Sym Citycom.300i Service Manual
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Sym Citycom.300i Service Manual

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FOREWORD
HOW TO USE THIS MANUAL
DK Version 1.0 2009
CONTENTS
SERIAL NUMBER
Citycom.300i

SERVICE MANUAL

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Table of Contents
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Summary of Contents for Sym Citycom.300i

  • Page 1: Service Manual

    FOREWORD HOW TO USE THIS MANUAL DK Version 1.0 2009 CONTENTS SERIAL NUMBER Citycom.300i SERVICE MANUAL...
  • Page 2 Homepage Contents Foreword This service manual contains the technical data of each component inspection and repairment for the SANYANG LH30W series scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment”, providing technicians with service guidelines. If the style or the mechanical structures of the scooter, LH30W series scooter, are different from those of the photos or pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3: General Information

    Homepage Contents How To Use This Manual This service manual describes the basic information of different system parts and system inspection & service for SANYANG LH30W series scooter. In addition, please refer to the manual contents in detail for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Homepage Contents Page Content Index General Information 1-1 ~ 1-16 2-1 ~ 2-17 Maintenance Information Lubrication System 3-1 ~ 3-8 Fuel Injection System 4-1 ~ 4-60 Engine Removal 5-1 ~ 5-11 Cylinder Head/ Valve 6-1 ~ 6-16 Cylinder/ Piston 7-1 ~ 7-8 “V”...
  • Page 5 Home page Contents Serial Number...
  • Page 6 Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Torque Values ........1-10 General Safty……………………………1-2 Troubles Diagnosis......1-12 Service Precautions ......1-3 Parts to Be Greased......1-16 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 needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks only.

  • Page 7: General Safety

    To this chapter contents 1. GENERAL INFORMATION work on these parts, wear insulated gloves and General safety wait until cooling off. Carbon monoxide Battery If you have to run your engine, make sure Caution that the place is well ventilated. Never run your engine in a closed area.

  • Page 8: Service Precautions

    To this chapter contents 1. GENERAL INFORMATION Never bend or twist a control cable to prevent unsmooth control and premature worn out. Service Precautions Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. ...
  • Page 9 To this chapter contents 1. GENERAL INFORMATION  The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if the another, be sure they are correctly installed.
  • Page 10 To this chapter contents 1. GENERAL INFORMATION  Lubricate the rotation face with specified lubricant  After service completed, make sure all on the lubrication points before assembling. connection points is secured. Battery positive (+) cable should be connected firstly. And the two battery terminals have to be greased after connected the cables.
  • Page 11 To this chapter contents 1. GENERAL INFORMATION When separating a connector, it locker has to be  Insert the terminal completely. unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. ...
  • Page 12 To this chapter contents 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.
  • Page 13 To this chapter contents 1. GENERAL INFORMATION  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 connection operation later. Clean rust  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...

  • Page 14: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL LH30W-6 Overall Length 2210 mm Front Telescopic Fork Suspension System Overall Width 785 mm Rear Unit Swing Overall Height 1445 mm Front 110 /70-16 52P Tire Specifications Wheel Base 1500 mm Rear 140 /70-16 65P...

  • Page 15: Torque Values

    To this chapter contents 1. GENERAL INFORMATION 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 Type Type Tighten Torque Tighten Torque 5 mm bolt、nut...
  • Page 16 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks Stopper nut for engine hanger 1.8~2.2 rubber Engine hanger nut 4.0~5.0 Engine hanger bolt 4.0~5.0 Engine connection bolt 3.5~4.5 Front wheel axle nut 5.0~7.0 Rear wheel shaft nut 10.0~12.0...
  • Page 17 To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis (Electronic Fuel Injection System) A. Engine cannot be started or difficult to be started Check and adjustment Fault condition Probable causes Press the fuel sprayer feed pipe and confirm whether there is petrol in the 1.
  • Page 18 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 causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Engine speed can not be Engine speed can be Lines in fuel tank evaporation system clogged increased.
  • Page 19 To this chapter contents 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Incorrect ignition timing (malfunction of ECU or Abnormal Normal AC generator) The gasket of the throttle body has air to suck or not 1.
  • Page 20 To this chapter contents 1. GENERAL INFORMATION E. CLUTCH AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch lining broken Driving shaft groove broken Engine can be started but motorcycle can not run Transmission gear damage Transmission gear worn out or burned...
  • Page 21 To this chapter contents 1. GENERAL INFORMATION Parts to Be Greased Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Seat catch Main stand pivot Speedometer gear/ Side stand pivot Clutch bearing front wheel bearing 1-16...
  • Page 22 Home page Contents 2. Maintenance Information Precautions in Operation€€€€€€€€€€€€€€€€€€€2-1 CVT System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-8 Periodical Maintenance Chart €€€€€€€€€€€2-2 Steering Mechanism€€€€€€€€€€€€€€€€€€€€€€€€€€€2-9 Engine Oil €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-3 Suspension System €€€€€€€€€€€€€€€€€€€€€€€€€€€2-9 Engine Oil Strainer Clean €€€€€€€€€€€€€€€€€€2-3 Disk Brake System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-10 Gear Oil €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-4 Brake Light Switch/Starting Inhibitor Switch€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-12 Fuel Line / Cable€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2-4 Headlight Beam Distance €€€€€€€€€€€€€€€€€€2-12...

  • Page 23: Maintenance Information

    To this chapter contents 2. Maintenance Information Periodical Maintenance Chart From the sales date: 3000 km-6 months / 9.000 km-18 months / 15.000 km-30 months= 6000 km-12 months / 12.000 km-24 months / 18.000 km-36 months= B The following services; A and B continuously for every +3.000 km or 6 months. The service intervals must be upheld within a maximum of + 10% C=Cleaning I=Inspection (replacement if necessary) A=Adjustment L=Lubrication R=Replacement Service...

  • Page 24: Engine Oil €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Engine Oil Turn off the engine, and situate the motorcycle vertically by main stand. Check the oil level with oil filler plug. Do not screw the oil filler plug into the engine when checking. If oil level is nearly low level, pour in the recommended oil to the upper level.

  • Page 25: Gear Oil €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Gear Oil Gear oil inspection bolt Situate the motorcycle vertically by the main stand. Turn off the engine. Inspect the gear oil level through the oil inspection bolt. Gear Oil Change Unscrew the gear oil filler bolt. Unscrew the drain bolt and drain the gear oil.

  • Page 26: Air Cleaner €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Primary adjustment should be carried out from bottom end of the throttle cable. Loosen the locknut, and adjust by turning the adjuster. Tighten the locknut, and check throttle operation condition. Adjuster Locknut Air Cleaner Air Cleaner Element Remove 9 screws from the air cleaner cover and then remove the cover.

  • Page 27: P.c.v. System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    Valve clearance (IN)：0.10‚0.02 mm. Valve clearance (EX)：0.15‚0.02 mm. Loosen fixing nut and turn the adjustment nut for adjustment. Caution  Re-check the valve clearance after tightened the fixing nut. Special tool: Tappet adjuster SYM-9001200-08 SYM-9001200-09 SYM-9001200-10 Special tool: Tappet adjuster wrench SYM-9001200...

  • Page 28: Ignition System€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Ignition System Caution  Ignition system is set by the manufacturer so it can not be adjusted.  Ignition timing check procedure is for checking whether CDI function is normal or not. Remove right side cover. Remove ignition timing inspection cap located on the right cover of the engine.

  • Page 29: Cylinder Compression Pressure€€€€€€€2

    To this chapter contents 2. Maintenance Information Cylinder Compression Pressure Warm up the engine. Turn off the engine. Remove the luggage box and the central cover. Remove the spark plug cap and the spark plug. Install the compression pressure gauge into the spark plug hole.

  • Page 30: Suspension System €€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Steering Mechanism Caution  Check all the wires and cables if they are interfered during the rotation of the steering handlebar. Make the front wheel be spaced from the ground. Turn the handlebar from right to left and check if it is turned smoothly.

  • Page 31: Disk Brake System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Disk Brake System 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.
  • Page 32 To this chapter contents 2. Maintenance Information Brake Lining Wear Lining 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  It is not necessary to remove brake hose when replacing the brake lining.

  • Page 33: Switch€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Brake Light Switch/Starting Inhibitor Stop switch Switch The brake lamp switch is to light up brake lamp as brake applied. Make sure that the engine can be started only when brake is applied. Headlight Beam Distance Turn on main switch Headlight beam adjustment.

  • Page 34: Battery €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    To this chapter contents 2. Maintenance Information Battery Open the seat. Remove 3 screws and remove the battery cover Battery cable remove： Disconnect the cable negative terminal (-), then the cable positive terminal (+) Remove the battery from the motorcycle.。 3 screws If there is some rust on battery posts, clean it with steel brush...

