Sym RV 250i Service Manual
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Sym RV 250i Service Manual

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FOREWORD
HOW TO USE THIS MANUAL
CONTENTS
SERIAL NUMBER
GTS
250i
/ RV
250i
GTS
300i
/ JOYMAX
300i

SERVICE MANUAL

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Table of Contents
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Summary of Contents for Sym RV 250i

  • Page 1: Service Manual

    FOREWORD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER 250i / RV 250i 300i / JOYMAX 300i SERVICE MANUAL...
  • Page 2 Homepage Contents Foreword This service manual contains the technical data of each component inspection and repair for the SANYANG LM25W5 / LM30W 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, LM25W5 / LM30W 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 LM25W5 / LM30W 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 1-1 ~ 1-18 General Information 2-1 ~ 2-18 Maintenance Information 3-1 ~ 3-8 Lubrication System 4-1 ~ 4-60 Fuel Injection System 5-1 ~ 5-12 Engine Removal 6-1 ~ 6-16 Cylinder Head / Valve 7-1 ~ 7-8 Cylinder / Piston 8-1 ~ 8-14 V-Belt Drive System...

  • Page 5: Serial Number

    Home page Contents Serial Number...

  • Page 6: Symbols And Marks

    Homepage Contents 1. General Information Symbols and Marks····························1-1 Torque Values ···································· 1-12 General Safety ····································1-2 Trouble Diagnosis······························ 1-14 Before Servicing·································1-3 Lubrication Points ····························· 1-18 Specifications ·····································1-9 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed. If supplemental information is needed for these symbols and marks, explanations will be added in the text instead of using the symbols or marks.

  • Page 7: General Safety

    To this chapter contents 1. General Information General Safety Carbon Monoxide Battery Before you start the engine, make sure the place Caution is well ventilated. Never start the engine in an unventilated place. If you have to start the engine ‧...

  • Page 8: Before Servicing

    To this chapter contents 1. General Information Before Servicing Always use SANYANG genuine parts and Never bend or twist control cables to avoid recommended oil. Using improper parts may unsmooth control and premature worn out. cause damage to or destruction of the vehicle. Rubber parts may become deteriorated when Special tools are designed for removal and old, and be damaged by solvent and oil easily.
  • 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 another, be sure they are correctly installed. In the contact surface has any damage.
  • Page 10 To this chapter contents 1. General Information Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery 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 Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated...
  • 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 LM25W5-6/7 Overall Length Front 2165 mm TELESCOPIC FORK Suspension System Overall Width Rear 870 mm UNlT SWING Overall Height Front 1395 mm 110 / 90-13 56P Tire Specifications Wheel Base Rear 1495 mm 130 / 70-13 57P...
  • Page 15 To this chapter contents 1. General Information Specifications LM25W5-P MAKER SANYANG MODEL LM25W7-7 Overall Length Front 2165 mm TELESCOPIC FORK Suspension System Overall Width Rear 870 mm UNlT SWING Overall Height Front 1395 mm 110 / 90-13 56P Tire Specifications Wheel Base Rear 1495 mm...
  • Page 16 To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL LM30W-6/T Overall Length Front 2165 mm TELESCOPIC FORK Suspension System Overall Width Rear 870 mm UNlT SWING Overall Height Front 1395 mm 110 / 90-13 56P Tire Specifications Wheel Base Rear 1495 mm 130 / 70-13 57P...

  • Page 17: Torque Values

    To this chapter contents 1. General Information Torque Values The torque values listed in below are for more important tightening torque values. Please see standard values for those not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 5 mm bolt、nut...
  • Page 18 To this chapter contents 1. General Information Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle 4.0~5.0 post Lock nut for steering stem 1.0~2.0 Steering top cone race 2.0~3.0 Front wheel axle nut 5.0~7.0 Rear wheel axle nut 11.0~13.0...

  • Page 19: Trouble Diagnosis

    To this chapter contents 1. General Information Trouble Diagnosis A. Engine hard to start or can not be started Check and adjustment Failure condition Possible causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.
  • Page 20 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 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not be 3.
  • Page 21 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) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
  • Page 22 To this chapter contents 1. General Information E. Clutch, Driving And Driving Pulley FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved. 4.

  • Page 23: Lubrication Points

    To this chapter contents 1. General Information Lubrication Points Acceleration cable/ Front & rear brake lever pivot Seat locker Steering shaft bearing Speedometer gear/ Side stand shaft Main stand shaft Clutch bearing front wheel bearing 1-18...

  • Page 24: Maintenance Information

    Home page Contents 2. Maintenance Information Precautions in Operation ···················· 2-1 Drive Belt ·············································· 2-8 Periodical Maintenance Schedule ······ 2-2 Steering Handle Top Bearing·············· 2-9 Engine Oil············································· 2-3 Cushion ················································ 2-9 Engine Oil Strainer Clean···················· 2-3 Disk Brake System······························· 2-10 Gear Oil·················································...

  • Page 25: Periodical Maintenance Schedule

    Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference which ever comes first.

  • Page 26: Engine Oil

    To this chapter contents 2. Maintenance Information 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 27: Gear Oil

    To this chapter contents 2. Maintenance Information Gear Oil Oil inspection bolt Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine. Gear Oil Change Remove oil inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained.

