Sym Jet 4 125 Manual
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Sym Jet 4 125 Manual

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SYM

SYMBOLS AND MARKS ................... 1-1

General Safety........................... 1-2
Service Precautions ................ 1-3
Specifications ............................. 1-9
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.
Warning
Caution
Grease
Locking sealant
Oil seal
Renew
Brake Fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools
Correct
Wrong
Indication Indication of components.
Directions
Means that serious injury or even death may result if procedures are not
followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
Limits to use SAE 85W-140 class oil. Warranty will not cover the damage
that caused by not apply with the limited gear oil.
King Mate G-3 is recommended.
Apply sealant, medium strength sealant should be used unless otherwise
specified.
Apply with lubricant.
Replace with a new part before installation.
Special service tools.
Meaning correct installation.
Meaning wrong installation.
Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
Torque Values (Engine) ..............1-10
Torque Values (Frame) ...............1-11
Troubles Diagnosis .....................1-12
Lubrication Points .......................1-16
1-1

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Александр
April 14, 2025

меняю аккумулятор .Нужен размер гнезда аккумулятора

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  • Page 1 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYMBOLS AND MARKS ....1-1 TORQUE VALUES (ENGINE) ....1-10 GENERAL SAFETY......1-2 TORQUE VALUES (FRAME) ....1-11 SERVICE PRECAUTIONS ....1-3 TROUBLES DIAGNOSIS .....1-12 SPECIFICATIONS ......1-9 LUBRICATION POINTS .......1-16 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.
  • Page 2 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS GENERAL SAFETY Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a Ÿ Battery emits explosive gases; flame is closed area. Run your engine in an open area, if strictly prohibited.
  • Page 3 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SERVICE PRECAUTIONS Ÿ Always use with SANYANG genuine parts Ÿ Never bend or twist a control cable to prevent and recommended oils. Using non-designed stiff control and premature worn out. parts for SANYANG motorcycle may damage the motorcycle.
  • Page 4 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Ÿ The length of bolts and screws for Ÿ Remove residues of the old gasket or sealant assemblies, cover plates or boxes is different before reinstallation, grind with a grindstone if from one another, be sure they are correctly the contact surface has any damage.
  • Page 5 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Ÿ Lubricate the rotation face with specified Ÿ Before battery removal operation, it has to lubricant on the lubrication points before remove the battery negative (-) cable firstly. assembling. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
  • Page 6 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Ÿ When separating a connector, it locker has to Ÿ Before terminal connection, check if the boot be unlocked firstly. Then, conduct the is crack or the terminal is loose. service operation. Ÿ Insert the terminal completely. Check if the terminal is covered by the boot.
  • Page 7 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Ÿ Do not let the wire harness contact with Ÿ Protect wires or wire harnesses with electrical rotating, moving or vibrating components as tape or tube if they contact a sharp edge or routing the harness. corner.
  • Page 8 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Ÿ Do not let the wire harness been twisted as Ÿ With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust. Ÿ 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...
  • Page 9 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS MAKER SANYANG MODEL AD12W1-6 Overall Length 1900 mm Front TELESCOPIC FORK Overall Width 665 mm Rear DOUBLE SWING ARM Overall Height 1040 mm Front 120/60-13 56J Wheel Base 1330 mm Rear 130/70-12 56J Front 42 kg Front DISK (ø...
  • Page 10 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) A.C. generator flange bolt 0.8~1.2 L side cover plate pan screw 0.5~0.7 RR. brake shoe anchor fixing 1.5~2.0 Rear brake arm flange bolt 0.7~1.1 Engine oil filter screen cover 1.0~2.0 Crankcase bolts 0.8~1.2...
  • Page 11 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting Hex socket bolt for 4.0~5.0 steering handlebar Mounting nut for steering rod 25.4 1.0~2.0 Cone seat for steering rod 25.4 0.2~0.3 Front wheel shaft nut 5.0~7.0 Rear wheel shaft nut 11.0~13.0...
  • Page 12 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain bolt 2. Check if the pipes, fuel tank to to check if there is gasoline carburetor and intake vacuum, inside the carburetor...
  • Page 13 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not be 3.
  • Page 14 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor 1.
  • Page 15 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved. 4.
  • Page 16 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS LUBRICATION POINTS Seat lock Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Speedometer gear / Rear wheel bearing Side stand shaft Main stand shaft Front wheel bearing 1-16...
  • Page 17 10. A.C. GENERATOR/STARTING CLUTCH MECHANISM DIAGRAM ....10-1 RIGHT CRANKCASE COVER PRECAUTIONS IN OPERATION ..10-2 INSTALLATION ........10-8 A.C.GENERATOR REMOVAL... 10-3 MOUNTED COIL SET RIGHT CRANKCASE COVER INSTALLATION ........10-8 REMOVAL ..........10-4 FLY WHEEL INSTALLATION .....10-8 STARTING CLUTCH ......10-5 MECHANISM DIAGRAM 5.0~6.0kgf-m 9.0~10.0kgf-m 1.0~1.4kgf-m...
  • Page 18 10. A.C. GENERATOR/STARTING CLUTCH PRECAUTIONS IN OPERATION General information Ÿ Refer to chapter 5: Engine removal and installation Ÿ Refer to chapter 1: The troubleshooting and inspection of A.C. generator Ÿ Refer to chapter 16: The service procedures and precaution items of starter motor Specification Unit: mm Item...
  • Page 19 10. A.C. GENERATOR/STARTING CLUTCH A.C. GENERATOR REMOVAL Flywheel Pulse generator Cooling fan Cooling fan shroud Coil Cable guide Drain out the engine oil. Remove the body cover. Exhaust muffler Remove the exhaust muffler. (2 bolts, 2 nuts) Remove the fan shroud. (4 bolts) Cooling fan shroud Remove the fan.
