Sym RS-50 Service Manual
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Sym RS-50 Service Manual

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MECHANISM ILLUSTRATIONS
RS-50

SERVICE MANUAL

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  • Page 1: Service Manual

    FORWARD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS RS-50 SERVICE MANUAL...
  • Page 2 Home page Contents F O R W A R D This service manual contains the technical data of each component inspection and repair for the SANYANG RS-21 50 series scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment”...

  • Page 3: General Information

    Home page Contents How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang RS-21 50 scooters. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Home page C O N T E N T S Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-6 LUBRICATION SYSTEM 4-1 ~ 4-4 ENGINE REMOVAL 5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON 6-1 ~ 6-4 ALTERNATOR 7-1 ~ 7-14 “V”...
  • Page 5 Home page Contents MODEL ILLUSTRATION BS05W SERIES Light / Starter switch Battery / Fuses / C.D.I. / start relay Oil tank cap Fuel tank cap Front winker light Helmet hook High & Low beam / Turn signal / Horn switch Frame number Tail light Head light...
  • Page 6 Home page Contents 1. GENERAL INFORMATION Symbols and Marks ·························· 1-1 Torque values···································1-8 General Safety ·································· 1-2 Cables and Harness Routing ··········1-10 Service Precautions ························· 1-3 Troubleshooting·······························1-13 Specifications ··································· 1-5 Lubrication Points····························1-17 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 procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    This chapter Contents 1. GENERAL INFORMATION General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed Battery emits explosive gases; flame is area. Run your engine in an open area, if you strictly prohibited.

  • Page 8: Service Precautions

    This chapter Contents 1. GENERAL INFORMATION Service Precautions Always use with Sanyang genuine parts and Rubber parts may become deteriorated when recommended oils. Using non-designed parts old, and prone to be damaged by solvent and oil. for Sanyang motorcycle may damage the Check these parts before installation to make motorcycle.
  • Page 9 This chapter Contents 1. GENERAL INFORMATION The ends of rubber hoses (for fuel, vacuum, or The length of bolts and screws for assemblies, coolant) should be pushed as far as they can go cover plates or boxes is different from one to their connections so that there is enough another, be sure they are correctly installed.

  • Page 10: Lubrication System

    This chapter Contents 1. GENERAL INFORMATION Specifications Make SANYANG MODEL BS05W1-6 Overall Length 1870 mm Front TELESCOPIC Suspension System Overall Width 700 mm Rear UNlT SWING Overall Height 1130 mm Front 100/90-12 (59J) Tire Specifications Wheel Base 1335 mm Rear 130/70-12 (59J) Front 46 kg...

  • Page 11: Specifications

    This chapter Contents 1. GENERAL INFORMATION Specifications Make SANYANG MODEL BS05W-A Overall Length 1870 mm Front TELESCOPIC Suspension System Overall Width 700 mm Rear UNlT SWING Overall Height 1130 mm Front 100/90-12 (T/L) Tire Specifications Wheel Base 1335 mm Rear 130/70-12 (T/L) Front 46 kg...
  • Page 12 This chapter Contents 1. GENERAL INFORMATION Specifications Make SANYANG MODEL BS05W-8 Overall Length 1870 mm Front TELESCOPIC Suspension System Overall Width 700 mm Rear UNlT SWING Overall Height 1130 mm Front 100/90-12 (59J) Tire Specifications Wheel Base 1335 mm Rear 130/70-12 (59J) Front 46 kg...

  • Page 13: Torque Values

    This chapter Contents 1. GENERAL INFORMATION Torque values Standard Torque Values for Reference Type Torque value Type Torque value 5 mm Bolt, nut 0.45 - 0.6kgf-m 5 mm Bolt 0.35 - 0.5kgf-m 6 mm Bolt, nut 0.8 - 1.2kgf-m 6 mm Bolt, SH nut 0.7 - 1.1kgf-m 8 mm Bolt, nut 1.8 - 2.5kgf-m...
  • Page 14 This chapter Contents 1. GENERAL INFORMATION Frame Thread Dia. Torque Value Item Q’ty Remarks (mm) (Kgf-m) Bolt for engine hanger (frame side) 4.5~5.5 Bolt for engine hanger (engine side) 5.0~7.0 Upper bolt for rear cushion 3.5~4.5 Under bolt for rear cushion 2.4~3.0 Nuts for exhaust pipe 1.0~1.4...
  • Page 15 This chapter Contents 1. GENERAL INFORMATION Cables and Harness Routing Note the following when routing cables and wire harnesses: • A loose wire, cable or harness may cause safety hazard. After clamping, check each wire to make sure it is secured. •...
  • Page 16 This chapter Contents 1. GENERAL INFORMATION Horn Throttle cable Main switch : Throttle cable : Front brake cable : Rear brake cable : Speedometer cable : Speedometer and handle switch wire 1-11...
  • Page 17 This chapter Contents 1. GENERAL INFORMATION CDI unit Fuse Start relay Spark plug Ignition coil Battery Thermo switch unit ACG. connector Fuel unit Regulator Oil level switch Power filter unit ASS’Y Resistor Air injection cut valve Thermo switch connector Auto by-starter Thermo switch 1-12...

