Sym HD2 200 Manuals

Manuals and User Guides for Sym HD2 200. We have 1 Sym HD2 200 manual available for free PDF download: Service Manual

Sym HD2 200 Service Manual

Sym HD2 200 Service Manual (273 pages)

Brand: Sym | Category: Motorcycle | Size: 40.15 MB

Table of Contents

General Information

6
- Table of Contents
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  18
- Troubleshooting-Carburetor Model
  20
- Troubleshooting-Efi Model
  24
- Lubrication Points
  28
Maintenance Information

30
- Periodical Maintenance Schedule
  31
- Fuel Lines / Cable
  32
- Air Cleaner
  33
- Spark Plug
  33
- Valve Clearance
  34
- Cylinder Compression Pressure
  35
- Ignition System
  35
- Brake System
  36
- Drive Belt
  36
- Brake Light Switch/Starting Inhibitor
  38
- Clutch Disc Wear
  38
- Headlight Beam Distance
  38
- Switch
  38
- Cushion
  39
- Nuts, Bolts Tightness
  39
- Side Stand
  39
- Steering Handle Top Bearing
  40
- Wheel/Tire
  40
- Special Tools List
  41
Home Page 3. Lubrication System

44
- Precautions in Operation
  45
- Troubleshooting
  45
- Engine Oil
  46
- Engine Oil Strainer Clean
  46
- Oil Pump
  47
- Gear Oil
  50
Fuel System

52
- Precautions in Operation
  53
- Trouble Diagnosis
  54
- Carburetor Removal
  55
- Vacuum Chamber
  55
- Air Cut-Off Valve
  57
- Auto By-Starter
  58
- Float Chamber
  59
- Fuel Tank
  61
- Air Cleaner
  62
Efi System Components

64
- Efi System Vehicle Configuration
  65
- Efi System Operation
  66
- Efi System Introduction
  67
- Fuel System
  68
- Ignition System
  69
- Sensors / Drives
  70
- Precautions in Operation
  77
- Efi System Components Description
  78
- Efi System Circuit
  94
- ECU Pin Configuration
  95
- Troubleshooting
  96
- Integrated Troubleshooting Procedure
  100
- Air Cleaner
  103
- Efi System Diagnosis Methods
  104
- Check Light Fault Codes Differentiation
  105
- Fault Code and Sensors Table
  106
- Fault Code and Check Light Flashing Lighting Identification Table
  107
- Efi System Diagnostic Tool - V70
  108
- Troubleshooting Table
  121
- Comprehensive Maintenance List
  122
Engine Removal

124
- Engine Removal
  125
- Engine Hanger Removal
  128
- Engine Hanger Bush Removal
  129
  - Engine Hanger Installation
    130
  - Engine Installation
    130
Home Page 7 . Cylinder Head / Valve

132
- Precautions in Operation
  133
- Troubleshooting
  134
- Cylinder Head Removal
  135
- Cylinder Head Disassembly
  137
- Cylinder Head Inspection
  138
- Valve Stem Replacement
  139
- Valve Seat Inspection and Service
  140
- Cylinder Head Reassembly
  142
- Cylinder Head Installation
  143
- Valve Clearance Adjustment
  145
Home Page 8. Cylinder / Piston

146
- Precautions in Operation
  147
- Troubleshooting
  147
- Piston Removal
  149
  - Piston Ring Installation
    151
  - Piston Installation
    152
  - Cylinder Installation
    152
V-Belt Drive System

154
- Precautions in Operation
  155
- Troubleshooting
  155
- Left Crankcase Cover
  156
- Drive Belt
  157
  - Drive Face
    159
  - Clutch Outer/Driven Pulley
    162
Home Page 10. Final Drive Mechanism

168
- Precautions in Operation
  169
- Troubleshooting
  169
- Final Drive Mechanism Disassembly
  170
- Final Drive Mechanism Inspection
  171
  - Bearing Replacement
    172
  - Final Drive Mechanism Reassembly
    175
AC. Generator / Start Clutch

178
- Precautions in Operation
  179
- ACG. Set Removal
  180
- Flywheel Removal
  180
- Right Crankcase Cover Removal
  180
- Start Clutch
  181
- ACG. Set Installation
  184
- Flywheel Installation
  184
- Right Crankcase Cover Installation
  184
Crankcase / Crankshaft

186
- Precautions in Operation
  187
- Troubleshooting
  187
- Crankcase Disassembly
  188
- Crankshaft Inspection
  190
- Crankcase Reassembly
  191
Home Page 13. Cooling System

194
- Precautions in Operation
  195
- Troubleshooting
  195
- System Test
  198
- Radiator
  199
- Water Pump
  201
- Thermostat
  205
Home Page 14. Body Cover

208
- Mechanism Diagram
  208
- Maintenance
  209
- Front Cover
  210
- Handle Front Cover
  211
- Handle Rear Cover
  212
- Side Cover
  213
Brake System

224
- Rear Brake System Diagram-Drum Brake
  225
- Rear Brake System Diagram- Disc Brake
  226
- Precautions in Operation
  227
- Troubleshooting
  228
- Hydraulic Disc Brake
  229
- Air Bleed
  230
- Brake Caliper
  230
- Brake Disk Inspection
  231
- Brake Master Cylinder
  231
Home Page 16. Steering / Front Wheel / Front Cushion

236
- Precautions in Operation
  237
- Steering Handle
  237
- Troubleshooting
  237
- Front Wheel
  240
- Front Cushion
  243
- Steering Stem
  244
  - Precautions in Operation
    247
  - Troubleshooting
    247
  - Muffler
    248
    
    Rear Wheel
    248
    
    Rear Cushion
    250
  - Mechanism Diagram
    252
  - Precautions in Operation
    253
  - Technical Specification
    253
  - Troubleshooting
    254
  - Battery
    256
  - Charging System
    256
  - Ignition System
    259
  - Starting System
    260
  - Meters
    261
  - Light / Bulb
    262
  - Switch / Horn
    265

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