Table Of Contents - Sym Jet 4 125 Manual

Table of Contents

General Information/Trouble Diagnosis1
Symbols And Marks1
General Safety2
Carbon Monoxide2
Gasoline2
Used Engine Oil2
Service Precautions3
Specifications9
Torque Values (Engine)10
Torque Values (Frame)11
Standard Torque Values For Reference11
Troubles Diagnosis12
Engine Hard To Start Or Can Not Be Started12
Engine Run Sluggish13
Engine Runs Sluggish14
Engine Runs Sluggish (High Speed)14
Clutch, Driving And Driving Pulley15
Lubrication Points16
A.c. Generator/Starting Clutch17
Mechanism Diagram17
Precautions In Operation18
General Information18
Specification18
Torque Value18
A.c. Generator Removal19
Right Crankcase Cover Removal20
Starting Clutch21
Starting Clutch Removal21
Starting Clutch Inspection21
Starting Clutch Installation23
Right Crankcase Cover Installation24
Mounted Coil Set Installation24
Flywheel Installation24
Crankcase/Crankshaft26
Operational Precautions27
Trouble Diagnosis27
Engine Noise27
Disassembly Of Crankcase28
Crankshaft Inspection30
Bearing Inspection30
Assembly Of Crankcase31
Body Cover33
Maintenance Information34
Body Covers Disassemble Sequence34
Handle Cover35
Front Cover36
Front Inner Box37
Body Cover/Rear Center38
Cover/Rear Fender38
Front Center Cover40
Luggage Box40
Floor Panel41
Side Cover42
Under Cover42
Brake43
Front Disc Brake System43
Rear Drum Brake System44
Trouble Diognosis46
Disc Brake46
Soft Brake Lever46
Hard Operation Of Brake Lever46
Hydraulic Brake System Inspection47
Brake Fluid Add47
Brake Fluid Replacement/Air-Bleed48
Brake Caliper49
Brake Lining Replacement49
Brake Disc Inspection50
Brake Master Cylinder50
Drum Brake-Drum53
Brake Drum53
Brake Lining53
Brake Panel54
Front Brake Panel55
Rear Brake Panel55
Steering/Front Wheel/Front Shock Absorber56
Hard Steering Stem57
Steering Stem Off Center57
Front Wheel Wobbling57
Soft Front Suspension57
Steering Handle58
Front Wheel59
Disc Brake Type59
Wheel Axle60
Wheel Rim60
Front Shock Absorber64
Front Fork/Steering Column64
Rear Wheel/Rear Shock Absorber66
Rear Wheel Wobbling67
Shock Absorber Too Soft67
Braking Noise67
Poor Brake Performance67
Exhaust Muffler68
Rear Wheel68
Rear Shock Absorber69
Electrical Equipment70
Charging System71
Ignition System71
Starting System71
No Power Supply73
Low Voltage73
Intermittent Power Supply73
Charging System Failure73
Charging Wire Diagram74
Current Leakage Inspection74
Voltage Check76
Charging Voltage/Current Inspection77
Voltage Regulator Inspection78
Main Wire Circuit Inspection78
Voltage Regulator Check78
Alternator Charging Coil79
Alternator Lighting Coil79
Resistor Check79
Ignition System Circuit80
Cdi Unit80
Ignition Coil81
Spark Plug Confirmation81
Primary Coil Check81
Secondary Coil82
Pulse Generator82
Starting Circuit83
Starter Magnetic Switch Inspection83
Starting Motor Removal84
Meter84
Light/Bulbs86
Headlight Bulb Replacement86
Front Turn Signal Lamp Bulb Replacement87
Main Switch/Horn88
Handle Switch89
Headlight Switch89
Starting Switch89
High/Low Beam Switch/ Seat Open89
Turn Signal Light Switch90
Brake Light Switch90
Horn90
Fuel Unit91
Wiring Diagram92
Periodical Maintenance Schedule94
Lubrication System95