  • Page 28: Air Cleaner

    To this chapter contents 2. Maintenance Information Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Adjustment nut Air Cleaner Air Cleaner Element Remove 8 screws from the air cleaner cover and then remove the cover.

  • Page 29: P.c.v. System

    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 30: Spark Plug

    To this chapter contents 2. Maintenance Information Spark Plug Recommended spark plug: CR8E Remove luggage box Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Spark plug gap: 0.6~0.7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary.

  • Page 31: Cylinder Compression Pressure

    To this chapter contents 2. Maintenance Information Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove luggage box and central cover Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.

  • Page 32: Steering Handle Top Bearing

    To this chapter contents 2. Maintenance Information Steering Handle Top Bearing Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.

  • Page 33: Disk Brake System

    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 34 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 35: Brake Light Switch / Start Switch

    To this chapter contents 2. Maintenance Information Brake Light Switch / Start Switch Stop switch The brake light switch is to light up brake lamp as brake applied. Make sure that starter motor can be operated only under brake applying. Headlight Distance Adjustment Turn on main switch Headlight beam adjustment.

  • Page 36: Battery

    To this chapter contents 2. Maintenance Information Battery Open the inner box lid. Loosen screw & remove the battery cover Battery cable remove： Disconnect the cable negative terminal (-), then the cable positive terminal (+) Remove the battery from the motorcycle.。 If there is some rust on battery posts, clean it with steel brush Install the battery in the reverse procedures of...

  • Page 37: Special Tools List

    SYM-1471110/20 L. Crank shaft puller Tappet adjusting wrench Tappet adjusting NAME NAME NAME SYM-1130000-HMA H9A SYM-9001200 SYM-9001200-08 09 10 R. crank case bearing 6201 Left crankshaft & oil seal Rocker arm shaft disassemble NAME NAME NAME assembles tool assembly socket.
  • Page 38 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 39 2. Maintenance Information Drive shaft & oil seal (25*40*8) Bearing driver 6205 Bearing puller 6303 NAME NAME NAME socket SYM-9615000-6205 SYM-9120200-HMA SYM-6303000-HMA H9A 6303 (Ø22mm) (Ø30mm) Bearing driver 6201 Crankcase bush puller Crankcase bush puller NAME NAME NAME SYM-9614000-6201 SYM-1120310...
  • Page 40 To this chapter contents 2. Maintenance Information Cylinder pressure gauge Vehicle circuit test tool kit Vehicle circuit test harness kit NAME NAME NAME SYM-HT07008 SYM-HE170008 SYM-HE170008-01 EFi System Diagnostic tool NAME 2-17...
  • Page 41 To this chapter contents 2. Maintenance Information NOTE: 2-18...

  • Page 42: Lubrication System

    Home page Contents 3. Lubrication System Mechanism Diagram ······························ 3-1 Engine Oil Strainer Clean ······················ 3-3 Precautions in Operation ······················ 3-2 Oil Pump ················································· 3-4 Troubleshooting ···································· 3-2 Gear Oil ··················································· 3-7 Engine Oil ··············································· 3-3 M echanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route...

  • Page 43: Precautions In Operation

    SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 180c.c. Change: 160c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) Unit: Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Oil pump Clearance between outer rotor and body 0.15~0.20...

  • Page 44: Engine Oil

    To this chapter contents 3. Lubrication System E ngine Oil Turn off engine, and park the scooter 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 45: Oil Pump

    To this chapter contents 3. Lubrication System O il Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Clip Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.
  • Page 46 To this chapter contents 3. Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Pins...
  • Page 47 To this chapter contents 3. Lubrication System Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0.1~0.3kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Install oil pump drive chain and sprocket, and then Clip install cir clip onto oil pump shaft.

  • Page 48: Gear Oil

    To this chapter contents 3. Lubrication System G ear Oil Gear oil join bolt Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m Make sure that the drain bolt washer can be re-used.
  • Page 49 To this chapter contents 3. Lubrication System Notes:...

  • Page 50: Efi System Components

    Home page Contents 4. Fuel Injection System EFi System Components····················· 4-1 Integrated Troubleshooting Procedure ······························································· 4-37 EFi System Vehicle Configuration ····· 4-2 Air Cleaner ············································ 4-40 EFi System Operation ························· 4-3 EFi System Diagnosis Methods ·········· 4-41 EFi System Introduction······················ 4-4 Check Light Fault Codes Differentiation Fuel System··········································...

  • Page 51: Efi System Vehicle Configuration

    To this chapter contents 4. Fuel Injection System EFi System Vehicle Configuration Right Injector MAP Sensor TW Sensor Sensor Left EFi Check light Rollover sensor Diagnostic coupler TA Sensor Fuel pump AISV Test switch...

  • Page 52: Efi System Operation

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

  • Page 53: Efi System Introduction

    To this chapter contents 4. Fuel Injection System EFi System Introduction Based on 4-stroke SOHC engine, displacement 250 c.c. electronically controlled fuel injection, fuel vapor absorbed by activated carbon canister. The engine burns off the blow-by fuel-gas in the crankcase through the fuel-air separating device.

  • Page 54: Fuel System

    To this chapter contents 4. Fuel Injection System Fuel System Fuel pump Injector Fuel pump relay Power relay Battery System Description After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the fuel pump operate.