  • Page 35: Special Tools List €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€2

    R. crank case bearing 6201 Left crankshaft & oil seal Rocker arm shaft disassemble NAME NAME NAME assembles tool assembly socket. SYM-9614000-HMA 6201 SYM-1332100-HMA RB1 SYM-1445100 Bearing driver set Assembly directs puller Drive shaft puller NAME NAME NAME SYM-6204024 SYM-2341110 SYM-2341120- HMA RB1 2-14...
  • Page 36 Steering head top thread Bearing driver HK1516 Bearing puller 6205 NAME NAME NAME wrench SYM-9100200-HMA RB1 SYM-5320010 SYM-9100400 HMA RAI 6205 HK1516 Right crankcase cover bearing Air operated bearing puller Oil seal driver 34*52*5 NAME NAME NAME 6201 puller SYM-9614000-HMA RB1 6201...
  • Page 37 2. Maintenance Information Drive shaft & oil seal (25*40*8) Clutchspring compressor Bearing puller 6303 NAME NAME NAME socket SYM-2301000-HMA SYM-9120200-HMA RB1 SYM-6303000- A 6303 („22mm) („30mm) Bearing driver 6201 Crankcase bush puller Crankcase bush puller NAME NAME NAME SYM-9614000-6201 SYM-1120310...
  • Page 38 To this chapter contents 2. Maintenance Information Note: 2-17...

  • Page 39: Lubrication System

    Home page Contents 3. LUBRICATION SYSTEM Precautions in Operation „„„„„„„„„„„„„„„„„„„„ 3-2 Engine Oil Strainer Clean „„„„„„„„„„„„„„„„„„„„ 3-3 Troubleshooting „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3-2 Oil Pump „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3-4 Engine Oil „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3-3 Gear Oil „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3-7 Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Spray Lubrication...

  • Page 40: Precautions In Operation

    To this chapter contents 3. LUBRICATION SYSTEM Precautions in Operation General Information: This chapter contains maintenance operation  for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 1400 c.c. Change: 1200 c.c. Oil viscosity SAE 10W-40 API SL (Recommended LIQUI MOLY Racing 4T 10W-40)

  • Page 41: Engine Oil

    To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the motorcycle 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.

  • Page 42: Oil Pump

    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. Clip Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump.
  • Page 43 To this chapter contents 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.
  • Page 44 To 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.

  • Page 45: Gear Oil

    To this chapter contents 3. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device.
  • Page 46 To this chapter contents 3. LUBRICATION SYSTEM Notes:...

  • Page 47: Fuel Injection System

    Home page Contents 4. Fuel Injection System Fuel Injection System Components „„„„„„„ 4-1 Integrated Fault Diagnosis Program„ 4-37 Fuel Injection System Configuration „„„„„ 4-2 Air Cleaner „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 4-40 Operation of Fuel Injection System„„„„„„„„ 4-3 Fault Diagnosis Note„„„„„„„„„„„„„„„„„„„„„„„„„„ 4-41 Fuel Injection System Introduction „„„„„„„„ 4-4 Warning Lamp Fault Codes Differentiation „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„...

  • Page 48: Fuel Injection System Components

    To this chapter contents 4. Fuel Injection System Fuel Injection System Configuration Right MAP Sensor, ISC, Fuel Injector Fuel Pump Sensor Roll Over Sensor Left EFI Check Light TW Sensor Diagnostic Coupler TA Sensor AISV...

  • Page 49: Operation Of Fuel Injection System

    To this chapter contents 4. Fuel Injection System Operation of Fuel Injection System Crankshaft Position Sensor Manifold Absolute Pressure Sensor INJECTOR Throttle Position Sensor IGN COIL Water Engine Control Temperature Unit Sensor FUEL PUMP Sensor LAMBDA CHECK LIGHT Roll Over Sensor Air Injection AISV Solenoid Valve...

  • Page 50: Fuel Injection System Introduction

    To this chapter contents 4. Fuel Injection System Fuel Injection System Introduction Based on 4-stroke SOHC engine, displacement 300 c.c. electronically controlled fuel injection system, evaporative fuel absorbed by the activated carbon canister. The engine burns off the blow-by fuel-gas from the crankcase through the fuel-air separating device.

  • Page 51: Fuel System Outline

    To this chapter contents 4. Fuel Injection System Fuel System Outline Fuel pump Injector Fuel pump relay Power relay Battery System Description After Key-on, the sensors send signals to the ECU. ECU controls the fuel pump relay, making the fuel pump operate.

  • Page 52: Ignition System Outline

    To this chapter contents 4. Fuel Injection System Ignition System Outline Intake air temperature Manifold absolute pressure Engine coolant temperature Throttle position Ignition coil Oxygen content ACG/ Flywheel Gear (23+1 Long tooth) Power relay Battery REG. REC. Principle ECU determines the appropriate ignition timing by receiving the signals from the CPS, TPS, O Sensor, MAP Sensor, TA Sensor and TW Sensor in accordance with the engine RPM.

  • Page 53: Sensors And Drives Outline

    To this chapter contents 4. Fuel Injection System Sensors and Drives Outline Crankshaft Position Sensor (CPS) Function: CPS inducts the teeth sequence on the flywheel and transmits voltage signals to ECU to make it work properly. Crankshaft position sensor Long tooth Flywheel Note: When starting, the TDC position is not known yet;...
  • Page 54 To this chapter contents 4. Fuel Injection System Roll Over Sensor (ROS) Function: As a safety device, when the motocycle is overturned, ROS cuts off the power supply of ECU and shut down the engine. Note: When the motorcycle is leaning more than 65 degrees, the power of ECU will be shut off. To restart the engine, you need to Key-on the main switch again.
  • Page 55 To this chapter contents 4. Fuel Injection System Manifold Absolute Pressure Sensor (MAP Sensor) / Engine Coolant Temperature Sensor (TW Sensor) / Intake Air Temperature Sensor (TA Sensor) MAP Sensor TA Sensor TW Sensor TW Sensor / TA Sensor: Using negative temperature coefficient thermistor, TW Sensor and TA Sensor measure outside temperature.
  • Page 56 To this chapter contents 4. Fuel Injection System Sensor Power relay Sensor Battery Sensor Ceramic tube Electrode Exhaust gas Atmosphere Rich ← 14.7 → Lean Function: Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts the air-fuel ratio by changing the fuel injection time.
  • Page 57 To this chapter contents 4. Fuel Injection System Throttle Position Sensor (TPS) Throttle position sensor Battery TPS output voltage Throttle valve opening angle Basic Principle: TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value change, determining the throttle position.
  • Page 58 To this chapter contents 4. Fuel Injection System Idle Speed Control Valve (Stepper Motor ISC) ISC Valve Battery Step Function: ECU controls ISC stepper motor to adjust the bypass intake air quantity and stablize the idle speed. 4-12...
  • Page 59 To this chapter contents 4. Fuel Injection System Air Injection Solenoid Valve (AISV) Function: AISV introduces appropriate air quantity to reduce pollutant emission. Basic Principle: When the engine speed and throttle opening are higher than the default value, ECU controls AISV opening or closure.

  • Page 60: Precautions In Operation

    To this chapter contents 4. Fuel Injection System Precautions in Operation General Information Warning Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and flame is ● strictly prohibited when working with gasoline. Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to prevent ●...

