Sym HP10T Series Service Manual

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CATALOGUE

FORWARD

HOW TO USE THIS MANUAL

MECHANISM ILLUSTRATIONS

HP10T/U/V SERIES

SERVICE MANUAL

Table of Contents

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Summary of Contents for Sym HP10T Series

Page 1 CATALOGUE FORWARD HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS HP10T/U/V SERIES SERVICE MANUAL...
Page 2 BACK TO TOP PAGE MAIN CATALOGUE FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG HP10 series motorcycles. 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
BACK TO TOP PAGE MAIN CATALOGUE HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG HP10 series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
Page 4 BACK TO TOP PAGE CATALOGUE Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION/TOUBLE DIAGNOSIS 2-1 ~ 2-18 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-14 FUEL SYSTEM 5-1 ~ 5-8 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14...
Page 5: Mechanism Illustrations
BACK TO TOP PAGE MAIN CATALOGUE MECHANISM ILLUSTRATIONS HP10U SERIES Oil lever Front brake lever FR. turning signal light Battery/Fuse Rear brake Luggage box lever Headlight Tail light/Rear turning signal light Seat lock Air cleaner Turning signal light/ Horn / High-low beam & Headlight/ touch-type seat open Starting switch...
Page 6 BACK TO TOP PAGE MAIN CATALOGUE MECHANISM ILLUSTRATIONS HP10T/V SERIES Oil stick Front brake lever FR. turning signal light Battery/Fuse Rear brake luggage box lever Headlight Tail light/R. turning signal light Seat lock Air cleaner Turning signal light/Horn/High-low Headlight/ beam & Touch-type Starting switch seat open switches Main switch...
Page 7 BACK TO TOP PAGE MAIN CATALOGUE MECHANISM ILLUSTRATIONS HK10T/V SERIES Oil stick Front brake lever FR. turning signal light Battery/Fuse Rear brake lever Luggage Headlight Tail light/R. turning signal light Seat lock Air cleaner Turning signal light/Horn/High-low beam & Touch-type Headlight/ seat open switches Starting switch...
Page 8: General Information/Trouble Diagnosis
(Recommended oil: KING MATE G-3 oil) Grease King Mate G-3 is recommended. King Mate gear oil (SYM HYPOID GEAR OIL ) IS recommended. (SAE Gear oil 85W-140) Locking...
Page 9: General Safety
Back to this chapter’s content 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 closed area. Run your engine in an open area, if •...
Page 10: Service Precautions
Back to this chapter’s content 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.
Page 11 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Remove residues of the old gasket or The length of bolts and screws for assemblies, sealant before reinstallation, grind with a cover plates or boxes is different from one grindstone if the contact surface has any another, be sure they are correctly installed.
Page 12 Back to this chapter’s content 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 13 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS When separating a connector, it locker has Before terminal connection, check if the boot to 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 14 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Do not let the wire harness contact with Protect wires or wire harnesses with rotating, moving or vibrating components as electrical tape or tube if they contact a sharp routing the harness. edge or corner.
Page 15 Back to this chapter’s content 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...
Page 16: Specifications
Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Specifications Maker SANYANG MODEL HP10U Overall Length 1750 mm Front TELESCOPE Suspension System Overall Width 615 mm Rear UNlT SWING Overall Height 1065 mm Front 90/90-10 50J Tire Specifications Wheel Base 1225 mm Rear 90/90-10 50J...
Page 17 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Maker SANYANG MODEL HP10T/V & HK10T/V Suspen Overall Length 1750 mm Front TELESCOPE sion System Overall Width 615 mm Rear UNlT SWING Tire Overall Height 1065 mm Front 90/90-10 50J Specifi Wheel Base 1225 mm cations...
Page 18: Torque Values (Engine)
Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Torque Values (Engine) Thread Dia. Torque Value Item Q’ty Remarks (mm) (Kg-m) Cylinder head nuts 1.8~2.2 Cylinder/cylinder head 0.7~1.0 Tighten to crankcase two-ends bolts Cylinder head left bolts 1.0~1.4 valve adjustment cap 1.3~1.7 Valve adjustment fixing nuts 0.7~1.1...
Page 19: Torque Values (Frame)
Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Torque Values (Frame) Thread Dia. Torque Value Item Q’ty Remarks (mm) (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 shaft nut 5.0~7.0...
Page 20 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline 1. No fuel in fuel tank inside the carburetor 2.
Page 21 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged Engine speed can be Engine speed can not 2.
Page 22 Back to this chapter’s content 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) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
Page 23: Clutch, Driving And Driving Pulley
Back to this chapter’s content 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.
Page 24: Lubrication Points
Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS LUBRICATION POINTS Acceleration cable/ Front & rear brake lever pivot Seat locker Steering shaft bearing Speedometer gear/ Side stand shaft Main stand shaft Clutch bearing front wheel bearing 1-17...
Page 25 Back to this chapter’s content 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS Note: 1-18...
Page 26: Table Of Contents
BACK TO TOP PAGE MAIN CATALOGUE 2. MAINTENANCE INFORMATION Precautions In Operation ......2-1 Cylinder Compression Pressure..... 2-9 Periodical Maintenance Schedule .....2-2 Driving System ......... 2-9 Lubrication System........2-3 Steering System ........2-10 Fuel System ..........2-4 Suspension System ......... 2-10 Air Cleaner ...........2-5 Front Disk Brake System......
Page 27: Periodical Maintenance Schedule
They are prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge. 2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment.
Page 28: Lubrication System
Back to this chapter’s content 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 29: Fuel System
Back to this chapter’s content 2. MAINTENANCE INFORMATION Gear Oil Gear oil refilling bolt 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.
Page 30: Air Cleaner
Back to this chapter’s content 2. MAINTENANCE INFORMATION AIR CLEANER Element Remove left side cover (4 bolts). Remove the air cleaner cover ( 6 screws) Remove element of air cleaner (4 bolts). Check the element if dirt or damaged. Replace it with new one if dirt or damaged.
Page 31: Crankcase Blow-By Ventilation
Back to this chapter’s content 2. MAINTENANCE INFORMATION Primary adjustment is conducted from cable button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Adjustment nut CRANKCASE BLOW-BY Blow-by hose VENTILATION Pull out the plug from draining hose to clean deposits...
Page 32: Carburetor Idling Speed Adjustment
Back to this chapter’s content 2. MAINTENANCE INFORMATION Valve clearance inspection and adjustment Check & adjust valve clearance with feeler gauge after open the valve adjustment hole cap. Valve clearance(IN/EX)：0.12±0.02 mm。 Loosen fixing nut and turn the adjustment nut for adjustment.
Page 33: Ignition System
Back to this chapter’s content 2. MAINTENANCE INFORMATION IGNITION SYSTEM Ignition Timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted Ignition timing check procedure is for checking whether CDI function is in normal or not.
Page 34: Cylinder Compression Pressure
Back to this chapter’s content 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turn off the engine. Remove the trunk and the central 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 foot-starting lever Caution Rotate the engine until the reading in the...