  • Page 55: Ignition System

    To this chapter contents 4. Fuel Injection System Ignition System Intake air temperature Manifold absolute pressure Engine coolant temperature Throttle position Ignition coil Oxygen content ACG/ Flywheel Gear (23+1 Long teeth) Crankshaft position Power relay sensor Battery REG. REC. Principle The computer programmed ignition system receives the signals from the Crankshaft position sensor, Throttle position sensor, O Sensor, MAP sensor, Intake air temperature sensor, Engine coolant...

  • Page 56: Sensors / Drives

    To this chapter contents 4. Fuel Injection System Sensors / Drives Crankshaft Position Sensor (CPS) Crankshaft position sensor Long tooth Flywheel Description Right after the engine is started; the crankshaft position sensor identifies the TDC position by detecting the logn tooth on the flywheel and ignites at the fixed angle. When the engine RPM reaches the specified speed, the ignition timing will change to the software mode.
  • Page 57 To this chapter contents 4. Fuel Injection System Roll Over Sensor Function As a safety device, when the motocycle tips over, it will cut off power supply of ECU and shut down the engine. Note The pendulum-type roll over sensor will cut off the power supply of ECU. Main switch should be turned Key-on again before the engine can be restarted.
  • Page 58 To this chapter contents 4. Fuel Injection System Manifold Absolute Pressure (MAP) / Engine Water Temperature (TW) / Intake Air Temperature (TA) Sensors MAP Sensor TA Sensor TW Sensor Engine water temperature / Intake air temperature sensor: Use the variable resistor of negative temperature coefficient (thermistor) to sense the outside temperature. The electrical resistance value goes down when the temperature rises.
  • Page 59 To this chapter contents 4. Fuel Injection System Sensor Power relay Sensor Battery Sensor Ceramics tube Electrode Emissions 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 60 To this chapter contents 4. Fuel Injection System Throttle Position Sensor (TPS) Battery U 5V 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 61 To this chapter contents 4. Fuel Injection System Idle Speed Control Valve (ISC stepper motor) Battery Step Function ECU controls ISC stepper motor to adjust the bypass intake air quantity and stablize the idle speed. 4-12...
  • Page 62 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 RPM and throttle opening are higher than the default value, ECU controls AISV opening or closure.

  • Page 63: 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 64: Efi System Components Description

    To this chapter contents 4. Fuel Injection System EFi System Components Description ECU (Electronic Control Unit) Functional 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 65: Throttle Body

    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 66: Map Sensor

    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 67 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 68 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 69 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 70 To this chapter contents 4. Fuel Injection System TW 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 71 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 72 To this chapter contents 4. Fuel Injection System 1. 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 73: Roll Over Sensor

    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 tilt 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 74 To this chapter contents 4. Fuel Injection System ISC (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 75 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 76 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 77: 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 78 To this chapter contents 4. Fuel Injection System Transistor 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 79 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 80: Efi System Circuit

    To this chapter contents 4. Fuel Injection System EFi System Circuit (20A) (15A) (20A) Charging Indicator Injection System warning lights MIL 21 TSSM Other Y Y Y appliances K-LINE 09 CRK-P 03 CRK-M Power relay IGP 01 W/BR Eng. Con. relay Eng.

  • Page 81: 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 + TSSM No use Test switch signal (A/D) CRK-P Crankshaft pos.

  • Page 82: Troubleshooting

    To this chapter contents 4. Fuel Injection System Troubleshooting EFi Circuit inspection Main switch on Bulbs broken? Fuse broken? Battery voltage is too low? Warning lights extinguished after 2 seconds? ECU Power line bad contact? Poor contact the main power switch? ECU fault？...
  • Page 83 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 Warning lights extinguished after 2 Inspection process in accordance with seconds? circuit inspection 1. Use diagnosis tool to view EMS fault content Display warning lights Fault Code?
  • Page 84 To this chapter contents 4. Fuel Injection System Idle flameout diagnosis Idle flameout Throttle line is not too 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 85 To this chapter contents 4. Fuel Injection System CO value revised anomaly Sensor equipped with the system, in principle, not adjusted CO value, such as CO value deviated from the normal range, check O Sensor and other agencies anomaly. Idle flameout Throttle line is not too jammed to revert to full closure? Link diagnosis tool to view EFI fault...

  • Page 86: Integrated Troubleshooting Procedure

    To this chapter contents 4. Fuel Injection System Integrated Troubleshooting Procedure Checking, Detection of Fault status Fault reasons Parts specifications adjusting maintenance projects determination Project and steps Battery Use meter direct Battery voltage Battery electricity Diagnosis tool ● ● ● ●...
  • Page 87 To this chapter contents 4. Fuel Injection System Continued from previous page Closed-loop Observation O2 O2 sensor O2 sensor fault O2 sensor ● ● ● ● systems for sensor voltage voltage is ECU fault voltage beating ● mobility changes (Standed maintained in a specifications: motorcycle so that...
  • Page 88 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 Remove fuel pump lines coupler. Release the fuel tube folder, removed the fuel tube. Remove the fuel tank fixed bolts (Bolt ×...

