Sym MAXSYM 400i Service Manual
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Sym MAXSYM 400i Service Manual

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MAXSYM 400i / 400i ABS / 600i ABS
SERVICE MANUAL
FOREWORD
CONTENTS
HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATION
201404

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Summary of Contents for Sym MAXSYM 400i

  • Page 1 MAXSYM 400i / 400i ABS / 600i ABS SERVICE MANUAL FOREWORD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATION 201404...
  • Page 2 Foreword This service manual contains the technical data of each component inspection and repair for the Sanyang MAXSYM 400i / 400i ABS / 600i ABS scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.
  • Page 3 How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang MAXSYM 400i scooter. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 Homepage Contents Contents Page Content Index 1-1 ~ 1-18 General Information 2-1 ~ 2-16 Maintenance Information 3-1 ~ 3-6 Lubrication System 4-1 ~ 4-58 Fuel Injection System 5-1 ~ 5-4 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 Home page Contents Mechanism Illustration Start / engine stop switch Front winker Luggage box Fuel tank / fuel pump Dimmer / winker / horn seat open / pass switch Main switch Coolant filler cap Taillight / rear winker Headlight Air cleaner Reserve tank Main stand Side stand...
  • Page 6 Homepage Contents 1. General Information Symbols and Marks ······················· 1-1 Torque Values ······························· 1-10 General Safety ······························ 1-2 Troubleshooting ···························· 1-12 Before Servicing ··························· 1-3 Lubrication Points ························· 1-16 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 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 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. ...
  • 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.
  • 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. ...
  • Page 11 To this chapter contents 1. General Information   Insert the terminal completely. When separating a connector, it locker has to be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. ...
  • 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 To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL LX40A Overall Length 2270 mm Front TELESCOPIC FORK Suspension System Overall Width 825 mm Rear UNlT SWING Overall Height 1410 mm Front 120 / 70-15 56S Tire Specifications Wheel Base 1555 mm Rear 160 / 60-14 65H...
  • Page 15 To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL LX60A Overall Length 2270 mm Front TELESCOPIC FORK Suspension System Overall Width 825 mm Rear UNlT SWING Overall Height 1410 mm Front 120 / 70-15 56S Tire Specifications Wheel Base 1560 mm Rear 160 / 60-14 65H...
  • Page 16 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 17 To this chapter contents 1. General Information Frame Torque Values Q’ty Thread Dia. (mm) Torque Value (Kg-m) Item 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 18 To this chapter contents 1. General Information Troubleshooting 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 19 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 20 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 1. Incorrect ignition timing Abnormal (malfunction of ECU or AC Generator) Check for any air sucked in through the throttle body insulator gasket...
  • Page 21 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 22 To this chapter contents 1. General Information Lubrication Points Acceleration cable/ Front & rear brake lever pivot Seat locker Steering stem bearing Front wheel bearing Side stand pivot Main stand pivot Rear wheel bearing 1-17...
  • Page 23 To this chapter contents 1. General Information NOTE: 1-18...
  • Page 24 Home page Contents 2. Maintenance Information Precautions in Operation ················· 2-1 Cylinder Compression Pressure ······ 2-8 Periodical Maintenance Schedule ····· 2-2 Drive Belt ······································ 2-8 Engine Oil ······································ 2-3 Steering Handle Top Bearing ··········· 2-9 Engine Oil Strainer Clean ················ 2-3 Cushion·········································...
  • Page 25 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 To this chapter contents 2. Maintenance Information Engine Oil Turn off engine, and park the vehicle in a flat surface with main stand. Check oil level with oil dipstick Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 27 To this chapter contents 2. Maintenance Information Gear Oil Oil inspection bolt Oil level inspection Park the vehicle on a 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 draining.
  • Page 28 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 Adjustment nut operation condition. Air Cleaner Air Cleaner Element Remove 6 screws from the air cleaner cover.
  • Page 29 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 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 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 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 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 limitation mark closed to the edge of brake disc. Caution  It is not necessary to remove brake hose when replacing the brake lining.
  • Page 35 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. Wheel / Tire Caution ...
  • Page 36 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 Valve rocker arm shaft L/Cover Radial Ball Brg 6006 Valve cotter remove & NAME NAME NAME disassemble tool Drive assembly tool SYM-1445100-01 SYM-9615010-REA 6006 SYM-1471110/20 Clutch spring compressor Tappet adjusting wrench Oil seal driver 45*65*10 NAME NAME NAME SYM-2301000-L4A SYM-9001200...
  • Page 38 To this chapter contents 2. Maintenance Information Driven pulley bearing installer Drive shaft bearing installer Counter shaft bearing driver NAME NAME NAME SYM-9100600-L4A DPB SYM-9100420-A6305 SYM-9610000-L4A N1820 NAME Clutch nut wrench NAME Universal holder NAME AC.G. FLYWHEEL PULLER SYM-9020200 SYM-2210100...
  • Page 39 To this chapter contents 2. Maintenance Information Crankshaft bearing install / Crankshaft bearing install tool Fuel pressure gauge NAME NAME NAME remove tool SYM-9100310-L4A (L6C) SYM-9100310-L4A (L6C) SYM-HT07010 Vacuum pressure gauge Cylinder pressure gauge Vehicle circuit test tool kit NAME NAME NAME...
  • Page 40 Disassembly: 350 c.c. Change: 330 c.c. Oil viscosity SEA 10W-40 (Recommended King serial oils) Gear oil Gear oil viscosity SEA 85W-140 (Recommended SYM Hypoid gear oils) Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Clearance between outer rotor and body 0.15~0.20...
  • Page 41 To this chapter contents 3. Lubrication System Engine Oil Turn off engine, and park the vehicle in a flat surface with main stand. Check oil level with oil dipstick Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 42 To this chapter contents 3. Lubrication System Oil Pump Removal Remove generator and starting gear. Remove the oil separator (bolt x 2). Oil separator Remove snap ring and take out oil pump driving chain and sprocket. Torque value: 0.8~1.2 Kg-m Make sure that pump shaft can be rotated freely.
  • Page 43 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 Oil Pump Reassembly...
  • Page 44 To this chapter contents 3. Lubrication System Install the oil pump cover and fixing pin properly SCREW×1 Tighten screw Make sure that oil pump shaft can be rotated freely. Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value: 0.8~1.2 Kg-m Make sure that oil pump shaft can be rotated freely.
  • Page 45 To this chapter contents 3. Lubrication System Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measurement device.
  • Page 46 Home page Contents 4. Fuel Injection System EFi System Components ·················· 4-1 Integrated Troubleshooting Procedure ····················································· 4-36 EFi System Vehicle Configuration ····· 4-2 Air Cleaner ····································· 4-39 EFi System Operation ······················ 4-3 EFi System Diagnosis Methods ········ 4-40 EFi System Introduction ··················· 4-4 Check Light Flault Codes Differentiation Fuel System ····································...