Page 35: Steering System
Back to this chapter’s content 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 alternative and check if turning is smoothly.
Page 36: Front Disk Brake System
Back to this chapter’s content 2. MAINTENANCE INFORMATION FRONT DISK BRAKE SYSTEM Brake hose 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 37: Added Brake Fluid
Back to this chapter’s content 2. MAINTENANCE INFORMATION ADDED BRAKE FLUID Master cylinder Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid Caution Upper limit Never mix or use dirty brake fluid to prevent Lower from damage brake system or reducing brake limit...
Page 38: Drum Brake System
Back to this chapter’s content 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 39: Brake Lamp Switch
Back to this chapter’s content 2. MAINTENANCE INFORMATION BRAKE LAMP SWITCH Rear brake light switch The brake light switch lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. Brake light switch- front disc brake WHEEL/TIRE Check if the tire pressure of front &...
Page 40: Battery
Back to this chapter’s content 2. MAINTENANCE INFORMATION Battery Battery Removal Open the seat cushion and then the battery cap. (2 screws) Battery cables removal: 1. At first, remove the negative “-“ cable. 2. Then, remove the positive “+” cable 3.
Page 41 (ψ28mm) (ψ20mm) Puller/presser for crankcase Puller/presser for crankcase Name Name Name Valve spring compressor bushing bushing Parts no. SYM-1120310 Parts no. SYM-1120320 Parts no. SYM-1471110/20 Valve clearance adjustment Name Name Name Valve spring compressor Valve clearance adjuster wrench Parts no. SYM-1471100 Parts no.
Page 42 Back to this chapter’s content 2. MAINTENANCE INFORMATION Name Name Name Bearing remover (inner type) Bearing remover (outer type) clutch spring compressor Parts SYM-6204002 Parts no. SYM-6204001 Parts no. SYM-2301000 Name Name Name Clutch mounting nut wrench Universal fixer Alternator flywheel remover Parts SYM-9020200 Parts no.
Page 43 Back to this chapter’s content 2. MAINTENANCE INFORMATION Notes: 2-18...
Page 44: Lubrication System
BACK TO TOP PAGE MAIN CATALOGUE 3. LUBRICATION SYSTEM Mechanism Illustration....... 3-1 Engine oil pump disassembly....3-4 Operational Precautions ......3-2 Engine oil pump inspection ...... 3-5 Trouble Diagnosis ........3-2 Engine oil pump Assembly ....... 3-5 Engine Oil ............ 3-3 Engine oil pump installation .....
Page 45: Special Service Tools
Oil pump connection screw 0.1~0.3kgf-m Gear oil draining bolt 0.8~1.2kgf-m Special Service Tools Strainer cap wrench SYM-ALL12361 One way clutch removing socket SYM-9020100 Trouble Diagnosis Low engine oil level Dirty oil Oil leaking No oil change in periodical Valve guide or seat worn out...
Page 46: Cleaning Engine Oil Strainer
Replace with new one if found. Install the oil strainer and spring. Install the oil strainer cap and tighten it. Special Service Tools: Strainer cap wrench SYM-ALL12361 Torque value：1.3~1.7 kgf-m Fill out oil to the oil filler (Oil viscosity SAE 10W-30) (Recommended King-Mate serial oils) Engine oil quantity：Replacement 700 c.c.
Page 47: Oil Pump Removal
Remove the engine right cover. Remove the one-way clutch and starting gear (1nut) Special Service Tools: One way clutch removing socket SYM-9020100 Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 screws). 2 screws Remove the oil pump.
Page 48: Oil Pump Inspection
Back to this chapter’s content 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit：below 0.12mm Check clearance between inner and outer rotors. Limit：below 0.12mm 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 body...
Page 49: Oil Pump Installation
Back to this chapter’s content 3. LUBRICATION SYSTEM Install driving gear and clamp. Caution Make sure if the oil pump can be rotated smoothly. Oil Pump Installation 2 screws Install the oil pump (2 screws). Install the starting gear. (Refer to chapter 10)
Page 50 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.
Page 51 Back to this chapter’s content 3. LUBRICATION SYSTEM Notes:...
Page 52: Fuel System
BACK TO TOP PAGE MAIN CATALOGUE 4. FUEL SYSTEM Mechanism Illustration .......4-1 Automatic By-Starter ....... 4-7 Operational Precautions......4-2 Float Chamber .......... 4-8 Trouble Diagnosis........4-3 Installation of Carburetor ......4-9 Removal of Carburetor .......4-4 Idle Speed Adjustment......4-9 Vacuum Chamber........4-4 Fuel Tank........... 4-10 Air Cut-off Valve ..........4-6 Fuel Pump ..........
Page 53: Specification
Back to this chapter’s content 4. FUEL SYSTEM OPERATIONAL PRECAUTIONS 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. Caution Do not bend or twist throttle valve cable. Damaged cable will make unstable driveability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.
Page 54: Trouble Diagnosis
Back to this chapter’s content 4. FUEL SYSTEM TROUBLE DIAGNOSIS Poor engine start Late ignition timing No fuel in fuel tank Malfunction of ignition system Clogged fuel tube Malfunction of carburetor Too much fuel in cylinder No spark from spark plug (malfunction of Power insufficiency and fuel consuming ignition system) Fuel system clogged...
Page 55 Back to this chapter’s content 4. FUEL SYSTEM CARBURETOR REMOVAL Air cleaner clamp Heat-isolator clamp Remove the trunk and seat cushion Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Remove air cut-off valve hose Disconnect automatic by-starter connectors.
Page 56 Back to this chapter’s content 4. FUEL SYSTEM Assembly Install injector needle, spring and fuel needle seat to vacuum piston. Caution Note direction as installing the piston set because wrong direction of the piston cab not be installed. Align the indent of vacuum diaphragm with the carburetor body.
Page 57: Air Cut-Off Valve
Back to this chapter’s content 4. FUEL SYSTEM Air Cut-off Valve Removal Removal the throttle cable seat (screws x 2) Remove the screws (screw x 2) of the air cut-off valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack.
Page 58: Automatic By-Starter
Back to this chapter’s content 4. FUEL SYSTEM AUTOMATIC BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the automatic by-starter with a new one if resistance value exceeds standard.
Page 59: Float Chamber
Back to this chapter’s content 4. FUEL SYSTEM FLOAT CHAMBER Disassembly Remove 3 mounting screws and then the float chamber cover. Remove the float pin and float valve. Checking Check float needle valve and valve seat for drop Drain screw difference damage, wear out, dirty or clogged.
Page 60: Installation Of Carburetor
Back to this chapter’s content 4. FUEL SYSTEM Assembly Install main jet, fuel needle jet holder, nozzle, idle jet and air-fuel mixture adjustment screw. Caution Air-fuel mixture Set the adjustment screw in according to adjustment screw number of turns noted before it was removed.