  • Page 18: Troubleshooting

    This chapter Contents 1. GENERAL INFORMATION Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline 1. No fuel in fuel tank inside the carburetor 2.
  • Page 19 This chapter Contents 1. GENERAL INFORMATION 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 1. Air cleaner clogged Engine speed can be Engine speed can not be 2.
  • Page 20 This chapter Contents 1. GENERAL INFORMATION Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC generator) Adjust the air screw of carburetor Good...
  • Page 21 This chapter Contents 1. GENERAL INFORMATION . CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged 3. Driving pulley spring broken Engine can be started but 4. Clutch ling broken motorcycle can not be driving 5.

  • Page 22: Lubrication Points

    This chapter Contents 1. GENERAL INFORMATION Lubrication Points Throttle cable/ Front & rear brake lever pivot Seat lock Engine hanger bushing Steering shaft bearing Rear wheel bearing Speedometer gear/ front Main stand shaft Side stand shaft wheel bearing 1-17...
  • Page 23 This chapter Contents 1. GENERAL INFORMATION Note: 1-18...
  • Page 24 Home page Contents 2. SERVICE MAINTENANCE INFORMATION General Information·································2-1 Suspension···········································2-10 Periodical Maintenance Schedule ··········2-2 Transmission Oil ··································2-11 Air Cleaner ···············································2-3 Spark Plug ············································2-11 Fuel Lines·················································2-3 Control Cable Lubrication ···················2-12 Fuel Filter ·················································2-4 Driver Belt ·············································2-12 Engine Oil Line ········································2-4 Ignition Timing ·····································2-12 Oil Pump Control Cable ··························2-5 Throttle Valve Operation······················2-12 Tire ····························································2-6...

  • Page 25: Periodical Maintenance Schedule

    25. Carbon cleaning for cylinder ☆ head, cylinder, piston head, and exhaust system. Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement...

  • Page 26: Service Maintenance Information

    ‧ Limit to use SAE 20 JASO FC class engine Clean Soap oil, otherwise, SYM is no responsible for the warranty. ‧ Recommended engine oil: MAX-2 serial oils. Squeeze out remaining oil Squeeze oil out...

  • Page 27: Fuel Filter

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Fuel Filter Remove the luggage box. Fuel filter Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking.

  • Page 28: Oil Pump Control Cable

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Oil Pump Control Cable Mounting nut Caution To adjust the oil pump control cable after adjusted the throttle grip play. Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.

  • Page 29: Tire

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Tire Caution Tire pressure should be checked when cold. Check tire for cracks, damage, nail, or other object stuck in tread. Recommended tire and tire pressure Front: Rear: Tire size 100/90-12 130/70-12 Tire pressure 1.75 2.25 (cold) kg/cm...

  • Page 30: Rear Brake Free Play

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Rear Brake Free Play: (Drum Brake 10～20mm Type) (3/8～3/4 in) Measure the free play of the rear brake lever at the end of the lever. Free play: 10-20 mm (3/8-3/4 in) Adjust the free play by turning the front brake adjustment nut if necessary.
  • Page 31 This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Brake System Hose: (Front Disc Brake Type) Make sure that the brake hose is corrosion or damage, and also check the system for leaking. Brake Fluid: Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit.
  • Page 32 This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Brake Lining Wear: (Rear Drum Brake Arrow Type) Replace the brake lining if the wear limit mark “△ ” on the brake arm aligning with the indicator of brake drum. Wear limit mark Brake Lining Wear: (Front Disc Brake Brake caliper Type)

  • Page 33: Steering System

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Steering System Caution The control cables can not interfere with the rotation of steering handle. Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut.

  • Page 34: Transmission Oil

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Transmission Oil Leak Oil level check bolt Draining bolt Check if the transmission is leak. Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.

  • Page 35: Control Cable Lubrication

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Control Cable Lubrication Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the Tooth face Belt width cables thoroughly. Driver Belt Remove left crankcase cover. Check if the belt is crack or worn out. Replace the belt if necessary.

  • Page 36: Carburetor Idle Speed Adjustment

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Pilot screw Caution Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. Idle speed check and adjustment have to be done after engine is being warn up.

  • Page 37: Headlight Adjustment

    This chapter Contents 2. SERVICE MAINTENANCE INFORMATION Headlight Adjustment Headlight mounting screw Remove the front cover. Turn the headlamp adjustment screw to adjust headlamp beam height. (C.W. is for increasing beam height, and C.C.W. is for decreasing beam height) Reinstall the front fender. Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting...
  • Page 38 Home page Contents 3. LUBRICATION SYSTEM Lubrication System Diagram············ 3-1 Oil Pump Removal ·····························3-3 Precautions In Operation·················· 3-2 Oil Pump Installation ·························3-3 Lubricant ············································ 3-2 Oil Pump/Oil Tube Air Bleeding ·······3-4 Trouble Shooting······························· 3-2 Oil Tank ··············································3-5 Lubrication System Diagram Oil lever switch Oil tank Oil tube...

  • Page 39: Precautions In Operation

    This chapter Contents 3. LUBRICATION SYSTEM Precautions In Operation Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump. If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation.

  • Page 40: Oil Pump Removal

    This chapter Contents 3. LUBRICATION SYSTEM Oil tube Oil output tube Oil Pump Removal Caution Before removing the oil pump, clean the oil pump and crankcase. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control cable, and remove the control cable.