  • Page 47 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 AISV Fuel pump Test switch...
  • Page 48 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 49 To this chapter contents 4. Fuel Injection System EFi System Introduction Based on 4-stroke SOHC engine, displacement 400 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 50 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 51 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 52 To this chapter contents 4. Fuel Injection System Sensors / Drivers Crankshaft Position Sensor (CPS) Crankshaft position sensor Flywheel Description The magnetic field type sensor generates a voltage signal to calculate engine speed with ACG gear ring (18-1 tooth). There is one tooth every 20 degree on the gear ring. But, one of the teeth is blank for the TDC calculating base.
  • Page 53 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 54 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 55 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 56 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 stabilized the idle speed. 4-11...
  • Page 57 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 58 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 59 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 33-pin socket on the unit. ● The hardware component consists of a 16-bit microcomputer that is its ●...
  • Page 60 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 61 To this chapter contents 4. Fuel Injection System MAP Sensor Functional Description: Powered by 5V DC from ECU. It has 3-pin sockets on the sensor. One ● terminal is for power, and 1 terminal are for signal output. And, the rest one is for ground.
  • Page 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 To this chapter contents 4. Fuel Injection System EFi System Circuit 4-30...
  • Page 76 To this chapter contents 4. Fuel Injection System ECU Pin Configuration (ON ECU) ECU Pin Note Pin NO. Pin code Wire color Note IGNITION POWER LOGIC GROUND HEGO O2 SENSOR SENSOR GROUND W/BR THROTTLE POSITION SENSOR SENSOR POWER OUTPUT (+5V) BATT BATTERY POWER GROUND1...
  • Page 77 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 78 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 79 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 80 To this chapter contents 4. Fuel Injection System CO value revised anomaly Sensor equipped with the system, in principle, not adjusted CO LLLvalue; 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 81 To this chapter contents 4. Fuel Injection System Integrated Troubleshooting Procedure Checking, Fault reasons Parts specifications Detection of Fault status adjusting determination maintenance projects Project and steps Battery ● Use meter direct ● Battery voltage ● Battery electricity ● Diagnosis tool measurement is 10 V above? ●...
  • Page 82 To this chapter contents 4. Fuel Injection System Continued from previous page Closed-loop ● Observation O2 ● O2 sensor ● O2 sensor fault ● O2 sensor ● ECU fault systems for senslor voltage voltage is voltage beating mobility changes (Standed maintained in a specifications: motorcycle so that...
  • Page 83 To this chapter contents 4. Fuel Injection System Remove fuel pump/fuel unit Remove side cover. Remove rear carrier Remove rear body cover. Remove floor panel. Remove under cover. (Refer to chapter 14) Fuel pump Remove fuel pump lines coupler. coupler Release the fuel tube folder, removed the fuel tube.
  • Page 84 To this chapter contents 4. Fuel Injection System Air Cleaner Bolt × 6 Air catheter fixed bolts × 1 Clean air cleaner element Remove air cleaner cover (bolt×8). Remove air cleaner filter (bolt×6). Use compressed air to remove the adhesion of dirt, if not too much dirt cleared, please new replacement.
  • Page 85 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 discriminate method), the two methods for maintenance.
  • Page 86 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 87 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 88 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 Throttle position sensor fault Lighting Throttle position sensor and wire long 0，short 6 0120 Fault detection procedures Please refer to the "EFI System components description"...
  • Page 89 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 button Function button Digital button Software cartridge Software cartridge slots...
  • Page 90 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 91 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 92 To this chapter contents 4. Fuel Injection System 1. ECU ID In the directory functions used "▲" "▼" button, select ECU ID project, press the "ENTER" buttom to the implementation of information systems function. ECU ID containing two functions: 1-1. ECU ID Datas 1-2.
  • Page 93 To this chapter contents 4. Fuel Injection System 1-2. ECU Pin Assign Use "▲" "▼" button, select the ECU pin project, and press the "ENTER" button 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 94 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 95 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: RPM (Idle:1550~1750) →Engine idle speed Engine SPD--- ● (Normal:0) →Fault code number FAULT NO.-------- ●...
  • Page 96 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: kPa (Above 98kPa) →Atmospheric pressure BARO------------ ● ºC (Outside Temp.) →Intake air temperature Intake Air---------- ●...
  • Page 97 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: (Set by ECU) →Idle Air Control Valve stepper motor learning LEARNED STEP--------------- ●...
  • Page 98 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 99 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 100 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 101 To this chapter contents 4. Fuel Injection System 6. CO ADAPTION In the directory functions used "▲" "▼" button, select "CO ADAPTION" project, press the "ENTER" button into the CO adjustment screen. Use "◄ left" and "right ►" or "▲" "▼" button, CO value can be adjusted. CO ADAPT: CO adjusted value.
  • Page 102 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 position temp. Code voltage press. state vacuum state control phenomena Detection sensor sensor system ...
  • Page 103 To this chapter contents 4. Fuel Injection System Comprehensive Maintenance List Maintenance Testing Procedures Test items Determine benchmarks Fault reasons Project ● Use meter direct ● Battery voltage ● Battery voltage = 10V Above ● Battery electricity Power and ● Battery connector loose measurement battery voltage voltage ●...
  • Page 104 4. Fuel Injection System 4-59...
  • Page 105 Homepage Contents 5. Engine Removal Precautions in Operation ......5-1 Engine Installation ......5-4 Removal of Engine .........5-2 Precautions in Operation  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 106 To this chapter contents 5. Engine Removal Removal of Engine Disconnect the seat dampers. Remove the air box cover. Disconnect the air temperature sensor coupler. Air temperature sensor coupler Remove the air box. Disconnect the starter motor wire. Starter motor wire Remove the spark plug cap.
  • Page 107 To this chapter contents 5. Engine Removal Remove fuel pipe, vacuum tube and throttle valve wire from the throttle body. Disconnect the EFi system coupler. Remove water hose from water pump. Water hose Remove the thermo-sensor wires. Water pump Remove the muffler (3 bolts, 2 nuts). Bolt X3...
  • Page 108 To this chapter contents 5. Engine Removal Remove the parking brake cable. Rear right cushion bolt Remove the rear brake caliper (2 bolts). Caution Do not operate brake lever after the caliper is removed to avoid clipping the brake pad. Remove the mounting bolt of rear right cushion.
  • Page 109 5. ENGINE REMOVAL...