Page 61: Fuel Tank
Back to this chapter’s content 4. FUEL SYSTEM FUEL TANK Fuel meter gauge removal Remove the left and right side-covers. Open seat cushion Remove the trunk assembly. Remove rear bracket. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove the bracket (nuts x 2) Remove the left and right floor board (bolts x 4)
Page 62: Fuel Tank Removal
Back to this chapter’s content 4. FUEL SYSTEM FUEL TANK REMOVAL Nut x 1 Remove the left and right side-covers. Open seat cushion Remove the trunk assembly. Remove rear bracket. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove the fuel pump bracket nut.
Page 63: Fuel Pump
Back to this chapter’s content 4. FUEL SYSTEM Fuel Pump Inspection Fuel hose Remove the body lower cover. Warn up engine and adjust its idle speed to standard value. Turn off the engine and remove the fuel pipe from carburetor. Wait for 5 minutes, and then re-start the engine.
Page 64: Air Cleaner
Back to this chapter’s content 4. FUEL SYSTEM AIR CLEANER Removal the element of the air cleaner Remove the air cleaner cover. (screws x 6) Screws x 6 Remove the element mounting screws of the air cleaner. (screws x 4) Screws x 4 Caution The air cleaner element is made of paper so...
Page 65 Back to this chapter’s content 4. FUEL SYSTEM Removal of Air Cleaner Fuel vapor hose EEC system hose Open the seat cushion Remove the trunk assembly (chapter 12) Remove the left side-cover. (chapter 12) Loose the air cleaner adapting-pipe clamp. Remove the fuel vapor separator hose.
Page 66 BACK TO TOP PAGE MAIN CATALOGUE 5. REMOVAL & INSTALLATION OF ENGINE Mechanism Illustration....... 5-1 Removal of Engine Suspension ....5-7 Operational Precautions ......5-2 Installation of Engine........5-8 Removal of Engine Bushing ...... 5-6 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5kgf-m...
Page 67 Back to this chapter’s content 5. REMOVAL & INSTALLATION 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.
Page 68: Engine Removal
Back to this chapter’s content 5. REMOVAL & INSTALLATION OF ENGINE ENGINE REMOVAL Open the seat cushion Remove the rear trunk assembly(Bolt× 4, Nut×1)。 Remove the battery negative (-) cable. Remove the battery positive (+) cable. Remove the left and right side covers. (2 screws 2 screws on each side on each side.) Remove the power connector of auto by-starter.
Page 69 Back to this chapter’s content 5. REMOVAL & INSTALLATION OF ENGINE Remove the fuel line, vacuum hose, and throttle Air cleaner guide screw valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and then the air cleaner guide. Throttle valve cable Remove the exhaust muffler (Bolt×2, Nut×2).
Page 70 Back to this chapter’s content 5. REMOVAL & INSTALLATION OF ENGINE Remove the rear shock absorber lower bolt. (bolt Bolt x 1 x 1) Remove the engine suspension nuts and bolts Bolt x 1 (engine side), and then remove the engine. With a bracket to support the engine to prevent from it damage by falling down as removing the engine.
Page 71 Place the detent section of the bushing remover toward the bushing, and drive both the pressing ring and bolt in to press the bushing out. Special Service Tools: Crankcase bushing remover/pressor SYM-1120310 Crankcase bushing remover/pressor SYM-1120320 Pressing In Place the flat section of the remover toward the bushing, and then drive the bushing, pressing ring, and bolt in to install the bushing.
Page 72: Engine Suspension Frame
Back to this chapter’s content 5. REMOVAL & INSTALLATION OF ENGINE ENGINE SUSPENSION FRAME One bolt on Removal each side Remove the right side bolt of engine suspension frame. ( one bolt on each side) Remove the engine suspension frame. Check if the engine suspension frame bushing and cushion rubber for damage.
Page 73: Installation Of Engine
Back to this chapter’s content 5. REMOVAL & INSTALLATION OF ENGINE INSTALLATION OF ENGINE Install the engine according to the reversing order of removal. Caution Note both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose.
Page 74: Cylinder Head/Valve
BACK TO TOP PAGE MAIN CATALOGUE 6. Cylinder Head/Valve Mechanism Illustration....... 6-1 Cylinder Head inspection ......6-9 Operational Precautions ......6-2 Replacement of valve guide ....6-10 Troubleshooting ......... 6-3 Inspection and correction of valve seat. 6-11 Cylinder Head Removal......6-4 Assembly of cylinder head......
Page 75 0.70~1.1kgf-m (apply with oil on bolt thread & seat) Spark plug 1.0~1.4kgf-m Special service tools Valve reamer: 5.0mm Valve spring compressor SYM-1471100 0r Valve guide driver: 5.0mm Valve spring compressor/installer SYM-1471110/20 Valve seat corrector Valve clearance adjustment wrench SYM-9001200 or Valve cover wrench SYM-ALL12361 Valve clearance adjuster SYM-9001210...
Page 76: Troubleshooting
Back to this chapter’s content 6. Cylinder Head/Valve TROUBLESHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinated or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure Low compression pressure 1.
Page 77: Cylinder Head Removal
Back to this chapter’s content 6. Cylinder Head/Valve CYLINDER HEAD REMOVAL Remove the cooling shroud from the engine outer cover. (screws x6) Screws x 6 Remove the crankcase blow-by system hose from the cylinder head. Remove the mounting nuts (bolts x4) of the 2 air injection system.
Page 78 Back to this chapter’s content 6. Cylinder Head/Valve Turn the flywheel in counter clockwise motion with T type wrench until the “Timing” mark on camshaft aligned with the mark on the cylinder head. Timing mark Remove camshaft mounting nut and washer. Bolts x 2 (bolts x 2) Caution...
Page 79: Cylinder Head Disassembly
6. Cylinder Head/Valve CYLINDER HEAD DISASSEMBLY Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wrench: SYM-ALL12361 Remove the stopper of the rocker arm shaft. (bolt x 1) Bolt x1 With 5mm bolt to drive into the rocker arm shaft, and then remove the rocker arm and the rocker arm.
Page 80 Back to this chapter’s content 6. Cylinder Head/Valve Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 25.57mm EX: Replacement when less than 25.41mm Inspect the camshaft bearing for looseness or wear out.
Page 81: Valve Disassembly
Back to this chapter’s content 6. Cylinder Head/Valve VALVE DISASSEMBLY Remove the valves Special Service Tool: Valve remover/installer SYM-1471110/20 Caution Place a rag under the bottom of the combustion chamber as disassembling to prevent from valve stem deformation. Remove the valve spring retainer, valve springs and valves.
Page 82: Cylinder Head Inspection
Back to this chapter’s content 6. Cylinder Head/Valve CYLINDER HEAD INSPECTION Cylinder Head Check if spark plug and valve holes are crack. Measure cylinder head wrapage with a straightedge and flat feeler gauge. Service limit: 0.05mm Valve spring free length Measure the free length of intake and exhaust valve springs.
Page 83: Valve Stem Replacement
Back to this chapter’s content 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.
