4kgf m Install and tighten spark plug Torque value 2 0 2 4kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation engine noise and leaking so that motorcycle s performance be effected Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head Align sprocket bolt hole with camshaft bolt hole Tighten the sprocket mounting bolt Caution Make sure timing marks are matched Install a new O ring onto thermostat and tighten its mounting bolts Loosen sprocket chain tensioner and let it contact with chain plate tightly Tighten the bolt cap of tensioner adjustment hole Install Ai
90. n I PKS 2 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 5 mm Remove the brake disk from wheel hub Check the disk for deformation and bend Allowable limit 0 30 mm N Caution The dirty brake lining or disk will reduce the brake performance Brake lining includes the asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Front Brake Master Cylinder Master Cylinder Removal N Caution Do not let foreign materials enter into the cylinder N Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Push the lead of brake light switch and then remove brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder socket bolts and the master cylinder 2 socket bolts 14 11 To this chapter contents 14 FRONT BRAKE amp FRONT WHEEL SYM Remove the rubber boot Remove the cir clip Cir clip Remove the piston and the spring Rubber boot Cag Clean the master cylinder with recommended brake fluid Master Cylinder Inspection Check the master cylinder for damage or scratch Replace it if necessary Measure the cylinder i
91. nd coat valve seat surface with emery and then slightly press the ground surface Clean up all emery coated onto cylinder and valve after ground Cylinder Head Reassembly Lubricate valve stem with engine oil and then insert the valve into valve guide Install new valve stem oil seal Install valve springs and retainers Caution The closed coils of valve spring should face down to combustion chamber Use valve spring compressor to press valve spring Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve spring remover SYM 1471110 Valve spring installer SYM 1471120 Tap valve stem to make valve retainer and valve stem sealing properly Caution Place and hold cylinder head on to working table so that can prevent from valve damaged 6 CYLINDER HEAD VALVE Intake valve Valve spring retainer 3 a Exhaust valve e g Valve a amp Valve stem seal a 47 Valve spring To this chapter contents 6 CYLINDER HEAD VALVE Cylinder Head Installation Install a new O ring into the indent of carburetor insulator and then install the insulator onto cylinder head with 2 bolts Carburetor insulator Install camshaft into cylinder head and align rocker pin with rocker arm pin hole Then insert the rocker arm pi
92. ndle from front fender left side Check the continuity between two points as indicated in the table below Start Switch 17 16 Headlight switch couplers Start switch To this chapter contents SYM 17 ELECTRICAL SYSTEM Headlight Switch Headlight switch rof m t Winker switch White Black Light green Hazard switch 17 17 To this chapter contents 17 ELECTRICAL SYSTEM Front Brake Switch While grasp the brake lever firmly the terminals of brown blue and green yellow of the brake should have continuity Replace the switch if damaged Rear Brake Switch While grasp the brake lever firmly the terminals of white black and green yellow of the brake should have continuity Replace the switch if damaged Horn Remove the horn from front fender left side Apply 12 V power source to two terminals of the horn the horn should sound Replace the horn if necessary 17 18 To this chapter contents SYM 17 ELECTRICAL SYSTEM Fuel Unit Remove the seat Remove the fuel tank cap Remove the rear center cover Disconnect the coupler of the fuel unit Remove the fuel unit 4 bolts Caution Great care shall be taken not to damage or bend the float arm of the gauge When the float arm shifts to the F position or the E position the resistance measured shall be as follows Resistance E Empty 97 5 107 5 F Full 4 10 Q Connect the wiring to t
93. ngerprint left on the bulb with alcohol 17 ELECTRICAL SYSTEM Install the bulb of the headlight in reverse order of removal Upon completion of replacement turn on the main switch to ensure the headlight works well Adjust the beam and distance of the headlight if necessary To this chapter contents 17 ELECTRICAL SYSTEM SYM Replacing the Front winker light Bulb Remove front winker lens with screw driver Groove Replace with new front winker light bulb i TIT Rear winker light Taillight Replacing Bulb of Taillight s Remove rubber cap of the taillight connector Remove the taillight connector and bulb 17 14 To this chapter contents SYM 17 ELECTRICAL SYSTEM Replace taillight bulb Replacing the rear winker light Bulb Taillight Remove rubber cap of the rear winker light connector Remove the rear winker light connector and bulb Replace rear winker light bulb 17 15 To this chapter contents 17 ELECTRICAL SYSTEM Switch Horn Main Switch Inspection Remove the front center cover Disconnect the main switch coupler Check the continuity between two points as indicted below Replacement of main switch Disconnect the coupler of the main switch Push out the main switch Align the main switch stopper with the meter cover groove and install main switch Install the main switch coupler Handle switches Disconnect the coupler of ha