  • Page 89: 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 intake temperature sensor coupler. Remove intake tube fixed bolt (bolt×1).

  • Page 90: Efi System Diagnosis Methods

    To this chapter contents 4. Fuel Injection System EFi System Diagnosis Methods When the motorcycle injection system in the wrong signal, 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. Overhaul, the diagnosis tool can be used for troubleshooting (refer to diagnosis tool use guide), or manually by the meter warning light inspection revealed that the fault codes (refer to checking signal fault codes discriminant method), the two methods for maintenance.

  • Page 91: Check Light Fault Codes Differentiation

    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 92: Fault Code And Sensors Table

    To this chapter contents 4. Fuel Injection System Fault Code and Sensors Table Fault Fault Description Parts Inspection codes Throttle position sensor fault TP Sensor and wire 0120 0105 Manifold absolute pressure sensor fault MAP sensor and wire 0115 Engine temperature sensor fault (water) TW Sensor and wire 0195 Engine oil temperature sensor fault (oil)

  • Page 93: Fault Code And Check Light Flashing Lighting Identification Table

    To this chapter contents 4. Fuel Injection System Fault Code and Check Light Flashing Lighting Identification Table Fault Check Check light flashing Fault Description Parts Inspection codes light state long 0，short 6 Throttle position sensor fault Lighting Throttle position sensor and wire 0120 Fault detection procedures Please refer to the "EFI System components description"...

  • Page 94: Efi System Diagnostic Tool - V70

    To this chapter contents 4. Fuel Injection System EFi System Diagnostic Tool - 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 Software cartridge Software cartridge slots...
  • Page 95 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 96 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 97 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 98 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 99 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 100 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 101 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---------- ºC (Outside Temp.) →Intake air temperature ●...
  • Page 102 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 103 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 104 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 105 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 106 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 107: 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 Code position temp. voltage press. state vacuum state control phenomena Detection sensor sensor system Can’t start Start...

  • Page 108: 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 109 To this chapter contents 4. Fuel Injection System Note: 4-60...
  • Page 110 Home page Contents . Removal & Installation of Engine Precautions in Operation···················· 5-1 Rear Fork ·············································· 5-9 Engine Removal ·································· 5-2 Engine Bush Removal ························· 5-11 Engine Hanger ····································· 5-8 Engine Installation ······························· 5-12 Precautions in Operation General Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame.

  • Page 111: Engine Removal

    To this chapter contents 5. Removal & Installation of Engine Engine Removal Open inner box cover. Remove battery cover (1 screw). Remove the battery negative (-) cable. Remove the battery positive (+) cable. Positive Negative Open the seat. Remove the luggage box (6 bolts, 2 screws). (Refer to chapter 14) Remove right and left side covers (4 screws on each side.).
  • Page 112 To this chapter contents . Removal & Installation of Engine Remove the temperature meter sensor and engine Temperature meter Engine temperature temperature sensor wire couplers. sensor sensor Throttle position sensor Remove throttle position sensor coupler. Inlet temperature sensor Remove inlet temperature sensor coupler. Remove secondary air electromagnetic valve pipe.
  • Page 113 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 start motor wire from the start relay. Start motor wire O2 sensor coupler Remove O2 sensor wire coupler. O2 sensor coupler Remove fuel pump relay wire coupler.
  • Page 114 To this chapter contents . Removal & Installation of Engine Carburetor type and other common Auto by-starter coupler Mechanical Remove the power coupler of auto by-starter. Remove the spark plug cap. Spark plug cap Remove the generator power wire and pulse Couplers of the generator and generator connector.
  • Page 115 To this chapter contents 5. Removal & Installation of Engine Remove the air cleaner inlet pipe connection bolt 1 Bolt (1 bolt). Remove the air cleaner connection bolts (2 bolts). Remove the air cleaner. 2 bolts Remove the exhaust muffler (3 bolts, 2 nuts). 2 nuts 3 bolts Drain out coolant, and remove coolant inlet hose.
  • Page 116 To this chapter contents . Removal & Installation of Engine Remove the coolant outlet hose and Outlet hose thermo-sensor wire. Thermo-sensor wire Remove rear brake hose clamp and rear brake caliper. Brake hose clamp 2 bolts Remove the right rear cushion lower bolt (1 bolt). Rear axle nut 2 bolts Remove the rear fork bolts (2 bolts).

  • Page 117: Engine Hanger

    To this chapter contents 5. Removal & Installation of Engine Remove left rear cushion lower bolt (1 bolt). 1 bolt With a bracket to support the engine to prevent Frame side bolt from it damage by falling down as removing the engine.

  • Page 118: 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 119 5. 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 120: Engine Bush Removal

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

  • Page 121: Engine Installation

    To this chapter contents 5. Removal & Installation of Engine Engine Installation 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. Route all cables and wires in accordance with the routine layout.

  • Page 122: Cylinder Head / Valve

    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 123: 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 124: 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 125: 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 126 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 127: 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 128 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 129: 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 130 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 131: 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 132: 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 133 To this chapter contents 6. Cylinder Head / Valve Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.

  • Page 134: 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 135: 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 136 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 137: 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 138 Home page Contents 7. Cylinder / Piston Mechanism Diagram ···························· 7-1 Piston Ring Installation ······················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ································ 7-7 Troubleshooting··································· 7-2 Cylinder Installation ····························· 7-7 Cylinder / Piston Removal··················· 7-3 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m...