  • Page 20 10. A.C. GENERATOR/STARTING CLUTCH Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller. Flywheel puller Pulse generator Remove the connectors of the A.C.
  • Page 21 10. A.C. GENERATOR/STARTING CLUTCH STARTING CLUTCH Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen lock nut and Lock nut gasket. Special service tools: Anti-loosen lock nut socket Universal fixture. Caution The mounting nut is left-turn thread. Lock nut socket Starting driven gear Remove the starting driven gear.
  • Page 22 10. A.C. GENERATOR/STARTING CLUTCH Check the starting driven gear for wear or Starting driven gear damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Starting reduction Check the starting reduction gear and shaft gear for wear or damage.
  • Page 23 10. A.C. GENERATOR/STARTING CLUTCH Installation Hex socket Install the components in the reverse bolt Plug Spring procedures of removal. Caution Add adhesive onto the thread of hex Roller socket bolt. Torque value: 1.0~1.4kgf-m Clutch body Clutch cover Shaft Starting clutch Installation Install reduction gear shaft and reduction gear.
  • Page 24 10. A.C. GENERATOR/STARTING CLUTCH RIGHT CRANKCASE COVER 6 bolts INSTALLATION Install setting pin and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.
  • Page 25 10. A.C. GENERATOR/STARTING CLUTCH Install the cooling fan. (4 bolts) Torque value: 0.8~1.2kgf-m Cooling fan Install the cooling fan shroud. (4 bolts) Exhaust muffler Install the exhaust muffler. (2 bolts, 2 nuts) Install the body cover. Add some engine oil according the specified quantity.
  • Page 26 11. CRANKCASE/CRANKSHAFT ..... 11-1 . 11-3 MECHANISM DIAGRAM DISASSEMBLY OF CRANKCASE .. 11-2 ..11-5 OPERATIONAL PRECAUTIONS CRANKSHAFT INSPECTION ....11-2 ..11-6 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE MECHANISM DIAGRAM 1.5~2.0 kgf-m 1.0~1.4 kgf-m 0.7~1.0 kgf-m 0.8~1.2 kgf-m 0.8~1.2 kgf-m 3.5~4.5 kgf-m 11-1...
  • Page 27 11. CRANKCASE/CRANKSHAFT OPERATIONAL PRECAUTIONS General Information l This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. l Complete following operations before disassembling crankcase. Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 V-belt Drive pulley Chapter 8...
  • Page 28 11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 2 bolts Remove the 2 bolts from the right crankcase. Remove the cam chain tensioner (hex socket 1 hex socket bolt bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
  • Page 29 11. CRANKCASE/CRANKSHAFT Remove the crankshaft from the right crankcase. Caution l The left and right bearings of crankshaft is to press-fit onto the crankshaft. Remove gasket and dowel pins (2). Scrape gasket residues off the crankcase contact surface. Caution l Do not damage contact surface of the crankcase.
  • Page 30 11. CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radical clearance of the big end at the vertical directions. Service limit : 0.05 mm Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.
  • Page 31 11. CRANKCASE/CRANKSHAFT ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution l Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and dowel pins then install two dowel pins and new crankcase gasket.
  • Page 32 11. CRANKCASE/CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer (19.8x30x5). Special service tools: the oil seal installer (19.8x30x5) 11-7...
  • Page 33 12. BODY COVER MAINTENANCE INFORMATION..12-2 FRONT CENTER COVER ....12-8 HANDLE COVER....... 12-3 LUGGAGE BOX .........12-8 FRONT COVER......... 12-4 FLOOR PANEL........12-8 FRONT INNER BOX......12-5 SIDE COVER........12-9 BODY COVER/REAR CENTER UNDER COVER .........12-10 COVER/REAR FENDER.....12-6 Right body cover Inner fender Tail light lens Right side cover RR.
  • Page 34 12. BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Front Handle cover Front wheel Luggage box & Seat Rear handle cover Top cover Rear carrier Left/right side cover Front fender Front cover Front center cover Under cover Rear fender Under spoiler Tail light Floor panel Front inner box...
  • Page 35 12. BODY COVER HANDLE COVER Removal: Remove 1 lower mounting screw of the handle front cover. screw ×1 Remove the mounting screws (4 screws) between the front handle cover and the rear handle cover. screws ×4 Removed the head light wire connectors. turn signal light connectors Removed the left/right turn signal light...
  • Page 36 12. BODY COVER FRONT COVER Removal Remove the top cover. Top cover bolt×1 Remove the 1 mounting bolt of front cover from the frame. Remove the front under cover 4 mounting screws between the front under cover and the frame . screws2 ×...
  • Page 37 12. BODY COVER Remove the 8 mounting screws between the front cover and the front inner box. screws 4 × Front cover Remove the front cover from the frame. Installation Install according to the reverse procedure of removal. FRONT INNER BOX Removal Remove the 8 mounting screws of front cover from the inner box A.
  • Page 38 12. BODY COVER Main switch cover Remove the main switch cover. Remove the front cover and front under 2 screws cover. Remove the 2 screws between the inner box and the floor panel. Remove the front inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal.
  • Page 39 12. BODY COVER 1 bolt Remove the 2 mounting bolts of the rear fender. 4 screws Remove the 4 mounting screws between the body cover and the frame. Bolts1 × Remove the left/right side 2 mounting bolts screws under rear of the body cover between the body cover and the frame.
  • Page 40 12. BODY COVER screws×4 FRONT CENTER COVER Removal Remove the 4 screws bolt in the battery cover. Remove the 1 screw in the front center screws×1 cover. Remove the front center cover. Installation Install the front center cover according to the reverse procedure of removal.
  • Page 41 12. BODY COVER screws×4 FLOOR PANEL Removal Remove the 4 screws in the battery cover. Remove the 1 screw in the front center screw×1 cover. Remove the front center cover. Front center cover screws×4 Remove the 4 bolts in the floor panel. Bolts1×2 Remove the luggage box and the double seat.