  • Page 110: Mechanism Diagram

    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 111 To this chapter contents 6. Cylinder Head / Valve Precautions in Operation  This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm.  Remove the engine from the frame before repairing the cylinder head. Specification LX40A Item...
  • Page 112 To this chapter contents . Cylinder Head / Valve Torque Value Cylinder head bolt (LH) 2.0~2.4 kg-m Cylinder head Nut 2.0~2.4 kg-m Sealing bolt of cam chain auto-tensioner 0.8~1.2 kg-m Bolt of cam chain auto-tensioner 1.2~1.6 kg-m Cam sprocket cover bolts 0.8~1.2 kg-m Cam sprocket bolt 1.0~1.2 kg-m...
  • Page 113 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 114 To this chapter contents . Cylinder Head / Valve 4 bolts Remove the side cover mounting blots of cylinder head, and then take out the side cover. Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position.
  • Page 115 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 Remove cam shafts. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Use a valve cotter remove &...
  • Page 116 To this chapter contents . Cylinder Head / Valve Remove valve cotters, spring retainers, springs Inlet valve Inner spring Spring retainer and valves. Exhaust valve Outer spring Cotter Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.
  • Page 117 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 (LX40A) : IN: Replacement when less than 35.600mm EX: Replacement when less than 35.250mm...
  • Page 118 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 33.70 mm Outer spring 38.80 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 119 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 120 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 121 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 122 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 123 To this chapter contents 6. Cylinder Head / Valve Install camshaft into cylinder head. 1 bolt Cam shaft setting plate Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Dowel pins Gasket Cylinder Head Installation Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head.
  • Page 124 To this chapter contents . Cylinder Head / Valve 4 bolts Install cylinder head side cover (4 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 125 To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover. 4 bolts Remove the cylinder head side cover. 4 bolts 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 126: Mechanism Diagram

