Table Of Contents - Sym Symply50 Service Manual

Table of Contents

Table Of Contents4
Mechanism Illustrations5
Special Tools6
General Information/Trouble Diagnosis8
Symbols And Marks8
General Safety9
Service Precautions10
Specifications16
Torque Values17
Engine Hard To Start Or Can Not Be Started19
Engine Run Sluggish (Speed Does Not Pick Up, Lack Of Power)20
Engine Runs Sluggish (Especially In Low Speed And Idling)21
Engine Runs Sluggish (High Speed)21
Clutch, Driving And Driving Pulley Troubles22
Lubrication Points23
Maintenance Information24
Specification24
Periodical Maintenance Schedule25
Lubrication System26
Engine Oil Capacity26
Oil Change26
Oil Viscosity26
Fuel System27
Fuel Pipe27
Fuel Filter27
Gear Oil27
Air Cleaner28
Throttle Valve Operation28
Valve Clearance Adjustment29
Valve Clearance Inspection And Adjustment30
Carburetor Idle Speed Adjustment30
Ignition System31
Spark Plug31
Ignition Timing31
Cylinder Compression Pressure32
Driving System32
Driving Belt32
Clutch Pad32
Steering System33
Suspension System33
Front Shock Absorber33
Rear Shock Absorber33
Front Disc Brake System34
Brake System Hose34
Brake Fluid34
Air Bleed Operation34
Added Brake Fluid35
Brake Lining Wear35
Drum Brake System36
Rear Brake Free Play: (Drum Brake Type)36
Brake Confirmation36
Wheel/Tire37
Brake Light Switch37
Battery Removal38
Battery Cables Removal38
Headlight Adjustment38
Nuts, Bolts Tightness38
Lubrication System Diagram39
Lubrication System - Operational Precautions40
Lubrication System Trouble Diagnosis40
Engine Oil41
Cleaning Engine Oil Strainer41
Oil Pump Removal42
Oil Pump Inspection43
Oil Pump Re-Assembly43
Oil Pump Installation44
Gear Oil Level Inspection45
Gear Oil Replacement45
Fuel System Diagram46
Fuel System - Precautions In Operation47
Fuel System Specification47
Fuel System Trouble Diagnosis48
Poor Engine Start48
Stall After Started48
Mixture Too Lean48
Carburetor Removal49
Vacuum Chamber Removal49
Vacuum Chamber Installation50
Accelerate Pump Removal And Installation51
Auto By-Starter Inspection52
Auto By-Starter Removal And Installation52
Float Chamber53
Idle Speed Adjustment54
Fuel Tank Removal55
Air Cleaner Removal And Installation56
Engine Removal57
Engine Diagram57
Engine Specification58
Removal Of Engine Suspension Bushing62
Engine Suspension Frame Removal And Installation63
Installation Of Engine64
Cylinder Head/Valve Diagram65
Cylinder Head/Valve Specification66
Cylinder Head/Valve Troubleshooting67
Low Compression Pressure67
High Compression Pressure67
White Smoke67
Camshaft Removal68
Camshaft Inspection69
Disassembly Of Camshaft Holder69
Inspection Of Camshaft Holder69
Cylinder Head Removal70
Cylinder Head Disassembly71
Cylinder Head Inspection72
Valve Guide Replacement73
Valve Seat Inspection And Service74
Valve Seat Grinding74
Cylinder Head Reassembly76
Camshaft Installation77
Cylinder Head Installation77
Cylinder/Piston Diagram79
Cylinder/Piston Specification80
Cylinder/Piston Trouble Diagnosis80
Cylinder Removal81
Cylinder Inspection82
Piston Removal83
Disassemble The Piston Rings83
Piston Ring Installation85
Piston Installation86
Cylinder Installation86
V-Belt Driving System/Kick Starter Arm/Starter Clutch87
V-Belt Driving System/Kick Starter Arm/Starter Clutch Specification88
Left Crankcase Cover Removal89
Installation Of The Left Crankcase Cover89
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch89
Driving Belt Removal90
Driving Belt Inspection90
Driving Belt Installation91
Install The Starter Clutch91
Sliding Pulley Removal92
Sliding Pulley Inspection93
Sliding Pulley Installation93
Driving Pulley Installation94
Clutch/Drive Pulley Disassembly95
Driven Pulley Spring96