  • Page 42 12. BODY COVER Remove the front cover and front under 2 screws cover. Remove the 2 mounting screws between the floor panel and the front inner box. Remove the floor panel. Installation Install the floor panel according to the reverse procedure of removal. SIDE COVER Removal Remove the left/right side 2 mounting...
  • Page 43 13. BRAKE MECHANISM DIAGRAM-FRONT BRAKE FLUID DISC BRAKE SYSTEM ......13-1 REPLACEMENT/AIR-BLEED .... 13-6 MECHANISM DIAGRAM-REAR BRAKE CALIPER ......13-7 DRUM BRAKE SYSTEM....13-2 BRAKE DISC........13-8 MAINTENANCE INFORMATION..13-3 BRAKE MASTER CYLINDER.... 13-8 TROUBLE DIAGNOSIS......13-4 DRUM BRAKE-DRUM......13-11 HYDRAULIC BRAKE SYSTEM BRAKE LING........13-11 INSPECTION ........13-5 BRAKE PANEL ........
  • Page 44 13. BRAKE MECHANISM DIAGRAM Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-2...
  • Page 45 13. BRAKE MAINTENANCE INFORMATION Precautions in Operation Caution Installing lining dusts may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. 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.
  • Page 46 13. BRAKE TROUBLE DIOGNOSIS DISC BRAKE Soft brake lever Uneven brake l Air inside the hydraulic system l Dirty brake lining/disc l Hydraulic system leaking l Poor wheel alignment l Worn master piston l Clogged brake hose l Worn brake pad l Deformed or warped brake disc l Poor brake caliper l Restricted brake hose and fittings...
  • Page 47 13. BRAKE HYDRAULIC BRAKE SYSTEM Hose connection INSPECTION Inspection Visual inspect for brake fluid leaking or damage. Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components.
  • Page 48 13. BRAKE Remove the master cylinder cap and master diaphragm. cylinder Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. diaphragm Clean dirty brake disc. CAUTION The dirty brake lining or disc will reduce the brake performance.
  • Page 49 13. BRAKE BRAKE CALIPER hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses. CAUTION l Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Make sure the brake lining condition.
  • Page 50 13. BRAKE BRAKE DISC Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. brake disc Allowable limit: 2.0 mm micrometer Remove the brake disc from wheel.
  • Page 51 13. BRAKE Inspection Check the master cylinder for damage or master cylinder scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Allowable limit: 11.055 mm Dial gauge Measure the outer diameter of the piston.
  • Page 52 13. BRAKE INSTALLATION master cylinder mounting seat Place the master cylinder onto handlebar, and install the split ring and bolts. The “ UP” mark on the split ring should face bolts x 2 upward. Align the split ring on the master cylinder seat with the alignment point on the split ring handlebar.
  • Page 53 13. BRAKE DRUM BRAKE-DRUM Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the dust. Caution ? Inhaling dust may cause respiration system disorder even cancer. Never use an air hose or a dry brush as to clean the brake parts.
  • Page 54 13. BRAKE Removal front brake cam Caution Brake linings must be replaced as a set. brake spring Remove brake shoes from the brake panel by pulling out the brake linings with two hands. Installation Apply a thin coat of grease to the brake cam anchor pin brake shoes and the anchor pin.
  • Page 55 13. BRAKE Installation Return spring Front FRONT BRAKE PANEL Wear Apply a thin cost of grease onto the brake indicator cam shaft. Oil seal Install the brake cam. Apply a thin cost of grease onto the oil seal Brake cam lip and then install the oil seal onto the brake cam shaft.
  • Page 56 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER MECHANISM DIAGRAM ....14-1 FRONT WHEEL........14-4 PRECAUTIONS IN OPERATION ..14-2 FRONT SHOCK ABSORBER.....14-9 TROUBLE DIAGNOSIS ..... 14-2 FRONT FORK/STEERING COLUMN.14-9 STEERING HANDLE ......14-3 MECHANISM DIAGRAM 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 3.1~3.5kgf-m 2.4~3.0kgf-m 5.0~7.0kgf-m 5.0~7.0kgf-m 14-1...
  • Page 57 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER PRECAUTIONS IN OPERATION General Information Ÿ Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. Ÿ Be careful not to allow oil or grease get on brake drum or linings. Torque values Front wheel axle 5.0~7.0kgf-m...
  • Page 58 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE REMOVAL Remove handle front & rear covers and the front cover (refer to chapter 12). Master cylinder Disc Brake Seat Remove the 2 bolts of the brake master cylinder, and then take out the master Split cylinder and the split ring.
  • Page 59 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a wrench to hold the handlebar bolt and Bolt then remove the nut. Take out the handlebar after removed the bolt. Installation Install the handlebar according to the reverse procedure of removal. Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat, acceleration handlebar, and acceleration cable.
  • Page 60 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: 0.2 mm. Wheel axle Wheel Rim Place the wheel onto a rotated bracket. Turn the wheel with hand and measure its wobble value with a dial gauge.
  • Page 61 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Remove the left axle ring and dust seal. Speedometer gear dust seal DISC BRAKE Remove the dust seal on the right side of speedometer gear. Remove the bearing with the inner type Bearing spacer bearing remover. Bearing Take out the bearing spacer and then remove the other bearing.
  • Page 62 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Caution Ÿ Do not install used bearing and replace the bearing once it has been removed. Ÿ Do not the bearing in tile motion when installing. Tool: C-type compressor or bearing compressor. This two example will to louse the bearing. Speedometer gear dust seal DISC BRAKE Disc Brake...
  • Page 63 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc (drum brake) or speedometer gear box. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease.
  • Page 64 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER Removal Remove the front fender, front lower spoiler, front guard, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left shock absorber. (bolt x 1) As for disc brake, remove the cable guide on the right shock absorber.
