Table Of Contents - SANYANG INDUSTRY CO. SYM Service Manual

Table of Contents

Vehicle View1
How To Use The Manual3
Table Of Contents4
Mechanism Illustrations5
General Information/Trouble Diagnosis6
Symbols And Marks6
Safety Information7
General Safety7
Service Precautions8
Specifications14
Torque Values15
Troubleshooting17
Engine Hard To Start Or Can Not Be Started17
Engine Run Sluggish (Speed Does Not Pick Up, Lack Of Power)18
Engine Runs Sluggish (Especially In Low Speed And Idling)19
Engine Runs Sluggish (High Speed)19
Clutch, Driving And Drivine Pulley Troubles20
Lubrication Points21
Maintenance Information22
Precautions In Operation22
Periodical Maintenance Schedule23
Lubrication System Maintenance24
Engine Oil Capacity24
Oil Change24
Cleaning The Oil Strainer24
Fuel System25
Gear Oil25
Fuel Pipe25
Fuel Filter25
Throttle Valve Operation26
Air Cleaner26
Crankcase Ventilation27
Valve Clearance Adjustment27
Carburetor Idle Speed Adjustment28
Spark Plug29
Ignition System29
Ignition Timing29
Cylinder Compression Pressure30
Driving System Maintenance30
Driving Belt30
Clutch Pad30
Steering System31
Suspension System31
Front Shock Absorber31
Rear Shock Absorber31
Front Disc Brake System32
Brake System Hose32
Brake Fluid32
Air Bleed Operation32
Added Brake Fluid33
Brake Lining Wear33
Drum Brake System34
Rear Brake Free Play34
Brake Confirmation34
Brake Light Switch35
Wheel/Tire35
Appointed Tire Pressure35
Battery Removal36
Headlight Adjustment36
Lubrication System Overview37
Lubrication System Trouble Diagnosis38
Engine Oil Replacement39
Oil Pump Removal40
Oil Pump Inspection40
Oil Pump Re-Assembly41
Gear Oil Inspection42
Gear Oil Replacement42
Fuel System Overview43
Mechanism Illustration43
Fuel System Trouble Diagnosis45
Poor Engine Start45
Stall After Started45
Rough Idle45
Carburetor Removal46
Vacuum Chamber46
Carburetor Installation47
Accelerate Pump Removal And Installation48
Auto By-Starter Inspection, Removal And Installation49
Float Chamber50
Installation Of Carburetor51
Idle Speed Adjustment51
Fuel Tank Removal52
Air Cleaner Removal And Installation53
Air Cleaner Element Cleaning53
Removal Of Engine54
Engine Mechanism Diagram54
Engine Removal56
Removal Of Engine Suspension Bushing59
Engine Suspension Frame Removal And Installation60
Engine Installation61
Cylinder Head/Valve62
Cylinder Head/Valve Troubleshooting64
Low Compression Pressure64
High Compression Pressure64
White Smoke64
Cylinder Head Removal65
Cylinder Head Disassembly67
Camshaft Inspection68
Valve Rocker Arm/Shaft Inspection69
Cylinder Head Inspection69
Valve Stem70
Valve Guide70
Valve Seat Inspection And Service71
Cylinder Head Reassembly73
Cylinder Head Installation74
Cylinder/Piston76
Cylinder/Piston Trouble Diagnosis77
Low Or Unstable Compression Pressure77
Knock Or Noise77
Smoking In Exhaust Pipe77
Cylinder Removal78
Cylinder Inspection79
Piston Removal80
Piston Ring Installation82
Piston Installation83
Cylinder Installation83
V-Belt Driving System/Kick Starter Arm/Starter Clutch84
Engine Can Be Started But Motorcycle Can Not Be Moved85
Shudder Or Misfire When Driving85
Insufficient Horsepower Or Poor High Speed Performance85
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch86
Left Crankcase Cover86
Kick Starter Arm Reassembly87
Installation Of The Left Crankcase Cover87