Page 84: Valve Seat Inspection And Service
Back to this chapter’s content 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.
Page 85 Back to this chapter’s content 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 86: Cylinder Head Reassembly
The closed coils of valve spring should face Valve down to combustion chamber. Install the valves with the valve remover/installer. Special Service Tool: Valve remover/installer SYM-1471110/20. Caution Place a rag under the bottom of the combustion chamber as disassembling to prevent from valve stem deformation.
Page 87: Cylinder Head Installation
Back to this chapter’s content 6. Cylinder Head/Valve Assembly the cylinder head. Caution The tangent of rocker shaft of intake valve should match with the bolt hole of camshaft mounting seat. CYLINDER HEAD INSTALLATION Lock pins Install the lock pins and new cylinder head gasket onto the cylinder head.
Page 88: Valve Clearance Adjustment
Adjustment nut. Standard Value : 0.12+/0.02mm Special Service Tool: Valve clearance adjustment wrench SYM-9001200 or valve clearance adjuster SYM-9001210. Install the 2 air injection system mounting bolts. (bolts x4) Bolts x 4...
Page 89 Back to this chapter’s content 6. Cylinder Head/Valve Install the cooling shroud of the engine body outer cover. (screws x 6) Install the engine onto the frame. Screws x 6 6-16...
Page 90 BACK TO TOP PAGE MAIN CATALOGUE 7. Cylinder/Piston Mechanism Illustrations......7-1 Piston Removal .......... 7-5 Operational Precautions ......7-2 Piston Ring Installation ......7-7 Trouble Diagnosis ........7-2 Piston Installation ........7-8 Cylinder Removal ........7-3 Cylinder Installation ........7-8 MECHANISM ILLUSTRATIONS 0.8~1.2kgf-m...
Page 91: Operational Precautions
Back to this chapter’s content 7. Cylinder/Piston OPERATIONAL PRECAUTIONS General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit: mm Item Standard Limit 49.995~50.015 50.500 － Bend/wrapage 0.050 Cylinder － Cylindrical roundness 0.050 －...
Page 92: Cylinder Removal
Back to this chapter’s content 7. Cylinder/Piston CYLINDER REMOVAL Cam chain plate Remove cylinder head. (refer to chapter 6) 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 93 Back to this chapter’s content 7. Cylinder/Piston Cover the holes of crankcase and cam chain with a piece of 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 94: Piston Removal
Back to this chapter’s content 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 95 Back to this chapter’s content 7. Cylinder/Piston Measure the outer diameter of piston pin. Service Limit: 12.96mm Measure the inner diameter of connecting rod small end. Service Limit: 13.06mm Measure the inner diameter of piston pin hole. Service Limit: 13.04mm Calculate clearance between piston pin and its hole.
Page 96: Piston Ring Installation
Back to this chapter’s content 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 below. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
Page 97: Piston Installation
Back to this chapter’s content 7. Cylinder/Piston PISTON INSTALLATION Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring Place a piece of cloth between piston skirt section and crankcase in order to prevent...
Page 98 BACK TO TOP PAGE MAIN CATALOGUE 8. V-BELT DRIVE SYSTEM/KICK STARTER Mechanism Illustrations......8-1 Kick starter..........8-3 Operational Precautions ......8-2 Drive belt ............. 8-4 Trouble Diagnosis ........8-2 Movable drive face ........8-6 Left crankcase cover ........8-3 Clutch/Driven pulley........8-9 MECHANISM ILLUSTRATIONS 5.0~6.0kgf-m 5.0~6.0kgf-m...
Page 99: Operational Precautions
Torque value: Special Service Tools Movable drive face nut: 5.0~6.0 kgf-m Clutch spring compressor SYM-2301000 Clutch outer nut: 5.0~6.0 kgf-m Bearing puller (inner type) SYM-6204002 driven pulley nut: 5.0~6.0 kgf-m Clutch mounting nut wrench SYM-9020200 Universal fixture SYM-2210100 TROUBLE DIAGNOSIS...
Page 100: Left Crankcase Cover
Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER LEFT CRANKCASE COVER Left crankcase cover removal Remove body cover Remove air cleaner (2 bolts) Remove kick starter (1 bolt) Remove engine left-side cover (7 bolts) 2 bolts Kick Starter Disassembly Remove snap ring and thrust washer from engine left-side cover.
Page 101: Drive Belt
Remove left crankcase cover Hold drive face with universal fixture, and remove nut and drive face. Special Service Tool: Universal fixture SYM-2210100 Universal fixture Hold the clutch outer with the universal fixture, and the remove the nut and the clutch outer.
Page 102 Install the clutch with universal fixture, and then tighten nut to specified torque value. Clutch outer Torque value: 5.0~6.0 kgf-m Special Service Tool: Universal fixture SYM-2210100 Universal fixer Caution When install the drive belt, if there is a arrow mark, then the arrow mark must point to rotation motion.
Page 103: Movable Drive Face
Remove left crankcase cover. Hold drive face with universal fixture, and then remove drive face nut. Remove drive face. Special Service Tool: Universal fixture SYM-2210100 Universal fixture Take out the drive belt from the drive face. Movable drive face Remove movable drive face set and drive face boss from crankshaft.
Page 104 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Inspection The operation of movable drive face is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the ramp plate rotation.
Page 105 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Apply with grease 4~5 g to inside of drive face boss hole, and install drive face boss. Caution The drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face surface Install movable drive face assembly onto crankshaft.
Page 106: Clutch/Driven Pulley
Release the clutch spring compressor and remove clutch and spring from driven pulley. Special Service Tool: Clutch spring compressor SYM-2301000 Clutch mounting nut wrench SYM-9020200 Remove oil seal collar from driven pulley. Oil seal collar Remove guide pin, guide pin roller, and sliding driven face, and then remove O-ring &...
Page 107 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Clutch lining Measure each clutch lining thickness. Replace Clutch lining 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: 154.6mm Free length Driven pulley...
Page 108 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Clutch Block Replacement Spring Remove snap and washer, and the remove Driving plate clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Check if shock absorption rubber is damage or Shock absorption...
Page 109 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Install snap ring and mounting plate onto setting pin. Snap ring REPLACEMENT OF DRIVEN PULLEY BEARING Remove inner bearing. Outer bearing Oil seal Caution If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
Page 110 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER INSTALLATION OF CLUTCH/DRIVEN PULLEY Oil seal ASSEMBLY Install new oil seal and O-ring onto sliding driven face. Apply with specified grease to lubricate the inside of sliding driven face. Specified grease O-ring Install sliding driven face onto driven face.
Page 111 Back to this chapter’s content 8. V-BELT DRIVE SYSTEM/KICK STARTER Notes: 8-14...
Page 112 BACK TO TOP PAGE MAIN CATALOGUE 9. FINAL DRIVE MECHANISM Mechanism Illustrations......9-1 Inspection of Final Drive Mechanism ..9-3 Precautions In Operation ......9-2 Bearing Replacement......... 9-4 Trouble Diagnosis ........9-2 Re-assembly of Final Drive Mechanism... 9-6 Disassembly of Final Drive Mechanism ... 9-3 MECHANISM ILLUSTRATIONS 2.0~2.4kgf-m...
