Sym HD2 125 Service Manual
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Sym HD2 125 Service Manual

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Foreword
How to Use This Manual
Contents
Mechanism Illustration
HD2 125 / 200
SERVICE MANUAL
20110209

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Summary of Contents for Sym HD2 125

  • Page 1 Foreword How to Use This Manual Contents Mechanism Illustration HD2 125 / 200 SERVICE MANUAL 20110209...
  • Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, HD2 125 / 200 is different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
  • Page 3 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG HD2 125 / 200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 Homepage CONTENTS Page Content Index 1-1 ~ 1-24 GENERAL INFORMATION 2-1 ~ 2-14 MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-60 FUEL INJECTION SYSTEM 6-1 ~ 6-8 ENGINE REMOVAL 7-1 ~ 7-14 CYLINDER HEAD / VALVE 8-1 ~ 8-8 CYLINDER / PISTON 9-1 ~ 9-14...
  • Page 5 Home page Contents MECHANISM ILLUSTRATIONS HD2 125 / 200 Battery/CDI Oil lever / Oil filter Water pump AC. Generator Winker relay Horn Fuel unit Radiator Ignition coil Luggage box Spark plug Fuel tank cap Front winker light Tail light/ Rear winker light...

  • Page 6: Table Of Contents

    Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Torque Values ........1-13 General Safety ........1-2 Troubleshooting-Carburetor Model ..1-15 Service Precautions ......1-3 Troubleshooting-EFi Model....1-19 Specifications ........1-9 Lubrication Points........ 1-23 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    To this chapter contents 1. GENERAL INFORMATION General safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you ‧...

  • Page 8: Service Precautions

    To this chapter contents 1. GENERAL INFORMATION Service Precautions Always use with Sanyang genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-designed parts unsmooth control and premature worn out. for Sanyang motorcycle may damage the motorcycle.
  • Page 9 To this chapter contents 1. GENERAL INFORMATION The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if 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 LC12W1-6 Overall Length 2070 mm Front Telescopic Fork Suspension System Overall Width 760 mm Rear Unit Swing Overall Height 1240 mm Front 100 / 80-16 50P Tire Specifications Wheel Base 1380 mm Rear 120 / 80-16 60P...
  • Page 15 To this chapter contents 1. GENERAL INFORMATION MAKER SANYANG MODEL LC12W2-6 Overall Length 2070 mm Front Telescopic Fork Suspension System Overall Width 760 mm Rear Unit Swing Overall Height 1240 mm Front 100 / 80-16 50P Tire Specifications Wheel Base 1380 mm Rear 120 / 80-16 60P...
  • Page 16 To this chapter contents 1. GENERAL INFORMATION MAKER SANYANG MODEL LC18W1-6 Overall Length 2070 mm Front Telescopic Fork Suspension System Overall Width 760 mm Rear Unit Swing Overall Height 1240 mm Front 100 / 80-16 50P Tire Specifications Wheel Base 1380 mm Rear 120 / 80-16 60P...
  • Page 17 To this chapter contents 1. GENERAL INFORMATION MAKER SANYANG MODEL LC18W2-6 Overall Length 2070 mm Front Telescopic Fork Suspension System Overall Width 760 mm Rear Unit Swing Overall Height 1240 mm Front 100 / 80-16 50P Tire Specifications Wheel Base 1380 mm Rear 120 / 80-16 60P...

  • Page 18: Torque Values

    To this chapter contents 1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Type Tighten Torque Tighten Torque 5 mm bolt、nut...
  • Page 19 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks Stopper nut for engine hanger 1.8~2.2 rubber Engine hanger nut 4.0~5.0 Engine hanger bolt 4.0~5.0 Engine connection bolt 3.5~4.5 Front wheel axle nut 5.0~7.0 Rear wheel shaft nut 10.0~12.0...

  • Page 20: Troubleshooting-Carburetor Model

    To this chapter contents 1. GENERAL INFORMATION Troubleshooting-Carburetor Model 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 21 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 1. Poor fuel supply Engine speed can be Engine speed can not be 2.
  • Page 22 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 Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good Poor...
  • Page 23 To this chapter contents 1. GENERAL INFORMATION E. Clutch, Driving And Driving Pulley PROBABLE CAUSES FAULT CONDITIONS 1. Driving belt worn out or deformation 2. Driving disk damaged 3. Driving pulley spring broken Engine can be started but 4. Clutch ling broken 5.

  • Page 24: Troubleshooting-Efi Model

    To this chapter contents 1. GENERAL INFORMATION Troubleshooting-EFi Model A. Engine cannot be started or difficult to be started Check and adjustment Fault condition Probable causes Press the fuel injector feed pipe and confirm whether there is fuel in the feed pipe 1.
  • Page 25 To this chapter contents 1. GENERAL INFORMATION B. Engine runs sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Accelerate gradually and check engine RPM 1. Clogged air cleaner Engine RPM cannot be 2.
  • Page 26 To this chapter contents 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Incorrect ignition timing (malfunction of Normal Abnormal ECU or AC Generator) Check for any air sucked in through the throttle body insulator gasket 1.
  • Page 27 To this chapter contents 1. GENERAL INFORMATION E. CLUTCH AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Worn out or damaged drive belt 2. Damaged movable drive face 3. Damaged driven face spring Engine can be started but the 4. Broken clutch weight vehicle cannot run 5.

  • Page 28: Lubrication Points

    To this chapter contents 1. GENERAL INFORMATION Lubrication Points Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Seat catch Speedometer gear/ Side stand pivot Main stand pivot Rear wheel bearing front wheel bearing 1-23...
  • Page 29 To this chapter contents 1. GENERAL INFORMATION Note: 1-24...
  • Page 30 Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ······················ 2-1 Brake Light Switch/Starting Inhibitor Switch ················································· 2-9 Periodical Maintenance Schedule ········ 2-2 Headlight Beam Distance ·················· 2-9 Fuel Lines / Cable ·································· 2-3 Clutch Disc Wear································ 2-9 Air Cleaner·············································· 2-4 Side Stand···········································...

  • Page 31: 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 1000 kilometers as a reference which ever comes first.

  • Page 32: Fuel Lines / Cable

    To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines / Cable Fuel tank Vacuum hose Remove luggage box. Remove rear carrier. Remove body covers. Check all lines, and replace it when they are deterioration, damage or leaking. Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

  • Page 33: Air Cleaner

    To this chapter contents 2. MAINTENANCE INFORMATION Air Cleaner 6 screws Air Cleaner Element Remove 6 screws from the air cleaner cover and then remove the cover. Remove 4 screws, and then remove the air 4 screws cleaner element. Caution The air cleaner element is made of paper so do not soap it into water or wash it with water.