  • Page 61: Description

    To this chapter contents 4. Fuel Injection System Fuel Injection System Components Description ECU (Engine Control Unit) Function Description: Powered by DC 8~16V, and has 36-pin socket on the unit. ● The hardware component consists of a 16-bit microcomputer that is its ●...
  • Page 62 To this chapter contents 4. Fuel Injection System Throttle Body Functional Description: Throttle body is the inlet air flow regulating device (similar to the ● carburetor). Throttle valve pivot drives the throttle position sensor synchronously ● and makes ECU detect the throttle opening immediately. Throttle valve positioning screw has been adjusted and marked on the ●...
  • Page 63 To this chapter contents 4. Fuel Injection System MAP Sensor Functional Description: Powered by 5V DC from ECU. It has 3-pin socket on the sensor. One ● terminal is for power, and 1 terminal are for signal output. And, the rest one is for ground.
  • Page 64 To this chapter contents 4. Fuel Injection System TA Sensor Functional Description:  Use ECU DC 5V power supply provided, has the two-pin coupler, a voltage output pin; another one for a grounding pin. Its main component is a negative temperature coefficient (resistance ●...
  • Page 65 To this chapter contents 4. Fuel Injection System Functional Description: Use ECU provided DC 5V power supply, has the three-pin coupler, one ● for the power supply pin; one for a voltage output pin; one for a grounding pin. Its main component is a sophisticated type of variable resistor. ●...
  • Page 66 To this chapter contents 4. Fuel Injection System Also, can be used for diagnosis tool confirm to the throttle output signal. 1. Connected to the "diagnosis tool", and open the main switch, but not to start engine. 2. "Diagnosis tool" screen switches to a "data analysis (01 / 03)" screen. 3.
  • Page 67 To this chapter contents 4. Fuel Injection System TW Sensor (Engine Coolant Temperature Sensor) Functional Description: Powered by 5V DC from ECU. It has the two-pin socket on the sensor. ● One terminal is for power output, and 1 terminal are for ground. Its main component is a negative temperature coefficient (resistance ●...
  • Page 68 To this chapter contents 4. Fuel Injection System Sensor Functional Description: Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply ● pins for heater; for a heater control pin; signal for a grounding pin; O for a signal pin.
  • Page 69 To this chapter contents 4. Fuel Injection System 3. Used the diagnosis tool to confirm of O sensor work situations: Connected the "diagnosis tool" to diagnosis coupler and open the ● main switch to start the engine. Engine to be completely warm-up (idling state operation "5 minutes" ●...
  • Page 70 To this chapter contents 4. Fuel Injection System Roll Over Sensor Functional Description: Control power of the power relay coil, has the three-pin socket. ● When vehicles lean angle greater than 65 degrees, roll over sensor will ● be the implementation of ECU system power off. At this point once again to restart the engine, the need to re-open a main switch.
  • Page 71 To this chapter contents 4. Fuel Injection System ISC Valve (stepper motor)： Functional Description: Use ECU provided power, has the four-pin socket. ● 4-pin coupler for the two motor coils of the power supply and ● grounding wire, grounding ECU power through the control and management of the stepper motor actuators.

  • Page 72: Fuel Pump

    To this chapter contents 4. Fuel Injection System Fuel Pump Functional Description:  Powered by DC 8~16V, and has four-pin socket on the pump.  The two terminals are connected to power source and ground respective. The ECU is to control and manage the operation of fuel pump through electrical power.
  • Page 73 To this chapter contents 4. Fuel Injection System Testing Procedures 3: Fuel pressure measurement: Use fuel pressure gauge, connected in series between the injector ● and the fuel tank. Cautions In the implementation of the fuel pressure measurement, will go to ●...

  • Page 74: Fuel Injector

    To this chapter contents 4. Fuel Injection System Fuel Injector Functional Description: Powered by DC 8~16V, and has two-pin socket on the injector. ● Its major component is the solenoid valve of high resistance driven by ● electronic current. The two terminals are connected to power source and ground ●...
  • Page 75 To this chapter contents 4. Fuel Injection System Ignition coil Functional Description: Use 8 ~ 16V DC power supply, has the two-pin socket. ● Two-pin socket for the power supply and grounding. Its main ● components for the high conversion ratio transformer. Through computer programs when the ignition is controlled, from ●...
  • Page 76 To this chapter contents 4. Fuel Injection System AISV Functional Description: Control power, has two-pin socket, one for the power supply pin, one ● for grounding pin. Secondary air injection solenoid valve at the Idle (3500 rpm below) ● actuator. At Idling, ECU control solenoid valve by the grounding circuit to be ●...

  • Page 77: Fuel Injection System Circuit

    To this chapter contents 4. Fuel Injection System Fuel Injection System Circuit (20A) (15A) Main (20A) switch Battery Charging Indicator Injection System Check Light MIL 21 Regulator Rectifier TSSM Test Switch Coupler Other Y Y Y appliances K-LINE Diagnostic Scanner Generator Coupler 03 CRK-P...

  • Page 78: Ecu Pin Configuration

    To this chapter contents 4. Fuel Injection System ECU Pin Configuration (ON ECU) ECU Pin Note Wire Wire Pin code Note Note color color code Drive components Power + ECU power + Pink TSSM No use Test switch signal (A/D) CRK-P Crankshaft Position Sensor- Warning Lights O/P...

  • Page 79: Fault Diagnosis

    To this chapter contents 4. Fuel Injection System Fault Diagnosis EFi Circuit Inspection Main switch on Bulbs broken? Fuse broken? Battery voltage is too low? Check light extinguished after 2 seconds? ECU Power line bad contact? Poor contact the main power switch? ECU fault？...
  • Page 80 To this chapter contents 4. Fuel Injection System Can not Start the engine or difficult to start inspection Difficulties or can not to start engine Check light extinguished after 2 Inspection process in accordance with seconds? circuit inspection 1. Use diagnosis tool to view EMS fault content Display check light Fault Code?
  • Page 81 To this chapter contents 4. Fuel Injection System Idle flameout diagnosis Throttle line is not too Idle flameout jammed to revert to full closure? 1. Link diagnosis tool to view EFI fault content 2. In accordance with Troubleshooting procedures on troubleshooting Idle CO value is set beyond the scope of (1.5% ~...
  • Page 82 To this chapter contents 4. Fuel Injection System CO value abnormal Sensor equipped with the system, in principle, not adjusted CO value, such as CO value deviated from the normal range, check Sensor and other agencies. Throttle line is not too jammed to Idle flameout revert to full closure? Link diagnosis tool to view EFI fault...

  • Page 83: Integrated Fault Diagnosis Program

    To this chapter contents 4. Fuel Injection System Integrated Failure Diagnosis Program Checking, Detection of Fault status Fault reasons Parts specifications adjusting maintenance projects determination Project and steps Use meter direct Battery voltage Battery electricity Diagnosis tool Battery ● ● ●...
  • Page 84 To this chapter contents 4. Fuel Injection System Continued from previous page Closed-loop Observation sensor sensor fault sensor ● ● ● ● systems for sensor voltage voltage is ECU fault voltage beating ● mobility changes (Standed maintained in a specifications: motorcycle so that long time within 100 ~ 900 mV...
  • Page 85 To this chapter contents 4. Fuel Injection System Remove fuel pump/fuel unit Remove side cover. Remove rear carrier Remove rear bodycover. Remove floor panel. Remove under cover. (refer to chapter 14) Fuel pump coupler Remove fuel pump lines coupler. Release the fuel tube folder, removed the fuel tube. Remove the fuel tank fixed bolts (Bolt Ž...

  • Page 86: Air Cleaner

    To this chapter contents 4. Fuel Injection System Air Cleaner Remove Remove left side body cover and luggage box. Remove rear carrier and body cover. Remove fuel gas recover tube. Remove waste gas purification system pipes. Remove TA Sensor coupler. Remove intake tube fixed bolt (boltŽ1).

  • Page 87: Fault Diagnosis Note

    To this chapter contents 4. Fuel Injection System Fault Diagnosis Note When the motorcycle injection system show the failure code, causing abnormal functioning of the engine or can not start engine, warning light at the meter will be lighting, to inform drivers to carry out maintenance.
  • Page 88 To this chapter contents 4. Fuel Injection System Check Light Fault Codes Differentiation Check light flashing mode If problem without diagnosis tool to be detected, it can be cross-access the test switch coupler, the motorcycle from the CHK lights flashing signal interpretation, and then the basis for the diagnosis of dynamic information tables on the priorities of light, and prompts you to the motorcycle to the emergence of some warning, or FLASH CODE is to determine what kind of fault, and exclusion.

  • Page 89: Fault Codes And Sensors Table

    To this chapter contents 4. Fuel Injection System Fault Codes and Sensors Table Fault Fault Description Parts to be checked codes TPS Fault Throttle position sensor and wire 0120 0105 Fault sensorand wire MAP Sensor 0115 TW Sensor Fault (Coolant) Engine temperature sensor and wire 0195 ET Sensor Fault (Cylinder Head)
  • Page 90 To this chapter contents 4. Fuel Injection System Fault Code and Warning Lamp Flashing Identification Table Fault Check Check light flashing Fault Description Parts Inspection codes light state Throttle position sensor fault Lighting Throttle position sensor and wire long 0，short 6 0120 Fault detection procedures Please refer to the "EFI System components description"...

  • Page 91: Efi Diagnostic Scanner - V70

    To this chapter contents 4. Fuel Injection System EFI Diagnostic Scanner - V70 Cable connector monitor Link cable Information transmission indicator Function set Button Button to turn the pages, and numerical adjustment Leave Executive buttom Function button Digital buttom Soft cartridge Soft cartridge slots Note: When problems arise, can be used for diagnosis tool of the fault is detected, and exclusion.