94. nner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit Allowable limit 12 550 mm Measure the outer diameter of the piston Replace the piston if its measured value exceeds allowable limit Allowable limit 12 654 mm Master Cylinder Assembly N Caution It is necessary to replace the whole set comprising piston spring piston cup and cir clip 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 cup Install the cir clip Piston cup Caution Never install cup lip in the opposite direction L wama i i s ia Make sure the cir clip is seated securely in the groove Install the rubber boot into groove properly Master cylinder 14 12 To this chapter contents SYM 14 FRONT BRAKE amp FRONT WHEEL Master Cylinder Install Install the rubber pad into the groove correctly Place the master cylinder onto handlebar and install the bolts Install the brake lever and connect leads to brake Brake lever bolt light switch Connect brake hoses with 2 new washers y 2 Washers Tighten the brake hose bolt to the specified torque
95. nt invisibility 1 1 To this chapter contents 1 GENERAL INFORMATION General Safety Carbon monoxide If you must run your engine ensure the place is well ventilated Never run your engine in a closed area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor A Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive material Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored A Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil A Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verified We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components A Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off 1 2 SYM Battery A Caution Battery emits explosive gases flame is strictly prohibited Keeps the place well ven
96. nto 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 A Caution Soap the residues into solvent so that the residues can be removed more easily Install dowel 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 A Caution Do not push piston into cylinder forcefully because piston and piston rings will be Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 Coolant hose 7 7 To this chapter contents 7 CYLINDER PISTON SYM Notes SYM 8 V BELT DRIVING SYSTEM KICK STARTER Mechanism Diagram 8 1 Cg TTE 8 4 Maintenance 8 2 su a satasuyasasasakassnaanaasakqaskuaswa 8 5 Trouble Diagnosis 8 2 Live Pa Gu u uu u uuu u lang ussssas 8 7 Left Crankcase Cover 8 3 Clutch Outer Driven Pulley 8 10 Mechanism Diagram 5 0 6 0kgf m 8 1 To this chapter contents 8 V BELT DRIVING SYSTEM KICK STARTER Maintenance Description Precautions in Operation General Information SYM Drive face clutch o
97. nut fixed plate Install driven sprocket drive chain drive chain cover and brake caliper Caution Note the chain lock clip direction Install rear wheel shaft connecter rear wheel 16 8 Brake disk bracket sh Moving direction SYM Master link Lock clip To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Driven sprocket inspection Check the condition of the driven sprocket teeth Replace the sprocket if it worn A Caution e The drive chain drive sprocket and driven sprocket must be also inspected for wear Disk Brake System Inspection Inspection By visual examination whether divulges or the damage with spanner inspection brake tube seam whether becomes less crowded and the inspection handle bar turn right or turn left or pressure the cushion whether besides the pipeline protection department whether there is interferes contacts other parts of Check the brake from behind the brake caliper Brake lining wears The brake pad must be replaced with new lining limit grooves when the brake pad wear limit reaches the brake disk A Caution e Check the rear brake lining must be removed rear wheel first Park the ATV on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settl
98. o indicate wrong readings Thermometer Never let the thermometer and the thermo switch contact the wall of the bowl which may result in wrong readings The thermo switch shall be placed in the coolant until the teeth are completely submerged 17 20 To this chapter contents SYM 17 ELECTRICAL SYSTEM Thermo unit Thermo unit Remove the thermo unit Hang the thermo unit in an oil heater heat the oil qmm measure m resistance at each temperature Temperature 50 C L sec I Caution Wear gloves and goggles when performing this test Caution Engine oil should be used as a heating medium as the test temperature must be higher than 100 C Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Thermo unit Water Temperature Indicator Light Disconnect the water temperature meter and connect it to engine ground Turn on the main switch The indicator light of the fuel meter should be lighting 17 21 To this chapter contents 17 ELECTRICAL SYSTEM SYM Notes 17 22 SYM 18 ELECTRICAL DIAGRAM LAE Bong NC IIS fi 3 11 __ MSEATI BH AH H s irapa em E m J 1 Bu dA Ei i n GRO ARI C BIB Hae Hi HT 10 ail Ta ET T ES H g 2 a JN ra P m m 15 j irum 15561043974 Wd 82
99. o starting clutch gear Hold flywheel and rotate starting clutch gear The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure Remove the rollers spring caps and springs of clutch on the one way clutch that located on the back of flywheel Check each roller and plug for wear or damage Install rollers plugs and springs x Ta wr YT 2 Roller Spring cap 10 5 Tothis chapter contents 10 ALTERNATOR STARTING CLUTCH Remove 3 hexagon bolts from starting one way clutch Disassembly Install the components in the reverse procedures of removal A Caution Tape a tightening tape onto the thread of hexagon bolt Torque value 1 0 1 4kgf m Installation Install reduction gear shaft and reduction gear Install starting clutch gear onto crankshaft 10 6 To this chapter contents SYM 10 ALTERNATOR STARTING CLUTCH Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Insert the oil through guide pin onto crankshaft Make sure that there is no other material stock on it If so clean it up Hold the flywheel with flywheel holder and tighten its nut Torque value 5 0 6 0kgf m Tool Flywheel holder Install spring and oil through A C G Set Installation Install the A C G coil set onto right crankcase cover 3 screws Install pulse generator 2 screw