  • Page 34: Valve Clearance

    To this chapter contents 2. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.

  • Page 35: Ignition System

    To this chapter contents 2. MAINTENANCE INFORMATION Ignition System Caution Transistor ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether ECU function is in normal or not. Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover.

  • Page 36: Drive Belt

    To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Remove mounting bolt located under air cleaner. Remove 7 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.
  • Page 37 To this chapter contents 2. MAINTENANCE INFORMATION Filling Out Brake Fluid Tighten the drain valve, and add brake fluid. Screws Operate the brake lever so that brake fluid Master cylinder cap contents inside the brake system hoses. Diaphragm plate Air Bleed Operation Upper Diaphragm Connect a transparent hose to draining valve.

  • Page 38: Brake Light Switch/Starting Inhibitor

    To this chapter contents 2. MAINTENANCE INFORMATION Make sure the brake lining condition. Replace Brake lining wear Lining limitation groove the lining if the brake lining wear limitation groove close to the brake disc. Brake Lining Replacement Compress the caliper and let the brake lining out of the caliper mounting plate.

  • Page 39: Side Stand

    To this chapter contents 2. MAINTENANCE INFORMATION Side Stand Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly.

  • Page 40: Wheel/Tire

    To this chapter contents 2. MAINTENANCE INFORMATION Wheel/Tire Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails, stones or other materials. Appointed tire pressure Tire size Front tire Rear tire Load for Tire 1.75 2.25...

  • Page 41: Special Tools List

    To this chapter contents 2. MAINTENANCE INFORMATION Special Tools List NAME NAME NAME R/L. CRANK DISASS. TOOL CRANK SHAFT PULLER L. CRANK SHAFT BRG. DRIVER SYM-1120000-H9A SYM-1130000-H9A SYM-9100200-H9A (ψ22mm) (ψ30mm) CRANK SHAFT BRG. FIXING NAME NAME NAME CRANK CASE BUSH PULLER...
  • Page 42 To this chapter contents 2. MAINTENANCE INFORMATION NAME NAME NAME INNER BEARING PULLER OUTER BEARING PULLER AC.G. FLYWHEEL PULLER SYM-6204002 SYM-6204001 SYM-3110A00 (12*20*5) (6901) WATER PUMP OIL SEAL WATER PUMP BEARING WATER PUMP MECHANICL NAME NAME NAME DRIVER DRIVER SEAL DRIVER...
  • Page 43 To this chapter contents 2. MAINTENANCE INFORMATION NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush (long) SYM-1130000-L SYM-1130010 SYM-1130031 NAME Extension bush (short) NAME NAME Fuel pressure gauge Vacuum pressure gauge SYM-1130032 SYM-HT07011 SYM-HT07010 NAME NAME...
  • Page 44 Home page Contents 3. LUBRICATION SYSTEM Precautions in Operation ···················· 3-2 Engine Oil Strainer Clean ···················· 3-3 Troubleshooting ·································· 3-2 Oil Pump ··············································· 3-4 Engine Oil ············································· 3-3 Gear Oil ················································· 3-7 Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Spray Lubrication...

  • Page 45: Precautions In Operation

    SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 110 c.c. Change: 100 c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) unit: mm 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 46: Engine Oil

    To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 47: Oil Pump

    To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Remove snap ring and take out oil pump driving chain and sprocket. Clip Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump.
  • Page 48 To this chapter contents 3. LUBRICATION SYSTEM Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor.
  • Page 49 To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value：0.8~1.2kgf-m Make sure that oil pump shaft can be rotated freely. Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft. Install starting gear and generator.

  • Page 50: Gear Oil

    To this chapter contents 3. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device.
  • Page 51 To this chapter contents 3. LUBRICATION SYSTEM Note:...
  • Page 52 Home page Contents 4. FUEL SYSTEM Precautions in Operation ....4-2 Auto By-Starter ........4-7 Trouble Diagnosis....... 4-3 Float Chamber ........4-8 Carburetor removal......4-4 Fuel Tank..........4-10 Vacuum chamber ........ 4-4 Air Cleaner ......... 4-11 Air Cut-Off Valve ......... 4-6 To fuel vapor separator...

  • Page 53: Precautions In Operation

    To this chapter contents 4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.

  • Page 54: Trouble Diagnosis

    To this chapter contents 4. FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system )

  • Page 55: Carburetor Removal

    To this chapter contents 4. FUEL SYSTEM Carburetor removal Throttle cable Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Disconnect automatic by-starter connector. Release the clamp strip of air cleaner. Air cleaner clamp Auto by-starter Air cleaner clamp...
  • Page 56 To this chapter contents 4. FUEL SYSTEM Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack. Installation Install needle, spring and needle seat to vacuum Needle seat Spring piston. Piston Needle Install vacuum piston to carburetor body and align...

  • Page 57: Air Cut-Off Valve

    To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve.

  • Page 58: Auto By-Starter

    To this chapter contents 4. FUEL SYSTEM Auto By-Starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter. Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the auto starter with a new one if resistance value exceeds standard.

  • Page 59: Float Chamber

    To this chapter contents 4. FUEL SYSTEM Float Chamber 3 Screws Float Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
  • Page 60 To this chapter contents 4. FUEL SYSTEM Assembly Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking fuel level Caution Pilot screw...

  • Page 61: Fuel Tank

    To this chapter contents 4. FUEL SYSTEM Fuel Tank Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts).) Remove body cover. Disconnect fuel unit connector. Remove fuel unit (4 screws). Caution ․Do not bend the float arm of fuel unit Fuel unit connector...

  • Page 62: Air Cleaner

    To this chapter contents 4. FUEL SYSTEM Air Cleaner Clamp strip of air cleaner Removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Loosen the clamp strip of air cleaner. Remove the Vapor hose. Remove the Air cleaner (2 bolts). Installation Install the tank in the reverse order of removal.
  • Page 63 To this chapter contents 4. FUEL SYSTEM Note: 4-12...
  • Page 64 Home page Contents 5. Fuel Injection System EFi System Components····················· 5-1 Integrated Troubleshooting Procedure ······························································· 5-37 EFi System Vehicle Configuration ····· 5-2 Air Cleaner ············································ 5-40 EFi System Operation ························· 5-3 EFi System Diagnosis Methods ·········· 5-41 EFi System Introduction······················ 5-4 Check Light Fault Codes Differentiation Fuel System··········································...