  • Page 92: Diagnostic Scanner Use Note

    3. Open the diagnosis left power switch, which turn on the LCD screen, the screen brightness adjustment knob to the appropriate brightness. 4. SYM and cartridge content display on screen (such as icon), by the beginning of the implementation of any button.
  • Page 93 To this chapter contents 4. Fuel Injection System Options main functional areas: 1. ECU ID 2. DATA STREAM 3. FREEZED DATA 4. TROUBLE CODE 5. ERASE TB CODE 6. CO ADAPTION Use "▲" "▼" button, select mobile anti-white subtitles implementation of the project, and then press the "ENTER"...
  • Page 94 DIAG. ID: 0002000000020 (Diagnosis tool ID) H/W VER: (Hardware version) S/H VER: 001 (Software Version) S/H VER: 001 (Software Version) DIAG. VER: 03 (Diagnosis Version) CALI ID: (Correction ID Code) MODEL: SYM GTS250 ECU NO: 001 NAME: HML 00203 4-48...
  • Page 95 To this chapter contents 4. Fuel Injection System 1-2. ECU Pin Assign Use "▲" "▼" button, select the ECU pin project, press the "ENTER" buttom to the implementation of the ECU pin functions. ECU pin assign total of 5 pages that can be used "◄ left" and "right ►" button, view the page note.
  • Page 96 To this chapter contents 4. Fuel Injection System 2. DATA STREAM In the directory functions used "▲" "▼" button, select "DATA STREAM" project, press the "ENTER" key to the implementation. A total of 3 pages, are able to use "◄ left" and "right ►" button, view injection system information. On the any screen, press the "EXIT"...

  • Page 97: Data Stream

    To this chapter contents 4. Fuel Injection System Data stream (1/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: Engie SPD--- RPM (Idle:1550~1750) →Engine idle speed ● FAULT NO.-------- (Normal:0) →Fault code number ●...
  • Page 98 To this chapter contents 4. Fuel Injection System Data stream (2/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: BARO------------ kPa (Above 98kPa) →Atmospheric pressure ● Intake Air---------- ƒC (Outside Temp.) →Intake air temperature ●...
  • Page 99 To this chapter contents 4. Fuel Injection System Data stream (3/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: LEARNED STEP--------------- (Set by ECU) →Idle Air Control Valve stepper motor learning ●...
  • Page 100 To this chapter contents 4. Fuel Injection System 3. FREEZED DATA Objective: When a sensor fault, the EMS system will record all the parameters of fault signals, in order to facilitate fault diagnosis. In the directory functions used "▲" "▼" button, select "FREEZED DATA" project, press the "ENTER" key to the implementation.
  • Page 101 To this chapter contents 4. Fuel Injection System 4. TROUBLE CODE In the functional directory select "TROUBLE CODE" project, press the "ENTER" button implementation, the message began to read fault. Fault Code: electronic injection system that had happened fault of the message (whether or not completion of repair).
  • Page 102 To this chapter contents 4. Fuel Injection System 5. ERASE TB CODE In the directory functions used "▲" "▼" button, select "ERASE TB CODE" project, press the "ENTER" key to the implementation. Conditions: The main switch "ON", or in the engine running state, the fault code can be removed. Fault code removed, namely showing the "ERASE TB SUCC.!".
  • Page 103 To this chapter contents 4. Fuel Injection System 6. CO ADAPTION In the directory functions used "▲" "▼" button, select "CO ADAPTION" project, press the "ENTER" buttom into the CO adjustment screen. Use "◄ left" and "right ►" or "▲" "▼" button, CO value can be adjusted. CO ADAPT: CO adjusted value.

  • Page 104: Troubleshooting Table

    To this chapter contents 4. Fuel Injection System Troubleshooting Table Test items Comprehensive testing program Parts closed- Throttle Engine Fault Power Fuel Ignition Engine Injection loop Abnormal position temp. Code voltage press. state vacuum state control phenomena Detection sensor sensor system ...

  • Page 105: Comprehensive Maintenance List

    To this chapter contents 4. Fuel Injection System Comprehensive Maintenance List Maintenance Testing Procedures Test items Determine benchmarks Fault reasons Project Power and ●Use meter direct ● Battery voltage ● Battery voltage = 10V Above ● Battery electricity measurement battery voltage ●...
  • Page 106 To this chapter contents 4. Fuel Injection System Note: 4-60...
  • Page 107 Home page Contents . Removal & Installation of Engine Operational Precautions€€€€€€€€€€€€€€€€€€€€€ 5-1 Rear Fork €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 5-8 Engine Removal €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 5-2 Removal of Engine Mount Bushing€€€€ 5-10 Engine Hanger €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 5-7 Installation of Engine€€€€€€€€€€€€€€€€€€€€€€€€€€€ 5-11 Operational Precautions General Information  Engine must be supported by a bracket or adjustable tool in height. ...

  • Page 108: Engine Removal

    To this chapter contents 5. Removal & Installation of Engine Engine Removal Negative Positive Open the seat. Remove battery cover (3 screw). Remove the battery negative (-) cable. Remove the battery positive (+) cable. Open the seat. Remove the luggage box (6 bolts). (Refer to chapter 13) Remove right and left side covers (4 screws on each side.)
  • Page 109 To this chapter contents . Removal & Installation of Engine Remove the thermo unit and TW sensor wire couplers. Thermo unit TW sensor Remove the throttle position sensor coupler. Throttle position sensor Remove the TA sensor coupler. Inlet temperature sensor Remove the AISV pipe.
  • Page 110 To this chapter contents 5. Removal & Installation of Engine Remove AC generator and crankshaft position sensor AC generator and crankshaft coupler. position sensor coupler Remove the start motor wire from the start relay. Start motor wire sensor coupler Remove sensor wire coupler.
  • Page 111 To this chapter contents . Removal & Installation of Engine Loosen 3 screws from rear mudguard. Remove the air cleaner connection bolts (2 bolts). Remove the air cleaner. 2 bolts Loosen the 3 bolts from muffler. Loosen the muffler band bolt (1 bolt). Remove the muffler.
  • Page 112 To this chapter contents 5. Removal & Installation of Engine Remove the right rear cushion lower bolt (1 bolt). rear cushion lower bolt 2 bolts Remove the rear fork bolts (2 bolts). Remove the rear wheel axle nut (1 nut). wheel axle nut Remove rear brake hose clamp and rear brake caliper.(2 bolts)

  • Page 113: Engine Hanger

    To this chapter contents . Removal & Installation of Engine Remove left rear cushion lower bolt (1 bolt). 1 bolt Remove frame side engine hanger bolts (each Frame side bolt side 1 bolt), and then remove engine. Engine Hanger Engine side bolt Removal Remove the engine side bolts of engine hanger.

  • Page 114: Rear Fork

    Drive the bearing out of the rear fork. Bearing installation Install new rear axle bearing and baring puller into rear fork. Special Service Tools: Rear fork bearing puller SYM-6303000-6303 6303 bearing puller Install the washer of the 6303 bearing puller. 6303 bearing puller washer...
  • Page 115 . Removal & Installation of Engine Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Bearing puller Use screw driver holder bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing.

  • Page 116: Removal Of Engine Mount Bushing

    Place the detent section of the bushing remover toward the bushing, and drive both the pressing ring and bolt in to press the bushing out. Special Service Tools: Crankcase bushing remover SYM-1120310 Crankcase bushing remover SYM-1120320 Pressing In Place the flat section of the remover toward the bushing, and then drive the bushing, pressing ring, and bolt in to install the bushing.

  • Page 117: Installation Of Engine

    To this chapter contents . Removal & Installation of Engine Installation of Engine Install the engine according to the reversing order of removal. Caution Note both feet and hands safety for  squeezing as engine installation. Do not bent or squeeze each wires or hose. ...

  • Page 118: Mechanism Diagram

    Home page Contents . Cylinder Head / Valve Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€ 6-1 Valve Stem Replacement€€€€€€€€€€€€€€€€€€€ 6-10 Precautions in Operation €€€€€€€€€€€€€€€€€€€ 6-2 Valve Seat Inspection and Service €€€ 6-11 Troubleshooting€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 6-3 Cylinder Head Reassembly €€€€€€€€€€€€€€€ 6-13 Cylinder Head Removal €€€€€€€€€€€€€€€€€€€€€€ 6-4 Cylinder Head Installation €€€€€€€€€€€€€€€€€...

  • Page 119: Precautions In Operation

    To this chapter contents 6. Cylinder Head / Valve Precautions in Operation General Information  This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm.  Cylinder head service can be carried out when engine is in frame. Specification Item Standard...

  • Page 120: Troubleshooting

    To this chapter contents . 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.

  • Page 121: Cylinder Head Removal

    To this chapter contents 6. Cylinder Head / Valve Cylinder Head Removal Remove engine. (Refer to chapter 5) Tensioner bolts Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.
  • Page 122 To this chapter contents . Cylinder Head / Valve Remove the side cover mounting blots of cylinder 3 bolts head, and then take out the side cover. Remove left crankcase cover, and turn the Timing mark Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position.

  • Page 123: Cylinder Head Disassembly

    Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.
  • Page 124 To this chapter contents . Cylinder Head / Valve Remove valve cotters, spring retainers, springs Inlet valve Inner spring Spring retainer and valves. Exhaust valve Cotter Outer spring Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.