  • Page 139: 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 LM25W5 LM30W Item Standard Limit Standard Limit I.D. 70.995~71.015 71.100 72.995~73.015 73.100 Out of round 0.050...

  • Page 140: Cylinder / Piston Removal

    To this chapter contents 7. Cylinder / Piston Cylinder / 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 141 To this chapter contents 7. Cylinder / Piston Measure the cylinder upper surface for warpage. Service limit: 0.05 mm Measure the clearance between piston rings and ring 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 142 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 143: 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. All marks on the piston rings must be forwarded to up side.

  • Page 144: 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 Do not let the opening of piston pin clip align with the piston cutout.
  • Page 145 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 146: V-Belt Drive System

    Home page Contents . V-Belt Drive System Mechanism Diagram···························· 8-1 Drive Belt ············································· 8-5 Precautions in Operation ···················· 8-2 Drive Face ············································ 8-7 Troubleshooting ·································· 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 147: Precautions In Operation

    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 Universal holder:...

  • Page 148: Left Crankcase Cover

    To this chapter contents . V-Belt Drive System Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (8 bolts) Remove 2 dowel pin and gasket. 8 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
  • Page 149 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 150: Drive Belt

    To this chapter contents . V-Belt Drive 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 Bearing stay collar Universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
  • Page 151 To this chapter contents 8. V-Belt Drive 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 152: Drive Face

    To this chapter contents . V-Belt Drive 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 153 To this chapter contents 8. V-Belt Drive 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 154 To this chapter contents . V-Belt Drive 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 155: Clutch Outer / Driven Pulley

    To this chapter contents 8. V-Belt Drive 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.
  • Page 156 To this chapter contents . V-Belt Drive System Clutch weight 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 157 To this chapter contents 8. V-Belt Drive 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 158 To this chapter contents . V-Belt Drive System Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 159 To this chapter contents 8. V-Belt Drive 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 160: Final Drive Mechanism

    Home page Contents . Final Drive Mechanism Mechanism Diagram ······························ 9-1 Final Drive Mechanism Inspection ······· 9-4 Precautions in Operation ······················ 9-2 Bearing Replacement ···························· 9-5 Troubleshooting ···································· 9-2 Final Drive Mechanism Reassembly ···· 9-8 Final Drive Mechanism Disassembly ··· 9-3 Mechanism Diagram Final shaft Final gear...

  • Page 161: Precautions In Operation

    Oil quantity: 180 c.c. (160 c.c. when replace) Torque value Gear box cover 2.6~3.0kgf-m Special tools Bearing (6205) driver SYM-9615000-6205 Bearing (6205) puller SYM-9100400 HMA RA1 6205 Bearing (6203) driver SYM-9620000 Drive shaft & oil seal (25*40*8) socket SYM-9120200-HMA Bearing (HK1516) driver SYM-9100200-HMA HK1516 Bearing (6204) driver...

  • Page 162: Final Drive Mechanism Disassembly

    To this chapter contents . Final Drive Mechanism Final Drive Mechanism Disassembly 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 163: Final Drive Mechanism Inspection

    To this chapter contents 9. Final Drive Mechanism Final Drive Mechanism Inspection Check if the drive shaft in burned, 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 164: Bearing Replacement

    SYM-6204001 Shaft protector SYM-6204010 Remove final shaft bearing and counter shaft bearing from left crankcase using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Inner bearing puller Caution Never install used bearings. Once bearing removed, it has to be replaced with new one.
  • Page 165 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 166 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 167: Final Drive Mechanism Reassembly

    Clutch nut wrench Drive shaft and seal install socket 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 168 Home page Contents 10. AC. Generator / Start Clutch Mechanism Diagram ···························10-1 Flywheel Removal ······························ 10-5 Precautions in Operation ···················10-2 Start Clutch ········································· 10-6 Right Crankcase Cover Removal ······10-3 Flywheel Installation ·························· 10-8 AC. Generator Removal······················10-4 AC.Generator Installation ·················· 10-9 Right Crankcase Cover Bearing ········10-4 Right Crankcase Cover Installation ··...

  • Page 169: Precautions In Operation

    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-6204022 Universal holder SYM-2210100 10-2...

  • Page 170: Right Crankcase Cover Removal

    To this chapter contents 10. AC. Generator / Start Clutch Right Crankcase Cover Removal Remove left 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 171: Ac. Generator Removal

    Replace it if necessary. Remove the bearing 6201with inner bearing puller. Special tool: Inner bearing puller SYM-6204022 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 172: Flywheel Removal

    Installs 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.G. flywheel puller. Special tool: AC.G. Flywheel puller SYM-3110000-HMA Flywheel puller Remove flywheel and starting driven gear. 10-5...

  • Page 173: Start Clutch

    To this chapter contents 10. AC. Generator / Start Clutch Start Clutch Start Clutch Inspection Remove start clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the start 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 174 To this chapter contents 10. AC. Generator / Start 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 175: 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 176: Ac.generator Installation

    To this chapter contents 10. AC. Generator / Start Clutch AC. Generator Installation 3 screws Install the AC.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase.
  • Page 177 To this chapter contents 10. AC. Generator / Start Clutch Notes: 10-10...

