SANYANG INDUSTRY CO. SYM Service Manual
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SANYANG INDUSTRY CO. SYM Service Manual

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Summary of Contents for SANYANG INDUSTRY CO. SYM

  • Page 1 SERVICE MANUAL...
  • Page 2 FORWARD This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle. The manual is shown with illustrations and focused on ¡ u Service Procedures¡ v , ¡ u Operation Key Points¡ v , and ¡ u Inspection Adjustment¡ v so that provides technician with service guidelines.
  • Page 3 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SYM series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    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 ..8 "V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/ STARTER CLUTCH 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...
  • Page 5 MECHANISM ILLUSTRATIONS Meter High&Low beam/Seat open/turn signal/horn Rear brake lever Start magnetic switch Horn/REG.REC Frame number Fuel tank / Fuel unit Front turn signal light Tail light RR. turning signal light Air cleaner Gear oil filling bolt Gear oil draining bolt Engine number/engine oil draining bolt...

  • Page 6: General Information/Trouble Diagnosis

    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 7: 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 8: 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.
  • Page 9 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 10 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 11 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 12 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 13 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 14: Specifications

    1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS MAKER SANYANG MODEL AY05W-6 Overall Length 2000mm Front TELESCOPIC FORK Overall Width 690mm Rear UNIT SWING ARM Overall Height 1125mm Front 90/80-16 51N Wheel Base 1330 mm Rear 90/80-16 51N Front 40 kg Front DISK (ø 226 mm)
  • Page 15 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Cylinder head bolts 0.8~1.2 Cylinder head left side cover bolts 0.8~1.2 Cylinder head nuts 0.8~1.2 Apply oil to thread Tappet adjust hole cap 1.0~2.0 Cylinder/cylinder head two-ends bolts 0.7~1.1 Tighten to crankcase Camshaft sprocket bolt...
  • Page 16 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting Hex socket 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 Rear wheel shaft nut 11.0~13.0...
  • Page 17 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 bolt 2. Check if the pipes, fuel tank to to check if there is gasoline carburetor and intake vacuum, inside the carburetor...
  • Page 18 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 19 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 20 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 21: Lubrication Points

    1. GENERAL INFORMATION/TROUBLE DIAGNOSIS LUBRICATION POINTS Seat lock Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Speedometer gear / Rear wheel bearing Side stand shaft Main stand shaft Front wheel bearing 1-16...

  • Page 22: Maintenance Information

    2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 IGNITION SYSTEM/SPARK PLUG .. 2-8 PERIODICAL MAINTENANCE CYLINDER COMPRESSION SCHEDULE ........2-2 PRESSURE........2-9 LUBRICATION SYSTEM ....2-3 DRIVING SYSTEM......2-9 FUEL SYSTEM........2-4 STEERING SYSTEM ......2-10 AIR CLEANER........2-5 SUSPENSION SYSTEM ....2-10 THROTTLE VALVE OPERATION ..2-5 FRONT DISK BRAKE SYSTEM ..

  • Page 23: Periodical Maintenance Schedule

    Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

  • Page 24: Lubrication System

    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 25: Fuel System

    Install the oil filling bolt. Torque value: 0.8~1.2 kgf-m Transmission oil capacity: 180 c.c.(170 c.c. for change) Recommended: genuine SYM HYPOID gear oil (SAE 85W-140). Fuel System Fuel Pipe Fuel filter Remove luggage box, side cover, center cover, body frame cover, and pedal, as well as front inner box.

  • Page 26: Throttle Valve Operation

    2. MAINTENANCE INFORMATION AIR CLEANER screws¡ Á 7 Element Remove left side cover. Remove 7 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¡...
  • Page 27 2. MAINTENANCE INFORMATION Fixing 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. Adjustment nut Crankcase blow-by system CRANKCASE VENTILATION Pull out the plug from draining hose to clean deposits Caution When always riding in rainy area or full...
  • Page 28 2. MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION AND ADJUSTMENT Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX): 0.05±0.02 mm/0.10±0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve-rocker arm is Valve clearance adjustment be adjusted to standard level when adjusting it, and re-check the valve...