  • Page 41: Oil Pump/Oil Tube Air Bleeding

    This chapter Contents 3. LUBRICATION SYSTEM Oil tube Oil Pump/Oil Tube Air Bleeding Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine Oil output tube damage.

  • Page 42: Oil Tank

    This chapter Contents 3. LUBRICATION SYSTEM Oil Tank Removal/Installation Remove the luggage box and seat. Remove the body cover and right side cover. Remove the oil input tube from oil pump, and then Oil tube drain oil to a clean container. Remove the oil switch wire of the oil indicator.
  • Page 43 This chapter Contents 3. LUBRICATION SYSTEM NOTES:...

  • Page 44: Engine Removal

    Home page Contents 4. ENGINE REMOVAL Maintenance Information················· 4-1 Engine installation ··························· 4-4 Engine removal ································ 4-2 Maintenance Information There are parts that require removal of engine for maintenance. Crankcase Crankshaft Related bolts tightening torque for removal of engine: Bolt for engine hanger (frame side) 4.5~5.5kgf-m Bolt for engine hanger (engine side) 5.0~7.0kgf-m...
  • Page 45 This chapter Contents 4. ENGINE REMOVAL Engine removal Spark plug cap Remove the luggage box and body cover. Remove right and left side cover. Remove the spark plug cap from the spark plug section. Fuel output tube Remove the fuel output tube from carburetor. Remove the vacuum tubes from inlet pipe.
  • Page 46 This chapter Contents 4. ENGINE REMOVAL Remove the wire couplers of auto by-starter and Couplers ACG. Remove the upper parts of the carburetor from its Carb. Upper parts upper side. Remove air cleaner mounting bolts. (2 bolts) Bolts Remove rear brake cable from engine rear-lower side.

  • Page 47: Engine Installation

    This chapter Contents 4. ENGINE REMOVAL Remove air injection cut valve tube. Bolts Remove two exhaust pipe connection nuts. Remove two bolts beside fan cover and exhaust pipe. Support the engine and then remove cushion Rear cushion under under mounting bolt. mounting bolt Remove engine mounting nut and bolt.

  • Page 48: Cylinder Head/Cylinder/Piston

    Home page Contents 5. CYLINDER HEAD/CYLINDER/PISTON Maintenance Information·················· 5-2 Cylinder Head ·····································5-3 Troubleshooting································ 5-2 Cylinder/Piston ···································5-5...
  • Page 49 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Maintenance Information Precautions in Operation The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. Remove all washes from the interfaces of cylinder head, cylinder and crankcase.

  • Page 50: Cylinder Head

    This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Tightening bolt Cylinder Head Cylinder Removal Removal luggage box and body covers. Remove spark plug cap. Remove fan cover. Remove engine shield. Tightening bolt Engine shield Remove two connection nuts of the exhaust pipe. Tightening bolt x 2 Remove exhaust muffle mounting bolt, and then remove the exhaust pipe.
  • Page 51 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 0.10 mm Cylinder Head Installation Tightening bolts Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder.
  • Page 52 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Cylinder/Piston Cylinder Removal Be careful to pull the cylinder up and prevent piston from damage. Caution Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously. Piston Removal Place a clean rag onto crankshaft to cover the piston.
  • Page 53 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 0.10 mm In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure. With the max.
  • Page 54 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Piston Ring Inspection Measure the end gap of each piston ring. Service limit: 0.40 mm Caution With the piston, push each piston ring into cylinder correctly. Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end, and then check its clearance.
  • Page 55 This chapter Contents 5. CYLINDER HEAD/CYLINDER/PISTON Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into Piston the crankcase. 〝EX〞mark Apply with two-stroke engine oil onto needle bearing and piston pin, and then install the piston pin onto connecting rod.

  • Page 56: Alternator

    Home page Contents 6. ALTERNATOR Maintenance Information················· 6-2 Alternator Installation······················· 6-4 Alternator Removal ·························· 6-3 3.8kgf-m...
  • Page 57 This chapter Contents 6. ALTERNATOR Maintenance Information Precautions in Operation The maintenance service of A.C. alternator can be carried out directly on the motorcycle. Please refer to Chapter 15 for the relative alternator inspection. Torque value: Flywheel 3.8kgf-m Tool General tool Rotor puller Universal holder Coil resistance value for the A.C.
  • Page 58 This chapter Contents 6. ALTERNATOR Cooling fan cover Alternator Removal Remove the body cover and rear side cover. Remove two bolts and then take out cooling fan cover. Bolt Remove four bolts, and then take out the cooling fan. Cooling fan Hold flywheel with universal holder.
  • Page 59 This chapter Contents 6. ALTERNATOR Disconnect alternator wire connector and pulse Wire harness connector generator connector. Remove the pulse generator and alternator four bolts, and then take out the alternator assembly. Caution Care to be taken for not damaging the alternator coil.
  • Page 60 Home page Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Maintenance Information················· 7-2 Drive Belt ···········································7-5 Trouble Shooting ····························· 7-2 Movable Driven Pulley······················7-6 Left Crankcase Cover ······················ 7-3 Clutch/Driven Pulley ·························7-10 Reassembly Of Kick Starter ············ 7-4 Installation Of The Left Crankcase Cover ···························································...

