Page 1: Table Of Contents
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYMBOLS AND MARKS ....1-1 TORQUE VALUES (ENGINE) ....1-10 GENERAL SAFETY......1-2 TORQUE VALUES (FRAME) ....1-11 SERVICE PRECAUTIONS ....1-3 TROUBLES DIAGNOSIS ..... 1-12 SPECIFICATIONS......1-9 LUBRICATION POINTS ....... 1-16 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 2: General Safety
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS GENERAL SAFETY Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a Battery emits explosive gases; flame is closed area. Run your engine in an open area, if strictly prohibited.
Page 3: Service Precautions
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SERVICE PRECAUTIONS Always use with SANYANG genuine parts Never bend or twist a control cable to prevent and recommended oils. Using non-designed stiff control and premature worn out. parts for SANYANG motorcycle may damage the motorcycle. Rubber parts may become deteriorated when Special tools are designed for remove and old, and prone to be damaged by solvent and...
Page 4 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS The length of bolts and screws for Remove residues of the old gasket or sealant assemblies, cover plates or boxes is different before reinstallation, grind with a grindstone if from one another, be sure they are correctly the contact surface has any damage.
Page 5 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Lubricate the rotation face with specified Before battery removal operation, it has to lubricant on the lubrication points before remove the battery negative (-) cable firstly. assembling. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
Page 6 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS When separating a connector, it locker has to Before terminal connection, check if the boot be unlocked firstly. Then, conduct the is crack or the terminal is loose. service operation. Insert the terminal completely. Check if the terminal is covered by the boot.
Page 7 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Do not let the wire harness contact with Protect wires or wire harnesses with electrical rotating, moving or vibrating components as tape or tube if they contact a sharp edge or routing the harness. corner. Thoroughly clean the surface where tape is to be applied.
Page 8 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS 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 positions.
Page 9: Specifications
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS MAKER SANYANG MODEL ALA125CC (AW12W-6) Overall Length 1870mm Front TELESCOPIC FORK Overall Width 698 mm Rear UNIT SWING Overall Height 1325 mm Front 110/70-12 47J Wheel Base 1325mm Rear 120/70-12 51J Front 41kg Front DISK (ø 190 mm)
Page 10: Torque Values (Engine)
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) A.C. generator fixing bolts 0.8~1.2 Pulse generator hex bolts 0.35~0.5 Gear oil filling bolt 1.0~1.4 Oil pump flat bolts 0.8~1.2 Crankcase flange bolts 0.8~1.2 Oil pump drive sprocket nut 0.8~1.2 Cylinder/cylinder head two-ends 0.7~1.1...
Page 11: Torque Values (Frame)
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting bolt for steering 4.0~5.0 handlebar Mounting nut for steering rod 25.4 1.0~2.0 Cone seat for steering rod 25.4 0.2~0.3 Front wheel axle nut 5.0~7.0 Rear wheel axle nut 11.0~13.0 Wheel hub/rim mounting...
Page 12: Troubles Diagnosis
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain 2. Check if the pipes, fuel tank to bolt to check if there is carburetor and intake vacuum, gasoline inside the...
Page 13 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Probable causes Fault condition Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not be 3.
Page 14 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Abnormal Normal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor 1.
Page 15 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved. 4.
Page 16: Lubrication Points
1. GENERAL INFORMATION/TROUBLE DIAGNOSIS LUBRICATION POINTS Acceleration cable/ Front & rear Steering shaft bearing brake lever pivot Speedometer gear / Rear wheel bearing Front wheel bearing Side stand shaft Main stand shaft 1-16...
Page 17 10. A.C. GENERATOR/STARTING CLUTCH MECHANISM DIAGRAM ....10-1 STARTING CLUTCH......10-5 PRECAUTIONS IN OPERATION ..10-2 ... 10-8 RIGHT CRANKCASE COVER INSTALLATION A.C.GENERATOR REMOVAL....10-3 ..10-8 MOUNTED COIL SET INSTALLATION . 10-4 FLY WHEEL INSTALLATION..... 10-8 RIGHT CRANKCASE COVER REMOVAL MECHANISM DIAGRAM 5.0~6.0kgf-m 9.0~10.0kgf-m 1.0~1.4kgf-m...
Page 18: Precautions In Operation
10. A.C. GENERATOR/STARTING CLUTCH PRECAUTIONS IN OPERATION General information Refer to chapter 5: Engine removal and installation Refer to chapter 1: The troubleshooting and inspection of A.C. generator Refer to chapter 16: The service procedures and precaution items of starter motor Specification Unit: mm Item...
Page 19: A.c.generator Removal
10. A.C. GENERATOR/STARTING CLUTCH A.C. GENERATOR REMOVAL Flywheel Pulse generator Cooling fan Cooling fan shroud Coil Cable guide Cooling fan shroud Drain out the engine oil. Remove the exhaust muffler. (2 bolts, 2 nuts) Remove the fan shroud. (4 bolts) Exhaust muffler Remove the fan.
Page 20: Right Crankcase Cover Removal
10. A.C. GENERATOR/STARTING CLUTCH Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller. Flywheel puller Pulse generator connector Remove the connectors of the A.C.
Page 21: Starting Clutch
10. A.C. GENERATOR/STARTING CLUTCH STARTING CLUTCH Starting Clutch Removal Hold the starting driven gear with the universal fixture. Lock nut Remove the 22mm anti-loosen lock nut and gasket. Special service tools: Anti-loosen lock nut socket Universal fixture. Caution Lock nut socket The mounting nut is left-turn thread.
Page 22 10. A.C. GENERATOR/STARTING CLUTCH Check the starting driven gear for wear or Starting driven gear damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Starting reduction gear Check the starting reduction gear and shaft for wear or damage.