  • Page 65: Efi System Vehicle Configuration

    To this chapter contents 5. Fuel Injection System EFi System Vehicle Configuration Fuel Pump Rollover Sensor TA Sensor ASIV Ignition Coil INJECTOR MAP Sensor TW Sensor O2 Sensor...

  • Page 66: Efi System Operation

    To this chapter contents 5. 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 67: Efi System Introduction

    To this chapter contents 5. Fuel Injection System EFi System Introduction Based on 4-stroke SOHC engine, displacement 180 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 68: Fuel System

    To this chapter contents 5. 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 69: Ignition System

    To this chapter contents 5. 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 70: Sensors / Drives

    To this chapter contents 5. 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 71 To this chapter contents 5. 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 72 To this chapter contents 5. 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 73 To this chapter contents 5. 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 74 To this chapter contents 5. 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 75 To this chapter contents 5. 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. 5-12...
  • Page 76 To this chapter contents 5. 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 77: Precautions In Operation

    To this chapter contents 5. 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 78: Efi System Components Description

    To this chapter contents 5. 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 79 To this chapter contents 5. 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 80 To this chapter contents 5. 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 81 To this chapter contents 5. 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 82 To this chapter contents 5. 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 83 To this chapter contents 5. 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 84 To this chapter contents 5. 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 85 To this chapter contents 5. 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 86 To this chapter contents 5. 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 87 To this chapter contents 5. 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 88 To this chapter contents 5. 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 89 To this chapter contents 5. 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 90 To this chapter contents 5. 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 91 To this chapter contents 5. 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 92 To this chapter contents 5. 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 93 To this chapter contents 5. 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 94: Efi System Circuit

    To this chapter contents 5. Fuel Injection System EFi System Circuit (20A) (20A) EFi Check light TSSM Other Y Y Y appliances K-LINE PU/R Power relay IGP 01 W/BR CRK-P CRK-M G/BR R/GR Fuel pump relay FLPR HEGO A/D HEGO HT ISCAP ISCBN BR/B...

  • Page 95: Ecu Pin Configuration

    To this chapter contents 5. 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 + PU/R ROLL TSSM Rollover Sensor Test switch signal (A/D) CRK-P Crankshaft pos.

  • Page 96: Troubleshooting

    To this chapter contents 5. 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 97 To this chapter contents 5. 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 98 To this chapter contents 5. 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 99 To this chapter contents 5. 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 100: Integrated Troubleshooting Procedure

    To this chapter contents 5. 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 101 To this chapter contents 5. 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 102 To this chapter contents 5. Fuel Injection System Remove fuel pump/fuel unit Remove rear carrier Remove the luggage box. Remove the center cover. Remove rear bodycover. (Refer to chapter 14) Remove / Install fuel pump and fuel unit Remove fuel pump remove fuel fixed bolts (Bolt ×...

  • Page 103: Air Cleaner

    To this chapter contents 5. 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. Screw ×...

  • Page 104: Efi System Diagnosis Methods

    To this chapter contents 5. 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 105: Check Light Fault Codes Differentiation

    To this chapter contents 5. 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 106: Fault Code And Sensors Table

    To this chapter contents 5. 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 107: Fault Code And Check Light Flashing Lighting Identification Table

    To this chapter contents 5. 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 108: Efi System Diagnostic Tool - V70

    To this chapter contents 5. 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 109 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 110 To this chapter contents 5. 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 111 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 5-48...
  • Page 112 To this chapter contents 5. 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 113 To this chapter contents 5. 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 114 To this chapter contents 5. 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 115 To this chapter contents 5. 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 116 To this chapter contents 5. 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 117 To this chapter contents 5. 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 118 To this chapter contents 5. 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 119 To this chapter contents 5. 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 120 To this chapter contents 5. 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 121: Troubleshooting Table

    To this chapter contents 5. 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 122: Comprehensive Maintenance List

    To this chapter contents 5. 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 123 To this chapter contents 5. Fuel Injection System NOTE: 5-60...
  • Page 124 Home page Contents . ENGINE REMOVAL Precautions in Operation ....6-1 Engine Hanger Bush Removal ... 6-6 Engine Removal........6-2 Engine Hanger Installation ....6-7 Engine Hanger Removal......6-5 Engine Installation....... 6-7 Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable. The following parts can be serviced as engine mounted on frame.

  • Page 125: Engine Removal

    To this chapter contents 6. ENGINE REMOVAL Removal of Engine AC. G. coupler Open seat and remove the luggage box (6 bolts and 1 screw). Remove the rear carrier (4 bolts). Remove the battery cover (2 screws). Remove the battery negative (-) post. Remove the battery positive (+) post.
  • Page 126 To this chapter contents . ENGINE REMOVAL Remove water hoses from water pump. Water hoses Water pump Remove the thermo-sensor wire. Remove the muffler (3 bolts, 2 nuts). 3 bolts 2 nuts Remove rear inner fender Right side Left side 2 Bolts 1 Bolt...
  • Page 127 To this chapter contents 6. ENGINE REMOVAL Remove the mounting bolt of right-rear cushion. 2 Bolts Remove the rear fork mounting bolt. (2 bolts) Remove rear wheel mounting nut. Rear wheel axle nut Remove rear fork and collars. Remove rear wheel. Remove the mounting bolt of left-rear cushion.

  • Page 128: Engine Hanger Removal

    To this chapter contents . ENGINE REMOVAL Remove the right and left side engine hanger Left side mounting bolts and nuts, then remove engine. Caution ․Support engine and frame separately with special supporters to prevent from engine or frame falling down. Engine hanger nut and bolt Right side Engine mounting nut and bolt...

  • Page 129: Engine Hanger Bush Removal

    To this chapter contents 6. ENGINE REMOVAL Engine Hanger Bush Removal Bush Check if engine hanger bush and cushion rubber bush for damage. Pressing out If engine hanger and the rear cushion rubber bush damaged. Then, with the bush remover / presser, Ø...