  • Page 29: Ignition System

    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 right side cover.
  • Page 30 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Open the seat. Remove the luggage box. 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 31 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 32 2. MAINTENANCE INFORMATION Brake hose 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 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 33 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 34 2. MAINTENANCE INFORMATION DRUM BRAKE SYSTEM Front Brake Free Play: (Drum brake) 10¡ ã 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 35 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 36 2. MAINTENANCE INFORMATION BATTERY Battery Removal Remove the 2 screws on the floor panel. Remove battery cap. (2 nuts) Battery cables removal: 1. At first, remove the negative “-” cable. 2. Then, remove the positive “+” cable. 3. Remove the battery. If there is some rust on battery posts, clean it with steel brush.
  • Page 37 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 38 3. LUBRICATION SYSTEM OPERATIONAL PRECAUTIONS General Information This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil. Oil viscosity Specifications Engine oil quantity Disassembly 800 c.c. Replacement 650 c.c. Oil viscosity SAE 10W-30 or equivalent Use SAE 5W-40 when outside temperature is below 0¢...

  • Page 39: Engine Oil

    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 40 3. LUBRICATION SYSTEM OIL PUMP Oil Pump Removal Remove the alternator (refer to chapter10). Remove the engine right crankcase cover. Make sure that the pump axle can be rotated freely. Remove the oil pump driving gear nut. Remove the oil pump . pump driving gear nut Oil Pump Inspection...
  • Page 41 3. LUBRICATION SYSTEM Oil Pump Re-assembly Fixing pin Oil pump body Drive shaft Install inner and outer rotors into the pump body. Align the indent on driving shaft with that of inner rotor. Install the driving shaft. Install the oil pump cover and fixing pin properly and then tighten screw.
  • Page 42 3. LUBRICATION SYSTEM Gear oil draining plug Filling bolt GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand. Turn off engine and remove both gear oil filling bolt and gear oil draining plug. Remove gear oil filling bolt and place a measurement cup under the draining plug.

  • Page 43: Mechanism Illustration

    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 44 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. 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 45 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 46: Carburetor Removal

    4. FUEL SYSTEM CARBURETOR REMOVAL clamp strip of isolator throttle valve cable 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 47 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 48 4. FUEL SYSTEM ACCELERATE PUMP Screws ¡ Ñ 2 Removal Loosen the fixing screws from carburetor. Remove the accelerate pump drive arm from Accelerate pump the carburetor. drive arm Remove 3 mounting screws and remove the float chamber cover. Remove 3 mounting screws and remove the float chamber cover.
  • Page 49 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. 10£ [ (Measured after engine stopped for more than 10 minutes) Replace the auto by-starter with a new one if resistance value exceeds standard.

  • Page 50: Float Chamber

    4. FUEL SYSTEM FLOAT CHAMBER screws× 3 float Disassembly Remove 3 mounting screws and remove the float chamber cover. Remove the float pin and float valve. float pin Checking Check float needle valve and valve seat for float pin drop difference damage, wear out, dirty or clogged.

  • Page 51: Installation Of Carburetor

    4. FUEL SYSTEM Installation Install main jet, slow jet and fuel amount adjustment screw. Cautions fuel amount Set the adjustment screw in according to number adjustment screw of turns noted before it was removed. Install the float needle valve, float and float pin. Checking Fuel Level Cautions Check again to ensure float valve, float for...

  • Page 52: Fuel Tank Removal

    4. FUEL SYSTEM FUEL TANK fuel unit connector Fuel unit removal Remove the seat. Remove the rear carrier. (3 bolts) Remove the luggage box and the double seat(4 bolts). 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 53: Air Cleaner

    4. FUEL SYSTEM AIR CLEANER air filter strap Removal Remove the seat . Remove the luggage box assembly (4 bolts). Loosen the clamp strip of air cleaner. Remove evaporative return hose. Remove the air cleaner body bolts (2 bolts). Remove the air cleaner. Installation bolts¡...