Page 23 10. A.C. GENERATOR/STARTING CLUTCH Hex socket Installation bolt Install the components in the reverse Plug Spring procedures of removal. Caution Add adhesive onto the thread of hex Roller socket bolt. Torque value: 1.0~1.4kgf-m Clutch body Clutch cover Starting clutch Oil pump cover Starting clutch Installation Install reduction gear shaft and reduction gear.
Page 24: Right Crankcase Cover Installation
10. A.C. GENERATOR/STARTING CLUTCH RIGHT CRANKCASE COVER 6 bolts INSTALLATION Install setting pin and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.
Page 25 10. A.C. GENERATOR/STARTING CLUTCH Install the cooling fan. (4 bolts) Cooling fan Cooling fan shroud Install the cooling fan shroud. (4 bolts) Install the exhaust muffler. (2 bolts, 2 nuts) Add some engine oil according the specified quantity. Exhaust muffler 10-9...
Page 26 11. CRANKCASE/CRANKSHAFT ....11-1 11-3 MECHANISM DIAGRAM DISASSEMBLY OF CRANKCASE ... 11-2 ..11-5 OPERATIONAL PRECAUTIONS CRANKSHAFT INSPECTION ....11-2 ..11-6 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE MECHANISM DIAGRAM 0.7~1.0 kgf-m 0.8~1.2 kgf-m 11-1...
Page 27: Trouble Diagnosis
11. CRANKCASE/CRANKSHAFT OPERATIONAL PRECAUTIONS General Information This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. Complete following operations before disassembling crankcase. Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 V-belt Drive pulley Chapter 8 AC generator/ Starting Clutch...
Page 28: Disassembly Of Crankcase
11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 2 bolts Remove the 2 bolts from the right side of crankcase. Remove the cam chain tensioner (hex socket 1 hex socket bolt bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
Page 29 11. CRANKCASE/CRANKSHAFT Remove the crankshaft from the right crankcase. Caution The left and right bearings of crankshaft is to press-fit onto the crankshaft. Remove gasket and dowel pins (2). Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the crankcase.
Page 30: Crankshaft Inspection
11. CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radical clearance of the big end at the vertical directions. Service limit : 0.05 mm Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.
Page 31: Assembly Of Crankcase
11. CRANKCASE/CRANKSHAFT ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and dowel pins then install two dowel pins and new crankcase gasket.
Page 32 11. CRANKCASE/CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer (25x37x6). Special service tools: the oil seal installer (25x37x6) 11-7...
Page 33 12. BODY COVER MAINTENANCE INFORMATION..12-2 BODY COVER/REAR FENDER ..12-7 HANDLE COVER .......12-3 FRONT CENTER COVER....12-9 FRONT COVER........12-4 LUGGAGE BOX ......... 12-9 UNDER COVER .........12-5 FLOOR PANEL ........12-9 FRONT INNER BOX......12-6 Rear carrier Double Seat Fuel tank Front handle cover Rear handle...
Page 34: Maintenance Information
12. BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Front handle cover Front cover Luggage box & Seat Rear handle cover Inner box Front center cover Rear carrier Front spoiler Left/right body cover Front cushion Left/right side cover Rear fender Battery cover Front fender Rear inner fender...
Page 35 12. BODY COVER HANDLE COVER Removal: Remove the left/right back mirror. Remove 2 lower mounting screws between the front handle cover and the rear handle cover. mounting screw ×2 Remove the mounting screws (4 screws) between the front handle cover and the rear handle cover.
Page 36 12. BODY COVER Remove the mounting screws (2 screws) right left between the rear handle cover and the frame. screws×2 Remove the speedometer cable. speedometer cable Remove the mounting screws (4 screws) between the rear handle cover and meter. Remove the left/right handle switch connectors.
Page 37 12. BODY COVER wire connectors Remove the front turn left/right signal light wire connectors. Remove the front cover. Installation: Install according to the reverse procedure of removal. UNDER COVER Removal Remove the 1×2 mounting screws between the left/right side cover and the floor panel. 1×2 screws Remove the 1×2 mounting screws between the left/right side cover and the frame.
Page 38 12. BODY COVER FRONT INNER BOX Removal Remove the front cover. Remove the 6 mounting screws of front cover from the inner box. 6 screws Remove the 1×2 mounting screws of front 2 screws spoiler from the inner box. 2 screws Remove the 1×2 mounting screws of front spoiler from the inner box.
Page 39 12. BODY COVER 1 screw Remove the screw on the main switch. Remove the main switch cover. Remove the front inner box A. Installation Install the inner box A and the front inner box B according to the reverse procedure of removal.
Page 40 12. BODY COVER Remove the 2×2 mounting screws between the body cover and the rear fender. 2×2 screws 1×2 screws Remove the 1×2 mounting screws between the body cover and the floor panel. Remove the 1 mounting screw between the body cover and front center cover.
Page 41 12. BODY COVER FRONT CENTER COVER Removal Remove the 1 mounting screw between the body cover and the front center cover. 1 screw Remove the 4 screws from the battery cover. 4 screws Remove the the battery cover. Remove the front center cover. Installation Install the cover according to the reverse procedure of removal.
Page 42 12. BODY COVER 4 screws Remove the 4 screws from the battery cover. Remove the battery cover. Remove the front center cover mounting screw. 1 screw 1×2 screws Remove the 1×2 screws between the body cover and the floor panel. 1×2 screws Remove the 1×2 screws between the left/right side cover and the floor panel.