  • Page 61: Maintenance Information

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Maintenance Information Precautions in Operation The surfaces of drive belt and driven pulley must be free of grease. Specification Item Standard value(mm) Limit(mm) Drive belt width 18.0 16.5 ID of movable drive face 20.035~20.085 20.120 OD of movable drive face boss...

  • Page 62: Left Crankcase Cover

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Left crankcase cover Left Crankcase Cover Left crankcase cover removal Remove left body side cover. Remove air cleaner. Remove kick start arm. Remove left crankcase cover. Kick start arm Disassembly of Kick Starter Return spring Remove snap clip and thrust washer from left crankcase cover.

  • Page 63: Reassembly Of Kick Starter

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Reassembly of Kick Starter Kick starter spindle Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle.

  • Page 64: Drive Belt

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Drive Belt Removal Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage reduction gear system.

  • Page 65: Movable Drive Face

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install the driven pulley that has installed the belt Drive shaft Drive face Drive belt onto drive shaft. Clutch/driven pulley Install the clutch with universal holder, and then Clutch outer tighten nut to specified torque value. Torque value: 3.8kgf-m Universal holder Movable Drive Face...
  • Page 66 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Removal Drive face boss Movable drive face Remove movable drive face set and drive belt from crankshaft. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable face. Movable drive face Weight roller Inspection Weight roller...
  • Page 67 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Check if movable drive face boss is worn or Movable drive face damage and replace it if necessary. Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit.
  • Page 68 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install movable drive face assembly onto Drive face boss Movable drive face crankshaft. Crankshaft Drive Face Installation Drive belt Press down Press drive belt into pulley groove, and then pull the belt on to crank shaft. Install drive face, washer and nut.

  • Page 69: Clutch/Driven Pulley

    This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch/Driven Pulley Clutch nut wrench Disassembly Remove drive belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much.
  • Page 70 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch weight Clutch weight Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 82.5 mm Free length Driven pulley...
  • Page 71 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Clutch Block Replacement Spring Drive plate Remove clip and washer, and then remove clutch weight and spring from drive plate. Caution Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity.
  • Page 72 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Install snap clip and mounting plate onto lock pin. Snap clip Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clip Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 73 This chapter Contents 7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER Installation of Clutch/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. O-ring Specified grease Install sliding pulley onto driven pulley. Sliding pulley Oil seal Install guide pin and guide pin roller.

  • Page 74: Final Driving Mechanism

    Home page Contents 8. FINAL DRIVING MECHANISM Maintenance Information ················· 8-2 Inspection of Final Driving Mechanism ···························································· 8-4 Troubleshooting ······························· 8-2 Bearing Replacement ······················· 8-4 Disassembly of Final Driving Mechanism ··························································· 8-3 Re-Assembly of Final Driving Mechanism ···························································· 8-4...

  • Page 75: Maintenance Information

    Oil quantity：120 c.c. (110 c.c. as replacement) Special tools: Inner type bearing puller (SYM-6204020) Outer type bearing puller (SYM-6204010) Final shaft oil seal installer (SYM-9125500) Drive shaft oil seal installer (SYM-9120200) Bearing driver 6204 (SYM-9110400) Bearing driver 6201 (SYM-9610001) Bearing driver 6203/6004UZ (SYM-9620000) L.

  • Page 76: Disassembly Of Final Driving Mechanism

    This chapter Contents 8. FINAL DRIVING MECHANISM Disassembly of Final Driving Oil filling hole Mechanism Remove driven pulley Drain gear oil out from gearbox. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side.

  • Page 77: Bearing Replacement

    Special tool: Gear Box Cover Final shaft bearing: Punch guide Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) Final shaft oil seal installer (SYM-9125500) Adapter Left Crankcase Drive shaft Drive shaft bearing: Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) L.
  • Page 78 This chapter Contents 8. FINAL DRIVING MECHANISM Install countershaft, final driven gear and thrust Final driven gear & shaft washer. Counter gear & shaft Install new gasket and lock pin. Install gearbox cover. Install clutch/driven pulley assembly. Install driven pulley, drive belt, and left crankcase side cover.
  • Page 79 This chapter Contents 8. FINAL DRIVING MECHANISM Notes:...

  • Page 80: Crankcase/Crankshaft

    Home page Contents 9. CRANKCASE/CRANKSHAFT Maintenance Information····················9-2 Crankshaft Removal ···························· 9-3 Troubleshooting··································9-2 Crankshaft Inspection ························· 9-4 Crankcase Disassembly ·····················9-3 Crankcase Installation························· 9-5 1.0kgf-m Apply liquid gasket...

  • Page 81: Maintenance Information

    Special Tools Crankcase disassemble tool (SYM-1120100-G5) Outer bearing puller (SYM-6204010) R. Crank shaft puller (SYM-1130000-R) R. Crank shaft install bush (SYM-1130020) L. Crank shaft puller (SYM-1130000-L) L. Crank shaft install bush (SYM-1130010) 20*32*6 Oil seal driver (SYM-9120200) Bearing driver 6204 (SYM-9110400)

  • Page 82: Crankcase Disassembly

    This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankcase Disassembly Remove the crankcase bolts. Bolts Crankcase puller Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase. Right crankcase Crankshaft Removal Crankcase puller As the diagram show with 3 special bolts to install the specified service tool onto the left crankcase.

  • Page 83: Crankshaft Inspection

    This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankshaft Inspection Measure the clearance of connecting rod big end. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.