  • Page 54: Engine Removal

    5. REMOVAL OF ENGINE MECHANISM DIAGRAM ...... 5-1 REMOVAL OF ENGINE SUSPENSION OPERATIONAL PRECAUTIONS ..5-2 BUSHING ..........5-6 ENGINE REMOVAL ......5-3 ENGINE SUSPENSION FRAME..5-7 INSTALLATION OF ENGINE ....5-8 MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5 kgf-m...
  • Page 55 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 56: Engine Removal

    5. REMOVAL OF ENGINE ENGINE REMOVAL Generator connector Open the seat. Remove the luggage box assembly (4 bolts ). Remove the body cover . Remove the power connector of auto by- start. Remove the generator connector and pulse generator connector. pulse generator Auto by-start connector...
  • Page 57 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 remove the air cleaner guide. Bolts¡ Ñ 2 Remove the exhaust muffler (Bolts × 2, Nuts ×...
  • Page 58 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 59 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, ¦ µ 28mm &¦ µ 20mm, to press the bushing out, and replace it with new one. Engine suspension bushing: ¦...
  • Page 60 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 61 5. REMOVAL OF ENGINE INSTALLATION OF ENGINE Engine suspension nut¡ Ñ 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 62: Cylinder Head/Valve

    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 63 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 64 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 65 6. CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL 4 bolts Remove the engine from the vehicle (Refer to chapter 5). Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head cover 4 bolts and then remove the cylinder head cover.
  • Page 66 6. CYLINDER HEAD/VALVE Turn the flywheel in counter-clockwise motion with T type wrench until the “T” mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position.
  • Page 67 6. CYLINDER HEAD/VALVE Remove cylinder head. Caution Loosen the nuts diagonally by 2-3 sequences. DISASSEMBLY CYLINDER HEAD Remove the fixed (bolt × 1), then remove the camshaft. Camshaft Remove the valve rocker arm shaft. Remove the valve rocker arm.
  • Page 68 6. CYLINDER HEAD/VALVE Use the special tool of compress valve springs. Remove valve spring removed location pin. Caution Do not over-compressed valve springs. Avoiding weaken the spring flexibility. Put out the spring stopper, spring and valve. Remove the valve cotter,valve spring retainer,valve oil seal .
  • Page 69 6. CYLINDER HEAD/VALVE VALVE ROCKER ARM/ SHAFT INSPECTION 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. Service Limit: Replace when it is above 9.910 mm Calculate the clearance between the rocker arm shaft and the rocker arm.
  • Page 70 6. CYLINDER HEAD/VALVE Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter. Service Limit: IN¡ ÷ 4.900mm EX¡ ÷ 4.900mm Valve guide Caution...

  • Page 71: Valve Seat Inspection And Service

    6. CYLINDER HEAD/VALVE Hold the cylinder head, and then press out old Valve guide driver valve guide from combustion chamber side. 13 mm 5.0mm Tool: Valve guide driver 5 mm (0.15in) Caution Check if new valve guide is deformation after pressed it in. When pressing in the new valve guide, cylinder head still must be kept in 100~150 ¢...
  • Page 72 6. CYLINDER HEAD/VALVE Valve seat inspection Roughness If the valve seat is too width, narrow or rough, correct it. Valve seat width Service limit: 1.6mm Check the contact condition of valve seat. 45° Valve seat grinding The worn valve seat has to be grinded with valve seat chamfer cutter.

  • Page 73: Cylinder Head Reassembly

    6. CYLINDER HEAD/VALVE Coat the valve seat surface with red paint. Install the valve through valve guide until the Contact surface too high valve contacting with valve seat, slightly press down the valve but do not rotate it so Old valve seat width that a seal track will be created on contact surface.

  • Page 74: Cylinder Head Installation

    6. CYLINDER HEAD/VALVE Use valve spring compressor to press valve spring. Install valve split locks and release the valve compressor. Caution In order to avoid to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch. Special tool: valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly.

  • Page 75: Valve Clearance Adjustment

    6. CYLINDER HEAD/VALVE Apply with oil onto the thread of cylinder head bolts and tighten the bolts in diagonally for 2-3 sequences. Do not over tightening the bolts to avoid the cylinder head deformation, noise created or leaking so that effects motorcycle’s performance.