  • Page 130: Engine Hanger Installation

    To this chapter contents . ENGINE REMOVAL Engine Hanger Installation Install engine hanger onto engine. Install engine mounting bolts & nuts and then tighten the nuts. Torque value: 4.0~5.0kgf-m Engine Installation Check if the bush of engine hanger parts and cushion for damage.
  • Page 131 To this chapter contents 6. ENGINE REMOVAL Note:...
  • Page 132 Home page Contents . CYLINDER HEAD / VALVE Mechanism Diagram····························7-1 Valve Stem Replacement ····················7-8 Precautions in Operation····················7-2 Valve Seat Inspection and Service·····7-9 Troubleshooting ··································7-3 Cylinder Head Reassembly·················7-11 Cylinder Head Removal ······················7-4 Cylinder Head Installation···················7-12 Cylinder Head Disassembly ···············7-6 Valve Clearance Adjustment ··············7-14 Cylinder Head Inspection ···················7-7 Mechanism Diagram 0.8~1.2kgf-m...

  • Page 133: Precautions In Operation

    To this chapter contents 7. 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 134: 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 135: Cylinder Head Removal

    To this chapter contents 7. CYLINDER HEAD / VALVE Cylinder Head Removal Vacuum tube Clamp strip Remove seat, luggage box and body cover. Remove engine. (Refer to chapter 5) Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator.
  • Page 136 To this chapter contents . CYLINDER HEAD / VALVE Remove the 2 cylinder head mounting bolts from 4 Nuts 2 Insulator bolts cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Cylinder head mounting Remove the cylinder head.

  • Page 137: Cylinder Head Disassembly

    Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120) Remove valve stem guide seal. Clean carbon deposits in combustion chamber.

  • Page 138: Cylinder Head Inspection

    To this chapter contents . 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: 0.5 mm Valve spring free length Measure the free length of intake and exhaust valve springs.

  • Page 139: Valve Stem Replacement

    To this chapter contents 7. CYLINDER HEAD / VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide.

  • Page 140: 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 141 To this chapter contents 7. CYLINDER HEAD / VALVE Use 60° cutter to cut a quarter lower part 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 142: Cylinder Head Reassembly

    Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120) Tap valve stem to make valve retainer and valve stem sealing properly. Caution Place and hold cylinder head on to working table so that can prevent from valve damaged.

  • Page 143: Cylinder Head Installation

    To this chapter contents 7. CYLINDER HEAD / VALVE Cylinder Head Installation Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts. Carburetor insulator Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole.
  • Page 144 To this chapter contents . CYLINDER HEAD / VALVE Tighten 4 nuts and washers on the cylinder head 4 Nuts 2 Insulator bolts upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover. Torque value: 2.0~2.4kgf-m Install and tighten spark plug Torque value: 2.0~2.4kgf-m Caution...

  • Page 145: Valve Clearance Adjustment

    To this chapter contents 7. CYLINDER HEAD / VALVE Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
  • Page 146 Home page Contents 8. CYLINDER / PISTON Mechanism Diagram ·························· 8-1 Piston Removal ··································8-4 Precautions in Operation ·················· 8-2 Piston Ring Installation······················8-6 Troubleshooting································· 8-2 Piston Installation ······························8-7 Cylinder Removal······························· 8-3 Cylinder Installation ···························8-7 Mechanism Diagram...

  • Page 147: Precautions In Operation

    To this chapter contents 8. CYLINDER / PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit：mm LC12W & LC18W Item Standard Limit ID ( LC18W not included) 56.995~57.015 57.016 Cylinder...
  • Page 148 To this chapter contents 8. CYLINDER / PISTON Cylinder Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth.

  • Page 149: Piston Removal

    To this chapter contents 8. CYLINDER / PISTON Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 150 To this chapter contents 8. CYLINDER / PISTON Measure the outer diameter of piston pin. Service Limit: 15.040 mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06 mm Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.

  • Page 151: Piston Ring Installation

    To this chapter contents 8. 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 152: Piston Installation

    To this chapter contents 8. CYLINDER / PISTON Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 153 To this chapter contents 8. CYLINDER / PISTON Note:...
  • Page 154 Home page Contents . V-BELT DRIVE SYSTEM Mechanism Diagram ··························· 9-1 Drive Belt ··············································9-4 Precautions in Operation···················· 9-2 Drive Face·············································9-6 Troubleshooting ·································· 9-2 Clutch Outer / Driven Pulley················9-9 Left Crankcase Cover ························· 9-3 Mechanism Diagram 3.5~4.5kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m...

  • Page 155: Precautions In Operation

    33.940 ID of drive face 34.000~34.025 34.060 Torque value Special Service Tools Driven face nut: 5.0~6.0kgf-m Clutch spring compressor: SYM-2301000 Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002 Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder: SYM-2210100 Bearing driver:...

  • Page 156: Left Crankcase Cover

    To this chapter contents . V-BELT DRIVE SYSTEM Left Crankcase Cover Left crankcase cover removal Remove body cover. Remove air cleaner. (2 bolts) Remove L crankcase cover. (7 bolts) Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.

  • Page 157: Drive Belt

    To this chapter contents 9. V-BELT DRIVE SYSTEM Driving Belt Removal Remove left crankcase cover Hold drive face with universal holder, and remove nut and drive face. Universal holder Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
  • Page 158 To this chapter contents . V-BELT DRIVE SYSTEM Installation Caution Pull out driven face to avoid it closing. Driven face Install driving belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.

  • Page 159: Drive Face

    To this chapter contents 9. V-BELT DRIVE SYSTEM Drive Face Removal Remove left crankcase cover. Hold generator flywheel with universal holder, and then remove drive face nut. Remove drive face. Universal holder Remove driving belt and movable drive face comp Movable drive face from crankshaft.
  • Page 160 To this chapter contents . 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 effected. Check if rollers are worn or damaged.
  • Page 161 To this chapter contents 9. 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 162: Clutch Outer/Driven Pulley

    To this chapter contents . V-BELT DRIVE SYSTEM Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt and clutch outer/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.
  • Page 163 To this chapter contents 9. V-BELT DRIVE SYSTEM Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 83.2 mm Free length Driven pulley...
  • Page 164 To this chapter contents . V-BELT DRIVE SYSTEM Clutch weight Replacement Spring Driving plate Remove snap ring and washer, and then remove 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 165 To this chapter contents 9. V-BELT DRIVE SYSTEM Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 166 To this chapter contents . 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 Movable driven face Install the movable driven face onto driven face.
  • Page 167 To this chapter contents 9. V-BELT DRIVE SYSTEM Note: 9-14...
  • Page 168 Home page Contents 10. FINAL DRIVE MECHANISM Mechanism Diagram ··························· 10-1 Final Drive Mechanism Inspection ·····10-4 Precautions in Operation···················· 10-2 Bearing Replacement ··························10-5 Troubleshooting ·································· 10-2 Final Drive Mechanism Reassembly ··10-8 Final Drive Mechanism Disassembly· 10-3 Mechanism Diagram Bearing (6004) Final shaft Final gear Counter gear...

