Sym Mio 100 Manuals

Manuals and User Guides for Sym Mio 100. We have 1 Sym Mio 100 manual available for free PDF download: Service Manual

SYM Mio 100 Service Manual

SYM Mio 100 Service Manual (215 pages)

Brand: SYM | Category: Scooter | Size: 7.16 MB

Table of Contents

2. Maintenance Information

24
- Service Manual
  1
- General Information
  3
- General Information
  6
- Symbols and Marks
  6
- General Safety
  7
- Carbon Monoxide
  7
- Brake Fluid
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  16
- Lubrication Points
  22
- Table of Contents
  24
- Periodical Maintenance Schedule
  25
- Lubrication System
  26
- Fuel System
  27
- Air Cleaner
  28
- Throttle Valve Operation
  28
- Crankcase Blow-By Ventilation
  29
- Valve Clearance Adjustment
  29
- Carburetor Idle Speed Adjustment
  30
- Ignition System
  31
- Spark Plug
  31
- Cylinder Compression Pressure
  32
- Driving System
  32
- Steering System
  33
- Suspension System
  33
- Front Disk Brake System
  34
- Drum Brake System
  36
- Wheel / Tire
  37
- Battery
  38
- Headlight Adjustment
  38
- Nuts¡ B Bolts Tightness
  38
- Special Service Tools Catalogue
  39
3. Lubrication System

42
- Operational Precautions
  43
- Trouble Diagnosis
  43
- Engine OIL
  44
- Cleaning Engine Oil Strainer
  45
- Oil Pump
  46
- Gear Oil
  49
4. Fuel System

50
- Operational Precautions
  51
- Trouble Diagnosis
  52
- Carburetor
  53
- Idle Speed Adjustment
  57
- Fuel Tank
  58
- Air Cleaner
  60
5. Removal & Installation of Engine

62
- Engine Removal
  62
- Operational Precautions
  63
- Engine Removal
  64
- Removal of Engine Bush
  67
  - Engine Hanger
    68
  - Installation of Engine
    69
6. Cylinder Head / Valve

70
- Operational Precautions
  71
- Troubleshooting
  72
- Cylinder Head Removal
  73
- Cylinder Head Disassembly (HU05U)
  75
- Cylinder Head Disassembly (HU10U/W)
  76
- Valve Disassembly
  78
- Cylinder Head Inspection
  79
- Valve Seat Inspection and Service
  81
- Cylinder Head Reassembly
  83
- Cylinder Head Installation
  84
- Valve Clearance Adjustment
  85
7. Cylinder / Piston

88
- Operational Precautions
  89
- Trouble Diagnosis
  89
- Cylinder Removal
  90
- Piston Removal
  92
  - Piston Ring Installation
    94
  - Piston Installation
    95
  - Cylinder Installation
    95
8. V-Belt Drive System / Kick Starter

96
- Operational Precautions
  97
- Trouble Diagnosis
  97
- Kick Starter
  98
- Left Crankcase Cover
  98
- Drive Belt
  100
- Movable Drive Face
  102
- Clutch / Driven Pulley
  105
9. Final Drive Mechanism

110
- Final Drive Mechanism
  110
- Operational Precautions
  111
- Trouble Diagnosis
  111
- Inspection of Final Drive Mechanism
  113
  - Bearing Replacement
    114
  - Re-Assembly of Final Driven Mechanism
    116
10. Alternator / Starting Clutch

118
- Alternator
  118
- Operational Precautions
  119
- Alternator Removal
  120
- Right Crankcase Cover Removal
  121
- Starting Clutch
  122
  - Right Crankcase Cover Installation
    124
  - Alternator Coil Set Installation
    125
  - Flywheel Installation
    125
11. Crankcase / Crankshaft

126
- Operational Precautions
  127
- Trouble Diagnosis
  127
- Disassembly of Crankcase
  128
- Crankshaft Inspection
  130
- Assembly of Crankcase
  131
12. Body Cover

134
- Maintenance Information
  135
- Front Cover
  136
- Handle Cover
  137
- Front Fender
  139
  - Brake
    139
- Front under Spoiler
  140
- Front Inner Cover
  141
- Luggage Box
  142
- Battery Cover
  143
- Rear Carrier
  143
- Rear Center Cover
  144
- Side Cover
  144
- 12. Body Cover
  145
- Center Cover
  145
- Floor Panel
  147
- Rear Fender
  148
- Rear Mudguard
  149
13. Brake

150
- Operational Precautions
  153
- System
  153
- Trouble Diagnosis
  154
- Hydraulic Brake System Inspection
  155
- Brake Fluid Replacement / Air-Bleed
  156
- Brake Caliper
  157
- Brake Disc
  158
- Brake Master Cylinder
  158
- Brake Lining
  161
- Drum Brake System
  161
- Brake Panel
  162
14. Steering / Front Wheel / Front Cushion

164
- Steering / Front Wheel / Front Cushion
  164
- Operational Precautions
  165
- Trouble Diagnosis
  165
- Steering Handle
  166
- Front Wheel
  168
- Front Cushion
  173
- Front Fork / Steering Column
  173
15. Rear Wheel / Rear Cushion

176
- Rear Wheel / Rear Cushion
  176
- Operational Precautions
  177
- Trouble Diagnosis
  177
- Exhaust Muffler
  178
  - Rear Wheel
    178
  - Rear Cushion
    179
16. Electrical Equipment

180
- Electrical Equipment
  180
- Operational Precautions
  181
  - Starting System
    181
- Specification
  182
- Trouble Diagnosis
  183
- Charging System
  184
- Ignition System
  190
  - Ignition Coil
    192
- Start System
  194
- Meter
  195
- Light / Bulb
  197
- Switch / Horn
  201
- Fuel Unit
  204
  - Emission Control System
    206
  - Electrical Diagram
    214

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