Page 113: Trouble Diagnosis
SYM-6204002 Bearing(6301) installer SYM-9610000 Outer type bearing puller SYM-6204001 Bearing(6203/6004UZ) installer SYM-9620000 Gear box oil seal installer SYM-9120200 Drive shaft puller SYM-13000 Gear box bearing installer SYM-9125500 Puller set SYM-13000-01 Bearing(6204) installer SYM-9110400 TROUBLE DIAGNOSIS Engine can be started but motorcycle can Gear oil leaks Excessive gear oil.
Page 114: Disassembly Of Final Drive Mechanism
Back to this chapter’s content 9. FINAL DRIVE MECHANISM Disassembly of Final Drive 7 screws Gasket Mechanism Remove the rear wheel (refer to chapter 15) Remove the clutch Drain gear oil out from gear box. Remove gear box cover and then remove the cover and the drive shaft.
Page 115: Bearing Replacement
Remove drive shaft bearing from left crankcase using following tools; Special Service Tool: Inner type bearing puller SYM-6204002 Install new drive shaft bearing into left crankcase. Special Service Tool: Bearing(6204) installer SYM-9110400 Bearing(6301) installer SYM-9610000 Bearing(6203/6004UZ) installer(Ø17)
Page 116 Using the bearing protector as pressing out the driving shaft from the gear box cover. Special Service Tool: Inner type bearing puller SYM-6204002 Shaft protector If the driving shaft is pulled out with its bearing, then remove the bearing with bearing puller and bearing protector.
Page 117: Re-Assembly Of Final Drive Mechanism
Install the driven pulley/clutch outer/belt/movable drive face/drive face. Universal fixture Install the left crankshaft cover and kick starter. Install the rear wheel. Add gear oil. ※Recommended usage: SYM HYPOID GEAR OIL (SAE 85W-140) (110 cc: standard capacity) (100 cc when replacement)
Page 118: Alternator/Starting Clutch
BACK TO TOP PAGE MAIN CATALOGUE 10. ALTERNATOR/STARTING CLUTCH Mechanism Illustrations......10-1 Starting Clutch.......... 10-5 Operational Precautions ......10-2 Right Crankcase Cover Installation..10-7 Alternator Removal........10-3 Alternator Coil Installation ...... 10-8 Right Crankcase Cover Removal ..10-4 Flywheel Installation ........ 10-8 MECHANISM ILLUSTRATIONS 5.0~6.0kgf-m 9.0~10.0kgf-m 1.0~1.4kgf-m...
Page 119: Operational Precautions
Oil screen cover 1.3~1.7kgf-m Starting clutch hex mounting bolt 9.0~10.0kg-m with oil on the thread Starting clutch hex socket bolt 1.0~1.4kg-m with adhesive Special service tools Flywheel puller SYM-3110A01 Universal fixture SYM-2210100 Anti-loosen mounting nut socket of starter gear SYM-A12590201 10-2...
Page 120: Alternator Removal
Bolts x2 Remove the fan shroud (2 screws, 2 bolts) Remove the fan. (4 bolts) Cooling fan Hold the flywheel with the universal fixture. Universal fixture Remove the 10mm nut on the flywheel. Special Service Tools: Universal Fixture SYM-2210100 10-3...
Page 121: Right Crankcase Cover Removal
Back to this chapter’s content 10. ALTERNATOR/STARTING CLUTCH Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller SYM-3110A01 Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller.
Page 122: Starting Clutch
Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen mounting nut and Mounting nut gasket. Special service tools: Nut puller of starter gear SYM-A12590201 Universal fixture. SYM-2210100 Caution The mounting nut is left-turn thread. Mounting nut socket Remove the starting driven gear.
Page 123 Back to this chapter’s content 10. ALTERNATOR/STARTING CLUTCH Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Check the starting idle gear and shaft for wear or damage.
Page 124: Right Crankcase Cover Installation
Special service tools: Anti-loosen mounting nut socket of starter gear SYM-A12590201 Anti-loose nut Universal fixture. SYM-2210100 socket Torque value: 9.0~10.0 kg-m RIGHT CRANKCASE COVER INSTALLATION Install dowel pin and new gasket on the crankcase.
Page 125: Alternator Coil Set Installation
Align insert on crankshaft with the flywheel groove, and then install the flywheel Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 5.0~6.0 kg-m Special service tool: Universal fixture. SYM-2210100 Install the cooling fan (4 bolts) Cooling fan 10-8...
Page 126 Back to this chapter’s content 10. ALTERNATOR/STARTING CLUTCH Install the cooling fan shroud ( 3 screws) Install the exhaust pipe ( 2 bolts, 2 nuts) 2 nuts Install the right side cover. (4 screws) Add some engine oil according the specified quantity.
Page 127 Back to this chapter’s content 10. ALTERNATOR/STARTING CLUTCH Notes: 10-10...
Page 128 BACK TO TOP PAGE MAIN CATALOGUE 11. Crankcase/Crankshaft Mechanism Illustrations......11-1 Disassembly of crankcase ...... 11-3 Operational Precautions ......11-2 Crankshaft Inspection......11-5 Trouble Diagnosis ........11-2 Assembly of crankcase ......11-6 MECHANISM ILLUSTRATIONS 1.5~2.0kgf-m 0.7~1.0kgf-m 0.8~1.2kgf-m 3.5~4.5kgf-m 11-1...
Page 129: Operational Precautions
Engine oil draining plug 3.5 ~ 4.5 kg-m Bolts for cam chain tensioner 0.8 ~ 1.2 kg-m Special Service Tools Oil seal (25X37X6)pressing tools SYM-9121600 TROUBLE DIAGNOSIS Engine noise Loose crankshaft bearing Loose crankshaft pin bearing Wear piston pin or piston pin hole...
Page 130: Disassembly Of Crankcase
Back to this chapter’s content 11. Crankcase/Crankshaft DISASSEMBLY OF CRANKCASE Hex socket bolt Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase. Remove the connection bolts (nuts x2) of the right-side crankcase. Nuts x2 Remove the right-side crankcase. Slightly shake the crankshaft and then remove it and the chain.
Page 131: Crankshaft Inspection
Back to this chapter’s content 11. Crankcase/Crankshaft Remove the gasket and the dowel pins. (2 pcs) Scrape gasket residues off the crankcase contact surface. Remove the oil seal of left-side crankcase. Caution Do not damage contact surface of the crankcase. Soap the gasket residues into solvent and the residues will be removed easily.
Page 132: Assembly Of Crankcase
Back to this chapter’s content 11. Crankcase/Crankshaft Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge. Service limit: Replace when it is more than 0.10 mm. 60 mm 90 mm Bearing Inspection clearance Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly.
Page 133 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: oil seal installer (25x37x6) (SYM-9121600) 11-6...