Driven Pulley Check96
Driven Pulley Bearing Inspection96
Clutch Block Replacement97
Replacement Of Driven Pulley Bearing98
Installation Of Clutch/Driven Pulley99
Final Driving Mechanism Diagram100
Final Driving Mechanism Specification101
Disassembly Of Final Driving Mechanism102
Inspection Of Final Driving Mechanism102
Bearing Replacement103
Re-Assembly Of Final Driving Mechanism105
Ac Generator106
Generator/Starting Clutch107
Right Crankcase Cover Removal108
Right Crankcase Cover Installation109
Mounted Coil Set Installation109
Flywheel Installation109
Crankcase/Crankshaft Diagram111
Crankcase/Crankshaft - Operating Precautions112
Crankcase/Crankshaft Specification112
Crankcase/Crankshaft Trouble Diagnosis112
Disassembly Of Crankcase113
Crankshaft Inspection115
Assembly Of Crankcase116
Body Cover Diagram118
Body Covers Disassemble Sequence119
Handle Cover Removal120
Front Cover Removal And Installation121
Front Under Cover Removal And Installation122
Front Inner Box A Removal123
Front Inner Box A Installation124
Body Cover/Rear Center Cover/Rear Fender Removal125
Body Cover/Rear Center Cover/Rear Fender Installation126
Front Center Cover Removal And Installation127
Luggage Box Removal And Installation127
Floor Panel Removal And Installation127
Brakes Diagram128
Brake - Precautions In Operation130
Brake Specifications130
Brake Trouble Diagnosis131
Soft Brake Lever131
Uneven Brake131
Poor Brake Performance131
Hydraulic Brake System Inspection132
Brake Fluid Add132
Brake Fluid Replacement/Air-Bleed133
Brake System133
Brake Caliper Removal And Installation134
Brake Pad Replacement134
Brake Disk Inspection135
Brake Master Cylinder Removal135
Brake Master Cylinder Installation137
Drum Brake-Drum Removal138
Brake Pad Inspection138
Brake Pad Removal And Installation139
Brake Panel Removal And Installation139
Front Brake Panel140
Rear Brake Panel140
Steering/Front Wheel/Front Shock Absorber Diagram141
Steering/Front Wheel/Front Shock Absorber Data142
Steering/Front Wheel/Front Shock Absorber Trouble Diagnosis142
Steering Handle Removal143
Steering Handle Installation144
Front Wheel Removal144
Front Wheel Inspection145
Wheel Rim Check145
Wheel Axle Check145
Bearing Inspection146
Front Shock Absorber Removal And Installation148
Front Fork/Steering Column Removal And Installation148
Rear Wheel/Rear Shock Absorber Diagram150
Rear Wheel/Rear Shock Absorber Specification151
Rear Wheel/Rear Shock Absorber Trouble Diagnosis151
Exhaust Muffler Removal And Installation152
Rear Wheel Inspection152
Rear Wheel Removal And Installation152
Rear Shock Absorber Removal And Installation153
Electrical Equipment Diagram154
Electrical Equipment - Precautions In Operation155
Charging System155
Starting System155
Electrical Equipment Specifications156
Electrical Equipment Trouble Diagnosis157
Charging Wire Diagram158
Current Leakage Inspection158
Battery Voltage Check160
Battery Charging160
Charging Voltage/Current Inspection (Battery)161
Voltage Regulator Inspection162
Alternator Charging Coil163
Alternator Lighting Coil163
Resistor Check163
Ignition System Circuit164
Cdi Unit164
Ignition Coil165
Spark Plug Confirmation165
Primary Coil Check165
Secondary Coil166
Pulse Generator166
Starting Circuit167
Starter Magnetic Switch Inspection167
Remove The Luggage Box167
Starting Motor Removal168
Meter Removal168
Headlight Bulb Replacement170
The Headlight Beam Adjustment170
Front Turn Signal Lamp Bulb Replacement171
Bulbs Replacement Of Tail Light/Brake Light/Rear Turn Signal Light171
Main Switch/Horn172
Handle Switch173
Headlight Switch173
Starting Switch173
High/Low Beam Switch/ Passing173
Turn Signal Light Switch174
Fuel Unit175
Wiring Diagram176