100. oil seal Puts on the left crank shaft Install the oil seal in the left crankcase with care not to damage the lip of the oil seal By oil seal driver 25 40 8 oil seal will knock into locate Special tool Oil seal Oil seal driver 25 40 8 mu Install the tensioner tighten the bolts Torque value 1 2 1 6kgf m Install the cam chain Install the cam chain setting plate Tensioner au TN 11 8 SYM 12 COOLING SYSTEM Mechanism Diagram System Test General Information Radiator Trouble Diagnosis Water Pump Trouble Diagnosis for Cooling System Thermostat Mechanism Diagram Cooling fan Thermo switch fan Radiator filler cap Reserve tank y Radiator 12 G3 m Thermo unit temp meter B i A p i gt Thermostat Water pump Coolant inlet pipe Coolant outlet pipe 12 1 To this chapter contents 12 COOLING SYSTEM SYM General Information General A Warning While the engine is running never attempt to open the radiator filler cap the pressurized hot coolant may shoot out and cause serious scalding injury No maintenance work is allowed to perform unless the engine is completely cooled down Refill the radiator with distilled water or specified additives Add coolant to the reservoir The cooling system can be serviced on the ATV Never spill the coolant to the painted surface Test the cooling system for any leakage after the
101. onents 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 Tothis chapter contents 1 GENERAL INFORMATION The length of bolts and screws for assemblies cover plates or boxes is different from one another be sure they are correctly installed In case of confusion Insert the bolt into the hole to compare its length with other bolts if its length out side the hole is the same with other bolts it is a correct bolt Bolts for the same assembly should have the same length Tighten assemblies with different dimension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated Bolts and fasteners should be kept clean and dry Do not apply oil to the threads When oil seal is installed fill the groove with grease install the oil seal with the name of the manufacturer facing outside and 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 name 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 va
102. 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 ATV Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause damage e Wash and clean parts with high ignition point solvent and blow dry with compressed air Pay special attention to O rings or oil seals because most cleaning agents have an adverse effect on them 1 GENERAL INFORMATION Never bend or twist a control cable to prevent unsmooth 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 the 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 Comp
103. onnect the throttle cable from the throttle valve and remove the valve spring Remove the fuel needle clamp and luel needle Assembly Place the fuel needle onto the throttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body A Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve cable 4 6 SYM Spring Needle clamp Fuel needle clip Fuel needle SYM 4 FUEL SYSTEM Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover Remove the fuel level plate float pin float and float valve Fuel level plate Inspection Check float valve and valve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt A Caution In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a y p Float valve new a new one Check for wear or damage 4 7 To this chapter contents 4 FUEL SYSTEM Remove main jet needle jet holder needle jet slow jet and air adjustment screw A
104. op the ATV to perform the adjustments Use a tachometer when adjusting engine RPM Screw in air adjustment screw gently then back up to standard turns Standard turns 1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1600 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the pilot screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure rpm and CO value are in standard value after engine running in stable If rom and CO value fluctuated repeat the procedures described above for adjusting to standard value L b E adjustment screw a 4 9 4 FUEL SYSTEM SYM Fuel Tank Fuel unit removal Open the seat Remove the front cover 2 screws Remove the front body cover 6 screws and 5 bolts Remove the tank cover 2 bolts Disconnect fuel unit coupler Remove fuel unit 4 bolts Caution Do not bend the float arm of fuel unit Do not fill out too much fuel to fuel tank Fuel unit inspection Refer to electrical equipment chapter 17 Fuel unit installation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage tt Fuel tank removal Open the seat Remove the front cover 2 screws Remove the front body cover 6 screws and 5 bolts
105. or 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 stop Do not operate the brake lever after the cap had been removed Otherwise the brake fluid will soread out if operated the lever Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid 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 valve do not release the brake lever Added Brake Fluid Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or DOT4 WELL RUN brake fluid A Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance 2 8 Screws Master cylinder cap Diaphragm plate Diaphragm To this chapter contents SYM 2 MAINTENANCE INFORMATION Brake Lining Wear Front brake 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 Caution To check front brake lining must be remove front wheel first Brake lining wear l