  • Page 76: Cylinder/Piston

    PEUGEOT 7. CYLINDER/PISTON MECHANISM DIAGRAM ....7-1 PISTON REMOVAL......7-5 PRECAUTIONS IN OPERATION ..7-2 PISTON RING INSTALLATION..7-7 TROUBLE DIAGNOSIS......7-2 PISTON INSTALLATION....7-8 CYLINDER REMOVAL .......7-3 CYLINDER INSTALLATION....7-8 MECHANISM DIAGRAM 0.8~1.2kgf-m...
  • Page 77 7.CYLINDER/PISTON PEUGEOT 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 37.00 ¡ Ð 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 78 PEUGEOT 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. camshaft chain 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 79 7.CYLINDER/PISTON PEUGEOT 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 80: Piston Removal

    PEUGEOT 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 81 7.CYLINDER/PISTON PEUGEOT Measure the outer diameter of piston pin. Service Limit: 12.980mm Measure the inner diameter of connecting rod small end. Service Limit: 13.020mm Measure the inner diameter of piston pin hole. Service Limit: 13.040mm Calculate clearance between piston pin and its hole.

  • Page 82: Piston Ring Installation

    PEUGEOT 7. CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston skirt. 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 83: Piston Installation

    7.CYLINDER/PISTON PEUGEOT 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 84 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH 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 3.5~4.5kgf-m 0.8~1.2kgf-m 5.0~6.0kgf-m...
  • Page 85 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH MAINTENANCE DESCRIPTION Precautions in operation General information ¡ E Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. ¡ E Driving belt and driving pulley surface must be free of grease. Specification Unit: mm Item...

  • Page 86: Left Crankcase Cover

    8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH air cleaner lock bolts 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 87 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Reassembly starter shaft gear driving gear Apply with some specified grease on the gear, shaft. Install the friction spring of driving gear onto convex part of the case cover. Install, return spring and starter shaft as diagram shown.
  • Page 88 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH DRIVING BELT sliding pulley Removal Remove left crankcase cover. Hold the sliding pulley with a universal fixture, and then remove the nut and sliding pulley. Universal fixer Hold driving pulley with universal fixture, and driving pulley remove nut and clutch outer.
  • Page 89 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Installation Pull out driving pulley and then insert the driving belt into the driven belt. Driven pulley Caution 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 90 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Special tool Remove the sliding pulley fixing nut and Crankshaft Sliding pulley remove the driving belt from the sliding pulley.
  • Page 91 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH 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 92 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Apply with grease 4~5 g to inside of driving Pulley bush shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Crankshaft Install siding pulley assembly onto crankshaft.
  • Page 93 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH 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 94 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Clutch pad Clutch pad Measure each clutch pad 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: 93.2mm Free length Driven pulley...
  • Page 95 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH 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 96 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Install snap ring and mounting plate onto setting pin. Snap ring Replacement of driven pulley bearing Remove inner bearing. Oil seal 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 97 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH Installation of clutch/driven pulley Oil seal 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 98: Final Driving Mechanism

    9. FINAL DRIVING MECHANISM MECHANISM DIAGRAM ....9-1 INSPECTION OF FINAL DRIVING OPERATIONAL PRECAUTIONS ..9-2 MECHANISM ........9-3 TROUBLE DIAGNOSIS......9-2 BEARING REPLACEMENT ....9-4 DISASSEMBLY OF FINAL DRIVING RE-ASSEMBLY OF FINAL DRIVING MECHANISM........9-3 MECHANISM ........9-6 MECHANISM DIAGRAM 2.6~3.0 kgf-m...