Page 43 13. BRAKE 13-1 BRAKE CALIPER ......13-8 MECHANISM DIAGRAM-FRONT DISC BRAKE SYSTEM..13-2 BRAKE DISC ........13-9 MECHANISM DIAGRAM-FRONT DRUM BRAKE SYSTEM .. 13-3 BRAKE MASTER CYLINDER ... 13-9 MECHANISM DIAGRAM-REAR DRUM BRAKE SYSTEM MAINTENANCE INFORMATION ..13-4 DRUM BRAKE-DRUM ....... 13-12 TROUBLE DIAGNOSIS .....
Page 44: Mechanism Diagram-Front Drum Brake System
13. BRAKE MECHANISM DIAGRAM Front Drum Brake System 0.8~1.2 kgf-m 2.8~3.2 kgf-m 11.0~13.0 kgf-m 13-2...
Page 45: Mechanism Diagram-Rear Drum Brake System
13. BRAKE MECHANISM DIAGRAM Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-3...
Page 46: Maintenance Information
13. BRAKE MAINTENANCE INFORMATION Precautions in Operation Caution Installing lining dusts 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. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
Page 47: Trouble Diagnosis
13. BRAKE TROUBLE DIOGNOSIS DISC BRAKE Soft brake lever Uneven brake 1. Air inside the hydraulic system 1. Dirty brake lining/disc 2. Hydraulic system leaking 2. Poor wheel alignment 3. Worn master piston 3. Clogged brake hose 4. Worn brake pad 4.
Page 48: Hydraulic Brake System Inspection
13. BRAKE HYDRAULIC BRAKE SYSTEM Hose connection INSPECTION Inspection Visual inspect for brake fluid leaking or damage. Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components.
Page 49: Brake Fluid Replacement/Air-Bleed
13. BRAKE Remove the master cylinder cap and master diaphragm. cylinder Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. diaphragm Clean dirty brake disc. CAUTION The dirty brake lining or disc will reduce the brake performance.
Page 50: Brake Caliper
13. BRAKE BRAKE CALIPER Removal hose bolt Place a container under the brake caliper, bolts x 2 and loosen the brake hose bolt and finally remove the brake hoses. CAUTION Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Make sure the brake lining condition.
Page 51: Brake Disc
13. BRAKE BRAKE DISC Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. brake disc Allowable limit: 2.0 mm micrometer Remove the brake disc from wheel.
Page 52 13. BRAKE Inspection Check the master cylinder for damage or master cylinder 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. Allowable limit: 11.055 mm Dial gauge Measure the outer diameter of the piston.
Page 53 13. BRAKE master cylinder INSTALLATION mounting Place the master cylinder onto handlebar, seat brake and install the split ring and bolts. The hose “UP” mark on the split ring should face upward. Align the split ring on the master cylinder seat with the alignment point on the handlebar.
Page 54: Drum Brake-Drum
13. BRAKE DRUM BRAKE-DRUM Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the dust. Caution •Inhaling dust may cause respiration system disorder even cancer. Never use an air hose or a dry brush as to clean the brake parts.
Page 55: Brake Panel
13. BRAKE Removal front brake cam Caution Brake linings must be replaced as a set. brake spring Remove brake shoes from the brake panel by pulling out the brake linings with two hands. Installation Apply a thin coat of grease to the brake cam 後...
Page 56 13. BRAKE Installation Return spring Front FRONT BRAKE PANEL Wear Apply a thin cost of grease onto the brake indicator cam shaft. Oil seal Install the brake cam. Apply a thin cost of grease onto the oil seal Brake cam lip and then install the oil seal onto the brake cam shaft.
Page 57 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER MECHANISM DIAGRAM ....14-1 FRONT WHEEL ......... 14-4 PRECAUTIONS IN OPERATION ..14-2 FRONT SHOCK ABSORBER..... 14-9 TROUBLE DIAGNOSIS......14-2 FRONT FORK/STEERING COLUMN 14-9 STEERING HANDLE......14-3 MECHANISM DIAGRAM 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 3.1~3.5kgf-m 2.4~3.0kgf-m 11.0~13.0kgf-m 5.0~7.0kgf-m 14-1...
Page 58 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER PRECAUTIONS IN OPERATION General Information Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. Be careful not to allow oil or grease get on brake drum or linings. Torque values Front wheel axle 5.0~7.0kgf-m...
Page 59 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE Acceleration REMOVAL handlebar seat screw Remove handle front & rear covers and the front cover (refer to chapter 12). Drum Brake Brake lever screw Remove the brake lever bolt & nut and then remove the front brake cable.
Page 60 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a wrench to hold the handlebar bolt and then remove the nut. Bolt Take out the handlebar after removed the bolt. Installation Install the handlebar according to the reverse procedure of removal. Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat, acceleration handlebar, and acceleration cable.
Page 61 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Drum brake type Support body bottom and lift front wheel free of ground. Remove the bolts, and disconnect speedometer cable. Remove the wheel axle nut and pull out the axle. Then, remove the front brake panel and the front wheel.
Page 62 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Remove the left axle ring and dust seal. Speedometer gear dust seal DISC BRAKE Remove the dust seal on the right side of speedometer gear. Remove the bearing with the inner type Bearing spacer bearing remover. Bearing Take out the bearing spacer and then remove the other bearing.
Page 63 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Caution Do not install used bearing and replace the bearing once it has been removed. Do not the bearing in tile motion when installing. Tool: C-type compressor or bearing compressor. This two example will to louse the bearing. Speedometer gear dust seal DISC BRAKE Disc Brake...
Page 64 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc (drum brake) or speedometer gear box. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease.
Page 65 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER Removal Remove the front fender, front lower spoiler, front guard, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left shock absorber. (bolt x 1) As for disc brake, remove the cable guide on the right shock absorber.