106. orrect valve clearance e Valve leaking e Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head 2 6 To this chapter contents SYM Drive Belt Loosen the 2 clamp strips of left crankcase cover and then remove the left crankcase cover vapor hose Remove bolts of the engine left side cover and the cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit 18 5mm or above Drive Chain Check the drive chain Park the ATV on a level ground and shift the transmission onto neutral Measure the drive chain slack midway between the sprockets Chain slack 15 25mm 5 8 1 inch Adjust the chain slack Loosen the axle holder lock bolts and turn drive chain adjusting nuts until get the correct slack Tighten the axle holder bolts Torque 3 25kgf m Caution This type ATV has a chain tensioner to adjust and protect drive chain Tensioner 2 MAINTENANCE INFORMATION 2 7 To this chapter contents 2 MAINTENANCE INFORMATION Brake System Disk Brake Brake System Hose Make sure the brake hoses for corrosion or leaking oil Brake Fluid Check brake fluid level in the brake fluid reservoir If the level is lower than the LOWER limit add brake fluid to UPPER limit Also check brake system f
107. otation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary A Caution e f remove the drive shaft from the crankcase upper side then its bearing has to be replaced Gear box Drive shaft bearing Counter shaft bearing s gr m rive shaft bearing Gear shift shaft bearing lock bolt Gear box cover Gear shift shaft bearing Counter shaft bearing chapter contents 9 FINAL DRIVING MECHANISM Bearing Replacement A Caution e Never install used bearings Once bearing removed it has to be replaced with new one Crankcase side Remove driving shaft bearing lock bolt and then remove driving shaft bearing from left crankcase using following tools Remove gear shift shaft bearing and counter shaft bearing from left crankcase using following tools Remove drive shaft oil seal Special tool Inner bearing puller E 1 Bearing driver Install new bearings into left crankcase Special tool Bearing driver 6204 Bearing driver 6202 Bearing driver 6203 Install drive shaft Drive shaft Special tool a install bush Drive shaft puller 1 UEAN Drive shaft install bush Extension bush long Extension bush short Apply with grease onto new drive shaft oil seal lip i19 Oil seal driver and then install the oil seal Special tool Oil seal driver 20x32x6 To this chapter contents 9 FINAL DRI
108. p cover 4 bolts Remove 9 bolts from the right crankcase cover Remove the right crankcase cover Remove dowel pin and gasket A C G Set Removal Remove 2 mounted bolts from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set Flywheel Removal Remove left crankcase cover Remove oil through and spring from crankshaft Hold the flywheel by drive face with universal holder and remove Its nut Special tool Universal Holder 1 a i LU F a 7 C 73 screws 2509 Oil through B n 6 7 B ue E h To this chapter contents 10 ALTERNATOR STARTING CLUTCH SYM Remove the oil through guide pin from crankshaft Pull out flywheel with A C G flywheel puller Special tool A C G Flywheel puller aa E Z E x p d h J a w mamaman 5 A M Flywheel puller Starting Clutch Removal Remove starting driven gear Remove the starter reduction gear and the shaft 10 4 Tothis chapter contents SYM 10 ALTERNATOR STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage Measure the ID and OD of the starting clutch gear Service Limit ID 20 1 mm OD 42 10 mm Check the starting reduction gear and shaft for wear or damage Install one way clutch ont
109. peration A Caution Whenever the thermostat and the thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then It must be replaced Technical Data Valve begins to open 71 80 C Valve stroke 3 5 4 5 mm at 80 C Assembly Install in reverse order of removal A Caution Always use a new O ring and apply a coat of grease on it before installing Temperature sensor Ie Installation Apply a coat of sealant or equivalent to the thread of temperature sensor and install it on the holder Connect the cable to the temperature sensor Refill the coolant and bleed out the air bubble Page 12 5 To this chapter contents 12 COOLING SYSTEM SYM Notes 12 14 SYM 13 BODY COVER Mechanism Diagram Rear center cover Maintenance Rear carrier Handle front cover Rear fender Handle protect cover Front fender Front center cover Footrest Mechanism Diagram Seat a Left handle protect cover Right handle protect cover Footrest bar Right footrest Front central cover Left footrest Front fender 13 1 To this chapter contents 13 BODY COVER SYM Maintenance Body covers disassemble sequence Handle cover Rear carrier Rear fender Handle protect cover Front center cover Rear c
110. r Injection system Al pipe 2 bolts Install carburetor insulator onto carburetor and tighten clamp strip bolt Install the vacuum hose of carburetor insulator 6 CYLINDER HEAD VALVE Al Pipe bolts To this chapter contents 6 CYLINDER HEAD VALVE Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 12 0 02 mm EX 0 12 0 02 mm Install the valve clearance adjustment hole cap 3 bolts Caution The gasket is paper type In case of broken replace it and clean the Remnant gasket Start the engine after assembly Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head otop the engine after confirmed and then install the intake valve adjustment hole cap Install the seat luggage box and the body cover Caution f lubricant does not flow to cylinder head engine components will be worn out seriously Thus it must be confirmed e When checking lubricant flowing condition run the engine in idle speed Do not accelerate engine speed 6 14 SYM 7 CYLINDER PISTON Mechanism Diagram 7 1 Piston Removal 7 4 Precautions
111. rd Contents How to use this manual and Mechanism Illustrations on the CD R version and can be access to these items by click the mouse If user wants to look for the content of each chapter selecting the words of each chapter on the contents can reach to each chapter There are two buttons Homepage and contents onto the top line of first page of the each chapter Thus if the user needs to check other chapters he can click the top buttons to back the homepage or contents The content of each chapter can be selected too Therefore when needs to checking the content inside of the chapter click the content words of the chapter so that can back to the initial section of the content In addition there is a To this chapter contents button at the second page of each content so that clicking the button can back to the contents of this chapter CONTENTS Content Index 1 1 1 20 GENERAL INFORMATION 2 1 2 14 SERVICE MAINTENANCE INFORMATION 2 3 1 3 8 LUBRICATION SYSTEM Ji Page 4 1 4 12 FUEL SYSTEM 5 1 5 6 ENGINE REMOVAL 6 1 6 14 0 CYLINDER HEAD VALVE 7 1 7 8 CYLINDER PISTON 8 1 8 14 V TYPE BELT DRIVING SYSTEM KICK STARTER 9 1 9 12 FINAL DRIVING MECHANISM 10 1 10 8 ALTERNATOR 11 1 11 8 CRANKSHAFT CRANKCASE 12 1 12 14 COOLING SYSTEM 0 N 13 1 13 10 B BODY COVER 14 1 14 14