  • Page 65 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a plastic hammer to tap the steering column slightly, and then remove the top ball bearing seat. Remove the lower-end cone bearing seat on the frame with a punch. Caution Do not damage the frame and the steering column.
  • Page 66 15. REAR WHEEL/REAR SHOCK ABSORBER MECHANISM DIAGRAM ....15-1 EXHAUST MUFFLER......15-3 PRECAUTIONS IN OPERATION ..15-2 REAR WHEEL ........15-3 TROUBLE DIAGNOSIS......15-2 REAR SHOCK ABSORBER ....15-4 MECHANISM DIAGRAM 3.5~4.5kgf-m 2.4~3.0kgf-m 0.8~1.2kgf-m 1.0~1.4kgf-m 11.0~13.0kgf-m 3.0~3.6kgf-m 15-1...
  • Page 67 15. REAR WHEEL/REAR SHOCK ABSORBER PRECAUTIONS IN OPERATION General Information As for the wheel removal, service, and installation procedures, please refer to the service manual of high speed tire. Specification Unit: mm Items Standard Limit Radial Wheel wobbling Axial Thickness of rear brake lining Torque values: Rear axle nut 11.0~13.0kgf-m...
  • Page 68 15. REAR WHEEL/REAR SHOCK ABSORBER EXHAUST MUFFLER Exhaust muffler Removal Remove the front-end nut of the exhaust muffler. (nuts x 2) Remove the bolts. (bolts x 2) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal. Caution Nuts x 2 Replace the exhaust muffler gasket if it is...
  • Page 69 15. REAR WHEEL/REAR SHOCK ABSORBER REAR SHOCK ABSORBER Removal Remove the luggage box. (bolts x 6) Remove the rear carrier. (bolts x 3) Remove the left & right body covers. (screws x 4, bolts x 3) Remove the air cleaner bolts (bolts x2) Remove the lower nut of the rear shock absorber (bolt x 1) Remove the upper nut of the rear shock...
  • Page 70 16. ELECTRICAL EQUIPMENT MECHANISM DIAGRAM ....16-1 STARTING SYSTEM ......16-14 PRECAUTIONS IN OPERATION ..16-2 METER ..........16-15 TROUBLE DIAGNOSIS ..... 16-4 LIGHTS/BULBS ......... 16-17 CHARGING SYSTEM......16-5 SWITCH..........16-19 IGNITION SYSTEM ......16-11 FUEL UNIT ........16-22 MECHANISM DIAGRAM Horn/turn signal Rear stop switch light/high &...
  • Page 71 16. ELECTRICAL EQUIPMENT PRECAUTIONS IN OPERATION Charging System l 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.) l MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water. l Battery must be taken out from scooter when charging the battery.
  • Page 72 16. ELECTRICAL EQUIPMENT Specification Charging System Items Specification Capacity/type 12V 6Ah STD:0.6A/5~10hrs, emergency charging: Charging rate 6A/0.5hrs Battery Full charged 13.1V Voltage (20? ) Under charged 12.3V Capacity 12V / 6.2A Lighting coil resistance (20? ) Between yellow-green: 0.8± 0.1O Alternator Charging coil resistance (20? ) Between white-green: 0.6±...
  • Page 73 16. ELECTRICAL EQUIPMENT TROUBLE DIAGNOSIS Charging System System Ignition No power supply No spark produced by spark plug l The spark plug is out of work l Dead battery l The cable is poorly connected, open or l Disconnect battery cable l Fuse burned out short-circuited - Between alternator and C.D.I.
  • Page 74 16. ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram green white green fuse(7A green yellow alternator REG.REC. battery green/black Auto by-starter Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Battery(-) terminal Connect an ammeter between the negative cable terminal and the battery negative...
  • Page 75 16. ELECTRICAL EQUIPMENT Battery Battery cover Removal Remove the battery cover. CAUTION Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, and then send to hospital.
  • Page 76 16. ELECTRICAL EQUIPMENT Voltage Check With a digital voltage meter or multi-meter to measure battery voltage. Voltage: Fully charged: 13.0 – 13.2V (at 20? ) Undercharged: Below 12.3 V (at 20? ) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal.
  • Page 77 16. ELECTRICAL EQUIPMENT digital voltmeter Charging Voltage/Current ammeter Inspection Caution l Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.1 V. If undercharged, the current changes dramatically. l While starting the engine, the starter Fuse ends motor draws large amount of current...
  • Page 78 Do not touch the probe of multi-meter by fingers, then the resistance values will be White incorrect because there is some resistance existence in human body. l To use the multi-meter recommended by SYM. Otherwise, the measured resistance Yellow Green might be different. 16-9...
  • Page 79 16. ELECTRICAL EQUIPMENT Alternator charging coil Auto Charging coil light coil by-star connector connector Caution The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 3P connector of the alternator. Measure the resistance between the white wire on the alternator and frame ground with Pulse generator...
  • Page 80 16. ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit green Blue /yellow green Black/ yellow Black/ white Black/red Pulse spark plug green Blue/yellow black/yellow Black/red green Black/white C.D.I. unit green main switch Ignition coil CDI UNIT Removal Remove the right body cover, then the C.D.I. unit can be removed from the frame.
  • Page 81 16. ELECTRICAL EQUIPMENT Ignition coil Ignition coil Removal Remove the luggage box, center cover. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix bolts for the ignition coil, and remove the ignition coil. Install the ignition coil in reverse order of removal.
  • Page 82 16. ELECTRICAL EQUIPMENT Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7-12 kO (20? ) Remove the spark plug cap, measure the resistance between plug cap side and green terminal.
  • Page 83 16. ELECTRICAL EQUIPMENT STARTING SYSTEM Starting Circuit Starter magnetic switch inspection Starter magnetic switch Turn main switch to "on", and operate the brake lever. Then press starting button to check if there a click sound. It is normal if there is a click sound. Remove the luggage box.