  • Page 169: Precautions In Operation

    SYM-9120200 Inner bearing puller: SYM-6204002 Outer bearing puller: SYM-6204001 Drive shaft puller: SYM-1130000-L Drive shaft install bush: SYM-1130010 Extension bush (long): SYM-1130031 Extension bush (short): SYM-1130032 Troubleshooting Engine can be started but motorcycle can not be moved. Damaged driving gear...

  • Page 170: Final Drive Mechanism Disassembly

    To this chapter contents 10. FINAL DRIVE MECHANISM Final Drive Mechanism Disassembly Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover and drive shaft. 7 bolts Remove final gear and shaft. Remove counter shaft and gear.

  • Page 171: Final Drive Mechanism Inspection

    To this chapter contents 10. FINAL DRIVE MECHANISM Final Drive Mechanism Inspection Check if the countershaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box. Rotate each bearing’s inner ring with fingers. Bearing Oil seal Check if bearings can be turned in smooth and...

  • Page 172: Bearing Replacement

    To this chapter contents 10. FINAL DRIVE MECHANISM Bearing Replacement Caution Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove driving shaft bearing and counter shaft bearing from left crankcase using following tools: Special tool: Inner bearing puller Install new drive shaft bearing and counter shaft...
  • Page 173 To this chapter contents 10. FINAL DRIVE MECHANISM Install new final shaft seal. Oil seal driver Special tool: Oil seal driver (27*42*7) Install new final shaft bearing. Special tool: Bearing driver Bearing driver (6203/6004UZ) Press out the drive shaft from gear box cover. Inner bearing puller Using shaft protector as operation.
  • Page 174 To this chapter contents 10. FINAL DRIVE MECHANISM Install a new drive shaft bearing onto gear box cover. Special tool: Bearing driver (6204) Bearing driver Install a new final shaft bearing and counter shaft Bearing driver bearing onto gear box cover. Special tool: Bearing driver (6203/6004UZ) Bearing driver (6301)

  • Page 175: Final Drive Mechanism Reassembly

    To this chapter contents 10. FINAL DRIVE MECHANISM Final Drive Mechanism Reassembly Apply with grease onto the oil seal lip of final driving shaft. Install countershaft, counter gear, final shaft and final driving gear. Final shaft Final drive gear Countershaft Install dowel pin and new gasket.
  • Page 176 To this chapter contents 10. FINAL DRIVE MECHANISM Apply with grease onto new oil seal lip, and then Oil seal driver install the oil seal. Special tool: Oil seal driver (20*32*6) Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase.
  • Page 177 To this chapter contents 10. FINAL DRIVE MECHANISM Note: 10-10...
  • Page 178 Home page Contents 11. AC. GENERATOR / START CLUTCH Mechanism Diagram ··························11-1 Start Clutch········································· 11-4 Precautions in Operation···················11-2 Flywheel Installation·························· 11-7 Right Crankcase Cover Removal ······11-3 ACG. Set Installation ························· 11-7 ACG. Set Removal······························11-3 Right Crankcase Cover Installation·· 11-7 Flywheel Removal ······························11-3 Mechanism Diagram 1.0~1.4kgf-m 5.0~6.0kgf-m...

  • Page 179: Precautions In Operation

    20.026~20.045 20.100 OD of starting clutch gear 42.175~42.200 42.100 Torque value Flywheel nut 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 1.0~1.4kgf-m Tools Special tools A.C.G. flywheel puller: SYM-3110A00 Universal holder: SYM-2210100 11-2...

  • Page 180: Right Crankcase Cover Removal

    To this chapter contents 11. AC. GENERATOR / START CLUTCH Right Crankcase Cover Removal 9 bolts Remove 9 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. 2 bolts ACG. Set Removal Remove 2 mounted bolts from pulse generator and then remove it.

  • Page 181: Start Clutch

    To this chapter contents 11. AC. GENERATOR / START CLUTCH Remove the oil through guide pin from crankshaft. Pull out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Flywheel puller Start Clutch Removal Remove starting driven gear. Remove mounting plate, starter reduction gear, and the shaft.
  • Page 182 To this chapter contents 11. AC. GENERATOR / START CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the starting clutch gear. Service Limit: ID: 20.1 mm OD: 42.10 mm Check the starting reduction gear and shaft for wear or damage.
  • Page 183 To this chapter contents 11. AC. GENERATOR / START CLUTCH Remove 3 hexagon bolts with air and hex socket wrenches. Disassembly Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt.

  • Page 184: Flywheel Installation

    To this chapter contents 11. AC. GENERATOR / START CLUTCH Flywheel Installation Align the key on crankshaft with the flywheel groove, and then install the flywheel. Insert the oil through guide pin onto crankshaft. Make sure that there is no other material stock on it.
  • Page 185 To this chapter contents 11. AC. GENERATOR / START CLUTCH Install the water pump cover onto crankcase cover. Connect water hose to the right crankcase cover and water pump cover. 11-8...
  • Page 186 Home page Contents 12. CRANKCASE / CRANKSHAFT Mechanism Diagram ··························12-1 Crankcase Disassembly ···················· 12-3 Precautions in Operation···················12-2 Crankshaft Inspection ······················· 12-5 Troubleshooting ·································12-2 Crankcase Reassembly ····················· 12-6 Mechanism Diagram 1.2~1.6kgf-m 1.0~1.5kgf-m 0.8~1.2kgf-m 1.5~3.0kgf-m 12-1...

  • Page 187: Precautions In Operation

    R/L. crank disassemble/ install tool: SYM-1300001-H9A L. crank shaft bearing driver: SYM-9100200-H9A Crank shaft bearing fixing socket: SYM-9100210-H9A Crank shaft puller: SYM-1130000-H9A L. crank shaft oil seal driver (25*40*8): SYM-9121600 Outer bearing puller: SYM-6204010 Inner bearing puller: SYM-6204020 Clutch nut wrench: SYM-9020200...