    Home page Contents 7. Cylinder / Piston Mechanism Diagram························ 7-1 Piston Ring Installation ··················· 7-7 Precautions in Operation ················· 7-2 Piston Installation ··························· 7-8 Troubleshooting ····························· 7-3 Cylinder Installation ························ 7-8 Cylinder / Piston Removal ················ 7-4 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 1.2~1.6kgf-m 1.0~1.4kgf-m...
  • Page 127 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 LX40A Item Standard Limit I.D. 82.995~83.015 83.100 Out of round 0.050 Cylinder Taper...
  • Page 128 To this chapter contents 7. Cylinder / Piston Specification Unit：mm LX60A Item Standard Limit I.D. 91.995~92.015 92.100 Out of round 0.050 Cylinder Taper 0.050 Warpage 0.050 Clearance 0.015~0.050 0.090 between piston ring and 0.015~0.050 0.090 ring groove 0.150~0.300 0.500 Piston/ 0.300~0.450 0.650 Piston ring end...
  • Page 129 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 130 To this chapter contents 7. Cylinder / Piston Measure the cylinder upper surface for warpage. Service limit: 0.050 mm Measure the clearance between piston rings and ring grooves. Service Limit: Top ring: 0.090 mm ring: 0.090 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.
  • Page 131 To this chapter contents 7. Cylinder / Piston cylinder. Measure the outer diameter of piston pin. Service Limit (LX40A) : 19.960 mm Service Limit (LX60A) : 21.960 mm Measure the inner diameter of connecting rod small end. Service Limit (LX40A) : 20.064 mm Service Limit (LX60A) : 22.071 mm Measure the inner diameter of piston pin hole.
  • Page 132 7. Cylinder / Piston...
  • Page 133 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. ...
  • Page 134 To this chapter contents 7. Cylinder / Piston Piston Installation 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 135 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 136 To this chapter contents 7. Cylinder / Piston NOTE: 7-11...
  • Page 137 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 8.5~10.5kgf-m 6.0~7.0kgf-m 0.7~1.1kgf-m...
  • Page 138 To this chapter contents 8. V-Belt Drive System Precautions in Operation General Information  Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.  Drive belt and drive pulley must be free of grease. Specification - LX40 Item Standard value Limit...
  • Page 139 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...
  • Page 140 To this chapter contents 8. 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 141 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 142 To this chapter contents 8. 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 143 To this chapter contents . 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 144 To this chapter contents 8. 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 145 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 affected. Check if rollers are worn or damaged.
  • Page 146 To this chapter contents 8. 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 147 To this chapter contents . 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 148 To this chapter contents 8. 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 149 To this chapter contents . 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 150 To this chapter contents 8. 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 151 To this To this chapter contents chapter . V-Belt Drive System contents 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 152: Table Of Contents

    Homepage Contents 9. Final Drive Mechanism Mechanism Diagram ......9-1 Final Drive Mechanism Inspection ..9-4 Precautions in Operation ....9-3 Bearing Replacement ......9-5 Troubleshooting ........9-3 Final Drive Mechanism Reassembly .. 9-7 Final Drive Mechanism Disassembly . 9-4 Mechanism Diagram –...
  • Page 153 9. Final Drive Mechanism Mechanism Diagram – LX60A Radial ball bearing 6206 UU Oil seal 45*65*10 Needle bearing NK22/20R Final shaft Counter gear Final gear Counter shaft Needle bearing NK22/20R Radial ball bearing 6305 Oil seal 25*40*7 Drive shaft Radial ball bearing CSB305C 2.4~3.0 kgf-m Needle bearing HKS 25*33*18...

  • Page 154: Precautions In Operation

    To this chapter contents 9. Final Drive Mechanism Precautions in Operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4 kg-m Tools Special tools Bearing (6203/6004UZ) driver Bearing (6204) driver...

  • Page 155: Final Drive Mechanism Disassembly

    To this chapter contents 9. 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. Remove gasket and dowel pin. 7 bolts Remove drive shaft. Remove final driving gear and shaft.

  • Page 156: Bearing Replacement

    To this chapter contents 9. Final Drive Mechanism Check bearings on gear box. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 157 To this chapter contents 9. Final Drive Mechanism Remove oil seal, and then remove final shaft bearing from left crankcase. Install new final shaft bearing. Press the bearing in with hydraulic presser. Tool: Bearing (6203/6004UZ) driver (27*42*7) driver Oil seal Press out the driving shaft from gear box cover.