  • Page 84 16. ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the battery cover. Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the starting motor power wire. Remove the starting motor mounting bolts and motor.
  • Page 85 16. ELECTRICAL EQUIPMENT Remove the rear handle cover. Remove the meter mounting screws. Take out the meter. High Beam Indicator Speedometer Time meter Turn Left Signal Turn Right Indicator Signal Indicator Fuel meter Odometer/Trip kilometer Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components.
  • Page 86 16. ELECTRICAL EQUIPMENT LIGHT/BULBS Headlight Bulb Replacement Rear the front handle cover. Disconnect the headlight wire connector. Press down the bulb spring locker and then remove the locker with turning it left motion. Remove the bulb. Replace the bulb with new one if necessary. (12V 35W/35W) Caution l Do not touch the bulb surface with fingers...
  • Page 87 16. ELECTRICAL EQUIPMENT Front Turn Signal Lamp Bulb Replacement Remove the front handle cover. Remove the wire connector of the turn signal light. Front turn signal light the wire connector of the turn signal light Pull out the bulb and replace it with new one. (12V 10W) Installation Install the bulb in reverse order of removal.
  • Page 88 16. ELECTRICAL EQUIPMENT MAIN SWITCH/HORN Main Switch Check Remove the headlight connector and the front cover. Disconnect main switch leads connector. Check connector terminals for continuity. color Black/ Red Green Black Green white Location LOCK main switch connector terminals main switch bolts x 2 Replacement Remove the main switch connector and fixing bolts (bolts x 2)
  • Page 89 16. ELECTRICAL EQUIPMENT Handle switch headlight switch Remove the front handle cover. Disconnect the connector of the handle switch. Check the continuity of follow pins listed below columns. Headlight switch color Brown Yellow Brown Yellow /White Pink Location starting switch headlight yellow brown /white...
  • Page 90 16. ELECTRICAL EQUIPMENT Turn signal light switch color Gray orange Location blue turn signal FROM R orange light switch PUSH OFF FROM L gray Sky blue Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever.
  • Page 91 16. ELECTRICAL EQUIPMENT FUEL UNIT Fuel unit Open the seat. Remove the luggage box(bolts x 4) . Remove the R.R. carrier(bolts x 3) . Remove the body cover. Disconnect the fuel unit wire connector. Caution Do not damage or bend the float arm as removing.
  • Page 93 2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 IGNITION SYSTEM/SPARK PLUG ..2-8 PERIODICAL MAINTENANCE CYLINDER COMPRESSION SCHEDULE ........2-2 PRESSURE ........2-9 LUBRICATION SYSTEM ....2-3 DRIVING SYSTEM ......2-9 FUEL SYSTEM ........2-4 STEERING SYSTEM......2-10 AIR CLEANER ........2-5 SUSPENSION SYSTEM ....2-10 THROTTLE VALVE OPERATION ..
  • Page 94 Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
  • Page 95 2. MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Caution Ÿ The vehicle must be parked on a level ground when checking oil capacity. Ÿ Run the engine for 2-3 minutes then stop, wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.
  • Page 96 Install the oil filling bolt. Torque value: 0.8~1.2 kgf-m Gear oil draining plug Transmission oil capacity: 180 c.c.(170 c.c. for change) Recommended: genuine SYM HYPOID gear oil (SAE 85W-140). Fuel System Fuel Pipe Fuel filter Remove luggage box, side cover, center cover, body frame cover, and pedal, as well as front inner box.
  • Page 97 2. MAINTENANCE INFORMATION AIR CLEANER screws×7 Element Remove left side cover. Remove 7 screws from the air cleaner cover. Remove element of air cleaner (3 screws). Check the element if dirt or damaged. Replace it with new one if dirt or damaged. Air cleaner element Caution Ÿ...
  • Page 98 2. MAINTENANCE INFORMATION Adjustment nut Primary adjustment is conducted from button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Fixing nut Crankcase blow-by system CRANKCASE VENTILATION Pull out the plug from draining hose to clean deposits Caution When always riding in rainy area or full...
  • Page 99 2. MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION Feeler gauge AND ADJUSTMENT Check & 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 It has to make sure that valve-rocker arm is be adjusted to standard level when Fixing nut adjusting it, and re-check the valve...
  • Page 100 2. MAINTENANCE INFORMATION IGNITION SYSTEM F mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for Ignition light checking whether C.D.I. function is in normal or not. Remove right side cover.
  • Page 101 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Open the seat. Remove the luggage box. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.
  • Page 102 2. MAINTENANCE INFORMATION STEERING SYSTEM Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing.
  • Page 103 2. MAINTENANCE INFORMATION Brake hose FRONT DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil, and also check brake system for leaking. BRAKE FLUID Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
  • Page 104 2. MAINTENANCE INFORMATION Brake fluid cap ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 Low limit WELL RUN brake fluid. Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.
  • Page 105 2. MAINTENANCE INFORMATION DRUM BRAKE SYSTEM Front Brake Free Play: (Drum brake) 10~ 20mm Measure free play of rear brake level at the end of the lever. Free play: 10-20 mm Adjust the free play by turning the front brake adjustment nut if necessary. “...
  • Page 106 2. MAINTENANCE INFORMATION BRAKE LIGHT SWITCH Brake light switch The brake light switch is to lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. WHEEL/TIRE Check if both front and rear tire pressure are within specification.
  • Page 107 2. MAINTENANCE INFORMATION BATTERY Battery Removal Remove the 2 screws on the floor panel. Remove battery cap. (2 nuts) Battery cables removal: 1. At first, remove the negative “ -” cable. 2. Then, remove the positive “ +” cable. 3. Remove the battery. If there is some rust on battery posts, clean it with steel brush.