Page 66 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a plastic hammer to tap the steering column slightly, and then remove the top ball bearing seat. Remove the lower-end cone bearing seat on the frame with a punch. Caution Do not damage the frame and the steering column.
Page 67 15. REAR WHEEL/REAR SHOCK ABSORBER MECHANISM DIAGRAM....15-1 EXHAUST MUFFLER......15-3 PRECAUTIONS IN OPERATION..15-2 REAR WHEEL........15-3 TROUBLE DIAGNOSIS ..... 15-2 REAR SHOCK ABSORBER ....15-4 MECHANISM DIAGRAM 3.5~4.5kgf-m 2.4~3.0kgf-m 0.8~1.2kgf-m 1.0~1.4kgf-m 3.0~3.6kgf-m 11.0~13.0kgf-m 15-1...
Page 68 15. REAR WHEEL/REAR SHOCK ABSORBER PRECAUTIONS IN OPERATION General Information As for the wheel removal, service, and installation procedures, please refer to the service manual of high speed tire. Specification Unit: mm Items Standard Limit Radial Wheel wobbling Axial Thickness of rear brake lining Torque values: Rear axle nut 11.0~13.0kgf-m...
Page 69 15. REAR WHEEL/REAR SHOCK ABSORBER EXHAUST MUFFLER Exhaust muffler Removal Remove the front-end nut of the exhaust muffler. (nuts x 2) Remove the bolts. (bolts x 2) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal. Caution Nuts x 2 Replace the exhaust muffler gasket if it is...
Page 70 15. REAR WHEEL/REAR SHOCK ABSORBER REAR SHOCK ABSORBER Removal Remove the left & right covers. (screws x 8) Remove the luggage box. (bolts x 4, nuts x 2, screw x 1) Remove the rear carrier. (bolts x 3) Remove the body cover (bolts x2) Remove the air cleaner bolts (bolts x2) Remove the lower nut of the rear shock absorber (bolt x 1)
Page 71 16. ELECTRICAL EQUIPMENT MECHANISM DIAGRAM ....16-1 STARTING SYSTEM ......16-14 PRECAUTIONS IN OPERATION ..16-2 METER ..........16-15 SPECIFICATION ........16-3 LIGHTS/BULBS ........16-17 TROUBLE DIAGNOSIS......16-4 MAIN SWITCH/HORN ......16-19 CHARGING SYSTEM......16-5 FUEL UNIT .........16-22 IGNITION SYSTEM ......16-11 MECHANISM DIAGRAM High & low beam/seat open/turn signal light/Horn Front/Rear stop switch Main switch...
Page 72: Precautions In Operation
16. ELECTRICAL EQUIPMENT PRECAUTIONS IN OPERATION Charging System 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.) MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water. Battery must be taken out from scooter when charging the battery.
Page 73: Specification
16. ELECTRICAL EQUIPMENT Specification Charging System Items Specification Capacity/type 12V 6Ah(MF) STD:0.6A/5~10hrs, emergency charging: Charging rate 6A/0.5hrs Battery Full charged 13.1V Voltage (20℃) Under charged 12.3V Capacity 12V / 6.2A Lighting coil resistance (20℃) Between yellow-green: 0.8±0.1Ω Alternator Charging coil resistance (20℃) Between white-green: 0.6±0.1Ω...
Page 74: Trouble Diagnosis
16. ELECTRICAL EQUIPMENT TROUBLE DIAGNOSIS Charging System System Ignition No power supply No spark produced by spark plug The spark plug is out of work Dead battery The cable is poorly connected, open or Disconnect battery cable short-circuited Fuse burned out - Between alternator and C.D.I.
Page 75: Charging System
16. ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram green white green fuse(7A green yellow alternator Battery REG.REC. 12V 6AH green/black Auto Ω by-starter Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
Page 76 16. ELECTRICAL EQUIPMENT Battery Removal Remove the 4 screws on the battery cover. (Screws x 4). Battery cover 4 screws CAUTION Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, and then send to hospital.
Page 77 16. ELECTRICAL EQUIPMENT Voltage Check With a digital voltage meter or multi-meter to measure battery voltage. Voltage: Fully charged: 13.0 – 13.2V (at 20℃) Undercharged: Below 12.3 V (at 20℃) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal. Connect the Charger negative (-) to the battery negative (-) terminal.
Page 78 16. ELECTRICAL EQUIPMENT digital voltmeter Charging Voltage/Current ammeter Inspection Caution Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.0 V. If undercharged, the current changes dramatically. Fuse ends While starting the engine, the starter motor draws large amount of current...
Page 79 Do not touch the probe of multi-meter by White fingers, then the resistance values will be incorrect because there is some resistance existence in human body. To use the multi-meter recommended by Yellow Green SYM. Otherwise, the measured resistance might be different. 16-9...
Page 80 16. ELECTRICAL EQUIPMENT Alternator charging coil Charging coil light coil Ignition connector connector connector Caution The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 3P connector of the alternator. Measure the resistance between the white wire on the alternator and frame ground with a multi-meter.
Page 81: Ignition System
16. ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit green Blue /yellow green Black/ yellow Black/ white Black/red Pluser spark plug green Blue/yellow black/yellow Black/red green Black/white C.D.I. unit green main switch Ignition coil CDI UNIT Removal Remove the right body cover, then the C.D.I. unit can be removed from the frame.
Page 82 16. ELECTRICAL EQUIPMENT Ignition coil Ignition coil Removal Remove the luggage box, center cover. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix bolts for the ignition coil, and remove the ignition coil. Install the ignition coil in reverse order of removal.