112. rged with current and duration prescribed above Large current and fast time to charge will render damage to the battery When installing the battery coat the cable terminal with grease 17 4 To this chapter contents SYM 17 ELECTRICAL SYSTEM Charging System Charging circuit Main switch Black Yellow Yellow Fuse 20A Yellow Battery Regulator rectifier Tl een UE AC Generator 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 l terminal and the battery negative terminal t Battery negative terminal Caution n the current leakage test set the current range at the largest scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse 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 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit 17 5 To this chapter contents 17 ELECTRICAL SYSTEM Inspection on Charging Voltage Voltmeter Fuse connecto A Caution e Before conducting the inspection be sure that the battery is fully charged If undercharged the current changes dramatically e
113. rminal Check the continuity of the large terminal end If there is no continuity replace the relay 17 10 To this chapter contents SYM 17 ELECTRICAL SYSTEM Removal of Starter motor Remove the seat Disconnect the cable negative terminal then the cable positive terminal Negative Remove starter motor cable Starter motor cable Loosen the lock bolts and remove the starter gt a motor Installation of Starter motor Install in reverse order of removal procedures 17 11 To this chapter contents 17 ELECTRICAL SYSTEM SYM Meters Removal Remove handle cover 3 Screws Main switch coupler Remove the front cover and then remove meter Q coupler and main switch coupler NU 2 j Y Meter set couplers ias mu r L M Remove speedometer cable 4 pa Loosen 4 bolts of the meter stay and then remove meter set and main switch Remove 4 nuts and meter wire and then remove meters Installation of Starter motor Install in reverse order of removal procedures 17 12 To this chapter contents SYM Light Bulb Replacing bulb for headlight Remove 1 screw for the headlight cover and remove the cover Turn the headlight bulb connector by clockwise Take out the bulb connector and the bulb Replace with new bulb if necessary A Caution e Never touch the bulb with finger which will create a heat point e Clean the fi
114. s SYM 1 GENERAL INFORMATION Do not let the wire harness contact with rotating Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness corner Thoroughly clean the surface where tape is to be applied Secure the rubber boot firmly as applying it on Keep wire harnesses far away from the hot wire harness parts a a Never Touch E Route wire harnesses to avoid sharp edges or Never use wires or harnesses which insulation corners and also avoid the projected ends of has been broken Wrap electrical tape around bolts and screws the damaged parts or replace them Never clamp or squeeze the wire harness as e Route harnesses so that they neither pull too installing other components tight nor have excessive slack Never clamp or squeeze the wire harness To this chapter contents 1 GENERAL INFORMATION SYM Do not let the wire harness been twisted as With sand paper to clean rust on connector installation pins terminals if found And then conduct C connection operation later 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 m rw T dh i Ln w i mcm FER AH ir r ii n Eu RU 23 4
115. s Tie the wire harness securely onto the indent of crankcase A Caution Make sure that the wire harness is placed under pulse generator Right Crankcase Cover Installation Install dowel pin and new gasket Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump shaft Install right crankcase cover 9 screws To this chapter contents 10 ALTERNATOR STARTING CLUTCH SYM Install the water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover 10 8 SYM 11 CRANKCASE CRANK Mechanism Diagram Disassembly of crankcase General information Crankshaft Inspection Trouble diagnosis Assembly of crankcase Mechanism Diagram 0 8 1 2kgf m 0 8 1 2kgf m Eng Oil drain bolt 1 1 1 5kgf m Gear oil drain bolt 1 1 1 5kgf m 11 1 To this chapter contents 11 CRANKCASE CRANK SYM General information Operational precautions This Section concerns disassembly of the crankcase for repair purpose Remove following components before disassembling crankcase Engine Section 5 Cylinder head Section 6 Cylinder and piston Section 7 Drive face and driven pulley Section 8 AC generator Start one way clutch Section 10 Starting motor Section 16 n case it requires replacing the crankshaft bearing the driving chain of engine oil pump or the timing chain it is pr
116. se order of removal procedures 13 4 SYM 13 BODY COVER Rear fender Remove rear carrier Pull the Seat Release Bar up in order to remove the seat This seat release bar is under the rear side of the rear fender Loosen the two bolts which connect the front fender and rear fender 2 bolts Loosen the 2 bolts which connect the rear tender and frame these 2 bolts just below the seat Loosen the 6 screws which connect the rear fender and footrest these 6 screws just be twin the rear fender two side 13 5 To this chapter contents 13 BODY COVER Loosen the 2 bolts which connect the rear tender and frame these 2 bolts just below the rear fender Remove taillight couplers and then remove rear fender Installation Install in reverse order of removal procedures 13 6 To this chapter contents SYM Front fender Remove Remove seat Remove fuel tank cap Remove 2 bolts and then remove rear center COVer Loosen the two bolts which connect the front fender and rear fender Remove 1 screw and then remove fixed support catch Remove front center cover 2 screws 2 screws 13 BODY COVER 13 7 13 BODY COVER SYM Remove front fender upper side 1 bolt Loosen the front fender two side bolts Loosen the 6 screws which connect the front fender and footrest these 6 screws just be twin the front fender two side Remove power outlet ri