  • Page 158: Final Drive Mechanism Reassembly

    To this chapter contents 9. Final Drive Mechanism Install a new final shaft bearing onto gear box cover. Tool: Bearing (6203/6004UZ) driver Press the bearing in with hydraulic presser. Install the driving shaft onto gear box cover and then place it to proper position. Apply with grease onto new oil seal lip, and then install the oil seal.
  • Page 159 To this chapter contents 9. Final Drive Mechanism Install dowel pin and new gasket. dowel Gasket Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4 kgf-m Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase.
  • Page 160 Homepage Contents 10. AC Generator / Starting Clutch Mechanism Diagram ..... 10-1 Flywheel Removal ......10-3 Precautions in Operation ..... 10-2 Flywheel Installation ...... 10-7 Right Crankcase Cover Removal . 10-3 A.C.G. Set Installation ....10-7 A.C.G. Set Removal ....... 10-3 Right Crankcase Installation ..

  • Page 161: Precautions In Operation

    To this chapter contents 10. AC Generator / Starting Clutch Precautions in Operation ‧ Refer to chapter 5: Engine removal and installation ‧ Refer to chapter 16: The troubleshooting and inspection of alternator ‧ Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm)

  • Page 162: Right Crankcase Cover Removal

    To this chapter contents 10. AC Generator / Starting Clutch Right Crankcase Cover Removal 12 bolts Remove 12 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. A.C.G. Set Removal 2 screws Remove 2 screws from pulse generator and then remove it.

  • Page 163: Flywheel Installation

    To this chapter contents 10. AC Generator / Starting Clutch Flywheel Installation Insert the pin onto crankshaft. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 8.5~10.5 kg-m Tool: Flywheel holder...
  • Page 164 Homepage Contents 11. Crankshaft / Crankcase Mechanism Diagram ...... 11-1 Crankshaft bearing replacement .. 11-5 Precautions in Operation ....11-2 Crankshaft bearing installation ..11-5 Troubleshooting ......11-2 Crankcase Assembly ...... 11-6 Crankcase Disassembly ....11-3 Mechanism Diagram – LX40A 0.7~1.1 kgf-m 6.0~7.0 kgf-m 2.0~2.4 kgf-m...

  • Page 165: Precautions In Operation

    To this chapter contents 11. Crankshaft / Crankcase Precautions in Operation  This Section concerns disassembly of the crankcase for repair purpose.  Remove following components before disassembling crankcase. ─Engine Section 5 －Cylinder head Section 6 －Cylinder and piston Section 7 －Drive pulley and driven pulley Section 8 －AC generator/Start driven gear...

  • Page 166: Crankcase Disassembly

    To this chapter contents 11. Crankshaft / Crankcase Tensioner Crankcase Disassembly Remove the cam chain. Loosen the bolt and remove the tensioner. Remove the water pump shaft locknut. Cam chain Water pump shaft locknut Remove the oil separator (bolt x 2). boltsX2 Remove the oil pump drive sprocket, driven Oil pump drive sprocket...
  • Page 167 To this chapter contents 11. Crankshaft / Crankcase Remove the left crankcase bolts (bolt x 11). Bolt x 11 Remove the right crankcase from the left crankcase. Remove the crankshaft and balancer shaft from the left crankcase. Check the main bearing on the crankcase for any wear.

  • Page 168: Crankshaft Bearing Replacement

    Use the crankshaft main bearing holder to fasten the upper and lower main bearing. Align the oil path on the main bearing and the crankcase. Press the main bearing into the crankcase. Special tool: main bearing installer / remover SYM-9100310-L4A 11-5...

  • Page 169: Crankcase Assembly

    To this chapter contents 11. Crankshaft / Crankcase Crankcase assembly Install the crankshaft and balancer shaft to the left crankcase. Marks on the crankshaft and balancer shaft The marks on the crankshaft and balancer shaft must be aligned. Assemble the right crankcase to the left crankcase.
  • Page 170 To this chapter contents 11. Crankshaft / Crankcase Install the oil separator (bolt x2). Tighten the bolts on the left crankcase ( bolt x 11). Bolt x 11 Tighten the water pump shaft locknut. Install the cam chain and tensioner. 11-7...
  • Page 171 To this chapter contents 11. Crankshaft / Crankcase NOTE: 11-8...
  • Page 172 Home page Contents 12. Cooling System Mechanism Diagram ...... 12-1 Radiator .......... 12-5 Precautions in Operation ....12-2 Steps to fill coolant after engine service ............12-7 Troubleshooting ......12-3 System Test ........12-4 Mechanism Diagram Reserve tank inlet pipe Reserve tank Radiator filler cap Thermo switch (fan)

  • Page 173: Precautions In Operation

    To this chapter contents 12. Cooling System Precautions in Operation Warning: ˙While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.

  • Page 174: Troubleshooting

    To this chapter contents 12. Cooling System Troubleshooting The engine temperature is too high  The water thermometer and the temperature sensor do not work properly.  The thermostat is stuck to close.  Insufficient coolant.  The water hose and jacket are clogged. ...

  • Page 175: System Test

    Stop the engine, and add coolant to proper level if necessary.  Tighten the radiator filler cap. Caution  In order to avoid the radiator rusting, please do not use the uncertified coolant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% 12-4...