  • Page 84: Crankcase Installation

    This chapter Contents 9. CRANKCASE/CRANKSHAFT Crankcase Installation Clean the crankshaft with solvent and blow it with Bearing driver 6204 compressed air. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase. Caution All rotation and sliding surfaces have to be applied with clean engine oil.
  • Page 85 This chapter Contents 9. CRANKCASE/CRANKSHAFT Assemble the right crankcase with assembly tools. Install right crankcase onto the crankshaft. R. Crank shaft puller Install right crankshaft puller and install bush onto R. Crank shaft crankshaft. install bush Screw the right crankshaft puller onto crankshaft. Turn the puller in C.W.

  • Page 86: Fuel System

    Home page Contents 10. FUEL SYSTEM Maintenance Information ················ 10-2 Float/Float Valve/Jet ·························10-6 Troubleshooting ······························ 10-2 Float Level Inspection ······················10-7 Throttle Valve ··································· 10-3 Carburetor Installation ·····················10-7 Carburetor Remove ························· 10-4 Reed Valve ········································10-7 Auto By-Starter ································ 10-4 Air Cleaner ········································10-8 Fuel unit Fuel cap Fuel tank...

  • Page 87: Maintenance Information

    This chapter Contents 10. FUEL SYSTEM Maintenance Information Precautions in Operations Warning Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Care must be taken when dealing with gasoline, and always work in a well-ventilated place and strictly prohibit flame.

  • Page 88: Throttle Valve

    This chapter Contents 10. FUEL SYSTEM Carburetor Throttle Valve upper part Removal Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Oil hose Inspection Throttle valve spring...

  • Page 89: Carburetor Remove

    This chapter Contents 10. FUEL SYSTEM Carburetor Remove Connection band Remove the air cleaner. 2 bolts Disconnect the auto by-starter and thermo switch connectors. Thermo switch connector Auto by-starter connector Carburetor Fuel hose Loosen draining screw and then drain out fuel upper part inside the carburetor.
  • Page 90 This chapter Contents 10. FUEL SYSTEM Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes.

  • Page 91: Float/Float Valve/Jet

    This chapter Contents 10. FUEL SYSTEM Float/Float Valve/Jet Removal Remove the float from carburetor body. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as...

  • Page 92: Float Level Inspection

    This chapter Contents 10. FUEL SYSTEM Float Level Inspection Measure float fuel level to have the upper end of float just contact with the float. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Carburetor Installation Fuel hose...

  • Page 93: Air Cleaner

    This chapter Contents 10. FUEL SYSTEM Inspection Reed valve Check the reed valve for damage and its reed strength. Reed stopper Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper.

  • Page 94: Brake System

    Home page Contents 11. BRAKE SYSTEM Front Disc Brake System ···············11-1 Disc Brake -Air Bleed······················· 11-6 Rear Drum Brake System ··············11-2 Disc Brake - Caliper ························· 11-6 Maintenance Information ···············11-3 Brake Disc········································· 11-7 Troubleshooting ·····························11-4 Disc Brake - Master Cylinder··········· 11-7 Hydraulic Disc Brake······················11-5 Drum Brake·······································...

  • Page 95: Rear Drum Brake System

    This chapter Contents 11. BRAKE SYSTEM Rear Drum Brake System 2.5kgf-m 11.0kgf-m 0.55kgf-m 11-2...

  • Page 96: Maintenance Information

    This chapter Contents 11. BRAKE SYSTEM Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.

  • Page 97: Troubleshooting

    This chapter Contents 11. BRAKE SYSTEM Troubleshooting Disc Brake Soft brake lever Hard operation of brake Tight brake lever 1. Air inside the hydraulic 1. Dirty brake lining/disc system 2. Poor wheel alignment 1. Blocked brake system 2. Hydraulic system leaking 3.

  • Page 98: Hydraulic Disc Brake

    This chapter Contents 11. BRAKE SYSTEM Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Lower level Cap plate Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir Diaphragm becomes horizontal, then remove the brake fluid reservoir.

  • Page 99: Disc Brake -Air Bleed

    This chapter Contents 11. BRAKE SYSTEM Drain valve Disc Brake -Air Bleed Air bubble 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. Caution Do not release the brake lever before the drain valve is closed.

  • Page 100: Brake Disc

    This chapter Contents 11. BRAKE SYSTEM Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel.
  • Page 101 This chapter Contents 11. BRAKE SYSTEM Master Cylinder Inspection Cylinder gauge Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
  • Page 102 This chapter Contents 11. BRAKE SYSTEM Install the rubber pad into the groove correctly. Master cylinder Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake lamp switch. Brake lamp switch Connect brake hoses with 2 new washers.

  • Page 103: Rear Drum Brake

    This chapter Contents 11. BRAKE SYSTEM Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
  • Page 104 This chapter Contents 11. BRAKE SYSTEM Installation Bolt Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin.
  • Page 105 This chapter Contents 11. BRAKE SYSTEM Notes: 11-12...
  • Page 106 Home page Contents 12. Body Cover Mechanism Illustration .....12-1 Center Cover........12-8 Maintenance Information....12-2 Body Cover ........12-9 Front Cover........12-3 Left & Right Side Foot Plates ...12-10 Handle Cover ........12-4 Floor Panel.........12-11 Front Fender ........12-6 Front under Spoiler ......12-12 Left & Right Side-Covers ....12-6 Inner Cover ........12-13 Rear Carrier ........12-7 Under Cover........12-15...