  • Page 178: Crankshaft / Crankcase

    Home page Contents 11. Crankshaft / Crankcase Mechanism Diagram ··························11-1 Crankcase Disassembly ···················· 11-3 Precautions in Operation···················11-2 Crankshaft Inspection ······················· 11-4 Troubleshooting ·································11-2 Crankcase Assembly························· 11-6 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 0.8~1.2kgf-m 11-1...

  • Page 179: Precautions In Operation

    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-6204001 Inner bearing puller SYM-6204022 Clutch nut wrench...

  • Page 180: 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 Clutch nut wrench SYM-9020200...

  • Page 181: Crankshaft Inspection

    To this chapter contents 11. Crankshaft / Crankcase 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 182 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-6204001 11-5...

  • Page 183: Crankcase Assembly

    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 184 To this chapter contents 11. Crankshaft / Crankcase 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 Right flank the wave washer piece certainly must install.
  • Page 185 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 186: Cooling System

    Home page Contents 12. Cooling System Mechanism Diagram ··························12-1 Change of Coolant ····························· 12-5 Precautions in Operation···················12-2 Radiator ·············································· 12-6 Troubleshooting ·································12-2 Water Pump ········································ 12-8 Diagnosis for Cooling System ··········12-3 Thermostat ········································· 12-12 Mechanism Diagram Radiator filler cap Reserve tank Reserve tank inlet pipe Thermo switch (fan) Cooling fan...

  • Page 187: Precautions In Operation

    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 Troubleshooting The engine temperature is too high The engine temperature is too low...

  • Page 188: Diagnosis For Cooling System

    To this chapter contents 12. Cooling System Diagnosis for Cooling System 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 189 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 190: Change Of Coolant

    Stop the engine. Add coolant to proper level if necessary. Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unclear trade mark refrigerant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% 12-5...

  • Page 191: Radiator

    To this chapter contents 12. Cooling System Check reserve tank Open the inner box lid. Check the liquid level in the reservoir. Add coolant to proper level if too low. Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in the cooling system the refrigerant backflow floods.
  • Page 192 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 193: 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. Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 194 To this chapter contents 12. Cooling System Check any wear and damage of the mechanical Mechanical seal seal and inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Water pump mechanical seal driver Replacement of Mechanical Seal Remove the inside bearing by inner bearing puller.
  • Page 195 To this chapter contents 12. Cooling System Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Install a new outside bearing to the right Water pump bearing crankcase cover.
  • Page 196 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 The rotor is left thread.

  • Page 197: Thermostat

    To this chapter contents 12. Cooling System Thermostat Thermo sensor 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 198 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 199 To this chapter contents 12. Cooling System Notes: 12-14...

  • Page 200: Body Cover Mechanism Diagram

    Home page Contents 13. Body Cover Mechanism Diagram ···························13-1 Front Under Spoiler ··························· 13-10 Maintenance ········································13-2 Rear Carrier ········································ 13-10 Handle Cover·······································13-3 Luggage Box ······································ 13-11 Front Cover ·········································13-4 Rear Body Cover································ 13-12 Meter Panel··········································13-6 Floor Panel ········································· 13-13 Inner Box ·············································13-7 Front Fender·······································...

  • Page 201: Maintenance

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

  • Page 202: Handle Cover

    To this chapter contents 13. Body Cover Handle Cover Remove Loosen the 2 screws from handle upper cover front end. 2 screws Loosen the 2 screws from handle upper cover rear end. Remove right and left handle side cover. 2 screws Remove the handle upper cover cap.

  • Page 203: Front Cover

    To this chapter contents 13. Body Cover Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Each side 2 screws Loosen 6 screws from the wind screen and remove the wind screen. 6 screws Loosen 4 screws from the meter visor and remove the meter visor.
  • Page 204 To this chapter contents 13. Body Cover Loosen 2 bolts from the front cover under side. 2 bolts Loosen 2 screws and 2 bolts from the front cover upper side. Each side 1 screw Each side 1 bolt Disconnect the headlight, foggy light and winker Headlight coupler light couplers.

  • Page 205: Meter Panel

    To this chapter contents 13. Body Cover Meter Panel Right side Left side Remove Remove wind screen garnish, wind screen, meter visor and front cover. Remove reserve tank cap. Loosen 4screws from right & left side of the meter panel. 4 screws Loosen 2 screws from in side of meter panel.

  • Page 206: Inner Box

    To this chapter contents 13. Body Cover Inner Box Reserve tank Remove Remove wind screen garnish, wind screen, meter visor, front cover, meter panel, R/L side cover and front under spoiler. Loosen 1 screw from reserve tank stay. 1 screw 1 screw 1 screw Loosen 1 screw from fuse box and remove it.
  • Page 207 To this chapter contents 13. Body Cover Remove the filler pipe cover. Loosen 3 screws of the filler pipe. 3 screws Loosen 2 bolts from inner box under side. Each side 1 bolt Loosen 2 bolts from inside of the inner box. Disconnect the hazard light and foggy light switch couplers.