  • Page 108 3. LUBRICATION SYSTEM MECHANISM DIAGRAM ....3-1 CLEANING ENGINE OIL STRAINER...3-3 OPERATIONAL PRECAUTIONS..3-2 OIL PUMP..........3-4 TROUBLE DIAGNOSIS ..... 3-2 GEAR OIL..........3-6 ENGINE OIL ........3-3 MECHANISM DIAGRAM Valve rocker Forcedly lubrication Camshaft Scoop lubrication Inner passage Connecting rod Forcedly lubrication Crankshaft Oil strainer...
  • Page 109 3. LUBRICATION SYSTEM OPERATIONAL PRECAUTIONS General Information This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil. Oil viscosity Specifications Engine oil quantity Disassembly 950 c.c. Replacement 700 c.c. Oil viscosity SAE 10W-30 or equivalent Gear Oil Capacity Disassembly 180 c.c.
  • Page 110 3. LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 111 3. LUBRICATION SYSTEM OIL PUMP bolts Oil Pump Removal Remove the alternator (refer to chapter10). Remove the engine right crankcase cover. Remove the one-way clutch and starting drive gear (1 nut). Make sure that the pump axle can be rotated freely.
  • Page 112 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body. Limit: below 2.0 mm Oil Pump Re-assembly Install inner and outer rotors into the pump...
  • Page 113 3. LUBRICATION SYSTEM Oil Pump Installation Install the oil pump (2 bolts). 2 bolts Install oil pump outer cover (2 bolts). oil pump outer cover 2 bolts Install the starting gear and the alternator. Start drive gear (Refer to chapter 10) GEAR OIL Filling bolt Oil Level Inspection...
  • Page 114 And then, tighten the bolt. Torque Value: 1.0~1.5 kgf-m ? Recommended to apply with SYM HYPOID GEAR OIL (SAE 85W-140) Start engine and run it for 2~3 minutes. Turn off engine and check if oil leaking.
  • Page 115 4. FUEL SYSTEM MECHANISM ILLUSTRATION .....4-1 AUTO BY-STARTER ......4-7 PRECAUTIONS IN OPERATION ..4-2 FLOAT CHAMBER......4-8 TROUBLE DIAGNOSIS ......4-3 INSTALLATION OF CARBURETOR ..4-9 CARBURETOR REMOVAL ....4-4 IDLE SPEED ADJUSTMENT....4-9 VACUUM CHAMBER......4-4 FUEL TANK ........4-10 AIR CUT-OFF VALVE......4-6 AIR CLEANER ........4-11 MECHANISM ILLUSTRATION Carburetor Fuel strainer...
  • Page 116 4. FUEL SYSTEM PRECAUTIONS IN OPERATION General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions l Do not bend or twist throttle valve cable. Damaged cable will make unstable drivability. l When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly l There is a drain screw in the float chamber for draining residual gasoline.
  • Page 117 4. FUEL SYSTEM TROUBLE DIAGNOSIS Power insufficiency and fuel consuming Poor engine start l Fuel system clogged l No fuel in fuel tank Malfunction of ignition system l Clogged fuel tube l Too much fuel in cylinder l No spark from spark plug (malfunction of ignition system) l Clogged air cleaner l Malfunction of automatic by-starter...
  • Page 118 4. FUEL SYSTEM throttle valve cable vacuum CARBURETOR REMOVAL hose Open the seat. Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Disconnect auto by-starter connectors. Release the clamp strip of air cleaner.
  • Page 119 4. FUEL SYSTEM Remove fuel needle seat, spring, and fuel needle injector needle. seat Check if the vacuum piston for wear out, fuel needle crack or other damage. spring Check if the diaphragm for damage or crack. injector Cautions needle Do not damage vacuum diaphragm.
  • Page 120 4. FUEL SYSTEM AIR CUT-OFF VALVE Removal Remove the vacuum hose clamp and then the vacuum hose. Screws × 2 Remove the screws (screw x 2) of the air cut-off valve and its cover. screws vacuum diaphragm Remove the spring and vacuum diaphragm. Check if the vacuum diaphragm for deterioration or crack.
  • Page 121 4. FUEL SYSTEM AUTO BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter Resistance value: Max. 10O (Measured after engine stopped for more than 10 minutes) Replace the auto by-starter with a new one if resistance value exceeds standard.
  • Page 122 4. FUEL SYSTEM FLOAT CHAMBER float Disassembly float pin Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. screws× 4 Checking Check float needle valve and valve seat for float pin drop difference damage, wear out, dirty or clogged.
  • Page 123 4. FUEL SYSTEM Installation Install main jet, slow jet and fuel amount adjustment screw. Cautions Set the adjustment screw in according to number of turns noted before it was removed. fuel amount adjustment screw Install the float valve, float, and float pin. Checking Fuel Level Cautions l Check again to ensure float valve, float for...
  • Page 124 4. FUEL SYSTEM FUEL TANK Fuel unit Fuel unit removal Remove the seat. Remove the luggage box assembly (2×2 nuts). Disconnect fuel unit connector. Remove fuel unit. Cautions l Do not bend the float arm of fuel unit. l Do not fill out too much gasoline to fuel tank.
  • Page 125 4. FUEL SYSTEM AIR CLEANER Removal Open the seat and remove the luggage box . Loosen the clamp strip of air cleaner. Remove evaporative return hose. Remove body cover. Remove the air cleaner body bolts (2 bolts). Remove the air cleaner. Installation Install the air cleaner in the reverse order of air filter strap...
  • Page 126 5. REMOVAL OF ENGINE MECHANISM DIAGRAM ......5-1 ENGINE SUSPENSION FRAME ..5-7 OPERATIONAL PRECAUTIONS..5-2 INSTALLATION OF ENGINE....5-8 ENGINE REMOVAL......5-3 REMOVAL OF ENGINE SUSPENSION BUSHING..........5-6 MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5 kgf-m...