  • Page 107: Maintenance Information

    This Chapter Contents 12. Body Cover Maintenance Information Body covers disassemble sequence: Handle Rear Cover Front cover Luggage box & seat Handle Left / right side Front fender Center cover cover Handle front cover Left/right side-covers Rear carrier Front under Spoiler Body cover Inner box Rear fender /...

  • Page 108: Front Cover

    This Chapter Contents 12. Body Cover Front Cover Removal Remove the 6 mounting screws from the inside of front inner box. Screws x 6 Remove the front screw (screw x 1) from the front cover. Screw x 1 Remove the lower screw (screw x 1) from the front cover.

  • Page 109: Handle Cover

    This Chapter Contents 12. Body Cover Handle Cover Removal Remove the handle rear cover (screw x 5). Disconnect the wire connectors of left & right switches. Remove the handle rear cover. Caution Open the hooks on the two end-section of the handlebar cover as removing the cover.
  • Page 110 This Chapter Contents 12. Body Cover Remove the handle front cover and speedometer set. (screws x 4) Screws x 4 Remove the speedometer cover. (screws x 3) Disassemble the speedometer cover and the speedometer set. (screws x 2) Installation Install according to the reverse procedure of removal.

  • Page 111: Front Fender

    This Chapter Contents 12. Body Cover Screw x 2 Front Fender Removal Remove the front fender screws. (left & right x 2) Remove the front fender. Installation Install according to the reverse procedure of removal. Left & Right Side-Covers Remove the mounting screws. (2 screws on left & right each side) Screw x 2 Remove the side cover.

  • Page 112: Rear Carrier

    This Chapter Contents 12. Body Cover Bolt x 4 Rear Carrier Removal Remove the hex-socket bolts (bolt x 4) of the rear carrier. Caution Do not open the fuel tank cap as removing the bolts so that prevent from bolts falling into the fuel tank.

  • Page 113: Center Cover

    This Chapter Contents 12. Body Cover Center Cover Remove the lower 2 screws in front of the center cover. Screw x 2 Remove the 1 upper screw inside of the luggage box. Screw x 1 Take out the center cover. Installation Install according to the reverse procedure of removal.

  • Page 114: 12. Body Cover

    This Chapter Contents 12. Body Cover Body Cover Removal Remove the rear carrier, luggage box and seat firstly. Remove the body cover mounting screw. (2 screws on each side) Screws on each side Gently split out the body cover a little bit with Seat locker cable hands and then lift the cover up slightly.

  • Page 115: Left & Right Side Foot Plates

    This Chapter Contents 12. Body Cover Bolt x 1 Left & Right Side Foot Plates Removal Remove the foot plates connection screws & bolt. (3 screws & 1 bolt on left & right each side) Screws x 3 Remove the rear connection screws. (1 bolt on left Bolt x 1 &...

  • Page 116: Floor Panel

    This Chapter Contents 12. Body Cover Floor Panel Removal Remove the center cover, luggage box, body side covers, and body cover firstly. Remove the battery cover. (screws x 3) Screw x 3 Remove the battery bracket (bolt x 2) and power Start relay cables.

  • Page 117: Front Under Spoiler

    This Chapter Contents 12. Body Cover Front under Spoiler Removal Remove the front fender, front cover. Remove the front fender, front brake system, and odometer cable, as well as the front wheel. Remove the inner box screw (left & right each side x 3), and 1 screw on the left &...

  • Page 118: Inner Cover

    This Chapter Contents 12. Body Cover Inner Cover Removal Remove the front cover and front under spoiler firstly. Remove the main switch cap. Ignition switch cap Remove the mounting bolts (2 bolts) of floor Panel. 2 bolts Remove 1 nut from the inner box lid. Nut ×1 Take out the front inner box.
  • Page 119 This Chapter Contents 12. Body Cover Remove the upper 1 bolt from the tail light. Bolt x 1 Remove the rear side 2 bolts. Bolt x 2 Tail light coupler Remove tail light and winker light coupler. Remove 1 bolt on the left & right each side of rear fender.

  • Page 120: Under Cover

    This Chapter Contents 12. Body Cover Under Cover Remove the under cover bolts. (left & right each side x 2) Bolts ×2 Remove the under cover. Installation Install according to the reverse procedure of removal. Rear Inner Fender Remove rear fender and tail light firstly. Remove 2 bolts, then remove the rear inner fender.
  • Page 121 This Chapter Contents 12. Body Cover NOTES: 12-16...
  • Page 122 Home page Contents 13. Steering/Front Wheel/Front Shock Absorber Mechanism Illustration ....... 13-1 Front Wheel ........13-4 Precautions in Operation....13-2 Front cushion........13-7 Trouble diagnosis ....... 13-2 Front fork/steering column ....13-7 Steering Handle........13-3 Mechanism Illustration 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 2.4~3.0kgf-m 3.1~3.5kgf-m 5.0~7.0kgf-m...

  • Page 123: Precautions In Operation

    This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Precautions in Operation General Information • Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. •...

  • Page 124: Steering Handle

    This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Steering Handle Master cylinder REMOVAL Remove handle front & rear cover and the front cover (refer to chapter 12). Disc Brake Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring.