  • Page 176: Radiator

    To this chapter contents 12. Cooling System Check reserve tank  Open the inner box lid.  Check the liquid level in the tank.  Add coolant to proper level if necessary. Caution  Add too much coolant in the reserve tank might cause overflow when the temperature increased.
  • Page 177 To this chapter contents 12. Cooling System Thermo switch coupler Disconnect the couplers for the thermo switch and fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Engine coolant. Remove reserve tank coolant inlet pipe. Remove the radiator and the cooling fun.

  • Page 178: Steps To Fill Coolant After Engine Service

    To this chapter contents 12. Cooling System Technical Data Valve begins to open 71 ~ 80℃ Valve stroke 3.5 ~ 4.5 mm at 80℃ Installation Install in reverse order of removal. Caution Always use a new oil ring and apply a coat of grease on it before installation.
  • Page 179 To this chapter contents 12. Cooling System Remove the engine circulation pipe, and pump in high pressure air to the pipe. Pump in high pressure Based on the above steps, coolant could be drained out. Steps to fill coolant: Open this tube Remove the tube connecting to thermostat(19320) cover.
  • Page 180 To this chapter contents 12. Cooling System Close the fuel tube (95001-08550) loop. Close this tube Fill up the coolant from filler neck (19039) without interruption. 12-9...
  • Page 181 To this chapter contents 12. Cooling System Check the air exhausted through the thermostat tube head until coolant come out. Thermostat tube head Thermostat cover joint end Check the air exhausted through the thermostat cover joint until coolant come out. Reconnect thermostat tube Reconnect thermostat tube(19320) to thermostat cover joint(19315)
  • Page 182 To this chapter contents 12. Cooling System Open the radiator cap, and turn on the engine. Overflow is normal. Continue adding water to radiator until equilibrant if the amount of water diminished. Maintain the liquid level in reserve tank between upper and lower limit.
  • Page 183 To this chapter contents 12. Cooling System NOTE: 12-12...
  • Page 184 Home page Contents 13. Body Cover Mechanism Diagram ······················ 13-1 Side Cover ···································· 13-11 Maintenance ································· 13-4 Rear Carrier ·································· 13-12 Handle Cover ································ 13-5 Luggage Box ································ 13-13 Front Cover ··································· 13-6 Rear Body Cover ··························· 13-14 Meter Panel ··································· 13-8 Floor Panel ···································...

  • Page 185: Mechanism Diagram

    13. Body Cover Mechanism Diagram Upper handle cover Double seat Left lower handle cover Right lower handle cover Rear back seat Right side cover Right floor panel Right body cover Inner box lid stiffener RH. RR. grip Inner box lid LH.
  • Page 186 13. Body Cover Mechanism Diagram Maintenance cover Left floor panel Left side cover RR. luggage box FR. luggage box Left body cover Rear cover Under cover Rear fender 13-3...

  • Page 187: Maintenance

    13. Body Cover Maintenance Body covers disassemble sequence: R/L. lower handle covers Double seat Wind screen garnish Upper handle cover Wind screen Rear back seat Front upper cover Front fender R/L. grip Meter visor Under cover R/L. body cover Meter panel R/L.

  • Page 188: 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 Installation Install in reverse order of removal procedures.

  • Page 189: 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 190 To this chapter contents 13. Body Cover Loosen 2 bolts from the front cover under side. 4 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 191: Meter Panel

    To this chapter contents 13. Body Cover Meter Panel 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. Each side 1 screws Loosen 2 screws from in side of meter panel.

  • Page 192: 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 193 To this chapter contents 13. Body Cover Loosen 2 bolts from inner box under side. Each side 2 bolts Loosen 2 bolts from inside of the inner box. Disconnect the hazard light and foggy light switch couplers. Remove inner box. Installation Install in reverse order of removal procedures.

  • Page 194: Side Cover

    To this chapter contents 13. Body Cover Side Cover Remove Loosen 2 screws from the side cover side end. 1 screw Loosen 2 screws from the side cover upper end. 2 screws Remove the side cover. Installation Install in reverse order of removal procedures. 13-11...

  • Page 195: Rear Carrier

    To this chapter contents 13. Body Cover Rear Carrier Remove Wind screen garni Loosen 4 bolts from the rear carrier and remove it. screen garnish garnish Installation Install in reverse order of removal procedures. 13-12...

  • Page 196: Luggage Box

    To this chapter contents 13. Body Cover Luggage Box 3 screws Remove Open the seat. Loosen 3 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 197: 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. Remove the cover Loosen right, left side and middle screws from rear side of the body cover. 3 screws Disconnect the tail light coupler.

  • Page 198: 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 199 To this chapter contents 13. Body Cover NOTE: 13-16...
  • Page 200 14. Brake System Mechanism Diagram ························ 14-1 Front Brake Caliper ························· 14-7 Precautions in Operation ·················· 14-2 Rear Brake Caliper ·························· 14-8 Troubleshooting ······························ 14-3 Brake Disk ······································ 14-9 Disk Brake System Inspection ·········· 14-4 Master Cylinder ······························· 14-9 Adding Brake Fluid ·························· 14-5 Anti-lock Brake System ····················...