  • Page 125: Cylinder Head Inspection

    To this chapter contents 6. Cylinder Head / Valve Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.05 mm Camshaft Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm...
  • Page 126 To this chapter contents . Cylinder Head / Valve Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: Inner spring 35.20 mm Outer spring 36.90 mm Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure &...

  • Page 127: Valve Stem Replacement

    To this chapter contents 6. Cylinder Head / Valve Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated Valve guide driver 5.0mm plate or toaster. Caution  Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it.

  • Page 128: Valve Seat Inspection And Service

    To this chapter contents . 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.
  • Page 129 To this chapter contents 6. Cylinder Head / Valve Use 60ƒ cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60‚ Use 45ƒ cutter to grind the valve seat to specified width.

  • Page 130: Cylinder Head Reassembly

    Special Service Tool: Valve cotter remove Valve cotter remove & assembly tool and assembly tool SYM-1471110-SY125 Tap the valve stems gently with a plastic hammer to make sure valve retainer and valve cotter is settled. Caution  Place and hold cylinder head on to working table so that can prevent from valve damaged.

  • Page 131: Cylinder Head Installation

    To this chapter contents 6. Cylinder Head / Valve Install camshaft into cylinder head. 2 bolts Cam shaft setting plate Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head.
  • Page 132 To this chapter contents . Cylinder Head / Valve Install cylinder head side cover (3 bolts). 3 bolts Tensioner bolts Install thermostat (2 bolts). Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt.

  • Page 133: Valve Clearance Adjustment

    To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment 4 bolts Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover. Remove the cylinder head side cover. 3 bolts Timing mark Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position.
  • Page 134 Home page Contents 7. Cylinder / Piston Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€€ 7-1 Piston Ring Installation €€€€€€€€€€€€€€€€€€€ 7-6 Precautions in Operation €€€€€€€€€€€€€€€€€€€€ 7-2 Piston Installation €€€€€€€€€€€€€€€€€€€€€€€€€€€€ 7-7 Trouble Diagnosis€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 7-2 Cylinder Installation €€€€€€€€€€€€€€€€€€€€€€€€€ 7-7 Cylinder and Piston Removal €€€€€€€€€€€€€ 7-3 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m...

  • Page 135: Precautions In Operation

    To this chapter contents 7. Cylinder / Piston Precautions in Operation General Information  Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit：mm Item Standard Limit 72.995~73.015 73.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston...

  • Page 136: Cylinder And Piston Removal

    To this chapter contents 7. Cylinder / Piston Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
  • Page 137 To this chapter contents 7. Cylinder / Piston Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.
  • Page 138 To this chapter contents 7. Cylinder / Piston Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.

  • Page 139: Piston Ring Installation

    To this chapter contents 7. Cylinder / Piston 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. Caution  Do not damage piston and piston rings as installation. ...

  • Page 140: Piston Installation

    To this chapter contents 7. Cylinder / Piston Piston Installation IN mark Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve. Install new piston pin clip. Clip end gap Caution ...
  • Page 141 To this chapter contents 7. Cylinder / Piston Coat some 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. Caution  Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
  • Page 142 Home page Contents . V-Belt Driving System Mechanism Diagram€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 8-1 Drive Belt €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€8-5 Maintenance Precaution €€€€€€€€€€€€€€€€€€€€€ 8-2 Drive Face€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€8-7 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 8-2 Clutch Outer / Driven Pulley€€€€€€€€€€€€€€€€8-10 Left Crankcase Cover€€€€€€€€€€€€€€€€€€€€€€€€€€ 8-3 Mechanism Diagram 5.0~6.0kgf-m 8.5~10.5kgf-m 5.0~6.0kgf-m...

  • Page 143: Maintenance Precaution

    Weight of weight roller 17.700~18.300 17.200 Torque value Special Service Tools  Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000  Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002  Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200...

  • Page 144: Left Crankcase Cover

    To this chapter contents . V-Belt Driving System Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket. 8 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
  • Page 145 If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Bearing replacement Remove bearing with special service tools Special tools: Inner bearing puller SYM-6204022 Install bearing with special service tools. Special tools: Right crank case bearing 6201 assembles tool SYM-9614000-HMA 6201...

  • Page 146: Drive Belt €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€8-5

    To this chapter contents . V-Belt Driving System Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool：universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer. Bearing stay collar Universal holder Caution...
  • Page 147 To this chapter contents 8. V-Belt Driving System Installation Caution  Pull out driven face to avoid it closing.  Cannot oppress friction plate comp in order to Driven face avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.

  • Page 148: Drive Face€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€8-7

    To this chapter contents . V-Belt Driving System Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Movable drive face Remove movable drive face comp and drive face boss from crankshaft.
  • Page 149 To this chapter contents 8. V-Belt Driving System Inspection Weight roller 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.
  • Page 150 To this chapter contents . V-Belt Driving System 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. Drive face boss Install movable drive face comp.

  • Page 151: Clutch Outer / Driven Pulley€€€€€€€€€€€€€€€€8-10

    To this chapter contents 8. V-Belt Driving System Clutch Outer/Driven Pulley Clutch nut wrench 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. Caution ...
  • Page 152 To this chapter contents . V-Belt Driving System Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.400 mm Free length Driven pulley...
  • Page 153 To this chapter contents 8. V-Belt Driving System Clutch weight Replacement Remove snap ring and washer, and then remove Spring Driving plate clutch weight and spring from driving plate. Caution  Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
  • Page 154 To this chapter contents . V-Belt Driving System Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Caution  If the inner bearing equipped with oil seal on Outer bearing Clipper side in the driven pulley, then remove the oil seal firstly.
  • Page 155 To this chapter contents 8. V-Belt Driving System Installation of Clutch Outer/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face.

  • Page 156: Final Drive Mechanism

    Home page Contents . Final Drive Mechanism Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 9-1 Inspection of Final Drive Mechanism€€€€€€€€€€€ 9-4 Precautions in Operation€€€€€€€€€€€€€€€€€€€€€€€€€€ 9-2 Bearing Replacement€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 9-5 Trouble Diagnosis€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 9-2 Re-Assembly of Final Drive Mechanism €€€€€€ 9-8 Disassembly of Final Drive Mechanism €€ 9-3 Mechanism Diagram Final shaft Final gear...

  • Page 157: Precautions In Operation

    Oil quantity: 180 c.c. (170 c.c. when replacing) Torque value Gear box cover 2.6~3.0kgf-m Special tools Bearing driver SYM-6204024 Bearing (6205) puller SYM-9100400 HMA RA1 6205 Drive shaft & oil seal (25*40*8) socket SYM-9120200-HMA Bearing (HK1516) driver SYM-9100200-HMA HK1516 Oil seal drive 34*52*5 SYM-9125500-HMA Inner bearing puller...

  • Page 158: Disassembly Of Final Drive Mechanism

    To this chapter contents . Final Drive Mechanism Disassembly of Final Drive Mechanism Remove the rear wheel. Remove the clutch. Drain out gear oil from gear box. Loosen 7 bolts and remove gear box cover bolts. 7 bolts Remove the gear box cover. Remove the gasket &...

  • Page 159: Inspection Of Final Drive Mechanism

    To this chapter contents 9. Final Drive Mechanism Inspection of Final Drive Mechanism Check if the drive shaft is worn or damaged and replace it if necessary. Caution  If remove the drive shaft from the gear box upper side, then its bearing has to be replaced.

  • Page 160: Bearing Replacement

    Shaft protector SYM-6204010 Remove final shaft bearing and counter shaft bearing from left crankcase using following tools. Special tool: Inner bearing puller SYM-620422 Inner bearing puller Caution  Never install used bearings. Once bearing removed, it has to be replaced with new one.
  • Page 161 Gear box cover side Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Inner bearing puller Remove oil seal, and then remove final shaft bearing from gear box cover using following tools.
  • Page 162 Apply with grease onto final shaft oil seal. Install the oil seal into gear box cover. Special tool: Oil seal driver 34*52*5 SYM-9125500-HMA Oil seal driver...

  • Page 163: Re-Assembly Of Final Drive Mechanism

    Drive shaft and seal install socket Mechanism Install drive shaft. Special tool: Drive shaft puller SYM-2341110- HMA RB1 Drive shaft socket & oil seal driver (25*40*8) SYM-9120200-HMA Clutch nut wrench SYM-9020200 Drive shaft puller Apply with grease onto drive shaft oil seal.
  • Page 164 Home page Contents 10. AC Generator / Starting Clutch Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€10-1 Flywheel Removal €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 10-5 Precautions in Operation €€€€€€€€€€€€€€€€€€€10-2 Starting Clutch€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 10-6 Right Crankcase Cover Removal €€€€€€10-3 Flywheel Installation €€€€€€€€€€€€€€€€€€€€€€€€€€ 10-8 AC Generator Removal€€€€€€€€€€€€€€€€€€€€€€€10-4 AC Generator Installation €€€€€€€€€€€€€€€€€€ 10-9 Right Cover Bearing €€€€€€€€€€€€€€€€€€€€€€€€€€€10-4 Right Crankcase Cover Installation €€...