  • Page 125: Front Wheel

    This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Front Wheel Removal Support body bottom and lift front wheel free of ground. Remove the screw, and disconnect speedometer cable from the gear box. Speedometer cable Remove the wheel axle nut and pull out the axle. Then, remove the front wheel.
  • Page 126 This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Bearing Disassembly Remove the left axle ring and dust seal. Remove the dust seal on the right side of speedometer gear. Speedometer Wheel side gear dust seal collar Bearing Dust seal Bearing bush Remove the bearing with the inner type bearing remover.
  • Page 127 This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Caution Do not install used bearing and replace the bearing once it has been removed. Do not the bearing in tile motion when installing. Tool: C-type compressor or bearing driver Both samples will damage bearing Align the flange part on the speedometer gear with the slot of wheel hub, and then install the speedometer gear box.

  • Page 128: Front Cushion

    This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber Front cushion Removal Remove the front fender, front under spoiler, front cover, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left cushion. (bolt x 1) As for disc brake, remove the cable guide on the right cushion.
  • Page 129 This Chapter Contents 13. Steering/Front Wheel/Front Shock Absorber With a plastic hammer to tap the steering ball race slightly, and then remove the top ball bearing race. Remove the lower-end cone bearing race on the frame with a punch. Caution Do not damage the frame and the steering race.

  • Page 130: Rear Wheel/Suspension

    Home page Contents 14. REAR WHEEL/SUSPENSION Maintenance Information ················· 14-2 Rear Wheel ······································· 14-3 Troubleshooting ······························· 14-2 Rear Shock Absorber ······················ 14-4 2.7 kgf-m 4.0 kgf-m 11.0 kgf-m 3.3 kgf-m 14-1...

  • Page 131: Maintenance Information

    This chapter Contents 14. REAR WHEEL/SUSPENSION Maintenance Information Specification Item Standard value (mm) Limit (mm) Rear wheel rim run out 2.0 (0.08 in) Torque Value Rear shock absorber upper mounting bolt: 4.0 kgf-m Rear shock absorber lower mounting bolt: 2.7 kgf-m Rear wheel nut: 11.0 kgf-m Rear wheel hub: 2.5 kgf-m Exhaust muffler nut: 1.2kgf-m...

  • Page 132: Rear Wheel

    This chapter Contents 14. REAR WHEEL/SUSPENSION Rear Wheel Remove Remove exhaust pipe nut. (2 connection nuts) Connection nuts Bolts Remove exhaust muffler bolt (3 bolts), then remove the muffler. Muffler Remove rear wheel shaft nut and then remove the rear wheel. Shaft nut Inspection As the diagram shown, measure wheel rim...

  • Page 133: Rear Shock Absorber

    This chapter Contents 14. REAR WHEEL/SUSPENSION Brake Hub Replacement Remove 4 nuts of cover and wheel rim, and then remove the wheel hub. Install the wheel hub and tighten the nuts. Tighten torque: 2.5 kgf-m Installation Install the rear wheel and tighten the nut. Tighten torque: 11.0 kgf-m Install exhaust pipe &...

  • Page 134: Electrical Equipment

    Home page Contents 15. ELECTRICAL EQUIPMENT Maintenance Information ·················· 15-2 Starting System·································· 15-12 Troubleshooting ································ 15-3 Oil Level Switch ································· 15-15 Battery ················································ 15-4 Fuel Unit ············································· 15-16 Charging System ······························· 15-5 Switch / Horn ······································ 15-18 Ignition System·································· 15-9 Bulb Replacement······························...

  • Page 135: Maintenance Information

    This chapter Contents 15. ELECTRICAL EQUIPMENT Maintenance Information Precautions in Operation 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. The ignition timing.

  • Page 136: Troubleshooting

    This chapter Contents 15. ELECTRICAL EQUIPMENT Troubleshooting No voltage Charging system does not operate properly Battery discharged The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage Engine does not crank smoothly...

  • Page 137: Battery

    This chapter Contents 15. ELECTRICAL EQUIPMENT Battery Negative terminal Positive terminal Battery Removal/Installation Turn off main switch. Open seat. Remove screw and the open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal.

  • Page 138: Charging System

    This chapter Contents 15. ELECTRICAL EQUIPMENT Charging System Green Main Switch Pink Black Yellow Auto By- starter Fuse 15A Green/ Pink Black Battery Regulator rectifier AC. Generator 15-5...
  • Page 139 This chapter Contents 15. ELECTRICAL EQUIPMENT Current Leakage Inspection Ammeter Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Battery (-) terminal Connect an ammeter between the negative cable terminal and the battery negative terminal. Ground circuit Caution In the current leakage test, set the current...
  • Page 140 This chapter Contents 15. ELECTRICAL EQUIPMENT The following problems are not related to the Caution charging system; correct it if any by following steps indicate in the checking list. To replace the old battery, use a new battery (1) The standard charging voltage and current with the same current and voltage.
  • Page 141 This chapter Contents 15. ELECTRICAL EQUIPMENT Regulator rectifier Inspection Regulator rectifier Remove the rear carrier. Remove the luggage box and body cover. Disconnect the 6P coupler of the regulator. Measurement Item Standard Value point Main switch Battery voltage (ON) connection wire Battery Battery voltage connection wire...