Page 83 16. ELECTRICAL EQUIPMENT Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7-12 kΩ(20℃) Remove the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 3-5 kΩ(20℃) Secondary coil is good if resistance within standard.
Page 84: Starting System
16. ELECTRICAL EQUIPMENT STARTING SYSTEM Starting Circuit Starter magnetic switch inspection Starter magnetic switch Turn main switch to "on", and operate the brake lever. Then press starting button to check if there a click sound. It is normal if there is a click sound. Remove the luggage box.
Page 85: Meter
16. ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the right side cover. (screws x3) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the starting motor power wire. Remove the starting motor mounting bolts and motor.
Page 86 16. ELECTRICAL EQUIPMENT Remove the rear handle cover. Remove the meter mounting screws. Take out the meter. Speedometer High Beam Indicator Turn Right Turn Left Signal Signal Indicator Indicator Odometer Fuel meter Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components.
Page 87 16. ELECTRICAL EQUIPMENT LIGHT/BULBS Headlight Bulb Replacement Remove the left/right back mirror. Remove the front handle cover. Disconnect the headlight wire connector. Press down the bulb spring locker and then remove the locker with turning it left motion. Remove the bulb. Replace the bulb with new one if necessary.
Page 88 16. ELECTRICAL EQUIPMENT Front Turn Signal Lamp Bulb Front turn Replacement signal light Remove the front cover. Remove the wire connector of the turn signal light. the wire connector of the turn signal light Pull out the bulb and replace it with new one. (12V 10W) Installation Install the bulb in reverse order of removal.
Page 89: Main Switch/Horn
16. ELECTRICAL EQUIPMENT MAIN SWITCH/HORN main switch connector terminals Main Switch Check Remove the headlight connector and the front cover. Disconnect main switch leads connector. Check connector terminals for continuity. color Black/ Green Red Green Black white Location LOCK ● ●...
Page 90 16. ELECTRICAL EQUIPMENT Handle switch headlight switch Remove the front handle cover. Disconnect the connector of the handle switch. Check the continuity of follow pins listed below columns. Headlight switch color Brown Brown Yellow Pink Yellow /White Location ● ● ●...
Page 91 16. ELECTRICAL EQUIPMENT Turn signal light switch color Gray orange Location blue ● ● turn signal FROM R ● ● orange light switch PUSH OFF FROM L ● ● gray Sky blue ● ● Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever.
Page 92: Fuel Unit
16. ELECTRICAL EQUIPMENT FUEL UNIT Fuel unit Open the seat. Remove the luggage box(bolts x 6) . Remove the engine start control switch wire connector. Disconnect the fuel unit wire connector. Caution Do not damage or bend the float arm as removing.
Page 94 2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 DRIVING SYSTEM......2-9 ..2-2 STEERING SYSTEM ......2-10 PERIODICAL MAINTENANCE SCHEDULE LUBRICATION SYSTEM ....2-3 SUSPENSION SYSTEM ....2-10 FUEL SYSTEM........2-4 FRONT DISK BRAKE SYSTEM ..2-11 AIR CLEANER........2-5 DRUM BRAKE SYSTEM ....2-13 THROTTLE VALVE OPERATION ..2-5 WHEEL/TIRE........
Page 95 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 96 2. MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Caution The vehicle must be parked on a level ground when checking oil capacity. Run the engine for 2-3 minutes then stop, wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.
Page 97 2. MAINTENANCE INFORMATION Gear Oil Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole. Remove the oil drain plug and drain gear oil into a measurement cup.
Page 98 2. MAINTENANCE INFORMATION AIR CLEANER Element Remove 6 screws from the air cleaner cover. Remove element of air cleaner (2 screws). Check the element if dirt or damaged. Replace it with new one if dirt or damaged. screws×6 screws×2 Caution Air cleaner element contains a paper made filter so do not try to clean it.
Page 99 2. MAINTENANCE INFORMATION Adjustment nut Primary adjustment is conducted from button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Fixing nut Caution When always riding in rainy area or full throttle position, maintenance period must be shorted.
Page 100 2. MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION Feeler gauge AND ADJUSTMENT Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX): 0.12±0.02/0.12±0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve-rocker arm is Fixing nut be adjusted to standard level when adjusting it, and re-check the valve...
Page 101 2. MAINTENANCE INFORMATION IGNITION SYSTEM F mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for Ignition light checking whether C.D.I. function is in normal or not. Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap.
Page 102 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Remove the luggage box and the center cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.
Page 103 2. MAINTENANCE INFORMATION STEERING SYSTEM 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 and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing.
Page 104 2. MAINTENANCE INFORMATION FRONT DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil, and also check brake system for leaking. Brake hose 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 105 2. MAINTENANCE INFORMATION Brake fluid cap ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 Low limit WELL RUN brake fluid. Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.
Page 106 2. MAINTENANCE INFORMATION DRUM BRAKE SYSTEM Front Brake Free Play: (Drum brake) 10∼20mm Measure free play of rear brake level at the end of the lever. Free play: 10-20 mm Adjust the free play by turning the front brake adjustment nut if necessary. “△”...
Page 107 2. MAINTENANCE INFORMATION Brake light switch BRAKE LIGHT SWITCH The brake light switch is to lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. WHEEL/TIRE Check if both front and rear tire pressure are within specification.
Page 108 2. MAINTENANCE INFORMATION Battery cover screws BATTERY Battery Removal Remove the 4 screws on the floor panel. Remove battery cap. (4 screws) Battery cables removal: 1. At first, remove the negative “-” cable. 2. Then, remove the positive “+” cable. 3.