  • Page 99: Final Driving Mechanism

    9. FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 2.6~3.0 kgf-m Recommended gear oil: 85W-140 Gear oil drain plug 1.0~1.5 kgf-m Oil quantity: 180 c.c. (170 c.c. when Gear oil filling bolt 1.0~1.5 kgf-m replacing) Tools...
  • Page 100 9. FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING 7 bolts MECHANISM Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7bolts) and then remove the gear box cover and the final driving shaft.
  • Page 101 9. FINAL DRIVING MECHANISM Check bearings on the gear box cover. bearing Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box & cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 102 9. FINAL DRIVING MECHANISM Press out the driving shaft from the Driving shaft crankcase. Remove oil seal from the crankcase. 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 left crankcase.
  • Page 103 9. FINAL DRIVING MECHANISM RE-ASSEMBLY OF FINAL DRIVING countershaft final driving shaft MECHANISM Install final driving shaft and final driving gear, countershaft, and countershaft gear. final shaft gear Install the setting pins(2 pins) and new gasket. dowel pins Apply with grease onto the oil seal lip of final 7 bolts driving shaft.
  • Page 104 10. A.C. GENERATOR PRECAUTIONS IN OPERATION ..10-1 RIGHT CRANKCASE COVER A.C.GENERATOR REMOVAL ...10-2 INSTALLATION ........10-4 RIGHT CRANKCASE COVER MOUNTED COIL SET REMOVAL .......... 10-3 INSTALLATION ........10-4 FLY WHEEL INSTALLATION..... 10-4 PRECAUTIONS IN OPERATION General information Refer to chapter 5: Engine removal and installation Refer to chapter 1: The troubleshooting and inspection of A.C.

  • Page 105: A.c. Generator/Starting Clutch

    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 106: Right Crankcase Cover Removal

    10. A.C. GENERATOR 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 107: Right Crankcase Cover Installation

    10. A.C. GENERATOR/STARTING CLUTCH RIGHT CRANKCASE COVER 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 108 10. A.C. GENERATOR Install the cooling fan. (4 bolts) 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 10-5...

  • Page 109: Crankcase/Crankshaft

    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 0.7~1.1 kgf-m 0.8~1.2 kgf-m 11-1...
  • Page 110 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 111 11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 2 bolt Remove the 2 bolt from the right crankcase. 1 hex socket bolt Remove the cam chain tensioner (hex socket 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 112 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 113 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 114 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. dowel pins Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.
  • Page 115 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 116: Body Cover

    12. BODY COVER MAINTENANCE INFORMATION..12-2 FRONT CENTER COVER....12-8 HANDLE COVER .......12-3 LUGGAGE BOX ......... 12-8 FRONT COVER........12-4 FLOOR PANEL ........12-8 FRONT INNER BOX......12-5 SIDE COVER ........12-9 BODY COVER/REAR CENTER UNDER COVER ......... 12-10 COVER/REAR FENDER ....12-6 Rear handle cover Double Seat Luggage box...
  • Page 117 12. BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Front Handle cover Front wheel Luggage box & Seat Rear handle cover Front cover Rear carrier Left/right side cover Front fender Under cover Front center cover Floor panel Rear fender Front inner box Tail light Be careful not to damage various covers in disassembly or re-assembly operation.
  • Page 118 12. BODY COVER HANDLE COVER Removal: Remove 1 lower mounting screw of the handle front cover. screw ¡ Á 1 Remove the mounting screws (4 screws) between the front handle cover and the rear handle cover. screws ¡ Á 4 Removed the head light wire connectors.
  • Page 119 12. BODY COVER FRONT COVER Top cover Removal Remove the top cover. bolt¡ Á 1 Remove the 1 mounting bolt of front cover from the frame. Remove the front under cover 4 mounting screws between the front under cover and the frame .
  • Page 120 12. BODY COVER Remove the 8 mounting screws between the front cover and the front inner box. screws 4 ¡ Á Front cover Remove the front cover from the frame. Installation Install according to the reverse procedure of removal. FRONT INNER BOX Removal Remove the 8 mounting screws of front cover from the inner box A.
  • Page 121 12. BODY COVER Main switch cover Remove the main switch cover. Remove the front cover and front under 2 screws cover. Remove the 2 screws between the inner box and the floor panel. Remove the front inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal.
  • Page 122 12. BODY COVER 1 bolt Remove the 2 mounting bolts of the rear fender. 4 screws Remove the 4 mounting screws between the body cover and the frame. Bolts1 ¡ Á Remove the left/right side 2 mounting bolts under rear of the body cover between the body cover and the frame.