  • Page 201: Precautions In Operation

    14. Brake System Precautions in Operation Caution Inhaling asbestos may cause disorders of respiration system or lung cancer; therefore, never use compressed air 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 202: Troubleshooting

    14. Brake System Troubleshooting Slack 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. Blocked brake hose 9.

  • Page 203: Disk Brake System Inspection

    14. Brake System Disk Brake System Inspection Inspection Examine for leaking or damage visually. Inspect brake tube seam with spanner to check if it becomes loose. Checking if there is any interferes, contacts between protected pipeline and other parts by turning the handle bar right or left, pressing the cushion up and down.

  • Page 204: Adding Brake Fluid

    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 maintain the brake system, it is supposed to cover the surface of rubber parts by rags.

  • Page 205: Brake Fluid Replacement / Air-Bleed

    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, hold and release 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 206 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 207 14. Brake System Rear Brake Caliper Removal Caliper mounting bolts ×2 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 208 14. Brake System 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. Brake disk Allowable limit: Front brake disk 4.5 mm Rear brake disk 4.5 mm...
  • Page 209 14. Brake System Remove the rubber pad. Remove the circlip. Cir clip Rubber Remove the piston and the spring. boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master Cylinder Inspection Master cylinder Check the master cylinder for damage or scratch. Replace it if necessary.
  • Page 210 14. Brake System Master Cylinder Install 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. Tighten the brake hose bolt to the specified torque Washers value.
  • Page 211 14. Brake System ABS (Anti-lock Brake System) ABS is designed to help prevent the wheel from locking up when hard brakes are applied while running straight. The ABS automatically regulates the brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping. Brake control function is identical to that of a conventional scooter.
  • Page 212 14. Brake System ABS indicator light: The ABS indicator light goes on when the ignition switch is turned on and goes off shortly after the scooter speed is over 5km/hr. If the indicator light is on, ABS may be out of function. However, the brake system can still work properly. You should have the ABS checked.
  • Page 213 14. Brake System ABS control unit (front view) ABS control unit (left rear view) ABS control unit (right rear view) 14-14...
  • Page 214 14. Brake System Speed sensor coupler Front wheel speed sensor Caution Do not remove the ABS control unit coupler when the main switch is ON, or the ABS control unit will be damaged. 14-15...
  • Page 215 14. Brake System ABS components location ABS indicator ABS / EFi system diagnostic tool coupler ABS control unit Rear wheel speed sensor Front wheel Front wheel speed sensor detective disk Rear wheel detective disk 14-16...
  • Page 216 14. Brake System ABS description Normal brake When the brake is applied, speed sensors detect the front and rear wheel speed. When there is no wheel slip, EV (inlet valve for maintaining pressure) keeps open and AV (outlet valve for pressure reduction) is closed.
  • Page 217 14. Brake System Continuous wheel slip When the wheel speed sensors detect continuous wheel slip, EV keeps closed and AV is open. Brake pressure is reduced (pulsing in the brake lever). Brake caliper lowers the pressure and braking force. Normal brake without wheel slip When the pressure reduction continues, the wheel speed sensors detect no wheel slip.
  • Page 218 14. Brake System ABS trouble code C1021 Abnormal ABS control unit C1014 Abnormal EV / AV relay C1054 Abnormal front EV C1052 Abnormal rear EV C1049 Abnormal front AV C1048 Abnormal rear AV C1059 Abnormal battery voltage (over) C1058 Abnormal battery voltage (too low) C1015 Abnormal oil pump C1033...
  • Page 219 14. Brake System NOTE: 14-20...
  • Page 220 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 ······································...

  • Page 221: Precautions In Operation

    To this chapter contents 14. Brake System Precautions in Operation Caution Inhaling asbestos may cause disorders of respiration system or lung cancer; therefore, never use compressed air or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. ...

  • Page 222: Troubleshooting

    To this chapter contents 14. Brake System Troubleshooting Slack 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 223: Disk Brake System Inspection

    To this chapter contents 14. Brake System Disk Brake System Inspection Inspection Examine for leaking or damage visually. Inspect brake tube seam with spanner to check if it becomes loose. Checking if there is any interferes, contacts between protected pipeline and other parts by turning the handle bar right or left, pressing the cushion up and down.

  • Page 224: 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 maintain the brake system, it is supposed to cover the surface of rubber parts by rags.

  • Page 225: 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, hold and release 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 226: 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 227: Rear Brake Caliper

    To this chapter contents 14. Brake System Rear Brake Caliper Caliper mounting 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 228: 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 229 To this chapter contents 14. Brake System Remove the rubber pad. Remove the circlip. Cir clip Rubber Remove the piston and the spring. boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
  • Page 230 To this chapter contents 14. Brake System Master Cylinder Install 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 231 To this chapter contents 14. Brake System NOTE: 14-12...
  • Page 232 Home page Contents 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 2.9~3.5kgf-m 6.0~8.0kgf-m 2.4~3.0kgf-m 6.0~8.0kgf-m 2.4~3.0kgf-m 2.4~3.0kgf-m 5.0~7.0kgf-m 15-1...