Page 109 3. LUBRICATION SYSTEM MECHANISM DIAGRAM ....3-1 CLEANING ENGINE OIL STRAINER... 3-3 OPERATIONAL PRECAUTIONS ..3-2 OIL PUMP ..........3-4 TROUBLE DIAGNOSIS......3-2 GEAR OIL ..........3-7 ENGINE OIL ........3-3 MECHANISM DIAGRAM Valve rocker Forcedly lubrication Camshaft Scoop lubrication Inner passage Connecting rod Forcedly lubrication Crankshaft...
Page 110: Lubrication System
SAE 10W-30 or equivalent (Recommended King-Mate serial oils) Gear Oil Disassembly 110 c.c. Replacement 100 c.c. Oil viscosity of gear oil SAE 85W-140 (Recommended King-Mate gear oil series SYM HYPOID GEAR OIL) unit : mm Items Standard Limit Inner rotor clearance 0.12 Clearance between outer 0.12...
Page 111 3. LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Page 112 3. LUBRICATION SYSTEM OIL PUMP bolts Oil Pump Removal Remove the alternator (refer to chapter10). Remove the engine right cover. Remove the one-way clutch and starting gear (1 nut). Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 bolts), and then the oil pump driving gear nut and the gear and oil pump driver chain.
Page 113 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body. Limit: below 2.0 mm Oil Pump Re-assembly Install inner and outer rotors into the pump...
Page 114 3. LUBRICATION SYSTEM Oil Pump Installation Install the oil pump (2 bolts). 2 bolts Install oil pump driver chain and drive gear. oil pump driver chain drive gear Install oil pump outer cover (2 bolts). oil pump outer cover 2 bolts Install the starting gear and the alternator.
Page 115 And then, tighten the bolt. Torque Value: 1.0~1.4 kgf-m ※Recommended to apply with SYM HYPOID GEAR OIL (SAE 85W-140) Start engine and run it for 2~3 minutes. Turn off engine and check if oil leaking.
Page 116 4. FUEL SYSTEM MECHANISM ILLUSTRATION ..... 4-1 AUTO BY-STARTER ......4-7 PRECAUTIONS IN OPERATION ..4-2 FLOAT CHAMBER ......4-8 TROUBLE DIAGNOSIS......4-3 INSTALLATION OF CARBURETOR .. 4-9 CARBURETOR REMOVAL ....4-4 IDLE SPEED ADJUSTMENT....4-9 VACUUM CHAMBER ......4-4 FUEL TANK ........
Page 117 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 or twist throttle valve cable. Damaged cable will make unstable driveability.
Page 118: Fuel System
4. FUEL SYSTEM TROUBLE DIAGNOSIS Power insufficiency and fuel consuming Poor engine start Fuel system clogged No fuel in fuel tank Malfunction of ignition system Clogged fuel tube Too much fuel in cylinder No spark from spark plug (malfunction of ignition system) Clogged air cleaner Malfunction of automatic by-starter...
Page 119 4. FUEL SYSTEM Carburetor Removal throttle valve cable vacuum hose Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Disconnect auto by-starter connectors. Release the clamp strip of air cleaner.
Page 120 4. FUEL SYSTEM Remove fuel needle seat, spring, and fuel needle injector needle. seat Check if the vacuum piston for wear out, fuel needle crack or other damage. spring Check if the diaphragm for damage or crack. injector Cautions needle Do not damage vacuum diaphragm.
Page 121 4. FUEL SYSTEM AIR CUT-OFF VALVE Removal Remove the vacuum hose clamp and then the vacuum hose. Screws ×2 Remove the screws (screw x 2) of the air cut-off valve and its cover. screws vacuum diaphragm Remove the spring and vacuum diaphragm. Check if the vacuum diaphragm for deterioration or crack.
Page 122 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 by-starter with a new one if resistance value exceeds standard.
Page 123 4. FUEL SYSTEM FLOAT CHAMBER float Disassembly float pin Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. screws× 4 Checking Check float needle valve and valve seat for float pin drop difference damage, wear out, dirty or clogged.
Page 124 4. FUEL SYSTEM Installation Install main jet, fuel needle jet seat, fuel needle jet, slow speed jet and fuel amount adjustment screw. Cautions Set the adjustment screw in according to number of turns noted before it was removed. fuel amount adjustment screw Install the float valve, float, and float pin.
Page 125 4. FUEL SYSTEM FUEL TANK Fuel unit connector Fuel unit removal Open the seat. Remove the luggage box. (6 bolts) Remove the engine starter control switch wire connector . Disconnect fuel unit connector. Remove fuel unit. Cautions Do not bend the float arm of fuel unit. Do not fill out too much gasoline to fuel tank.
Page 126 4. FUEL SYSTEM AIR CLEANER Removal Remove the seat . Remove the luggage box assembly (6 bolts). Disconnect the engine start control switch connector. Loosen the clamp strip of air cleaner. Remove evaporative return hose. Remove the air cleaner body bolts (2 bolts). Remove the air cleaner.
Page 127: Engine Removal
5. REMOVAL OF ENGINE MECHANISM DIAGRAM ...... 5-1 . 5-6 REMOVAL OF ENGINE SUSPENSION BUSHING OPERATIONAL PRECAUTIONS ..5-2 ENGINE SUSPENSION FRAME..5-7 ENGINE REMOVAL ......5-3 INSTALLATION OF ENGINE ....5-8 MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5kgf-m 4.5~5.5 kgf-m...
Page 128 5. REMOVAL OF ENGINE OPERATIONAL PRECAUTIONS General Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3.