Page 134: Body Cover
BACK TO TOP PAGE MAIN CATALOGUE 12. BODY COVER Mechanism Diagram(Mood 100) ....12-1 Luggage box ......... 12-9 Mechanism Diagram(Excellent 100) ..12-2 Rear Carrier ........... 12-9 Maintenance Information .......12-3 Side cover ..........12-10 Handle cover ...........12-4 Plug main cover ........12-10 Front cover(HP10U) ........12-5 Body cover ..........
Page 135 Back to this chapter’s content 12. BODY COVER HP10T/V body covers Seat Rear fender Rear carrier Handle cover (rear) Handle cover Luggage box (front) Front inner Right side Left body cover upper cover cover Right body cover Plug main cover Left side cover Front guard...
Page 136: Maintenance Information
Back to this chapter’s content 12. BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Central cover Front Handle Cover Front fender Front under Spoiler Luggage & seat Rear Handle cover Left/right side covers Front inner cover Front cover Rear carrier Floor panel Body cover Rear fender...
Page 137: Handle Cover
Back to this chapter’s content 12. BODY COVER HANDLE COVER Removal: Remove the handle front cover mounting screws (2 screws) of the handle from the handle rear cover. Screws x 2 Remove lower mounting screws (screws x2) of the handle front cover. Separate the upper hooks of handle two sides so that the handle covers can be separated.
Page 138: Front Cover(Hp10U)
Back to this chapter’s content 12. BODY COVER FRONT COVER (HP10U) Screws x 2 Removal Remove the mounting screws (screws x 2)of front fender from the front inner cover side. Remove the front mounting screw (screw x 1) of the front cover. Push the front cover upward and then pull it forward so that the lower mounting groove of front cover can be separated from the lower...
Page 139 Back to this chapter’s content 12. BODY COVER FRONT UNDER SPOILER (HP10T/V) 2 Screws on each side Removal Remove the rear screws (screws x4) of the front under spoiler. Remove the front wheel. Remove the lower screws (screws x2) of the front under spoiler.
Page 140: Front Under Spoiler (Hp10U)
Back to this chapter’s content 12. BODY COVER Remove the wire coupler of turn signal light. 方向燈繼電器 Remove the front under spoiler. Installation Install according to the reverse procedure of removal. FRONT UNDER SPOILER (HP10U) 2 screw on each side Remove the 2 rear screws on both left &...
Page 141: Front Fender (Hp10U)
Back to this chapter’s content 12. BODY COVER Disconnect the turning signal light coupler. 方向燈繼電器 Remove the front under spoiler. Installation Install according to the reverse procedure of removal. FRONT FENDER (HP10U) Remove the front wheel. (nut x 1) Nut x 1 Remove the inner-up screws (bolts x2) from the front fender.
Page 142: Luggage Box
Back to this chapter’s content 12. BODY COVER LUGGAGE BOX Screws x 1 Remove the mounting screw & bolt (screw x 1, bolts x4) from the luggage box. Bolts x4 Take out the luggage box upward. REAR CARRIER Bolts x3 Remove the rear carrier mounting bolts (bolts x3) Installation Install according to the reverse procedure of...
Page 143: Side Cover
Back to this chapter’s content 12. BODY COVER SIDE COVER Removal Remove the 2 screws on both left & right sides covers. 2 screws on each side Remove the 1 screw on both left & right sides of 1 screws on each side the floor panel.
Page 144: Body Cover
Back to this chapter’s content 12. BODY COVER BODY COVER Removal Remove the right and left side covers (screws Remove the luggage box (screw x1, bolts x4) Remove the rear carrier (bolts x3) Remove the two side screws. (2 screws on each side) 2 screws on each side...
Page 145: Floor Panel
Back to this chapter’s content 12. BODY COVER FLOOR PANEL Removal Remove the front cover, front fender, front under spoiler, plug main cover and body side cover as well as body cover. Remove the 4 floor panel plugs. There are 4 floor panel mounting bolts. Plugs x4 Remove the floor panel mounting bolts.
Page 146: Front Inner Cover
Back to this chapter’s content 12. BODY COVER FRONT INNER COVER Removal Remove the front cover and the front under spoiler. Remove the main switch cap. (screw x 1) Screws x 1 Remove the fuel refilling cap. Remove the rear mounting screw (screw x 1) of the inner cover.
Page 147: Rear Fender
Back to this chapter’s content 12. BODY COVER Pry out all wire clamps and then take out the front luggage box. Installation Install the front luggage box according to the reverse procedure of removal. REAR FENDER Remove the 2 bolt on the two sides. (1 bolts on each side).
Page 148 BACK TO TOP PAGE MAIN CATALOGUE 13. Brake Mechanism Diagram-Front Disc Brake Brake Fluid Replacement/Air-bleed..13-7 System ............13-1 Brake Caliper ........... 13-8 Mechanism Diagram-Front Drum Brake Brake Disc..........13-9 System ............13-2 Brake Master Cylinder ......13-9 Mechanism Diagram-Rear Drum Brake Drum Brake ..........
Page 149: Mechanism Diagram-Front Drum Brake System
Back to this chapter’s content 13. Brake MECHANISM DIAGRAM-FRONT DRUM BRAKE SYSTEM 0.8~1.2kgf-m 2.8~3.2kgf-m 5.0~7.0kgf-m 13-2...
Page 150: Mechanism Diagram-Rear Drum Brake System
Back to this chapter’s content 13. Brake MECHANISM DIAGRAM-REAR DRUM BRAKE SYSTEM 11.0~13.0kgf-m 2.8~3.2kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m 13-3...
Page 151: Operational Precautions
Back to this chapter’s content 13. Brake OPERATIONAL PRECAUTIONS Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.
Page 152: Trouble Diagnosis
Back to this chapter’s content 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.
Page 153: Hydraulic Brake System Inspection
Back to this chapter’s content 13. Brake HYDRAULIC BRAKE SYSTEM INSPECTION Hose connection Inspection of Hydraulic Brake System 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 154: Brake Fluid Replacement/Air-Bleed
Back to this chapter’s content 13. Brake Remove the master cylinder cap and diaphragm. Master Add good quality brake fluid and it has to add cylinder same brand brake fluid into the master cylinder. Clean dirty brake disc. Diaphragm Caution The dirty brake lining or disc will reduce the brake performance.
Page 155: Brake Caliper
Back to this chapter’s content 13. Brake BRAKE CALIPER Removal Place a container under the brake caliper, and Hose bolt loosen the brake hose bolt and finally remove the Bolts x 2 brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper.
Page 156: Brake Disc
Back to this chapter’s content 13. Brake Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 3.5 mm Micrometer Remove the brake disc from wheel.
Page 157 Back to this chapter’s content 13. Brake Inspection Check the master cylinder for damage or scratch. Master cylinder Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
Page 158 Back to this chapter’s content 13. Brake Installation Place the master cylinder onto handlebar, and Mounting seat install the split ring and bolts. The “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 159: Brake Drum
Back to this chapter’s content 13. Brake DRUM BRAKE SYSTEM Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust. Caution Inhaling asbestos dust may cause respiration system disorder even cancer.