  • Page 188: Crankcase Disassembly

    To this chapter contents 12. CRANKCASE / CRANKSHAFT Crankcase Disassembly Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the bolt and remove the tensioner. Cam chain setting plate 2 bolts Loosen 2 bolts on the right crankcase. 4 bolts Loosen 4 bolts on the left crankcase.
  • Page 189 12. CRANKCASE / CRANKSHAFT Remove crank by left crank shaft. Refer to chapter 2: Special tools Special tool: R/L. crank case disassemble/install tool (SYM-1120000-H9A) Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface.

  • Page 190: Crankshaft Inspection

    To this chapter contents 12. CRANKCASE / CRANKSHAFT Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.

  • Page 191: Crankcase Reassembly

    To this chapter contents 12. CRANKCASE / CRANKSHAFT Crankcase Reassembly Special tool: R/L. crank case disassemble/install tool L. crank shaft bearing driver Crank shaft bearing fixing socket Crank shaft puller Clutch nut wrench The new bearing and bearing driver, puts on the left crank case.
  • Page 192 To this chapter contents 12. CRANKCASE / CRANKSHAFT Install R/L. crank case disassemble/install tool on Crank shaft the left crank case. puller Again turns on crank shaft puller on the crankshaft spiral tooth. Caution Crank shaft puller lock into on as far as possible the crank spiral tooth, prevented pulls the bad crank spiral tooth.
  • Page 193 To this chapter contents 12. CRANKCASE / CRANKSHAFT Tighten 4 bolts on the crankcase. 4 bolts Torque value: 0.8~1.2kgf-m Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal.
  • Page 194 Home page Contents 13. COOLING SYSTEM Mechanism Diagram ··························13-1 System Test········································ 13-5 Precautions in Operation···················13-2 Radiator ·············································· 13-6 Troubleshooting ·································13-2 Water Pump ········································ 13-8 Trouble Diagnosis for Cooling System Thermostat ········································· 13-12 ·····························································13-3 Thermo switch (fan) Mechanism Diagram Cooling fan Radiator filler cap Reserve tank Radiator filler cap...

  • Page 195: 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 196 To this chapter contents 13. COOLING SYSTEM Trouble 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 cooled down, open cap to Water leaking problem leakage? check the capacity of...
  • Page 197 To this chapter contents 13. 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 198: System Test

    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. By-pass pipe Concentration: 50% 13-5...

  • Page 199: Radiator

    To this chapter contents 13. COOLING SYSTEM Check reserve tank Remove the front cover, and then remove reserve tank filler cap. Check the liquid level in the reservoir. Add coolant to proper level if too low. Reinstall the reserve tank filler cap. Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in...
  • Page 200 To this chapter contents 13. COOLING SYSTEM Remove coolant outlet pipe and reserve tank pipe, Reserve tank pipe and then remove radiator and cooling fan. Coolant outlet pipe Disassembly Loosen the 4 bolts from the fan duct, and then remove the fan duct and radiator plate. Cooling fan Loosen the 4 bolts from the fan and remove the bolts x3...

  • Page 201: Water Pump

    To this chapter contents 13. 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 202 To this chapter contents 13. 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. Replacement of Mechanical Seal Water pump bearing Remove the inside bearing by inner bearing puller.
  • Page 203 To this chapter contents 13. 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 204 To this chapter contents 13. 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 205: Thermostat

    To this chapter contents 13. COOLING SYSTEM Thermostat By-pass pipe Temperature sensor Please refer to chapter 17 for inspection of temperature sensor. Removal Remove the luggage box and body cover. Drain out the coolant. Disconnect the cable of temperature sensor. Disconnect the by-pass pipe.
  • Page 206 To this chapter contents 13. COOLING SYSTEM Inspection Visually inspect thermostat for any damage. 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.
  • Page 207 To this chapter contents 13. COOLING SYSTEM Note: 13-14...

  • Page 208: Mechanism Diagram

    Home page Contents 14. BODY COVER Mechanism Diagram··························· 14-1 Rear Carrier ········································· 14-9 Maintenance ········································ 14-2 Body Cover·········································· 14-10 Front Cover ········································· 14-3 Inner Box ············································· 14-11 Handle Front Cover ···························· 14-4 Floor Panel ·········································· 14-12 Handle Rear Cover······························ 14-5 Front Fender········································...

  • Page 209: Maintenance

    To this chapter contents 14. BODY COVER Maintenance Body covers disassemble sequence: Handle front cover Front cover Seat & Luggage box Handle rear cover Front under spoiler Rear carrier Inner box Body cover Right front fender B Left front fender B Rear fender Front fender Center cover...

  • Page 210: Front Cover

    To this chapter contents 14. BODY COVER Front Cover Removal Loosen 8 screw frome the front cover. 4 screws Loosen 2 screw bottom of front handle cover. 2 screws Remove headlight coupler, and then remove front cover. Headlight coupler Installation Install in reverse order of removal procedures.

  • Page 211: Handle Front Cover

    To this chapter contents 14. BODY COVER Handle Front Cover Disassembly Loosen 2 screws from handle rear cover rear side. 2 Screws Loosen 1 screw from front handle cover. Screw×1 Winker relay coupler Remove the winker relay coupler. Remove the handle front cover. 14-4...

  • Page 212: Handle Rear Cover

    To this chapter contents 14. BODY COVER Handle Rear Cover Remover Remove front cover. Remove speedometer cable. Disconnect each switch connectors. Speedometer cable Switch connectors Remove electric line coupler from the radiator. Coupler 2 Screws Loosen 2 screws from the handle rear cover. Loosen 1 screw from backside of the handle rear cover.