  • Page 233: 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 234: Steering Handle

    To this chapter contents Master cylinder Steering Handle 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. 2 bolts Holder Fixing nut Loosen the deceleration throttle cable fixing nut.
  • Page 235 To this chapter contents 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. Remove the right handle switch. 2 screws Switch connecter Loosen handle mounting nut.

  • Page 236: Front Wheel

    To this chapter contents 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. In case that the brake pad is accidentally squeezed out, use a screwdriver to force it back to the place.
  • Page 237 Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) Inner Disassembly bearing 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 238 To this chapter contents 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 evenly.

  • Page 239: Front Cushion

    To this chapter contents Front Cushion 3 bolts at both Remove side Remove front cover, front under spoiler and front fender. Remove three bolts at both sides. Remove front wheel. Remove front brake caliper. Remove speedometer cable. 15-8...

  • Page 240: 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 241 To this chapter contents Lubricate the top cone race seat with grease. Steering lock nut Screw the cone race into top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turn. Return 1/2 turn Torque value: 0.25kgf-m Caution ...
  • Page 242 To this chapter contents NOTE: Steering stem adjustment: When the steering stem is too tight. Steps: please refer to figure 1 Stay front wheel on the ground, and make sure that the component ①,②,③,④ are connected all together appropriately. Lock the component 53220-HMA-00(STRG. HEAD TOP THREAD COMP.) with the torque of 350 ...
  • Page 243 Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram ······················ 16-1 Rear Wheel ··································· 16-3 Operational Precautions ················· 16-2 Rear Fork ····································· 16-5 Troubleshooting ···························· 16-2 Rear Cushion ································ 16-6 Muffler ·········································· 16-3 Mechanism Diagram 3.5~4.5kgf-m 2.8~3.2kgf-m 3.5~4.5kgf-m...

  • Page 244: Operational Precautions

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Operational Precautions 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 245: 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 246 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 247: 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 248: 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 249 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 ································ 17-17 Battery ········································· 17-4 Fuel Unit ······································...

  • Page 250: 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. ...

  • Page 251: Troubleshooting

    To this chapter contents 17. Electrical System Troubleshooting No voltage Intermittent power supply  Battery over discharged  The connector of the charging system becomes  The cable disconnected loose  The fuse is blown  Poor connection of the battery cable ...

  • Page 252: 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 253: Fuse

    To this chapter contents 17. Electrical System Fuse Fuse circuit diagram 17-5...

  • Page 254: Charging System

    To this chapter contents 17. Electrical System Charging System Black Green Yellow Regulator rectifier Inspection (KΩ) ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞...
  • Page 255 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 256 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 257 17. Electrical System ECU. coupler (ECU. side) 01 pin(R/Y): Drive components Power. 03 pin(L/O): Crankshaft position sensor positive 09 pin(G): Crankshaft position sensor negative 18 pin(Y/G)： Ignition coil 17-9...
  • Page 258 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 of ignition coil Remove the cap from the spark plug.

  • Page 259: Starting System

    To this chapter contents 17. Electrical System Starting System White Black Blue Green Sky blue Yellow Orange Inspection of starter relay Open the main switch. Press the brake. Push the starter switch. If a sound of “Looh Looh” is heard, it indicates the relay is working properly.
  • Page 260 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 261: Meter

    To this chapter contents 17. Electrical System Meter Meter circuit diagram Meter (Ignition) Fuse 10A 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 Parking right indicator Fuel injection indicator...
  • Page 262 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 263: Light / Bulb

    To this chapter contents 17. Electrical System Light / Bulb Headlight and foggy light circuit diagram (Headlight) White Fuse 15A 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 20A Passing switch...
  • Page 264 To this chapter contents 17. Electrical System Headlight bulb replacement Pull out the rubber socket, and press the 2 springs, then remove light bulb. Specification: Lo-beam bulb 12V 55W (H11) Hi-beam bulb 12V 55W (H11) Caution It would be much easier to replace the light ...

  • Page 265: Switch / Horn

    To this chapter contents 17. 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 coupler Wire Color Black Blake Replacement of main switch...
  • Page 266 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 267: Fuel Unit

    To this chapter contents 17. Electrical System Fuel Unit Fuel Pump and 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 268: 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 working, disconnect the green and black/blue leads, and connect jump wires to the terminals, then turn on the main switch.

  • Page 269: 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 ...
  • Page 270 To this chapter contents 17. Electrical System NOTE: 17-22...
  • Page 271 Homepage Contents 18. Wiring Diagram 18-1...
  • Page 272 18. Wiring Diagram 18-2...
  • Page 273 18. Wiring Diagram 18-3...
  • Page 274 Homepage Contents 18. Wiring Diagram NOTE: 18-4...

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