Page 160: Brake Panel
Back to this chapter’s content 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. Installation Apply a thin coat of grease to the brake cam and 後...
Page 161 Back to this chapter’s content 13. Brake Installation Front Return spring Front brake panel Apply a thin cost of grease onto the brake cam Wear indicator shaft. Install the brake cam. Oil seal Apply a thin cost of grease onto the oil seal lip Brake cam and then install the oil seal onto the brake cam shaft.
Page 162: Steering/Front Wheel/Front Shock Absorber
BACK TO TOP PAGE MAIN CATALOGUE 14. Steering/Front Wheel/Front Shock Absorber Mechanism Illustrations......14-1 Front wheel ..........14-4 Operational Precautions ......14-2 Front Shock absorber ......14-9 Trouble diagnosis........14-2 Front fork/steering column..... 14-9 Steering Handlebar........14-3 MECHANISM ILLUSTRATIONS 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 3.1~3.5kgf-m...
Page 163: Operational Precautions
Front shock absorber: Upper nut 2.4~3.0kgf-m Tools Special service tools Steering column wrench Bearing remover Inner type bearing remover SYM-6204002 Attachment, 32×35 mm Attachment, 42×47 mm Steering column nut wrench Steering column top cone ring nut wrench Trouble diagnosis Hard steering stem...
Page 164: Steering Handlebar
Back to this chapter’s content 14. Steering/Front Wheel/Front Shock Absorber STEERING HANDLEBAR Acceleration handlebar REMOVAL seat screw Remove handlebar front & rear covers, and the front guard (refer to chapter 12). Drum Brake Brake lever Remove the brake lever bolt & nut, and then screw remove the front brake cable.
Page 165: Front Wheel
Back to this chapter’s content 14. Steering/Front Wheel/Front Shock Absorber With a wrench to hold the handlebar bolt and then remove the nut. Take out the handlebar after removed the bolt. Handlebar nut Handlebar bolt Installation Install the handlebar according to the reverse procedure of removal.
Page 166: Drum Brake
Back to this chapter’s content 14. Steering/Front Wheel/Front Shock Absorber Drum Brake Support body bottom and lift front wheel free of ground with a stand. 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 167 Remove the bearing with the inner type bearing remover. Bearing spacer Take out the bearing spacer and then remove Bearing the other bearing. Tool: Inner type bearing remover SYM-6204002 Bearing Dust seal Wheel side collar Disassembly (Drum Brake) DRUM BRAKE Dust seal Remove the right dust seal.
Page 168 Back to this chapter’s content 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. Both samples will damage the bearing Disc Brake Speedometer gear...
Page 169 Back to this chapter’s content 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 170: Front Shock Absorber
Back to this chapter’s content 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.
Page 171 Back to this chapter’s content 14. Steering/Front Wheel/Front Shock Absorber With a plastic hammer 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 172: Rear Wheel/Rear Shock Absorber
BACK TO TOP PAGE MAIN CATALOGUE 15. Rear Wheel/Rear Shock Absorber Mechanism Illustrations......15-1 Exhaust pipe ..........15-3 Operational Precautions ......15-2 Rear Wheel..........15-3 Trouble Diagnosis ........15-2 Shock absorber ........15-4 MECHANISM ILLUSTRATIONS 3.5~4.5kgf-m 2.4~3.0kgf-m 0.8~1.2kgf-m 11.0~13.0kgf-m 1.0~1.4kgf-m 3.0~3.6kgf-m 15-1...
Page 173 Back to this chapter’s content 15. Rear Wheel/Rear Shock Absorber OPERATIONAL PRECAUTIONS 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 (mm) Limit (mm) Radial Wheel wobbling Axial...
Page 174: Exhaust Muffler
Back to this chapter’s content 15. Rear Wheel/Rear Shock Absorber EXHAUST MUFFLER Removal Remove the front-end nut of the exhaust muffler. (nut x 2) Remove the bolts. (bolts x 2) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal.
Page 175 Back to this chapter’s content 15. Rear Wheel/Rear Shock Absorber REAR SHOCK ABSORBER Bolts x2 Removal Remove the left & right covers. (screws x 8) Remove the luggage box. (bolts x4, nuts x2, screw x1) 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...
Page 176 BACK TO TOP PAGE MAIN CATALOGUE 16. Electrical Equipment Mechanism Illustrations......16-1 Starting system ........16-15 Operational Precautions ......16-2 Instrument panel ........16-16 Trouble Diagnosis ........16-4 Lamps/bulbs ........... 16-18 Charging system........16-5 Switch/horn..........16-21 Ignition system ........16-11 Fuel sender ..........16-23 MECHANISM ILLUSTRATIONS Voltage regulator / Resistor Rectifier...
Page 177: Electrical Equipment
Back to this chapter’s content 16. Electrical Equipment OPERATIONAL PRECAUTIONS 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 178 Back to this chapter’s content 16. Electrical Equipment Specification Charging System Specification Items HP10T HP10U/V Capacity/type 12V6Ah / YTX7A-BS Charging rate STD:0.6A/5~10hrs, emergency charging: 6A/0.5hrs Battery Full charged 13.1V Voltage (20℃) Under charged 12.3V Capacity 14V / 3A Between yellow-green: Between yellow-green: Lighting coil resistance (20℃) 0.1-0.8Ω...
Page 179: Trouble Diagnosis
Back to this chapter’s content 16. Electrical Equipment Trouble diagnosis Charging System Ignition System No power supply No spark produced by spark plug Dead battery The spark plug is out of work Disconnect battery cable The cable is poorly connected, open or Fuse burned out short-circuited Faulty main switch...
Page 180: Charging System
Back to this chapter’s content 16. Electrical Equipment CHARGING SYSTEM Wire Diagram Fuse (7A) Green White Yellow Alternator Voltage regulator / Battery Rectifier Green /black Pink Automatic by-starter Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
Page 181: Voltage Check
Back to this chapter’s content 16. Electrical Equipment BATTERY Removal Remove the battery cover (screws x 3) 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 182 Back to this chapter’s content 16. Electrical Equipment Warning Strictly keep flames away from a charging battery. The charging ON/OFF is controlled by the charger’s switch. Do not control the charging by battery jump wires. Turn the charger’s switch OFF at first before or after charging to prevent from sparks created on the connectors and explosion.
Page 183 Back to this chapter’s content 16. Electrical Equipment Connect a tachometer. Turn on the headlamp to high beam and start the engine. Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage/current. Specified Charging Current: (headlamp OFF) 0.6A or more/2500rpm 1.2 A or more / 6000 rpm (headlamp ON) 0.4A or more/2500rpm 1.0 A or more / 6000 rpm...
Page 184: Voltage Regulator Inspection
Do not touch the probe of multi-meter by fingers, then the resistance values will be incorrect because there is some resistance existence in human body. To use the multi-meter recommended by SYM. Otherwise, the measured resistance might be different. 16-9...