  • Page 165: Precautions In Operation €€€€€€€€€€€€€€€€€€€10-2

    5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.8~2.2kgf-m Special tools AC.G. flywheel puller SYM-3110000-HMA Left crank case cover 6201 bearing puller SYM-9614000-HMA RB1 6201 Inner bearing puller SYM-6204025 Universal holder SYM-2210100 10-2...

  • Page 166: Right Crankcase Cover Removal

    To this chapter contents 10. AC Generator / Starting Clutch Right Crankcase Cover Removal Remove right side cover. Remove seat and luggage box (Refer chapter 13) Remove the exhaust muffler (3 bolts, 2 nuts). 2 nuts 3 bolts Drain out the engine oil and coolant (refer chapter Remove coolant hoses.
  • Page 167 Remove the bearing 6201 with inner bearing puller. Special tool: Inner bearing puller SYM-6204025 Inner bearing puller Install the bearing 6201 bearing with special tool. Special tool: Right crankcase cover bearing 6201 presser SYM-9614000-HMA RB1 6201 Inner bearing presser 10-4...

  • Page 168: Flywheel Removal

    Install shaft protector onto the crank shaft. Special tool: Shaft protector Shaft protector Reduction gear Remove starter reduction gear and shaft. Pull out flywheel with AC generator flywheel puller. Special tool: Flywheel puller SYM-3110000-HMA Flywheel puller Remove flywheel and starting driven gear. 10-5...

  • Page 169: Starting Clutch

    To this chapter contents 10. AC Generator / Starting Clutch Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 25.050 mm OD: 42.100 mm Check the starting reduction gear and shaft for wear or damage.
  • Page 170 To this chapter contents 10. AC Generator / Starting Clutch Remove the starting gear Loosen 3 starting clutch socket bolts from one way clutch and remove one way clutch. 3 bolts Push out the roller set and check each roller for wear or damage.

  • Page 171: Flywheel Installation

    Install starting driven gear onto one way clutch. Align the key on crankshaft with the flywheel Groove groove, and then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Torque value: 5.0~6.0kgf-m Special tool: Universal Holder SYM-2210100 10-8...

  • Page 172: Ac Generator Installation

    To this chapter contents 10. AC Generator / Starting Clutch AC Generator Installation 3 screws Install the AC Generator coil onto right crankcase cover (3 screws). Install the CPS (2 screws). Tie the wire harness securely onto the indent of crankcase.
  • Page 173 To this chapter contents 10. AC Generator / Starting Clutch Notes: 10-10...
  • Page 174 Home page Contents 11. Crankcase / Crank Mechanism Diagram€€€€€€€€€€€€€€€€€€€€€€€€€€€11-1 Crankcase Disassembly€€€€€€€€€€€€€€€€€€€€ 11-3 General Information €€€€€€€€€€€€€€€€€€€€€€€€€€€11-2 Crankshaft Inspection €€€€€€€€€€€€€€€€€€€€€€€ 11-4 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€11-2 Crankcase Reassembly€€€€€€€€€€€€€€€€€€€€€ 11-6 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 0.8~1.2kgf-m 11-1...

  • Page 175: General Information €€€€€€€€€€€€€€€€€€€€€€€€€€€11-2

    1.2~1.6kgf-m Special tools R/L. crank disassemble tool SYM-1120000-HMA H9A L. crank shaft bearing puller SYM-9100100 Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Crank shaft puller SYM-1130000-HMA H9A Outer bearing puller SYM-6204010 Inner bearing puller SYM-6204025 Clutch nut wrench...

  • Page 176: Crankcase Disassembly

    Hold left crank shaft puller nut by clutch nut wrench, and turn the shaft puller to press out crank shaft from left crankcase. Special tool: Crank case disassemble SYM-1120000-HMA H9A L. Crank shaft puller SYM-1130000-HMA H9A Crank case disassemble tool Clutch nut wrench...

  • Page 177: Crankshaft Inspection

    To this chapter contents 11. Crankcase / Crank Remove crankshaft and wave washer 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.
  • Page 178 Check the inner ring to see it links firmly on the bearing. Crank bearing If any roughness, noise and loose linkage are Out bearing puller detected, replace the bearing with new one. Caution  The bearing shall be replaced in pair. Special tool: Outer bearing puller SYM-6204010 11-5...

  • Page 179: Crankcase Reassembly

    Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Crank shaft install socket Turn in the crank shaft puller spiral tooth to the left crank shaft. Special tool: L. Crank shaft puller SYM-1130000-HMA H9A Crank shaft puller 11-6...
  • Page 180 To this chapter contents 11. Crankcase / Crank Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft into left crankcase. Crank shaft puller Put wave washer onto right crank bearing. Caution ...
  • Page 181 Install the oil seal in the left crankcase with special Oil seal driver tool. Special tool: Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Setting plate Tensioner Install the cam chain tensioner & and tighten the bolts.

  • Page 182: Cooling System

    Home page Contents 12. Cooling System Mechanism Diagram€€€€€€€€€€€€€€€€€€€€€€€€€€€12-1 Coolant Replacement €€€€€€€€€€€€€€€€€€€€€€€€ 12-5 General Information €€€€€€€€€€€€€€€€€€€€€€€€€€€12-2 Radiator €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 12-6 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€12-2 Water Pump €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 12-8 Cooling System Fault Elimination€€€€€12-3 Thermostat €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 12-12 Mechanism Diagram Reserve tank filler cap Reserve tank Reserve tank inlet pipe Thermo switch (fan) Cooling fan...

  • Page 183: General Information €€€€€€€€€€€€€€€€€€€€€€€€€€€12-2

    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 ...
  • Page 184 To this chapter contents 12. Cooling System Cooling System Fault Elimination The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.
  • Page 185 To this chapter contents 12. Cooling System Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12→ 0V)? temperature gauge over 3 checks? E-2.

  • Page 186: Coolant Replacement

    To this chapter contents 12. Cooling System Coolant Replacement Warning  Never attempt to carry out service work on the cooling system unless the engine is completely cooled down, otherwise, you may get scalded. Remove the reserve tank cap cover, and then remove tank cap.

  • Page 187: Radiator

    To this chapter contents 12. Cooling System Check reserve tank  Open the inner box lid.  Check the coolant level in the reserve tank.  Add coolant to proper level if too low. Caution  Do not make the coolant level in the reserve tank too high.
  • Page 188 To this chapter contents 12. Cooling System Disconnect the couplers for the thermo switch and Thermo switch coupler fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Engine coolant inlet pipe Cooling fan coupler Remove reserve tank coolant inlet pipe.

  • Page 189: Water Pump

    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. ...
  • Page 190 Drive the mechanical seal and inner seal out of the right crankcase. Special tools: Inner bearing puller Water pump bearing drive SYM-9100100 Caution  Replace a new mechanical seal after removing it. Mechanical seal Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new mechanical seal.
  • Page 191 Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) SYM-9120500-H9A Install a new outside bearing to the right crankcase cover. Special tools: Water pump bearing Water pump bearing driver (6901)
  • Page 192 To this chapter contents 12. Cooling System Install the seal washer into the rotor. Caution  Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and Water pump rotor tighten. Torque Value: 1.0~1.4kgf-m Caution ...

  • Page 193: Body Cover

    To this chapter contents 12. Cooling System Thermostat Thermo unit Please refer to chapter 17 for inspection of thermo unit. Removal Remove the luggage box and body cover. Drain out the coolant. Remove the thermostat cover. (2 bolts) 2 bolts Remove the thermostat.
  • Page 194 To this chapter contents 12. Cooling System Place the thermostat into heated water to check its operation. 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,...
  • Page 195 To this chapter contents 12. Cooling System Notes: 12-14...
  • Page 196 Home page Contents 13. Body Cover Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€13-1 Front Under Spoiler €€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-10 Maintenance €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-2 Side Garnish€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-10 Handle Front Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€13-3 Front Fender€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-11 Wind Screen €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-4 Luggage Box €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-12 Front Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-4 Rear Carrier €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-13 Handle upper cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€13-5 Rear Body Cover€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€...

  • Page 197: Wind Screen €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-4

    To this chapter contents 13. Body Cover Maintenance Body covers disassemble sequence: Front cover lid Luggage box & seat Wind screen garnish Front cover Rear carrier Wind screen Inner box Rear fender Handle lower covers Handle under cover Rear body cover Handle upper cover R/L.

  • Page 198: Handle Front Cover

    To this chapter contents 13. Body Cover Handle Front Cover Remove Loosen 2 screw bottom of front handle cover Loosen 2 screws from left and right side for handle front cover after side Wind Screen Lift and right 2 screws Remove the 5 screws from to meter visor.