  • Page 208: Side Cover

    To this chapter contents 13. Body Cover Side Cover Remove Loosen 2 screws from the side cover side end. 2 screws Loosen 2 screws from the side cover upper end. 2 screws Remove the side cover. Installation Install in reverse order of removal procedures. 13-9...

  • Page 209: Front Under Spoiler

    To this chapter contents 13. Body Cover Front Under Spoiler Each side 1 bolt Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover and R/L side cover. Loosen 2 screw and 2 bolts from the front under spoiler upper end.

  • Page 210: Luggage Box

    To this chapter contents 13. Body Cover Luggage Box 2 screws Remove Open the seat. Loosen 2 screws from the luggage box rear cover. Disconnect the luggage box light and switch coupler. Remove the luggage box rear cover. 2 bolts Loosen 2 bolts from luggage box front side 4 bolts Loosen 4bolts from luggage box rear side.

  • Page 211: Rear Body Cover

    To this chapter contents 13. Body Cover Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel. Each side 1 screw Loosen right and left side screws from rear side of the body cover. Each side 1 screw Disconnect the tail light coupler.

  • Page 212: Floor Panel

    To this chapter contents 13. Body Cover Floor Panel Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover, R/L side cover, front under spoiler, inner box, luggage box and body cover. Loosen 4 bolts and 2 screws from floor panel. Each side 2 bolts Remove floor panel.

  • Page 213: Rear Fender

    To this chapter contents 13. Body Cover Rear Fender Loosen 4 bolts from rear fender. Each side 1 bolt 2 bolts Remove the rear fender. Installation Install in reverse order of removal procedures. 13-14...

  • Page 214: Brake System

    Home page Contents 14. Brake System Mechanism Diagram ···························· 14-1 Brake Fluid Replacement / Air-bleed·· 14-6 Precautions in Operation ···················· 14-2 Front Brake Caliper······························ 14-7 Troubleshooting ·································· 14-3 Rear Brake Caliper ······························· 14-8 Disk Brake System Inspection············ 14-4 Brake Disk ············································ 14-9 Adding Brake Fluid······························...

  • Page 215: Precautions In Operation

    To this chapter contents 14. Brake System Precautions in Operation Caution Inhaling asbestos 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. The brake caliper can be removed without removing the hydraulic system.

  • Page 216: Troubleshooting

    To this chapter contents 14. Brake System Troubleshooting 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 217: 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 218: 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 219: Brake Fluid Replacement / Air-Bleed

    To this chapter contents 14. Brake System Brake Fluid Replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay valve the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.

  • Page 220: 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 221: 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 222: 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 223 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 224 To this chapter contents 14. Brake System Master Cylinder Installation 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 225 To this chapter contents 14. Brake System Note: 14-12...

  • Page 226: Steering / Front Wheel / Front Cushion

    Home page Contents 15. Steering / Front Wheel / Front Cushion Mechanism Diagram ···························· 15-1 Front Wheel ·········································· 15-5 Precautions in Operation ···················· 15-2 Front Cushion ······································ 15-8 Troubleshooting ·································· 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 227: Precautions In Operation

    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 Troubleshooting...

  • Page 228: 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 229 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 230: 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 231 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 232 To this chapter contents 15. Steering / Front Wheel / Front Cushion Assembly Dist collar Dust seal 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. 6201U Caution Carefully install the bearing in correct and...

  • Page 233: 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 234: Steering Stem

    Remove top cone race and 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 235 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 236: Rear Wheel / Rear Fork / Rear Cushion

    Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram ···························16-1 Rear Wheel ········································· 16-3 Precautions in Operation ···················16-2 Rear Fork ············································ 16-5 Troubleshooting ·································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 237: Precautions In Operation

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Precautions in Operation General Information 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...

  • Page 238: Muffler

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Muffler Removal Loosen the 2 nuts from exhaust muffler front side. 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler. Installation Install in reverse order of removal procedures.
  • Page 239 To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Remove rear wheel axle nut. 1 nut Remove rear fork and both side collars. Remove the rear wheel. 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.

  • Page 240: 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 241: 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 Upper bolt Removal Remove the luggage box, rear carrier and body covers.

  • Page 242: Electrical System

    Home page Contents 17. Electrical System Mechanism Diagram ··························17-1 Starting System ································· 17-11 Precautions in Operation···················17-2 Meter··················································· 17-13 Specification ·······································17-2 Light / Bulb········································· 17-15 Troubleshooting ·································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 ·······································...

  • Page 243: Precautions In Operation

    To this chapter contents 17. Electrical System Precautions in Operation When removing 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 244: Troubleshooting

    To this chapter contents 17. Electrical System Troubleshooting 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 Improper operation of the main switch Poor connection or short-circuit of the Low voltage discharging system...

  • Page 245: Battery

    To this chapter contents 17. Electrical System Battery Removal Loosen 1 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 246: Fuse

    To this chapter contents 17. Electrical System Fuse Fuse circuit diagram Fuse box (Headlight) Fuse 20A Headlight (Hi-beam) Black Meter Green White Headlight Blue (Lo-beam) Winker & hazard Yellow control unit (Meter & Operate) Fuse 15A Key relay Main switch REG.