Page 185 Back to this chapter’s content 16. Electrical Equipment Alternator charging coil Caution The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 4P connector of the alternator. Measure the resistance between the white wire on the alternator and frame ground with a multi-meter.
Page 186: Ignition System
Back to this chapter’s content 16. Electrical Equipment IGNITION SYSTEM Ignition System Circuit (For HP10T model) Green Blue / yellow Black Black / red /yellow Black Exciter coil /white CDI unit Green Principle of operation: 1) The alternator is turned by the starting motor and created electrical current, and then charge to the capacitor.
Page 187 Back to this chapter’s content 16. Electrical Equipment CDI UNIT Removal Remove the side cover. Remove the rear carrier. Remove the body cover. Please refer to chapter 12 for these components removal. Remove the CDI. Inspection Disconnect the connector from the CDI unit. Make the following inspection at each terminal of the harness side connector.
Page 188: Ignition Coil Removal
Back to this chapter’s content 16. Electrical Equipment Ignition coil Removal Remove the luggage box, central cover. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix bolts for the ignition coil, and remove the coil. Install the coil in reverse order of removal.
Page 189: Pulse Generator
Back to this chapter’s content 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.
Page 190 Back to this chapter’s content 16. Electrical Equipment Start System Start Circuit Main Fuse switch Rear brake switch Start switch Black Green Yellow /yellow Battery /red Green Ignition switch Front brake switch Start relay inspection Start relay Turn main switch ON. Operate the brake lever.
Page 191: Instrument Panel
Back to this chapter’s content 16. Electrical Equipment Start Motor Removal Remove the right side cover. (screws x3) Remove the air cleaner mounting bolts. (bolts x2) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box.
Page 192: Installation
Back to this chapter’s content 16. Electrical Equipment Remove the rear handlebar cover. Screws x2 Remove the instrument panel mounting screws. (screws x4) Take out the instrument panel. Installation Install the instrument panel in reverse order of removal. 16-17...
Page 193: Headlight Bulb Replacement
Back to this chapter’s content 16. Electrical Equipment Light/Bulb Headlight Bulb Replacement Remove the rear screw of the handlebar front cover (screws x4) Remove the side screw of the handlebar front cover (screw x2) Remove the front handlebar cover. Disconnect the headlight wire connector, and then remove the rubber boot.
Page 194 Back to this chapter’s content 16. Electrical Equipment Front Turn Signal Light Bulb Replacement (for HP10U model) Remove the light cover of the turn signal light. ( screw x 2) Pull out the bulb and replace it with new one. (12V/10W) Installation Install the bulb in reverse order of removal.
Page 195 Back to this chapter’s content 16. Electrical Equipment Fog Light Bulb Replacement Remove the front fender (screws x3) Remove the light seat. Pull out the bulb and replace it with new one. (12V/5W) Installation Install the bulb in reverse order of removal. Bulbs Replacement Of Tail Light / Brake Light / Rear Turn Signal Light.
Page 196: Brake Light Switch
Back to this chapter’s content 16. Electrical Equipment Main switch/Horn Main Switch Check Remove front fender. (bolts x3) Disconnect main switch leads connector. Check connector terminals as following pins for continuity. BAT1 BAT2 Location Main switch connector terminals LOCK Black Black/ Wire color Green White...
Page 197 Back to this chapter’s content 16. Electrical Equipment Headlight switch Headlight switch Location ● Brown Wire color Brown Yellow Pink Yellow /white Start switch Start switch Yellow Pink Brown Location Headlight Start FREE switch switch Wire color Yellow/red green Brown / white Yellow Green...
Page 198: Fuel Gauge
Back to this chapter’s content 16. Electrical Equipment Horn Remove the front fender. Connect the light blue wire on the horn to the battery positive (+) terminal, and the green wire to the battery negative (-) terminal. Then, the horn should sound. Replace it if necessary.
Page 199 Back to this chapter’s content 16. Electrical Equipment Notes: 16-24...
Page 200 BACK TO TOP PAGE MAIN CATALOGUE 17. Emission Control System Names Of Mechanisms In The Catalytic Converting System....17-4 Emission Control System ....... 17-1 Secondary Air Introduction System ..17-5 Function Of Mechanisms In The Crankcase Blow-By System (P.C.V) ..17-8 Emission Control System .......
Page 201: 17. Emission Control System
Back to this chapter’s content 17. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) Construction: Reduce HC to pollute air. To absorber fuel vapor and saving fuel consumption Fuel cap (closed type) Fuel vapor separator Vacuum hose Fuel tank Fuel hose Carburetor Vapor hose...
Page 202: E.e.c. System Service
Back to this chapter’s content 17. Emission Control System E.E.C. SYSTEM SERVICE Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. Leak test: 1) Disconnect the PCV hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge...
Page 203: Catalytic Converting System
Back to this chapter’s content 17. Emission Control System CATALYTIC CONVERTING SYSTEM (CATA) Construction: Catalytic converter Exhaust muffler Engine Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless O, N gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.
Page 204: Secondary Air Introduction System
Back to this chapter’s content 17. Emission Control System SECONDARY AIR INTRODUCTION SYSTEM Secondary air Construction filter Carburetor Intake valve Flesh air Vacuum hose Engine Cylinder head Air injection cut valve Reed valve Flesh air Mixture gas First burn exhaust Exhaust valve Purged exhaust gas Vacuum...
Page 205 Back to this chapter’s content 17. Emission Control System Service Points/Trouble Diagnosis: Diesel 1. Malfunction of air inject cut valve (AICV). 2. System hose leakage. 3. abnormal ignition timing 4. lean mixture gas 5. abnormal fuel supply Rich Exhaust Gas: 1.
Page 206 Back to this chapter’s content 17. Emission Control System 2. Warm-up test: Start engine. Remove the air injection filter Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet Reed valve Exhaust muffler Air filter...
Page 207: Crankcase Blow-By System (P.c.v)
Back to this chapter’s content 17. Emission Control System CRANKCASE BLOW-BY SYSTEM (P.C.V.) 1. Construction: Blow-by pipe Fuel vapor separator Exhaust pipe Carburetor Air filter Crankcase Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.
Page 208: Inspection Items
Back to this chapter’s content 17. Emission Control System INSPECTION ITEMS Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1.
Page 209 Back to this chapter’s content 17. Emission Control System COUNTERMEASURE FOR EMISSION POLLUTANTS NOT WITHIN STANDARD AS IN IDLE SPEED (4-STROKE ENGINE) conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2) Keep the CO value in Clean the carburetor...
Page 210: Electrical Diagram
TO HP10U/V MAIN CATALOGUE DIAGRAM ELECTRICAL 18. ELECTRICAL DIAGRAM 18-1...
Page 211 TO HP10T MAIN CATALOGUE DIAGRAM ELECTRICAL 18. ELECTRICAL DIAGRAM 18-2...

This manual is also suitable for:

Hp10u seriesHp10v series x pro100Smile 100