117. sen the socket bolts for the front brake master cylinder and remove front brake master cylinder Caution Do not let foreign materials enter into the cylinder Handle protect cover brocket bolts Loosen 2 screws and then remove handle left switch and choke hosing 15 4 To this chapter contents SYM 15 STEERING SUSPENSION Remove switch wire band Remove handle mounting bolt and then remove the handle upper holder handle Remove 2 nuts to remove handle under holder Installation Install in reverse order of removal procedures Torque value Handlebar under holder nut 4 0kgf m Handlebar upper holder bolt 2 4kgf m 15 5 To this chapter contents 15 STEERING SUSPENSION Steering Shaft Remove Remove cotter pins and loosen right and left steering tie rod nuts Remove tie rod Remove the cotter pin below steering shaft and remove steering shaft nut and washer Bend out the steering shaft holder nut fixed plate Loosen 2 bolts and then remove steering shaft holder nut fixed plate pressed plate and steering shaft Inspection Check oil rings for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit 039 5 mm Fixed plate Oil rings Installation w F Install in reverse order of removal procedures x Apply with grease onto oil liner and holder Torque value ed Steering shaft holder bolt 3 4kgf m lt 5 s Steering s
118. spindle oil seal Special tool Oil seal driver 14x28x7 Install the shift spindle bracket Add gear oil k gt Gear oil quantity 750c c i Shift spindle bracket 9 11 To this chapter contents 9 FINAL DRIVING MECHANISM SYM Notes SYM 10 ALTERNATOR STARTING CLUTCH Mechanism Diagram Starting Clutch Precautions in Operation Flywheel Installation Right Crankcase Cover Removal A C G Set Installation A C G Set Removal Right Crankcase Cover Installation 10 7 Flywheel Removal Mechanism Diagram B 1 0 1 4kgf m 5 0 6 0kgf m 8 1 2kgf m 10 1 To this chapter contents 10 ALTERNATOR STARTING CLUTCH SYM Precautions in Operation General information Refer to chapter 17 The troubleshooting and inspection of alternator Refer to chapter 17 The service procedures and precaution items of starter motor Specification ID of starting clutch gear 20 026 20 045 20 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 9 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with adhesive 8 mm bolts 0 8 1 2kgf m 12 mm bolts 1 0 1 4kgf m Tools Special tools A C G flywheel puller SYM 3110A00 Universal holder SYM 2210100 10 2 To this chapter contents SYM 10 ALTERNATOR STARTING CLUTCH Right Crankcase Cover Removal Remove left footrest and muffler Drain out the engine oil and coolant and then remove coolant hoses Remove water pum
119. t LH 2 0 2 4kgf m Cylinder head Nut 2 0 2 4kgf m Sealing bolt of cam chain auto tensioner 0 8 1 2kgf m Bolt of cam chain auto tensioner 1 2 1 6kgf m Cam sprocket cover bolts 0 8 1 2kgf m Cam sprocket bolt 0 8 1 2kgf m Spark plug 1 0 1 2kgf m Tools Special service tools Valve reamer 5 0mm Valve guide driver 5 0mm Valve spring compressor To this chapter contents SYM 6 CYLINDER HEAD VALVE Troubleshooting Engine performance will be affected by troubles on engine top parts The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated Low compression pressure 1 Valve Improper valve adjustment Burnt or bent valve Improper valve timing e Valve spring damage Valve carbon deposit 2 Cylinder head e Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston e Piston ring worn out High compression pressure e Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto tensioner wear out or damage Camshaft sprocket Rocker arm or rocker arm shaft wear out To this chapter contents 6 CYLINDER HEAD VALVE Cylinder Head Removal Remove seat luggage box and body cover Remove engine Refer to chapter 5 Remove the clamp strip bolt of carburetor and disconnect vacuum tube from the c
120. t and rear measurements Toe in 5 10mm If the toe in is out of standard adjust it by hanging the length of the tie rods equally by turning the tie rod while holding the ball joint Loosen two side tie rod lock nuts turn the tie rods to adjustment toe in Tighten the lock nuts Torque value 5 0kgf m 15 11 To this chapter contents 15 STEERING SUSPENSION SYM Note 15 12 SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Mechanism Diagram Disk Brake System Inspection Maintenance Description Adding Brake Fluid Trouble Diagnosis Brake fluid replacement Air bleed 16 11 Rear Wheel Rear Brake Caliper Rear Wheel Shaft Connecter Brake Disk Rear Wheel Axle Rear Brake Master Cylinder Disk Brake System Inspection Rear Cushion Mechanism Diagram Rear brake master cylinder A Brake hose bolts 3 5kgf m lin ae To front pressure control valve im mmn ias i Rear pressure control valve Air bleed valve 0 5kgf 6 Brake disk bolts 4 25kgf m J Rear wheel axle nuts 9 2kgf m T W Rear brake master cylinder B dis Rear axle holder bolts 9 2kgf m Driven gear nuts 4 6kgf m Rear wheel nuts 2 4kgf m Rear axle castle nuts 5 0kgf m 16 1 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Maintenance Description Operational precautions A Ca