Driving Belt Removal88
Driving Belt Installation89
Install The Starter Clutch89
Sliding Pulley Removal90
Sliding Pulley Inspection91
Sliding Pulley Installation91
Driving Pulley Install92
Clutch/Driven Pulley Disassembly93
Clutch Block Replacement95
Installation Of Clutch/Driven Pulley97
Final Driving Mechanism Overview98
Final Driving Mechanism Trouble Diagnosis99
Final Driving Mechanism Disassembly100
Final Driving Mechanism Inspection100
Bearing Replacement101
Final Driving Mechanism Re-Assembly103
Ac Generator104
Generator/Starting Clutch105
Right Crankcase Cover Removal106
Right Crankcase Cover Installation107
Mounted Coil Set Installation107
Flywheel Installation107
Crankcase/Crankshaft Diagram109
Crankcase/Crankshaft Specification110
Crankcase/Crankshaft Trouble Diagnosis110
Engine Noise110
Crankcase Disassembly111
Crankshaft Instpection113
Crankcase Assembly114
Body Cover Diagram116
Body Covers Disassembly Sequence117
Handle Cover118
Front Cover119
Front Inner Box120
Body Cover/Rear Center Cover/Rear Fender121
Front Center Cover123
Luggage Box123
Floor Panel123
Side Cover124
Under Cover125
Brake Diagram126
Rear Drum Brake System Diagram127
Brake Specifications128
Brake Trouble Diagnosis129
Soft Brake Lever129
Uneven Brake129
Hard Operation Of Brake Lever129
Hydraulic Brake System Inspection130
Brake Fluid Add130
Brake Fluid Replacement/Air-Bleed131
Brake System131
Brake Caliper Removal And Installation132
Brake Disc Inspection133
Brake Master Cylinder133
Master Cylinder Installation135
Drum Brake-Drum136
Brake Lining136
Brake Panel137
Steering/Front Wheel/Front Shock Absorber Diagram139
Hard Steering Stem140
Steering Stem Off Center140
Front Wheel Wobbling140
Front Suspension Noise140
Steering Handle Removal141
Front Wheel Removal142
Front Wheel Inspection143
Front Wheel Disassembly143
Disc Brake145
Front Shock Absorber Removal And Installation147
Mechanism Diagram149
Rear Wheel/Rear Shock Absorber Diagram149
Rear Wheel Wobbling150
Poor Brake Performance150
Braking Noise150
Shock Absorber Too Soft150
Exhaust Muffler151
Rear Wheel Inspection151
Rear Wheel Removal151
Rear Shock Absorber Removal And Installation152
Electrical Equipment Diagram153
Charging System - Precautions154
Ignition System - Precautions154
Starting System - Precautions154
Electrical Equipment Specification155
No Power Supply156
No Spark Produced By Spark Plug156
Engine Does Not Crank Smoothly156
Starter Motor Does Not Work156
Trouble Diagnosis156
Charging Wire Diagram157
Current Leakage Inspection157
Charging System157
Battery158
Voltage Check159
Battery Charging159
Charging Voltage/Current Inspection160
Voltage Regulator Inspection161
Alternator Charging Coil Check162
Alternator Lighting Coil Check162
Resistor Check162
Ignition System Circuit163
Cdi Unit Check163
Ignition Coil Removal164
Spark Plug Confirmation164
Primary Coil Check164
Secondary Coil165
Pulse Generator Check165
Starting Circuit166
Starter Magnetic Switch Inspection166
Remove The Luggage Box166
Starting System166
Starting Motor Removal167
Meter Removal167
Headlight Bulb Replacement169
The Headlight Beam Adjustment169
Front Turn Signal Lamp Bulb Replacement170
Main Switch Check171
Main Switch Replacement171
Handle Switch172
Turn Signal Light Switch173
Horn173
Fuel Unit174
Wiring Diagram175
Special Tools176