  • Page 127 5. REMOVAL OF ENGINE OPERATIONAL PRECAUTIONS General Information Ÿ Engine must be supported by a bracket or adjustable tool in height. Ÿ The following parts can be serviced with the engine installed on the frame. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3.
  • Page 128 5. REMOVAL OF ENGINE ENGINE REMOVAL Auto by-start connector Open the seat. Remove the rear carrier (3 bolts ). Remove the luggage box assembly (4 bolts ). Remove the body cover (4 screws, 3 bolts). Remove the power connector of auto by- start.
  • Page 129 5. REMOVAL OF ENGINE Remove the fuel pipe, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and remove the air cleaner guide. Bolts× 2 Remove the exhaust muffler (Bolts × 2, Nuts ×...
  • Page 130 5. REMOVAL OF ENGINE Brake cable nut Remove the rear brake cable nut. Remove the rear brake cable. Remove the rear shock absorber lower bolt. Shock absorber lower bolt Loose the strap screw of engine left guide, and then remove the engine left guide. Strap screw of guide Engine suspension nuts Remove the engine suspension nuts and...
  • Page 131 5. REMOVAL OF ENGINE REMOVAL OF ENGINE SUSPENSION BUSHING If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / presser, Φ28mm &Φ20mm, to press the bushing out, and replace it with new one. Engine suspension bushing: Φ28mm Rear shock absorber bushing: Φ20mm Pressing out...
  • Page 132 5. REMOVAL OF ENGINE ENGINE SUSPENSION FRAME Bolt of engine suspension frame (right side) Removal Remove the left side bolt of engine suspension frame. Remove the right side bolt of engine Bolt of engine suspension suspension frame. frame (left side) Check if the engine suspension frame bushing and cushion rubber for damage.
  • Page 133 5. REMOVAL OF ENGINE INSTALLATION OF ENGINE Bolt of engine suspension frame (right side) Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones. Install the engine according to the reversing order of removal.
  • Page 134 6. CYLINDER HEAD/VALVE MECHANISM DIAGRAM ....6-1 CYLINDER HEAD INSPECTION..6-7 PRECAUTIONS IN OPERATION ..6-2 VALVE SEAT INSPECTION AND TROUBLE SHOOTING ...... 6-3 SERVICE ..........6-9 CAMSHAFT REMOVAL..... 6-4 CYLINDER HEAD REASSEMBLY ..6-11 CYLINDER HEAD REMOVAL ... 6-6 CYLINDER HEAD INSTALLATION ..6-12 CYLINDER HEAD DISASSEMBLY..
  • Page 135 6. CYLINDER HEAD/VALVE PRECAUTIONS IN OPERATION General Information Ÿ This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm. Ÿ Cylinder head service cannot be carried out when engine is in frame. Specification unit: mm Item...
  • Page 136 6. CYLINDER HEAD/VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure. Low compression pressure 1.
  • Page 137 6. CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head cover 4 bolts and then remove the cylinder head cover. A.I. 4 bolts screw Loosen the screw of camshaft chain adjuster and remove O-ring.
  • Page 138 6. CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the cylinder head. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit IN: Replacement when less than 20.570mm EX: Replacement when less than 19.410 Inspect the camshaft bearing for looseness or wear out.
  • Page 139 6. CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Remove double seat, luggage box and front center cover. Remove the engine (refer to Chapter 5). Remove the cooling fan cover. Remove the engine shroud . Remove the camshaft sprocket. Remove the 2 cylinder head mounting bolts dowel pins from cylinder head left side cover.
  • Page 140 6. CYLINDER HEAD/VALVE After removed valve cotters, release the valve cotters compressor and then take out spring retainer, valve spring and valves. Caution In order to avoid to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch. Special Service Tool: Valve spring compressor.
  • Page 141 6. CYLINDER HEAD/VALVE Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter. Service Limit: IN? 4.900mm 4.900mm Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer.
  • Page 142 6. CYLINDER HEAD/VALVE Hold the cylinder head, and then press out old valve guide from combustion chamber side. Valve guide driver Tool: Valve guide driver 5 mm 13 mm 5.0mm (0.15in) Caution Ÿ Check if new valve guide is deformation after pressed it in.
  • Page 143 6. CYLINDER HEAD/VALVE Valve seat inspection Roughness If the valve seat is too width, narrow or rough, correct it. Valve seat width Service limit: 1.6mm Check the contact condition of valve seat. 45° Valve seat grinding The worn valve seat has to be grinded with valve seat chamfer cutter.
  • Page 144 6. CYLINDER HEAD/VALVE Coat the valve seat surface with red paint. Install the valve through valve guide until the Contact surface too high valve contacting with valve seat, slightly press down the valve but do not rotate it so Old valve seat that a seal track will be created on contact width surface.
  • Page 145 6. CYLINDER HEAD/VALVE Use valve spring compressor to press valve spring. Install valve split locks and release the valve compressor. Caution In order to avoid to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch. Special tool: valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly.
  • Page 146 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 Especial tool 　 feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the adjustment nut.
  • Page 147 7. CYLINDER/PISTON MECHANISM DIAGRAM ....7-1 PISTON REMOVAL......7-5 PRECAUTIONS IN OPERATION ..7-2 PISTON RING INSTALLATION ..7-7 TROUBLE DIAGNOSIS ..... 7-2 PISTON INSTALLATION ....7-8 CYLINDER REMOVAL ...... 7-3 CYLINDER INSTALLATION ....7-8 MECHANISM DIAGRAM 0.8~1.2kgf-m...
  • Page 148 7. CYLINDER/PISTON PRECAUTIONS IN OPERATION General Information Ÿ Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification unit: mm Item Standard Limit 52.395~52.415 52.50 Bend/wrap age Less than 0.05 0.050 Cylinder Roundness Less than 0.01 0.050 Cylindrical Less than 0.05...