Page 129 5. REMOVAL OF ENGINE ENGINE REMOVAL pulse generator Open the seat. connector Remove the luggage box assembly (4 bolts ). Remove the body cover . Generator Remove the power connector of auto by- Auto by-start connector connector start. Remove the generator wire and pulse generator connector.
Page 130 5. REMOVAL OF ENGINE Remove the fuel pipe, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and then the air cleaner guide. Bolts×2 Remove the exhaust muffler (Bolts × 2, Nuts × 2). Remove the rear wheel (Nut ×...
Page 131 5. REMOVAL OF ENGINE Remove the rear brake cable nut. Brake cable nut Remove the rear brake cable. Remove the rear shock absorber lower bolt. Rear shock absorber bolt Loose the strap screw of engine left guide, and then remove the engine left guide. Strap screw of guide Remove the engine suspension nut and bolt (engine side), and then remove the engine.
Page 132 5. REMOVAL OF ENGINE REMOVAL OF ENGINE SUSPENSION BUSHING If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / presser, Φ28mm &Φ20mm, to press the bushing out, and replace it with new one. Engine suspension bushing: Φ28mm Rear shock absorber bushing: Φ20mm Pressing out...
Page 133 5. REMOVAL OF ENGINE ENGINE SUSPENSION FRAME Removal Remove the right side bolt of engine suspension frame. Remove the left side bolt of engine suspension frame. Bolt of engine suspension frame (left side) Check if the engine suspension frame bushing and cushion rubber for damage. If so, replace with new ones.
Page 134 5. REMOVAL OF ENGINE INSTALLATION OF ENGINE Engine suspension nut×1 Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones. Install the engine according to the reversing order of removal. Caution Notice both feet and hands safety for squeezing as engine installation.
Page 135 6. CYLINDER HEAD/VALVE MECHANISM DIAGRAM ....6-1 CYLINDER HEAD INSPECTION..6-8 PRECAUTIONS IN OPERATION ..6-2 6-10 VALVE SEAT INSPECTION AND SERVICE TROUBLE SHOOTING.......6-3 CYLINDER HEAD REASSEMBLY ..6-12 CAMSHAFT REMOVAL .....6-4 CYLINDER HEAD INSTALLATION ..6-13 CYLINDER HEAD REMOVAL ....6-6 CAMSHAFT INSTALLATION ....6-13 CYLINDER HEAD DISASSEMBLY ..6-7 VALVE CLEARANCE ADJUSTMENT ..
Page 136: Cylinder Head/Valve
6. CYLINDER HEAD/VALVE PRECAUTIONS IN OPERATION General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm. Cylinder head service cannot be carried out when engine is in frame. Specification unit: mm Item Standard...
Page 137 6. CYLINDER HEAD/VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure. Low compression pressure 1.
Page 138 6. CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head bolts and then remove the cylinder head (4 bolts). 4 bolts Loosen the screw of camshaft chain adjuster screw and remove O-ring.
Page 139 6. CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Camshaft Service Limit bearing IN: Replacement when less than 25.29 mm EX: Replacement when less than 25.12 mm Inspect the camshaft bearing for looseness or wear out.
Page 140 6. CYLINDER HEAD/VALVE Measure the valve rocker arm I.D. Service Limit: Replace when it is above 10.100 mm Measure the active O.D. of the valve rocker arm shaft and valve rocker arm. Service Limit: Replace when it is above 9.910 mm Calculate the clearance between the rocker arm shaft and the rocker arm.
Page 141 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts dowel pins from cylinder head left side cover. Remove cylinder head gasket and 2 dowel pins. Remove chain plate. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution Do not damage the matching surfaces of cylinder and cylinder head.
Page 142 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack. Measure cylinder head flat with a straightedge and flat feeler gauge. Service limit: 0.5mm Valve spring free length Measure the free length of intake and exhaust valve springs.
Page 143 6. 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. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Page 144 6. 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. Caution Do not let emery enter into between valve stem and valve guide.
Page 145 6. 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. 1.0mm Caution Make sure that all roughness and uneven faces had been grinded.
Page 146 6. CYLINDER HEAD/VALVE After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded. Valve cotters CYLINDER HEAD REASSEMBLY Valve stem oil seal Lubricate valve stem with engine oil, and Valve spring then insert the valve into valve guide.
Page 147 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Cylinder head gasket Lock pins Install the lock pins and new cylinder head gasket onto the cylinder head. Install the camshaft chain plate. Chain plate Install the cylinder head. CAMSHAFT INSTALLATION Assemble the camshaft holder. 5mm blot Install the exhaust valve rocker arm set onto the camshaft holder showing “EX”...
Page 148 6. CYLINDER HEAD/VALVE Install the lock pins. Install the camshaft holder, gasket and nut onto the cylinder head. Tighten the cylinder head nuts. (4 nuts) At first, tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.
Page 149 7. CYLINDER/PISTON MECHANISM DIAGRAM ....7-1 PISTON RING INSTALLATION..7-7 PRECAUTIONS IN OPERATION ..7-2 PISTON INSTALLATION....7-8 TROUBLE DIAGNOSIS......7-2 CYLINDER INSTALLATION ....7-8 CYLINDER REMOVAL .......7-3 PISTON REMOVAL......7-5 MECHANISM DIAGRAM 0.8~1.2kgf-m...
Page 150: Cylinder/Piston
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 Item Standard Limit 58.50 58.2~58.5 － Bend/wrap age 0.050 Cylinder Roundness 0.005 0.050 Cylindrical 0.005 0.050 Top ring 0.025~0.060 0.090...
Page 151 7. CYLINDER/PISTON CYLINDER REMOVAL 2 bolts Cylinder Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-adjuster. Cam chain Cam chain guide auto-adjuster Remove cam chain plate. Remove cylinder. Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase.