  • Page 213: Side Cover

    To this chapter contents 14. BODY COVER Side Cover Remove Loosen 3 screws from the lift side cover. 3 screws Loosen 3 screws from the right side cover. 3 screws Remove the right & left side cover. Installation Install in reverse order of removal procedures. 14-6...
  • Page 214 To this chapter contents 14. BODY COVER Front Under Spoiler Remove Remove front cover. Loosen 4 screw of the inner box side. 4 screws Loosen 2 screws from front side of the front under spoiler. 2 screws Remove the front under spoiler. Installation Install in reverse order of removal procedures.
  • Page 215 To this chapter contents 14. BODY COVER Luggage Box 4 nuts Remove Open seat. Loosen 4 nuts & 2 bolt of the luggage box. 2 bolts Loosen 1 screw from front side of the body cover. 1 screw Remove the luggage box. Installation Install in reverse order of removal procedures.
  • Page 216 To this chapter contents 14. BODY COVER Rear Carrier 4 bolts Remove Loosen 4 bolts from the rear carrier. Remove the rear carrier. Installation Install in reverse order of removal procedures. 14-9...
  • Page 217 To this chapter contents 14. BODY COVER Body Cover Rubber Remove Remove luggage box and rear carrier. Remove the fuel tank cap and rubber. Fuel tank cap Loosen 2 bolts from the taillight underneath. 2 bolts Loosen 4 screw from the center cover. 4 screw Remove electric line coupler from the taillight and seat look cable.
  • Page 218 To this chapter contents 14. BODY COVER Main switch cover Inner Box Remove Remove the front cover. Loosen 1 bolt from the setting at hook and remove the hook. Remove main switch cover. 1 bolt Loosen 2 screws from the under spoiler. 2 screws Remove the inner box.
  • Page 219 To this chapter contents 14. BODY COVER Floor Panel Remove Loosen 4 screws from the right & left step bar. Remove the right & left step bar covers. 4 screws 2 bolts Loosen 2 screws from the right & left step bar, and then remove step bars.
  • Page 220 To this chapter contents 14. BODY COVER Front Fender Removal Remove the front wheel before removing the front fender. Remove speedometer cable. (1 screw) From front fender left side remove brake pipe clip. 14-13...
  • Page 221 To this chapter contents 14. BODY COVER 3 bolts Use T flex socket wrench, remove front fender in upside bolt. (3 bolts) Downward presses the front fender, will cause it to be separated from the front cushion, and then take down to front.
  • Page 222 To this chapter contents 14. BODY COVER Rear Fender Remove luggage box and seat. Remove rear carrier. Remove body cover. Remove fuel tank. Remove rear fender upper side bolts. (2 bolts) 2 bolts Remove rear fender. Installation Install in reverse order of removal procedures. Center Fender Remove air cleaner.
  • Page 223 To this chapter contents 14. BODY COVER Note: 14-16...
  • Page 224 Contents Homepage 15. BRAKE SYSTEM Front Brake System Diagram 15-1 Hydraulic Disc brake......15-6 ....Rear Brake System Diagram-Drum Brake Air Bleed ..........15-7 .............. 15-2 Brake Caliper ........15-7 Rear Brake System Diagram- Disc Brake Brake Disk Inspection......15-8 ..............

  • Page 225: Rear Brake System Diagram-Drum Brake

    To this chapter contents 15. BRAKE SYSTEM Rear Brake System Diagram – Drum Brake 15-2...

  • Page 226: Rear Brake System Diagram- Disc Brake

    To this chapter contents 15. BRAKE SYSTEM Rear Brake System Diagram – Disc Brake 3.0~4.0kgf-m 0.5~0.6kgf-m 4.0~4.5kgf-m 15-3...

  • Page 227: Precautions In Operation

    To this chapter contents 15. 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 228: Troubleshooting

    To this chapter contents 15. BRAKE SYSTEM Troubleshooting Disk Brake Soft brake lever Uneven brake 1. Air inside the hydraulic system 1. Dirty brake lining/disk 2. Hydraulic system leaking 2. Poor wheel alignment 3. Worn master piston 3. Clogged brake hose 4.

  • Page 229: Hydraulic Disc Brake

    To this chapter contents 15. BRAKE SYSTEM Hydraulic Disk Brake Master cylinder Close the drain valve of the hydraulic Lower disc brake. Plate level Replace the brake fluid. Diaphragm Before the brake fluid reservoir is removed, turn Upper the handle so that the brake fluid reservoir level becomes horizontal, then remove the brake fluid reservoir.

  • Page 230: Air Bleed

    To this chapter contents 15. BRAKE SYSTEM Drain valve Air bubble Air Bleed 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. CAUTION • Do not release the brake lever before the drain valve is closed.

  • Page 231: Brake Disk Inspection

    To this chapter contents 15. BRAKE SYSTEM Brake Disk Inspection Visually check the brake disc for wear or Brake disc break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel.
  • Page 232 To this chapter contents 15. BRAKE SYSTEM Master Master Cylinder Inspection cylinder Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
  • Page 233 To this chapter contents 15. BRAKE SYSTEM Install the rubber cap into the groove correctly. Master cylinder Place the master cylinder onto handlebar, and install the master cylinder seat and its bolts. Alignment The “UP” mark on the seat should face upward. point Align the master cylinder seat with the alignment point on the handlebar.
  • Page 234 To this chapter contents 15. BRAKE SYSTEM Rear Drum Brake Remove brake drum Remove wheel and brake drum. To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
  • Page 235 To this chapter contents 15. BRAKE SYSTEM Install brake lining Apply with a thin coat of grease to the brake Brake cam cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Lock pin Wipe off the excessive grease from brake cam and the anchor pin.
  • Page 236 Home page Contents 16. STEERING / FRONT WHEEL / FRONT CUSHION Mechanism Diagram·························· 16-1 Front Wheel ········································ 16-5 Precautions in Operation ·················· 16-2 Front Cushion····································· 16-8 Troubleshooting ································ 16-2 Steering Stem ····································· 16-9 Steering Handle ································· 16-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 2.4~3.0kgf-m...

  • Page 237: Precautions In Operation

    0.2 ~ 0.3kgf-m Locating screw for the speedometer cable 0.15 ~0.3kgf-m Front cushion upper lock bolt 2.4 ~ 3.0kgf-m Special Tools Steering handle top thread wrench SYM-5320000 Inner bearing puller SYM-6204020 Steering nut wrench SYM-6204010 Driver 32*35mm Driver 42*47mm Troubleshooting...
  • Page 238 To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSHION Steering Handle Holder Removal Remove the handle front cover, handle rear cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake.
  • Page 239 To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSHION Installation Install handle and align with bolt hole. Install bolt and nut and then tighten it. Bolt Torque value: 4.5kgf-m Apply with grease onto throttle cable and the sliding surface of handle.

  • Page 240: Front Wheel

    To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSHION Front Wheel Remove First by the bracket strut frame base, causes the front wheel to float off. Remove the speedometer cable. Turn loose the axle nut. Wheel axle Speedometer cable Pull out the front wheel axle.
  • Page 241 Remove dust seal, bearing and retainer hear box from right side. Special tools: Inner bearing puller (SYM-6204020) Assembly Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist. Speedometer gear box Dist collar collar.
  • Page 242 To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSH Installation Open out brake lining with brake caliper. Place the front wheel between the front cushion. Shaft nut Caution Gear box groove Align the gear box groove with the stopper flange.