  • Page 199: Front Cover

    To this chapter contents 13. Body Cover Front Cover Remove Loosen 2 screws from the front cover emblem. 2 screws Loosen 3 bolts from the front cover front end. 3 bolts Loosen 8 screws from each side 4 screws for front cover after side Disassemble the headlight coupler Remove the front cover.

  • Page 200: Handle Upper Cover

    To this chapter contents 13. Body Cover Handle upper cover Disassemble the speedometer set couplers speedometer set couplers Loosen 2 screws from the handle front cover upper side. winker relay coupler 2 screw Remove the 4 screw from the handle lower cover rear side.

  • Page 201: Handle Lower Cover

    To this chapter contents 13. Body Cover Handle lower cover Loosen the 2 screws from handle lower cover. screws Remove the handle stand nut and bolt. Improve the direction handle up. Stand nut and Remove the handle lower cover. bolt Installation Install in reverse order of removal procedures.

  • Page 202: Inner Box

    To this chapter contents 13. Body Cover Inner Box Remove Remove 1 screw on the fuse box stay and . 1 screw on the reserve tank stay. Remove the dc power outlet connect. power outlet connect Remove main switch cap bolt then remove main switch cap.
  • Page 203 To this chapter contents 13. Body Cover Reserve Remove fuel tank cap and rubber. tank Loosen 1 screw and 1 bolt from left and right side for inner box down side 1 bolt Remove reserve tank cap then separate the reserve Reserve tank cap Remove the inner box.

  • Page 204: Side Cover

    To this chapter contents 13. Body Cover Side Cover Remove: Loosen 1 screw from left and right side for side covers font side. Loosen 1 screw from left and right side for side covers rear upper side. Remove side cover. Installation Install in reverse order of removal procedures.

  • Page 205: Side Garnish

    To this chapter contents 13. Body Cover Front Under Spoiler 1 screw Remove Remove the side cover. Loosen 1 screws and 1 bolt from the front spoiler front side. 1 screw Remove the front spoiler. Installation Install in reverse order of removal procedures. Side Garnish Loosen 1 screw from left and right side for side 1 screw...

  • Page 206: Front Fender

    To this chapter contents 13. Body Cover Front Fender Each side 2 bolt Remove front fender B Loosen each side 2 bolts from front fender B. Remove the front fender B. Installation Install in reverse order of removal procedures. Remove front fender A Loosen 3 bolts from the front fender above the inside Loosen 2 screws from the front fender above the...

  • Page 207: Luggage Box

    To this chapter contents 13. Body Cover Luggage Box screws Remove Open the seat. Loosen 3 screws from the battery cover. Remove the battery cover. 6 bolts Loosen 6 bolts from luggage box. Disconnect the luggage box light and switch coupler.

  • Page 208: Rear Carrier

    To this chapter contents 13. Body Cover Rear Carrier Loosen 1 screw front the rear center cover. Loosen 2 bolts front tail light upper side. 2 bolts Tail each side 2 bolts Loosen each side 2 bolts from body inside. Remove the rear carrier.

  • Page 209: Rear Body Cover

    To this chapter contents 13. Body Cover Rear Body Cover floor panel Remove Loosen Each side 2 screws from rear end of floor panel. Each side 2 screws Loosen 2 bolts from rear fender. 2 bolts Disconnect the tail light coupler. coupler Tail light Remove the body cover.

  • Page 210: Floor Panel

    To this chapter contents 13. Body Cover Floor Panel Remove Remove side garnish, front cover, front spoiler, R/L side cover, inner box, luggage box and body cover. Remove each side 2 caps from floor panel. Each side 2 caps 4 bolts Loosen 4 bolts from floor panel Loosen each side 1 screws from floor panel rear side.

  • Page 211: Under Cover

    To this chapter contents 13. Body Cover Under Cover Each side 2 bolts from under cover. Each side 2 bolts Remove the under cover. Installation Install in reverse order of removal procedures. 13-16...

  • Page 212: Brake System

    Home page Contents 14. Brake System Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€€ 14-1 Brake Fluid Replacement €€€€€€€€€€€€€€€€€€ 14-6 Maintenance Description €€€€€€€€€€€€€€€€€€€€ 14-2 Front Brake Caliper€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 14-7 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 14-3 Rear Brake Caliper€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 14-8 Disk Brake System Inspection€€€€€€€€€€€€ 14-4 Brake Disk €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 14-9 Adding Brake Fluid€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€...
  • Page 213 To this chapter contents 14. Brake System Maintenance Description Operational precautions Caution  Inhaling brake dust 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. ...

  • Page 214: Trouble Diagnosis

    To this chapter contents 14. Brake System Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8.

  • Page 215: Disk Brake System Inspection

    To this chapter contents 14. Brake System 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.

  • Page 216: Adding Brake Fluid

    To this chapter contents 14. Brake System Adding Brake Fluid Front brake master cylinder 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.

  • Page 217: Brake Fluid Replacement

    To this chapter contents 14. Brake System Brake fluid replacement Brake bleeder valve Connect drain hose to brake bleeder valve. Open the valve on the calipers and delay valve the brake lever until the old brake fluid is entirely drained out. Close the valve and add specified brake fluid into the brake master cylinder.

  • Page 218: Front Brake Caliper

    To this chapter contents 14. Brake System Front Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the brake hoses. Caution  Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.

  • Page 219: Rear Brake Caliper

    To this chapter contents 14. Brake System Rear Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution  Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.

  • Page 220: Brake Disk

    To this chapter contents 14. Brake System Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: Front brake disk 2.5 mm Micrometer...

  • Page 221: Master Cylinder

    To this chapter contents 14. Brake System Remove the rubber pad. Remove the cir clip. Cir clip Rubber Remove the piston and the spring. boot Clean the master cylinder with recommended Piston brake fluid. Piston Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
  • Page 222 To this chapter contents 14. Brake System 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 light switch. 2 bolts Connect brake hoses with 2 new washers.
  • Page 223 To this chapter contents 14. Brake System Note: 14-12...
  • Page 224 Home page Contents 15. Steering / Front Wheel / Front Cushion Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-1 Front Wheel €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-5 Operational Precautions €€€€€€€€€€€€€€€€€€€€€ 15-2 Front Cushion €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-8 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-2 Steering Stem€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-9 Steering Handle €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 15-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 2.4~3.0kgf-m...

  • Page 225: Trouble Diagnosis

    Locating screw for the speedometer cable 0.15 ~0.3kgf-m Front cushion upper lock bolt 2.4 ~ 3.0kgf-m Front brake disk 4.0~4.5kgf-m Special Tools Steering handle top thread wrench SYM-5320000、SYM-5321100 Inner bearing puller SYM-6204020 Steering nut wrench SYM-6204010 Driver 32*35mm Driver 42*47mm Trouble Diagnosis...

  • Page 226: Steering Handle

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Steering Handle Master cylinder Remove Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake.
  • Page 227 To this chapter contents 15. Steering / Front Wheel / Front Cushion Loosen 2 bolts from the master cylinder of the rear Master cylinder brake. Remove holder and master cylinder. Holder 2 bolts Loosen left handle switch connecter. Loosen 2 screws from left side handle switch holder.

  • Page 228: Front Wheel

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Wheel 2 screws Loosen 2 bolts from the front brake caliper and remove it Caution  Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out.
  • Page 229 Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) Inner bearing Disassembly puller Remove brake disk (5 bolts). Remove dust seal, bearing and dist collar from left side. Remove dust seal and bearing from right side. Special tools: Inner bearing puller SYM-6204020 15-6...
  • Page 230 To this chapter contents 15. Steering / Front Wheel / Front Cushion Assembly Dist collar Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist. collar. Bearing Install the right side bearing. 6202U Caution ...

  • Page 231: Front Cushion

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Cushion 2 bolts Remove Remove front cover, front under spoiler and front fender. Remove front wheel. Remove front brake caliper. Remove speedometer cable. Speedometer cable 4 bolts Loosen 4 bolts from steering stem.

  • Page 232: Steering Stem

    Caution  Place the steel ball onto a parts container to prevent from missing. Special tools: Steering stem top thread wrench SYM-5320010 Handle stand nut wrench SYM-5321100 Handle stand nut wrench Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats.
  • Page 233 To this chapter contents 15. Steering / Front Wheel / Front Cushion Lubricate the top cone race seat with grease. Steering lock nut Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turns.
  • Page 234 Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€16-1 Rear Wheel €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 16-3 Operational Precaution €€€€€€€€€€€€€€€€€€€€€€16-2 Rear Fork €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 16-5 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€16-2 Rear Cushion€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 16-6 Muffler€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€16-3 Mechanism Diagram 11.0~13.0kgf-m 3.5~4.5kgf-m 2.4~3.0kgf-m 4.0~5.0kgf-m 4.0~5.0kgf-m 16-1...