  • Page 123: Luggage Box

    12. BODY COVER Front center cover screws¡ Á 5 FRONT CENTER COVER Removal Remove the 5 screws bolt. Remove the front center cover. Installation Install the front center cover according to the reverse procedure of removal. 4 bolts LUGGAGE BOX Removal Open the seat.
  • Page 124 12. BODY COVER Remove the front cover and front under 2 screws cover. Remove the 2 mounting screws between the floor panel and the front inner box. Remove the floor panel. Installation Install the floor panel according to the reverse procedure of removal. SIDE COVER Removal Remove the left/right side 2 mounting...
  • Page 125 12. BODY COVER Bolts2 ¡ Á UNDER COVER Removal Remove the floor panel. Remove the left/right side cover. Remove the left/right side 4 mounting bolts between the under cover and frame. Remove the under cover. Installation Install the under cover according to the reverse procedure of removal.

  • Page 126: Brake System

    13. BRAKE MECHANISM DIAGRAM-FRONT BRAKE FLUID DISC BRAKE SYSTEM...... 13-1 REPLACEMENT/AIR-BLEED.... 13-6 MECHANISM DIAGRAM-REAR BRAKE CALIPER ......13-7 DRUM BRAKE SYSTEM....13-2 BRAKE DISC ........13-8 MAINTENANCE INFORMATION ..13-3 BRAKE MASTER CYLINDER ... 13-8 TROUBLE DIAGNOSIS ..... 13-4 DRUM BRAKE-DRUM ....... 13-11 HYDRAULIC BRAKE SYSTEM BRAKE LING ........
  • Page 127 13. BRAKE MECHANISM DIAGRAM Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-2...
  • Page 128 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 129 13. BRAKE TROUBLE DIOGNOSIS DISC BRAKE Soft brake lever Uneven brake Air inside the hydraulic system Dirty brake lining/disc Hydraulic system leaking Poor wheel alignment Worn master piston Clogged brake hose Worn brake pad Deformed or warped brake disc Poor brake caliper Restricted brake hose and fittings Worn brake lining/disc Low brake fluid...
  • Page 130 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 131: Brake Fluid Replacement

    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 132 13. BRAKE BRAKE CALIPER hose bolt Removal Place a container under the brake caliper, 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 133 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 134 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 135 13. BRAKE INSTALLATION master cylinder mounting seat Place the master cylinder onto handlebar, and install the split ring and bolts. The “UP” mark on the split ring should face bolts x 2 upward. Align the split ring on the master cylinder seat with the alignment point on the split ring handlebar.
  • Page 136 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 ¡ E 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 137 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 anchor pin «...
  • Page 138 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 139: Steering/Front Wheel/Front Shock Absorber

    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 5.0~7.0kgf-m 14-1...
  • Page 140 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 141 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE REMOVAL Remove handle front & rear covers and the front cover (refer to chapter 12). Master cylinder Disc Brake Seat Remove the 2 bolts of the brake master cylinder, and then take out the master Split cylinder and the split ring.
  • Page 142 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a wrench to hold the handlebar bolt and Bolt then remove the nut. 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 143 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: 0.2 mm. Wheel axle Wheel Rim Place the wheel onto a rotated bracket. Turn the wheel with hand and measure its wobble value with a dial gauge.
  • Page 144 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. Take out the bearing spacer and then Bearing remove the other bearing.
  • Page 145 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 146 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 147: Front Shock Absorber

    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 148 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 149: Mechanism Diagram

    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 150 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 151 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 152 15. REAR WHEEL/REAR SHOCK ABSORBER REAR SHOCK ABSORBER Removal Remove the luggage box. (bolts x 4) Remove the rear carrier. (bolts x 3) Remove the left & right body covers. (screws x 4, bolts x 3) Remove the air cleaner bolts (bolts x2) Remove the lower nut of the rear shock absorber (bolt x 1) Remove the upper nut of the rear shock...
  • Page 153 16. ELECTRICAL EQUIPMENT MECHANISM DIAGRAM ....16-1 STARTING SYSTEM ......16-14 PRECAUTIONS IN OPERATION ..16-2 METER ..........16-15 TROUBLE DIAGNOSIS......16-4 LIGHTS/BULBS ........16-17 CHARGING SYSTEM......16-5 SWITCH ..........16-19 IGNITION SYSTEM ......16-11 FUEL UNIT .........16-22 MECHANISM DIAGRAM Horn/turn signal light/high & low Rear stop switch beam Winker relay REG.REC Horn...