  • Page 243: Front Cushion

    To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSH Front Cushion Remove Remove front cover, front under spoiler and front fender. Remove front brake caliper. Remove front wheel. Remove front cushion upper mounting bolts, and then remove front cushion. 4 bolts Installation Align the cover flange with upper level of the...

  • Page 244: Steering Stem

    To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSH Steering Stem Remove Steering lock nut Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing.
  • Page 245 To this chapter contents 16. STEERING / FRONT WHEEL / FRONT CUSH Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.0~2.0kgf-m Steering lock nut Install in reverse order of removal procedures. Top cone-race Shake steering handle up &...
  • Page 246 Home page Contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Mechanism Diagram ··························· 17-1 Muffler ················································· 17-3 Precautions in Operation···················· 17-2 Rear Wheel ········································· 17-3 Troubleshooting ·································· 17-2 Rear Cushion······································ 17-5 Mechanism Diagram 3.5~4.5kgf-m 2.4~3.0kgf-m 1.0~1.2kgf-m 4.0~5.0kgf-m 10.0~12.0kgf-m 3.2~3.8kgf-m 17-1...

  • Page 247: Precautions In Operation

    To this chapter contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Precautions in Operation General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit...

  • Page 248: Muffler

    To this chapter contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Muffler Removal Loosen the 2 nuts from exhaust muffler front side. Caution Disconnect the O2 sensor coupler before removing the exhaust pipe. O2 Sensor 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side.
  • Page 249 To this chapter contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Inspection Rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm Rear fork bearing Free play Rotate the inner ring of the bearing with a finger.

  • Page 250: Rear Cushion

    To this chapter contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Installation Install the rear wheel. Install the inside collar on the rear fork. Install the rear fork onto the rear wheel shaft. Mount the outside collar on the rear fork. Tighten the rear wheel shaft nut.
  • Page 251 To this chapter contents 17. REAR WHEEL / REAR FORK / REAR CUSHION Note: 17-6...

  • Page 252: Mechanism Diagram

    Home page Contents 18. ELECTRICAL SYSTEM Mechanism Diagram ··························18-1 Meters················································· 18-10 Precautions in Operation···················18-2 Light / Bulb········································· 18-11 Technical Specification······················18-2 Switch / Horn······································ 18-14 Troubleshooting ·································18-3 Fuel Unit ············································· 18-17 Battery ·················································18-4 Cooling Fan Thermo Switch ············· 18-18 Charging System ································18-5 Thermo Unit ·······································...

  • Page 253: Precautions In Operation

    To this chapter contents 18. ELECTRICAL SYSTEM Precautions in Operation When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.

  • Page 254: Troubleshooting

    To this chapter contents 18. ELECTRICAL SYSTEM Troubleshooting No voltage Intermittent voltage 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 charging ●...
  • Page 255 To this chapter contents 18. ELECTRICAL SYSTEM Battery Removal Loosen 4 screws and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the motorcycle. 4 screws Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 256: Battery

    To this chapter contents 18. ELECTRICAL SYSTEM Charging System Charging circuit Fuse 20A Main switch AC Generator Regulator rectifier Battery Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal.
  • Page 257 To this chapter contents 18. 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 258 To this chapter contents 18. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the luggage box, rear carrier and body covers. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check points Standard value...

  • Page 259: Ignition System

    To this chapter contents 18. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram Main switch Fuse 20A Ignition coil Battery Spark plug AC. generator Ignition coil inspection Remove the luggage box. Disconnect the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding.

  • Page 260: Starting System

    To this chapter contents 18. ELECTRICAL SYSTEM Starting System Starting circuit diagram Brake light Front brake switch Fuse 20A Fuse 15A Rear brake switch Starter relay Starter switch Battery Starter motor Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch.

  • Page 261: Meters

    To this chapter contents 18. ELECTRICAL SYSTEM Removal of Starter motor Remove the battery cover (5 screws). Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove the luggage box. Remove the air cleaner. Loosen the lock bolts and remove the starter 2 Bolts motor.

  • Page 262: Light / Bulb

    To this chapter contents 18. ELECTRICAL SYSTEM Position light Light / Bulb Replacing bulb for headlight Remove the front cover. Headlight adjustment screw Headlight couplers Disconnect the terminal coupler from the headlight. Headlight bulb Remove the headlight bulb. Replace with new bulb if necessary. Caution Never touch the bulb with finger, which will create a heat point.
  • Page 263 To this chapter contents 18. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Remove the front winker lens (screw x 2). Replace with new front winker light bulb. Replacing the Rear winker light Bulb Remove the rear winker lens (1 screw). Replace with new rear winker light bulb.
  • Page 264 To this chapter contents 18. ELECTRICAL SYSTEM Replacing Bulb of taillight Remove the taillight lens (2 screws). Replace taillight or winker light bulb. 18-13...

  • Page 265: Switch / Horn

    To this chapter contents 18. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position LOCK Main switch Black / Wire Color Black Green White...
  • Page 266 To this chapter contents 18. ELECTRICAL SYSTEM Dimmer and Passing switch Dimmer and passing switch PASS Position PASSING Winker switch Horn switch Wire color Brown White / White Blue Dimmer and passing switch / White Green Winker switch Position FROM R Winker switch PUSH OFF Horn switch...
  • Page 267 To this chapter contents 18. ELECTRICAL SYSTEM Brake Switch While grasp the brake lever firmly, the terminals of white/green and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake switch Horn Remove the front cover. Horn Apply 12 V power source to two terminals of the horn, the horn should sound.
  • Page 268 To this chapter contents 18. ELECTRICAL SYSTEM Fuel Unit Fuel unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove the body cover. Disconnect the coupler of the fuel unit. Fuel unit coupler Remove the fuel unit (screw x 4). Caution Great care shall be taken not to damage or bend the float arm of the gauge.
  • Page 269 To this chapter contents 18. 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 270 To this chapter contents 18. ELECTRICAL SYSTEM 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 Thermo unit Caution Wear gloves and goggles when performing...
  • Page 271 To this chapter contents 18. ELECTRICAL SYSTEM Note: 18-20...
  • Page 272 Homepage Contents 19. WIRING DIAGRAM HD2 125 19-1...
  • Page 273 Homepage Contents 19. WIRING DIAGRAM HD2 200 19-2...

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