  • Page 235: Operational Precaution €€€€€€€€€€€€€€€€€€€€€€16-2

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit...

  • Page 236: Muffler€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€16-3

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Muffler Removal Loosen the 1 mounting bolt by exhaust muffler front side. Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler. Installation Install in reverse order of removal procedures. Caution 3 bolts 1 bolt...
  • Page 237 16. Rear Wheel / Rear Fork / Rear Cushion Inspection rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm Installation Install in reverse order of removal procedures. Torque Value: Rear wheel axle nut 11.0~13.0kgf-m...

  • Page 238: Rear Fork

    (6303) onto rear fork. Install assembly directs puller bearing puller. Special Service Tools: Rear fork bearing 6303 bearing puller SYM-6303000-HMA H9A 6303 Assembly directs puller SYM-2341110 Use screw driver hold bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing.

  • Page 239: Rear Cushion

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Install the bearing lock cir clip. Cir clip Outside collar Bearing (6303UU) Inside collar Rear Cushion Left Removal Upper bolt Remove the luggage box, rear carrier and body covers.

  • Page 240: Electrical System

    Home page Contents 17. Electrical System Mechanism Diagram-LH30W €€€€€€€€€€€17-2 Starting System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-11 Maintenance Data €€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-2 Meters €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-13 Technical Specification€€€€€€€€€€€€€€€€€€€€17-2 Light / Bulb€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-15 Trouble Diagnosis €€€€€€€€€€€€€€€€€€€€€€€€€€€€17-3 Switch / Horn€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-18 Battery €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-4 Fuel Unit €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-20 Fuse €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-5 Cooling Fan Thermo Switch €€€€€€€€€€€€17-21 Charging System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-6 Thermo Unit €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-22 Ignition System€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€17-9...

  • Page 241: Technical Specification

    To this chapter contents 17. Electrical System 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. ...
  • Page 242 To this chapter contents 17. Electrical System Trouble Diagnosis No voltage Intermittent power supply  Battery discharged  The connector of the charging system becomes  The cable disconnected loose  The fuse is blown  Poor connection of the battery cable ...
  • Page 243 To this chapter contents 17. Electrical System Battery Removal Open the seat. Loosen 3 screw and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery. Voltage Check Use the digital voltmeter to check the voltage of the battery.
  • Page 244 To this chapter contents 17. Electrical System FUSE Fuse circuit diagram 17-5...

  • Page 245: Charging System

    To this chapter contents 17. Electrical System Charging System Charging circuit Main switch Reg. Rec. Fuse 15A AC. G. Fuse 30A Starting relay Battery Charging system Black lamp Green Starting motor Yellow Regulator rectifier Inspection (KΩ) ∞ ∞ ∞ ∞ ∞...
  • Page 246 To this chapter contents 17. Electrical System Inspection on AC. Generator coil Remove the luggage box, rear carrier and body covers. Ω Disconnect 3 pin couplers of the generator coil. Connect an ohmmeter to the each terminal end. Ω Check the continuity of the each terminal end, and Ω...
  • Page 247 To this chapter contents 17. Electrical System Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...

  • Page 248: Ignition System

    To this chapter contents 17. Electrical System Ignition System Main switch Side stand Roll over sensor Power relay switch GR/L Fuse 15A Engine stop switch Fuse 20A Ignition coil AC. G. Battery Tachometer ECU. coupler (ECU. side) 01 pin(R/Y)： Drive components Power. 03 pin(G/W)：...
  • Page 249 To this chapter contents 17. Electrical System Inspection on ignition coil Remove the right floor garnish. Disengage the connector of the ignition coil. Measure the resistance between the terminals of the primary winding. Standard resistance: 2.8ƒ15% Ω (20‡C) Replacement on ignition coil Remove the cap from the spark plug.

  • Page 250: Starting System

    To this chapter contents 17. Electrical System Starting System Starting circuit diagram Front brake switch Fuse 20A Main switch Brake light Rear brake switch Start relay Battery Side stand switch Start switch Engine stop relay Start motor Engine stop switch White Black Blue...
  • Page 251 To this chapter contents 17. Electrical System 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 green/yellow cable to the battery negative terminal.
  • Page 252 To this chapter contents 17. Electrical System Meters Meter circuit diagram Meter (Ignition) Fuse 15A Main switch Turn right indicator Fuse 20A Turn left indicator Thermo sensor Eng. temperature Fuel injection indicator indicator Battery Fuel unit Fuel indicator Meter illumination Speed sensor GR/W Speedometer...
  • Page 253 To this chapter contents 17. Electrical System Removal of meter Remove front cover, handle front cover, handle upper cover. (Refer chapter 14) Disconnect the coupler of the speedometer, and take off the meter. Meter coupler 4 screws Loosen 4 screws from meter panel. Remove the speedometer.
  • Page 254 To this chapter contents 17. Electrical System Light / Bulb Headlight and foggy light circuit diagram White Black Blue (Headlight) Green Brown Fuse 20A Lo-beam relay Head light Control Hi-beam light Beam switch Main switch Light switch Fuse 15A High beam indicator Fan fuse 15A Position &...
  • Page 255 To this chapter contents 17. Electrical System Headlight bulbs replacement Setting stay Remove front cover. (Refer chapter 13) Disconnect the rubber sleeve and the terminal coupler from the headlight. Remove setting stay and take out the headlight bulb. Replace with new bulb if necessary. Specification: Lo-beam bulb 12V 35W...
  • Page 256 To this chapter contents 17. Electrical System Front winker light and Position light bulb Front winker light Replacement Remove front cover. (Refer chapter 13) Position light Disconnect the rubber sleeve and turn the foggy Front winker light bulb Position light bulb light bulb seat in C.C.W.
  • Page 257 To this chapter contents 17. Electrical System Switch / Horn Main switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below BAT1 BAT2 Position LOCK 1 blot 2 blots Wire Color Black Blake Replacement of main switch...
  • Page 258 To this chapter contents 17. Electrical System High and low Left handle switch Passing beam switch Remove the handle cover and front cover. Disconnect the coupler of left handle switch. Check the continuity between two points as indicated in the table below High and low beam switch PASS Position...
  • Page 259 To this chapter contents 17. Electrical System Fuel Unit Fuel unit 6 bolts Open the seat. Remove the luggage box. Remove the rear carrier. Remove right & left side cover. Remove the body cover Remove the floor panel. Disconnect the coupler of the fuel unit. Loosen 6 bolts from fuel unit and remove it.
  • Page 260 To this chapter contents 17. Electrical System Cooling Fan Thermo Switch 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.
  • Page 261 To this chapter contents 17. Electrical System Thermo Unit Thermo sensor Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50‚C 80‚C 100‚C 120‚C Standard (Ω ) 134~149 47.5~57.0 26~29 14.8~17.2 Caution Wear gloves and goggles when performing this ...
  • Page 262 To this chapter contents 17. Electrical System Note: 17-23...

  • Page 263: Emission Control System

    Home page Contents 18. Emission Control System Emission Control System Classification Positive Crankcase Ventilation System €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 18-1 (P.C.V.) €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€18-5 Emission Control System Description Inspection Items€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€18-6 €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 18-1 Countermeasure for Abnormal Emission Evaporative Emission Control System Pollutants€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€18-7 (E.E.C.) €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 18-2 Catalytic Converter (CATA) €€€€€€€€€€€€€€€€ 18-4 Emission Control System Classification 1.
  • Page 264 To this chapter contents 18. Emission Control System Evaporative Emission Control System (E.E.C.) Construction:  Reduce HC to pollute air.  To absorb fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Automatic control Vapor hose...
  • Page 265 To this chapter contents 18. Emission Control System Evaporative Emission Control System (E.E.C.) Inspection 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leakage test: 1) Disconnect the Purge Control Valve hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge...
  • Page 266 To this chapter contents 18. Emission Control System Catalytic Converter (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx to harmless CO O, N gases.
  • Page 267 To this chapter contents 18. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Drain pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: ...
  • Page 268 To this chapter contents 18. Emission Control System Inspection Items Fuel Evaporation Control System 1. Visual inspect the carbon canister and hoses for damage. 2. Leaking check. 3. Function test of the purge control solenoid. Catalytic converter 1. Check if exhaust gas content is within standard. 2.
  • Page 269 To this chapter contents 18. Emission Control System Countermeasure for Abnormal Emission Pollutants Conduct periodical inspection (check one time for 3000 km/3 months) Test exhaust emissions at idle speed. Adjust ECU. Clean fuel injector Keep the CO value in 0.5~2.5% (note 3) by adjusting fuel injection quantity.

  • Page 270: Electrical Diagram

    Home page Contents 19. Electrical Diagram LH30W EFi Electrical Diagram 19-1...

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