121. t flame when working with gasoline A Cautions Do not bend off throttle cable Damaged throttle cable will make unstable drive ability e When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassemble auto by starter and air cut valve arbitrarily Specification Throttle handle clearance Tool Special service tools Vacuum air pressure pump Fuel level gauge 4 2 To this chapter contents 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 e Clogged air cleaner e Malfunction of carburetor chock e Malfunction of throttle operation Stall after started e Malfunction of carburetor chock Incorrect ignition timing Malfunction of carburetor Dirty engine oil Air existing in intake system Incorrect idle 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 Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system 4 FUEL SYSTEM Mixture too lean Clogged fuel injec
122. ter 13 check for any leakage from weld seam Remove the front under cover Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Removal Coolant leakage Sets at a vessel underneath the water pump dismantles the drain bolt to leak off in the cooling system refrigerant Remove the front cover front under cover and front fender To this chapter contents SYM 12 COOLING SYSTEM Disconnect the couplers for the thermo switch and fan motor Remove coolant upper side pipe Loosen the radiator 1 bolts Thermo switch coupler Fan motor coupler Remove coolant outlet pipe and then remove radiator and cooling fan Disassembly Loosen the 3 bolts from the fan duct and then Thermo switch z Cooling fan remove the fan duct i duct bolts x3 Loosen 3 screws from the fan motor and take off the fan motor Remove nut to remove the fan from fan motor cong tan motor screws x3 Assembly Install fan motor onto fan duct and insert the fan into the motor shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please refer to chapter 17 for the inspection of the thermo switch A Caution Liquid packing must be applied to the thermo switch before installing to avoid damaging th
123. the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Add specified brake fluid and bleed the system 16 16 SYM To this chapter contents SYM 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Rear Cushion Removal Support the frame Remove cotter pin and remove rear cushion under bolt Remove cotter pin and remove rear cushion upper bolt Installation Install rear cushion upper bolt and install cotter pin Install rear cushion under bolt and install cotter pin 16 17 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Note 16 18 SYM 17 ELECTRICAL SYSTEM Mechanism Diagram Meters Maintenance Data Light Bulb Technical Specification Switch Horn Trouble Diagnosis Fuel Unit Battery Cooling Fan Thermo Switch Charging System Thermo unit Ignition System Water Temperature Indicator Light 17 21 Starting System Mechanism Diagram Main switch C D I Unit AN L control unit ig UE e Battery ET Or rg Headlight relay X Fuse box ae Hazard oa a control unit Winker relay Ignition coil Start amp light amp winker amp horn switch Fuel unit Horn Regulator rectifier Thermo unit Spark plug 17 1 To this
124. the old battery use a new battery with the same current and voltage The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any one of the problems takes place 1 The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction 2 The charging voltage and current are too much higher than the standard values The following problems are not related to the charging system correct it if any by following steps indicate in the checking list 1 The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rom Bulbs used exceed their rate and consume too much power replacement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not replacement battery is aged and does not have enough capacity Battery used does not have enough electricity or is over charged The fuse of the ammeter is blown The ammeter is improperly connected 3 The charging current is normal but the voltage is not fuse of the voltmeter is blown To this chapter contents SYM Inspection on regulator rectifier Remove the seat rear carrier and rear fender Disconnect two 3 pin couplers of the regulator rectifier Inspection the rectifier coupler to the wire
125. tilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water and then go to hospital to see an ophthalmologist If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor Keep electrolyte beyond reach of children Brake shoe Do not use an air hose or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid dust flying A Caution Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep the brake fluid beyond reach of children To this chapter contents SYM Service Precautions Always use with SANYANG genuine parts and recommended oils Using non designed parts for SANYANG ATV may damage the ATV 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 ATV use
126. ting bolt 4 6kgf m Swing arm pivot bolt 9 2kgf m 16 2 SYM To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION Trouble Diagnosis Soft brake lever O O1 QO IN gt Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining disk Low brake fluid Blocked brake hose Warp bent brake disk Bent brake lever Hard operation of brake lever Q N Blocked brake system Poor brake caliper Blocked brake pipe Seized worn master cylinder piston Bent brake lever Uneven brake 1 2 3 Dirty brake lining disk Poor wheel alignment Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Vibration or Wobble 1 Axle is not tightened well 2 Bent rim 3 Axle bearings are worn 4 Faulty tires 5 Rear axle bearing holder is faulty Hard Suspension 1 Bent damper rod 2 Faulty swing arm pivot bushings Soft Suspension 1 Weak shock absorber damper 2 Weak shock absorber spring 16 3 To this chapter contents 16 REAR BRAKE amp REAR WHEEL amp REAR CUSHION SYM Rear Wheel Remova