Engine Oil Capacity95
Oil Change95
Cleaning The Oil Strainer95
Gear Oil96
Fuel System96
Fuel Pipe96
Fuel Filter96
Air Cleaner97
Throttle Valve Operation97
Crankcase Ventilation98
Valve Clearance Adjustment98
Valve Clearance Inspection And Adjustment99
Carburetor Idle Speed Adjustment99
Emission Adjustment In Idle Speed99
Ignition Timing100
Spark Plug100
Cylinder Copmression Pressure101
Driving System101
Driving Belt101
Clutch Pad101
Steering System102
Suspension System102
Brake System Hose103
Brake Fluid103
Filling Out Brake Fluid103
Air Bleed Operation103
Added Brake Fluid104
Brake Lining Wear104
Drum Brake System105
Rear Brake Free Play105
Brake Confiramtion105
Wheel/Tire106
Appointed Tire Pressure106
Appointed Tire106
Headlight Adjustment107
Nuts, Bolts Tighteness107
Battery Removal107
Battery Cables Removal107
Low Engine Oil Level109
Low Oil Pressure109
Dirty Oil109
Engine Oil110
Cleaning Engine Oil Strainer110
Oil Pump Removal111
Oil Pump Disassembly111
Oil Pump Inspection112
Oil Pump Re-Assembly112
Oil Pump Installation113
Gear Oil Replacement114
Poor Engine Start117
Stall After Started117
Mixture Too Lean117
Rough Idle117
Carburetor Removal118
Vacuum Chamber118
Air Cut-Off Valve120
Auto By-Starter121
Valve Inspection121
Float Chamber122
Installation Of Carburetor123
Checking Fuel Level123
Idle Speed Adjustment123
Standard Turns123
Fuel Unit Removal124
Fuel Unit Installation124
Fuel Tank Removal124
Fuel Tank Installation124
Air Cleaner Element Cleaning125
Removal Of Engine126
Engine Removal128
Suspension Bushing131
Pressing Out131
Pressing In131
Engine Suspension Frame132
Installation Of Engine133
Engine Suspension Nut133
Rear Shock Absorber Bolt133
Rear Wheel Axle Nut133
Cylinder Head/Valve134
Camshaft Removal137
Camshaft Inspection138
Cylinder Head Removal139
Cylinder Head Disassembly139
Cylinder Head Inspection140
Valve Spring Free Length140
Valve Stem141
Valve Guide141
Valve Guide Replacement141
Valve Seat Inspection And Service142
Valve Seat Inspection143
Valve Seat Width143
Valve Seat Grinding143
Cylinder Head Reassembly144
Cylinder Head Installation145
Cylinder/Piston147
Low Or Unstable Compression Pressure148
Knock Or Noise148
Smoking In Exhaust Pipe148
Engine Overheat148
Cylinder Removal149
Piston Removal151
Disassemble The Piston Rings151
Piston Ring Installation153
Piston Installation154
Cylinder Installation154
V-Belt Driving System/Kick Starter Arm155
Engine Can Be Started But Motorcycle Can Not Be Moved156
Shudder Or Misfire When Driving156
Insufficient Horsepower Or Poor High Speed Performance156
Left Crankcase Cover157
Installation Of The Left Crankcase Cover157
V" Type Belt Driving System/Kick Starter Arm157
Driving Pulley Install162
Clutch/Driven Pulley163
Clutch Lining164
Driven Pulley Spring164
Driven Pulley164
Driven Pulley Bearing Inspection164
Clutch Block Replacement165
Replacement Of Driven Pulley Bearing166
Installation Of Clutch/Driven Pulley167
Final Driving Mechanism168
Gear Oil Leaks169
Noise169
Disassembly Of Final Driving Mechanism170
Inspection Of Final Driving Mechanism170
Bearing Replacement171
Re-Assembly Of Final Driving Mechanism173
Table Of Contents177
Mechanism Illustrations178