  • Page 149 7. CYLINDER/PISTON CYLINDER REMOVAL 2 bolts Cylinder Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-adjuster. Cam chain Cam chain guide auto-adjuster Remove cam chain plate. Remove cylinder. Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase.
  • Page 150 7. CYLINDER/PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.
  • Page 151 7. CYLINDER/PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 152 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 14.96mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06mm Measure the inner diameter of piston pin hole. Service Limit: 15.04mm Calculate clearance between piston pin and its hole.
  • Page 153 7. CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston skirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Ÿ Do not damage piston and piston rings as installation. Ÿ...
  • Page 154 7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Piston pin Install new piston pin snap ring. Caution Ÿ Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 155 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MECHANISM DIAGRAM ....8-1 KICK STARTER ARM......8-3 MAINTENANCE DESCRIPTION ..8-2 DRIVING BELT........8-4 TROUBLE DIAGNOSIS ..... 8-2 SLIDING PULLEY.......8-6 LEFT CRANKCASE COVER ..... 8-3 CLUTCH/DRIVEN PULLEY ....8-9 MECHANISM DIAGRAM 5.5~6.0kgf-m 5.5~6.0kgf-m 1.0~1.5kgf-m 5.0~6.0kgf-m...
  • Page 156 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MAINTENANCE DESCRIPTION Precautions in operation General information ? 　Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. ? 　Driving belt and driving pulley surface must be free of grease. Specification Unit: mm Item Standard value Limit...
  • Page 157 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM air cleaner lock bolts LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (2 bolts) Remove kick starter arm. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent. Remove engine left-side cover (8 bolts).
  • Page 158 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVING BELT Removal Remove left crankcase cover. Hold the driving pulley with a universal fixture, and then remove the nut and driving pulley. Universal fixer Hold driving pulley with universal fixture, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
  • Page 159 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving belt into the driving pulley. Sliding driven Caution pulley Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.
  • Page 160 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Universal fixture Remove the driving belt from the pulley. Sliding pulley Remove sliding pulley set and driving pulley hub from crankshaft.
  • Page 161 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.
  • Page 162 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install siding pulley assembly onto crankshaft. Sliding pulley Crankshaft Pulley hub...
  • Page 163 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM CLUTCH/DRIVEN PULLEY Special nut wrench Disassembly Remove driving belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut...
  • Page 164 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch lining Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 2.5mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 163.7mm Free length Driven pulley...
  • Page 165 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch Block Replacement Driving plate Remove snap and washer, and the remove Spring clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption rubber Check if shock absorption rubber is damage or deformation.
  • Page 166 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Install snap ring and mounting plate onto setting pin. Snap ring Replacement of driven pulley bearing Remove inner bearing. Oil seal Outer bearing Caution Ÿ If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
  • Page 167 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation of clutch/driven pulley Oil seal Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Specified grease O-ring Install sliding pulley onto driven pulley. Guide pin Sliding pulley Oil seal...
  • Page 168 9. FINAL DRIVING MECHANISM MECHANISM DIAGRAM ....9-1 INSPECTION OF FINAL DRIVING OPERATIONAL PRECAUTIONS..9-2 MECHANISM........9-3 TROUBLE DIAGNOSIS ..... 9-2 BEARING REPLACEMENT....9-4 DISASSEMBLY OF FINAL DRIVING RE-ASSEMBLY OF FINAL DRIVING MECHANISM ........9-3 MECHANISM........9-6 MECHANISM DIAGRAM Countershaft Final driving shaft Final driving gear Countershaft gear Driving gear...
  • Page 169 9. FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 0.8~1.2 kgf-m Recommended gear oil:85W-140 Gear oil drain plug 1.0~1.4 kgf-m Oil quantity: 100 c.c. (90 c.c. when Gear oil filling bolt 0.8~1.2 kgf-m replacing) Tools Special service tools...
  • Page 170 9. FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING MECHANISM Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7bolts) and then remove the cover and the final driving shaft.
  • Page 171 9. FINAL DRIVING MECHANISM Final driving Check bearings on gear box and cover. shaft Rotate each bearing’ s inner ring with fingers. Final driving gear Countershaft gear Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box &...
  • Page 172 9. FINAL DRIVING MECHANISM Press out the driving shaft from the crankcase. Remove oil seal from the gear box. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution Using the bearing protector as pressing out the driving shaft from the left crankcase.
  • Page 173 9. FINAL DRIVING MECHANISM RE-ASSEMBLY OF FINAL DRIVING Countershaft Final shaft MECHANISM Install final shaft and final shaft driven gear, countershaft. Final shaft driven gear Install the setting pins(2 pins) and new gasket. Dowel pins Gasket Apply with grease onto the oil seal lip of final driving shaft.
  • Page 174 SERVICE MANUAL...
  • Page 175 FORWARD This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle. The manual is shown with illustrations and focused on ? Service Procedures? , ? Operation Key Points? , and ? Inspection Adjustment? so that provides technician with service guidelines.
  • Page 176 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SYM series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 177 CONTENTS CONTENTS GENERAL INFORMATION/TROUBLE DIAGNOSIS ........1 MAINTENANCE INFORMATION ..............2 LUBRICATION SYSTEM ................3 FUEL SYSTEM ................... 4 ENGINE REMOVAL..................5 CYLINDER HEAD/VALVE ................6 CYLINDER/PISTON..................7 "V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM ...... 8 FINAL DRIVING MECHANISM ..............9 A.C.
  • Page 178 MECHANISM ILLUSTRATIONS Headlight switch/starter switch Fuse &C.D.I Battery Front light/ Fuel tank cap Position light Front turn signal light Air Cleaner Kick starter pedal Engine number/ Engine oil Side stand draining bolt High& Low beam/ Turn signal/Horn switch Storage box Frame number Tail light Oil level...

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