  • Page 142: Ignition System

    This chapter Contents 15. ELECTRICAL EQUIPMENT Ignition System Green Black/Yellow Blue/Yellow Fuse 15A Black/Blue Black CDI. Battery 15-9...
  • Page 143 This chapter Contents 15. ELECTRICAL EQUIPMENT Ignition Coil Inspection IG. Coil Remove left side cover. Measure the primary coil resistance Resistance :0.19~0.23KΩ (A)→ (B) Measure the secondary coil resistance Resistance : 8.2~9.3KΩ (A)→ (C) Remove the high voltage coil cap, and measure its negative (-) terminal for the secondary coil resistance.
  • Page 144 This chapter Contents 15. ELECTRICAL EQUIPMENT CDI Electrical System Circuit Inspection CDI unit Remove battery cover. Disconnect the CDI unit coupler, and check its circuit to diagnosis related ignition components. CDI Electrical System Circuit Inspection ITEM Measure at: Standard (at 20℃) Continuity (battery voltage) as Main Switch Black/ Blue -green...

  • Page 145: Starting System

    This chapter Contents 15. ELECTRICAL EQUIPMENT Starting System Red/White Main switch Fuse 15A Black Start switch Yellow Stop switch Starter Motor /Red Battery Green/ Yellow Starter relay Green 15-12...
  • Page 146 This chapter Contents 15. ELECTRICAL EQUIPMENT Starter Relay Inspection Starter relay Remove battery cover. Connect both the green/yellow (-) and the Starter relay yellow/red (+) pins to battery posts directly. If the red and red/white pins are also in continuity, it means it is in normal.
  • Page 147 This chapter Contents 15. ELECTRICAL EQUIPMENT Starter Motor Removal/Disassembly Remove body cover. Remove bolt and oil pump control cable. Disconnect starter motor harness coupler. Remove 2 bolts for separation starter motor and Starter motor gasket. Remove 2 bolts for disassembly the starter motor. Coupler Armature Motor housing...

  • Page 148: Oil Level Switch

    This chapter Contents 15. ELECTRICAL EQUIPMENT Oil Level Switch Troubleshooting Main switch Fuse If the oil level in oil tank is in specified level, but the oil level indicator still goes on. 1. Remove body cover. 2. Disconnect oil gauge wire, and turn the main Indicator switch to ON position.

  • Page 149: Fuel Unit

    This chapter Contents 15. ELECTRICAL EQUIPMENT Fuel Unit Fuel unit coupler Removal/Installation Remove the luggage box and seat. Remove the rear carrier. Remove the body covers. Disconnect the fuel unit coupler. Turn the plastic cap in CCW direction and then Fuel unit remove the fuel unit plastic cap.
  • Page 150 15. ELECTRICAL EQUIPMENT CARB. THERMO SWITCH Power filter unit Ass’y Thermo switch unit Inspection Disconnect the thermo switch unit coupler Remove the thermo switch unit Disconnect the power filter unit ass’y coupler Remove the power filter unit ass’y. Disconnect the heater coupler Heater Earth Remove the heater.

  • Page 151: Switch / Horn

    This chapter Contents 15. ELECTRICAL EQUIPMENT Switch / Horn Remove handle covers and front cover. Remove front inner box. Check continuity on each switch. The connected circles with a line are that they should be in continuity. Main Switch Wire Black / Black Green...
  • Page 152 This chapter Contents 15. ELECTRICAL EQUIPMENT Light Switch Light switch Wire color Brown Yellow Light red Mark ● ● ● ● Start Switch Wire color Yellow / Red Green Mark Start switch FREE ● ● PUSH Light switch Start switch Front / Rear Brake Light Switch If the switch is in continuity as braking, it is in normal.

  • Page 153: Bulb Replacement

    This chapter Contents 15. ELECTRICAL EQUIPMENT Bulb Replacement Position light Headlight/position light Remove front cover. Headlight Remove the rubber boot. Rubber boot Press down the bulb spring locker and then remove the locker with turning it in CCW motion. Replace the bulb with new one if necessary. Caution Do not touch the bulb surface with fingers because the bulb will create hot-spot so that...
  • Page 154 This chapter Contents 15. ELECTRICAL EQUIPMENT Position light Remove the bulb seat with turning it in CCW motion. Position light seat Check if the bulb is burnt or damage, and replace it if necessary. Front winker light inner lens screws Remove the light outer lens of the winker light.
  • Page 155 This chapter Contents 15. ELECTRICAL EQUIPMENT Tail light / Brake light Remove the outer lens of the tail & brake light. (screw x 2) 2 Screws Check if the bulb is burnt or damage, and replace it if necessary. Rear winker light Pry out the light cover from the preset slot onto the lower parts of cover.
  • Page 156 This chapter Contents 15. ELECTRICAL EQUIPMENT Meter Remove the front cover, and then remove the meter wire coupler. Remove speedometer cable. Remove handle rear cover. Remove handle front cover and meter. (4 screws) 4 screws Take out the bulb seat from the bottom of instrument panel.

  • Page 157: Electrical Diagram

    Home page Contents 16. ELECTRICAL DIAGRAM 16-1...
  • Page 158 Home page Contents 16. ELECTRICAL DIAGRAM Notes: 16-2...

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