  • Page 154: Charging System

    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 155 16. ELECTRICAL EQUIPMENT Specification Charging System Items Specification Capacity/type 12V 6Ah STD:0.6A/5~10hrs, emergency charging: Charging rate 6A/0.5hrs Battery Full charged 13.1V Voltage (20¢ J ) Under charged 12.3V Capacity 12V / 6.2A Lighting coil resistance (20¢ J ) Between yellow-green: 0.8¡ Ó 0.1£ [ Alternator Charging coil resistance (20¢...
  • Page 156 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 157: Electrical Equipment

    16. ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram green white green fuse(10A green yellow alternator REG.REC. battery 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. Battery(-) terminal Connect an ammeter between the negative cable terminal and the battery negative...
  • Page 158 16. ELECTRICAL EQUIPMENT Battery Battery cover Removal Remove the battery cover. 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 159 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¢ J ) Undercharged: Below 12.3 V (at 20¢ J ) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal.
  • Page 160 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 13.1 V. If undercharged, the current changes dramatically. While starting the engine, the starter Fuse ends motor draws large amount of current...
  • Page 161 Do not touch the probe of multi-meter by fingers, then the resistance values will be White incorrect because there is some resistance existence in human body. To use the multi-meter recommended by SYM. Otherwise, the measured resistance Yellow Green might be different. 16-9...
  • Page 162 16. ELECTRICAL EQUIPMENT Alternator charging coil Auto Charging coil light coil by-star 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 Pulse generator...
  • Page 163 16. ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit green Blue /yellow green Black/ yellow Black/ white Black/red Pulse 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 164 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 165 16. ELECTRICAL EQUIPMENT Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7-12 k£ [ (20¢ J ) Remove the spark plug cap, measure the resistance between plug cap side and green terminal.
  • Page 166 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 167 16. ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the battery cover. 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 168 16. ELECTRICAL EQUIPMENT Remove the rear handle cover. Remove the meter mounting screws. Take out the meter. Speedometer High Beam Indicator Odometer Turn Right Signal Turn Left Signal Indicator Indicator Fuel meter High Beam Indicator Speedometer Time meter Turn Left Signal Turn Right Indicator Signal...
  • Page 169 16. ELECTRICAL EQUIPMENT LIGHT/BULBS Headlight Bulb Replacement Rear 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. (12V 35W/35W) Caution Do not touch the bulb surface with fingers...
  • Page 170 16. ELECTRICAL EQUIPMENT Front Turn Signal Lamp Bulb Front turn signal light Replacement Remove the front handle 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 171 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 green green Black Location ¡ ´ ¡ ´ main switch bolts x 2 ¡...
  • Page 172 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 173 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 ¡ ´ ¡...

  • Page 174: Fuel Unit

    16. ELECTRICAL EQUIPMENT FUEL UNIT Fuel unit Open the seat. Remove the luggage box(bolts x 4) . Remove the R.R. carrier(bolts x 3) . Remove the body cover. Disconnect the fuel unit wire connector. Caution Do not damage or bend the float arm as removing.

  • Page 176: Special Tool

    REMOVE ACG FLY WHEEL PURPOSE: REMOVE ONE-WAY CLUTCH FIX NUT ITEM: BEARING DISASSEMBLER ITEM: UNIVERSAL HOLDER NO£ º SYM-2210100 NO£ º SYM- 6202Z / 6204 PURPOSE:HOLD THE MDF/CLUTCH OUTER PURPOSE: REMOVE THE BEARING ITEM: CLUTCHSPRING COMPRESSOR ITEM: CLUTCH NUT WRENCH NO£ º SYM-2301000 NO£...

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