127. tion General Information Engine shall be removal in the conditions of necessary repair or adjustment to the transmission system only The following parts can be serviced as engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor The engine has to be supported with special service tools that can be lifted or adjustable rm Specification Engine oil capacity Disassembly 1000 c c Gear oil capacity Torque Value Engine hanger bolt 4 5kgf m Exhaust muffler mounting bolt 3 0kgf m Exhaust muffler connection nut 1 2kgf m To this chapter contents 5 ENGINE REMOVAL Removal of Engine Remove the seat Remove battery negative post Remove battery positive post Remove front fender fender the footrest refer chapter 13 Negative Remove starter motor wire from start relay PL Remove the spark plug cap and remove ignition cable by mounting clamp Disconnect A C Generator wire couplers 5 2 To this chapter contents SYM 5 ENGINE REMOVAL Remove the exhaust muffler 2 bolts 2 nuts Disconnect the choke cable Disconnect the carburetor upper parts and cable Remove fuel pipe and vacuum pipe Release the clamp strip of air cleaner duct Release the 2 nuts of carburetor insulator and then remove the carburetor Release the clamp strips of left crankcase cover ducts
128. tor 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 Mixture too rich e Clogged air injector e Malfunction of float valve Fuel level too high in float chamber Malfunction of carburetor chock Dirty air cleaner 4 3 4 FUEL SYSTEM SYM Carburetor Remove Install Removal Drain out fuel in the float chamber Loosen the choke cable fixed iron sheet screw from plate Hemove the choke cable Remove the carburetor top parts from the carburetor Disconnect the fuel hose Release the clamp strip of air cleaner Helease the 2 nuts of carburetor insulator and then remove the carburetor Installation Install in reverse order of removal procedures 4 4 SYM 4 FUEL SYSTEM Air Cut Off Valve 2 screws Disassembly Remove 2 screws Remove air cut off valve cover spring and valve Air cut off valve Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restrict replace carburetor assembly Check the vacuum pipe o ring is in normal Assembly Install in reverse order of removal procedures 4 5 To this chapter contents 4 FUEL SYSTEM Throttle Valve Disassembly Remove carburetor upper parts and then remove throttle valve and throttle cable Disc
129. uddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance F Poor handling V FAULT CONDITIONS Steering is heavy One wheel is wobbling Vehicle pulls to one side PROBABLE CAUSES Drive belt worn out or deformation Ramp plate of movable drive face damaged Driving pulley spring broken Clutch weights broken Drive slide shaft gear groove broken Transmission gear damaged Clutch weights spring broken Clutch outer stuck with clutch weights Connection parts in clutch and shaft worn out or burned Drive belt worn out or deformation Weight roller worn out Movable drive face shaft worn out Driven pulley spring deformation Driven pulley shaft worn out Greased in drive belt and driven face PROBABLE CAUSES Damaged steering bearing Damaged steering shaft bushing Bent rim Improperly installed wheel hub Excessive wheel bearing play Bent swing arm Bent frame owing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Improper wheel alignment Bent frame 1 17 To this chapter contents 1 GENERAL INFORMATION SYM Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand Brake dragging Abnormal Drive chain too tight e Damaged wheel bearing Wheel bearing needs lubrication Spin freely Check tire pressure O
130. uter and driven pulley can be serviced on the motorcycle Driving belt and driving pulley must be free of grease Specification Unit mm Driving belt width ID of drive face boss OD of drive face OD of roller ID of clutch outer Thickness of clutch weight Free length of driven pulley spring OD of driven pulley ID of drive face Torque value e Driven face nut 5 0 6 0kgf m e Clutch outer nut 5 0 6 0kgf m Trouble Diagnosis Engine can be started but motorcycle can not be moved 1 Worn driving Belt 2 Worn drive face 3 Worn or damaged clutch weight 4 Broken driven pulley Shudder or misfire when driving 1 Broken clutch weight 2 Worn clutch weight Standard value mm Limit mm Special Service Tools Clutch spring compressor SYM 2301000 Inner bearing puller SYM 6204002 Clutch nut wrench 39 x 41 mm SYM 9020200 Universal holder SYM 2210100 Bearing driver SYM 9100100 Insufficient horsepower or poor high speed performance 1 Worn driving belt 2 Insufficient spring force of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly To this chapter contents SYM 8 V BELT DRIVING SYSTEM KICK STARTER Left Crankcase Cover Left crankcase cover removal Release the clamp strips of left crankcase cover ducts and then remove the ducts Remove left crankcase cover 7 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in t
131. ution Inhaling asbestos may cause disorders of respiration system or cancer therefore never use air hose or dry brush to clean brake parts Use vacuum cleaner or other authorized tool instead The brake caliper can be removed without removing the hydraulic system After the hydraulic system is removed or the brake system is felt to be too soft bleed the hydraulic system e While refilling brake fluid care should be taken not to let the foreign material entering into the brake system Do not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage Check the operation of the brake system before riding Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Specifications Standard Limit mm The thickness of front and rear brake disk 4 000 2 500 Front and rear brake disk eccentricity lt 0 100 0 300 Master cylinder inner diameter 11 000 11 043 11 055 Master cylinder outer diameter 10 957 10 984 10 945 Diameter of rear disk 190 000 Thickness of rear brake lining 5 100 2 000 Tire pressure as cold 0 8 kg cm 12psi Torque values Brake hose bolt 3 50kgf m Bolt for brake caliper 3 25kgf m Bolts for the brake disk 4 25kgf m Brake lever nut 1 00kgf m Air bleed valve 0 50kgf m Rear wheel nut 2 40kgf m Rear axle castle nut 5 00kgf m Rear axle holder bolt 9 20kgf m Rear wheel axle nut 9 20kgf m Rear cushion moun

Track Runner 200 SERVICE MANUAL

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