Page 152 7. CYLINDER/PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.
Page 153 7. CYLINDER/PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts 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 154 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 14.980mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06mm Measure the inner diameter of piston pin hole. Service Limit: 15.04mm Calculate clearance between piston pin and its hole.
Page 155 7. CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston shirt. 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 156 7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Install new piston pin snap ring. Piston pin Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
Page 157 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MECHANISM DIAGRAM ....8-1 KICK STARTER ARM ......8-3 MAINTENANCE DESCRIPTION ..8-2 DRIVING BELT........8-4 TROUBLE DIAGNOSIS......8-2 SLIDING PULLEY ......8-6 LEFT CRANKCASE COVER ....8-3 CLUTCH/DRIVEN PULLEY....8-9 MECHANISM DIAGRAM 5.0~6.0kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m 0.8~1.2kgf-m...
Page 158 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MAINTENANCE DESCRIPTION PRECAUTIONS IN OPERATION GENERAL INFORMATION • Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. • Driving belt and driving pulley surface must be free of grease. Specification Unit: mm Item Standard value Limit...
Page 159: V" Type Belt Driving System/Kick Starter Arm
8. V-BELT DRIVING SYSTEM/KICK STARTER ARM air cleaner lock nut LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (2 bolts) Remove kick starter arm. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent. Remove engine left-side cover (8 bolts).
Page 160 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVING BELT Removal Remove left crankcase cover. Hold the driving pulley with a universal fixture, and then remove the nut and driving pulley. Universal fixer Hold driving pulley with universal fixture, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
Page 161 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving pulley. Sliding driven Caution pulley Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.
Page 162 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Universal fixture Remove the driving belt from the pulley. Sliding pulley Remove sliding pulley set and driving pulley hub from crankshaft.
Page 163 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.
Page 164 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install siding pulley assembly onto crankshaft. Sliding pulley Crankshaft Pulley hub...
Page 165 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM CLUTCH/DRIVEN PULLEY Special nut wrench DISASSEMBLY Remove driving belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut...
Page 166 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch lining Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 2.0mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 163.7mm Free length Driven pulley...
Page 167 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch Block Replacement Driving plate Remove snap and washer, and the remove Spring clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption rubber Check if shock absorption rubber is damage or deformation.
Page 168 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Install snap ring and mounting plate onto setting pin. Snap ring REPLACEMENT OF DRIVEN PULLEY BEARING Oil seal Remove inner bearing. Outer bearing Caution If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
Page 169 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM INSTALLATION OF CLUTCH/DRIVEN Oil seal PULLEY ASSEMBLY Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Specified grease O-ring Install sliding pulley onto driven pulley. Guide pin Sliding pulley Oil seal...
Page 170 9. FINAL DRIVING MECHANISM MECHANISM DIAGRAM ....9-1 INSPECTION OF FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS ..9-2 BEARING REPLACEMENT....9-4 TROUBLE DIAGNOSIS......9-2 ..9-6 RE-ASSEMBLY OF FINAL DRIVING MECHANISM ..9-3 DISASSEMBLY OF FINAL DRIVING MECHANISM MECHANISM DIAGRAM final driving shaft countershaft final driving gear 1.0~1.4 kgf-m countershaft gear driving gear...
Page 171: Final Driving Mechanism
9. FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover bolts 1.8~2.2 kgf-m Recommended oil: KING MATE serial gear Gear oil drain plug bolt 3.5~4.5 kgf-m oils Gear oil filling bolt 1.0~1.4 kgf-m Oil quantity: 110 c.c.
Page 172 9. FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING MECHANISM Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7 bolts) and then remove the cover and the final driving shaft.
Page 173 9. FINAL DRIVING MECHANISM Check bearings on gear box and cover. final driving shaft Rotate each bearing’s inner ring with fingers. final driving gear Check if bearings can be turned in smooth countershaft gear and silent, and also check if bearing outer ring is mounted on gear box &...
Page 174 9. FINAL DRIVING MECHANISM Press out the driving shaft from the gear box. Driving shaft Remove oil seal from the gear box. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution Using the bearing protector as pressing out the driving shaft from the gear box cover.
Page 175 Torque: 1.8~2.2 kgf-m Install the clutch/sliding driving pulley. Install the driving pulley, belt and left crankshaft cover. Install the rear wheel. Add gear oil. Recommended usage: SYM HYPOID GEAR OIL (SAE 85W-140) (110 cc: standard capacity) (100 cc: when replacement) 7 bolts...
Page 176 SERVICE MANUAL...
Page 177 CONTENTS CONTENTS GENERAL INFORMATION/TROUBLE DIAGNOSIS ........1 MAINTENANCE INFORMATION ..............2 LUBRICATION SYSTEM................3 FUEL SYSTEM .....................4 ENGINE REMOVAL..................5 CYLINDER HEAD/VALVE................6 CYLINDER/PISTON..................7 "V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......8 FINAL DRIVING MECHANISM..............9 A.C. GENERATOR/STARTING CLUTCH ............10 CRANKCASE/CRANKSHAFT ..............11 BODY COVER ....................12 BRAKE SYSTEM..................13 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER ......14 REAR WHEEL/SUSPENSION..............15 ELECTRICAL EQUIPMENT .................16...
Page 178 MECHANISM ILLUSTRATIONS High& Low beam/Seat Meter open/turn signal/horn Start magnetic switch Rear brake lever Head light/ Position light Fuel tank / Fuel unit Horn/REG.REC Front turn Tail light signal light RR. turning signal light Air cleaner Gear oil filling Front disk brake bolt Engine number Gear oil...

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