  • Page 247: 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 Black system lamp Green Yellow Starting motor Regulator rectifier Inspection (KΩ) ∞ ∞ ∞ ∞ ∞...
  • Page 248 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. Ω Connect an ohmmeter to the each terminal end. Check the continuity of the each terminal end, and Ω...
  • Page 249 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 250 To this chapter contents 17. Electrical System Ignition System Ignition circuit diagram VCU. Main switch Side stand Roll over sensor Power relay switch GR/L Fuse 15A Engine stop switch Fuse 20A Ignition coil ENG. Control unit AC. G. (ECU) Battery Crankshaft position sensor Tachometer...
  • Page 251 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: 2.8Ω±15% (20ºC) Replacement on ignition coil Remove the cap from the spark plug.

  • Page 252: Starting System

    To this chapter contents 17. Electrical System Starting System Starting circuit diagram Main switch Front brake switch Fuse 20A Brake light Rear brake switch Start relay Battery Start switch Start motor Side stand switch SB/O Engine stop relay White Black Blue Engine stop switch Green...
  • Page 253 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 254: Meter

    To this chapter contents 17. Electrical System Meter Meter circuit diagram Meter (Ignition) Fuse 15A Turn right indicator Main switch Fuse 20A Turn left indicator Charge High beam indicator indicator REG. REC. Side stand warning light Eng. temperature indicator Thermo sensor Battery Foggy right indicator Fuel injection indicator...
  • Page 255 To this chapter contents 17. Electrical System Removal of meter Remove wind screen garnish, wind screen, meter visor, front cover, meter visor. (Refer chapter 14) Disconnect the coupler of the speedometer, and take off the meter panel and meter. Meter coupler 4 screws Loosen 4 screws from meter panel.

  • Page 256: Light / Bulb

    To this chapter contents 17. Electrical System Light / Bulb Headlight and foggy light circuit diagram (Headlight) White Fuse 20A Black Blue Green Brown Position & meter illumination light Lo-beam light Lo-beam relay Light switch Beam switch Hi-beam light Hi-beam relay Main switch Fuse 15A Passing switch...
  • Page 257 To this chapter contents 17. Electrical System Headlight bulb replacement Hold the headlight bulb socket. Rotate the headlight bulb and remove it. Replace with new bulb if necessary. Specification: Lo-beam bulb 12V 55W (H11) Hi-beam bulb 12V 55W (H11) Caution Headlight bulb can be replaced without removing the front cover.
  • Page 258 To this chapter contents 17. Electrical System Foggy light bulb replacement Hold the foggy light bulb socket. Rotate the foggy light bulb and remove it. Replace with new bulb if necessary. Specification: Foggy light bulb 12V 27W Installation Install the bulb of the headlight in reverse order of removal.

  • Page 259: Switch / Horn

    To this chapter contents 17. Electrical System Switch / Horn 2 blots 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 Main switch coupler Wire Color Black Blake...
  • Page 260 To this chapter contents 17. Electrical System Left handle switch High and low 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 Position Winker switch...

  • Page 261: Fuel Unit

    To this chapter contents 17. Electrical System Fuel Unit Fuel unit 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 4 bolts from fuel unit and remove it.

  • Page 262: Cooling Fan Thermo Switch

    To this chapter contents 17. Electrical System Cooling Fan 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 263: Thermo Unit

    To this chapter contents 17. Electrical System Thermo Unit Thermo unit 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 test.

  • Page 264: Emission Control System

    Home page Contents 18. Emission Control System Mechanisms in the Emission Control Catalytic Converter (CATA)················· 18-4 System ··················································18-1 Secondary Air Introduction System ··· 18-5 Functions of Mechanism in the Emission Positive Crankcase Ventilation System Control System·····································18-1 (P.C.V.) ·················································· 18-8 Fuel Evaporative Emission Control System Inspection Items···································...
  • Page 265 To this chapter contents 18. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) Construction: Reduce HC to pollute air. To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Vacuum hose Fuel tank Blow-by hose Air cleaner Engine Vapor hose Purge control valve...
  • Page 266 To this chapter contents 18. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge...
  • Page 267 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 harmless CO gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.
  • Page 268 To this chapter contents 18. Emission Control System Secondary Air Introduction System 1. Construction Secondary air filter Fuel injector Intake valve Flesh air Vacuum hose Engine Cylinder head Flesh air Mixture gas First burn exhaust Reed valve Purged exhaust gas Air injection solenoid valve Vacuum Exhaust valve...
  • Page 269 To this chapter contents 18. Emission Control System 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject solenoid valve (AISV). b. System hose leakage. c. Abnormal ignition timing. d. Lean mixture gas. e. Abnormal fuel supply. Rich Exhaust Gas: a.
  • Page 270 To this chapter contents 18. Emission Control System Warm-up test: Start engine. Remove the air injection filter. Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet Reed valve Air filter Secondary air inject Exhaust muffler...
  • Page 271 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 Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.
  • Page 272 To this chapter contents 18. Emission Control System Inspection Items Secondary air injection system 1. Visually inspect the reed valve, air injection solenoid valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Evaporative Emission Control System 1.
  • Page 273 To this chapter contents 18. Emission Control System Note: 18-10...

  • Page 274: Electrical Diagram

    Home page Contents . Electrical Diagram LM25W5 / LM30W Electrical Diagram 19-1...
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