Sym Symply50 Service Manual
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Sym Symply50 Service Manual

Symply50
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SERVICE MANUAL
Symply² 50

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Summary of Contents for Sym Symply50

  • Page 1 SERVICE MANUAL Symply² 50...
  • 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 Front turn signal light Fuel tank / Fuel unit Horn/REG.REC Frame number Tail light Head light/ Position light RR. turning signal light Air cleaner Gear oil filling bolt Gear oil draining bolt Front disk brake Engine number...

  • Page 6: Special Tool

    SPECIAL TOOL ITEM: OUTER BEARING PULLER ITEM: ACG FLYWHEEL PULLER NO£ º SYM-6204010 NO£ º SYM-3110A00 PURPOSE: REMOVE THE BEARING PURPOSE: REMOVE ACG FLYWHEEL ITEM: LOCK NUT PULLER ITEM: UNIVERSAL HOLDER NO£ º SYM-9020100 NO£ º SYM-2210100 PURPOSE: PURPOSE:HOLD THE MDF/CLUTCH OUTER...
  • Page 7 SPECIAL TOOL ITEM: GY6 STARTER GEAR PULLER NO£ º SYM-2822100-GY6 PURPOSE:REMOVE THE STARTER GEAR...

  • Page 8: 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 9: 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 10: Service Precautions

    1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SERVICE PRECAUTIONS Always use with SANYANG genuine parts Never bend or twist a control cable to prevent and recommended oils. Using non-designed stiff control and premature worn out. parts for SANYANG motorcycle may damage the motorcycle. Rubber parts may become deteriorated when Special tools are designed for remove and old, and prone to be damaged by solvent and...
  • Page 11 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 12 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 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 14 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 15 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 16: Specifications

    1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS MAKER SANYANG MODEL AAA(AV05W-6) Overall Length 1906mm Front Telescopic fork Overall Width 694mm Rear Single swing arm Overall Height 1138 mm Front 120/70-12(56J) Wheel Base 1327mm Rear 130/70-12(56J) Front 40kg Front DISK (ø 190 mm) Rear 59kg Total...
  • Page 17 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 nuts 1.8~2.2 Apply oil to thread Cylinder/cylinder head two-ends bolts 0.7~1.1 Tighten to crankcase Cam holder nut 1.0~1.4 Right crank case cover bolts 0.8~1.2 Pulse generator bolts 0.35~0.5...
  • Page 18 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting bolt for steering 4.0~5.0 handlebar Mounting nut for steering rod 25.4 1.0~2.0 Cone seat for steering rod 25.4 0.2~0.3 Front wheel shaft nut 5.0~7.0 Rear wheel shaft nut 11.0~13.0 Wheel hub/rim mounting...
  • Page 19 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain 2. Check if the pipes, fuel tank to bolt to check if there is carburetor and intake vacuum, gasoline inside the...
  • Page 20 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 21 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 22 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 23: Lubrication Points

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

  • Page 24: Maintenance Information

    2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 CYLINDER COMPRESSION PERIODICAL MAINTENANCE PRESSURE........2-9 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 ..2-11 THROTTLE VALVE OPERATION ..2-5 DRUM BRAKE SYSTEM ....

  • Page 25: 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 26 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 27: Fuel System

    2. MAINTENANCE INFORMATION Gear Oil Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole. Remove the oil drain plug and drain gear oil into a measurement cup.

  • Page 28: Air Cleaner

    2. MAINTENANCE INFORMATION AIR CLEANER Element 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¡ Á 7 Caution Air cleaner element contains a paper made filter so do not try to clean it.
  • Page 29 2. MAINTENANCE INFORMATION Adjustment nut Primary adjustment is conducted from button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Fixing nut Caution When always riding in rainy area or full throttle position, maintenance period must be shorted.
  • Page 30 2. MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION Feeler gauge AND ADJUSTMENT Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX):0.06±0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve-rocker arm is be adjusted to standard level when Fixing nut adjusting it, and re-check the valve...

  • Page 31: Spark Plug

    2. MAINTENANCE INFORMATION IGNITION SYSTEM F mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for Ignition light checking whether C.D.I. function is in normal or not. Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap.
  • Page 32 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Remove the luggage box and the center cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.
  • Page 33 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 34 2. MAINTENANCE INFORMATION FRONT DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil, and also check brake system for leaking. Brake hose BRAKE FLUID Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
  • Page 35 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 36 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 37 2. MAINTENANCE INFORMATION 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. Brake light switch WHEEL/TIRE Check if both front and rear tire pressure are within specification.
  • Page 38 2. MAINTENANCE INFORMATION BATTERY Battery cover screws Battery Removal Remove the 4 screws on the floor panel. Remove battery cap. (4 screws) Battery cables removal: 1. At first, remove the negative “-” cable. 2. Then, remove the positive “+” cable. 3.

  • Page 39: Lubrication System

    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 40 Use SAE 5W-40 when outside temperature is below 0¢ J . Gear Oil Disassembly 110 c.c. Replacement 100 c.c. Oil viscosity of gear oil SAE 85W-140 (Recommended King-Mate gear oil series SYM HYPOID GEAR OIL) unit : mm Items Standard Limit Inner rotor clearance 0.12...

  • Page 41: 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 42 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. pump driving gear nut 3 bolts Remove oil pump body bolts (3 bolts).
  • Page 43 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body. Limit: below 2.0 mm Drive shaft Oil Pump Re-assembly...
  • Page 44 3. LUBRICATION SYSTEM 2 O-rings Oil Pump Installation Install the 2 O-rings. Install the oil pump pin. 3 bolts Install the oil pump. Install the oil pump body bolts (3 bolts). Install the oil pump driving gear nut. Install the alternator (refer to chapter10). Install the engine right crankcase cover.
  • Page 45 And then, tighten the bolt. Torque Value: 1.0~1.5 kgf-m ¡ ° Recommended to apply with SYM HYPOID GEAR OIL (SAE 85W-140) Start engine and run it for 2~3 minutes. Turn off engine and check if oil leaking.
  • Page 46 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 47 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 48 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 49: 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 50 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 51 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 52 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 53: 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 54: Idle Speed Adjustment

    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 55: 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 56 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 57: Engine Removal

    5. REMOVAL OF ENGINE MECHANISM DIAGRAM ...... 5-1 . 5-6 REMOVAL OF ENGINE SUSPENSION BUSHING OPERATIONAL PRECAUTIONS ..5-2 ENGINE SUSPENSION FRAME..5-7 ENGINE REMOVAL ......5-3 INSTALLATION OF ENGINE ....5-8 MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5 kgf-m...
  • Page 58 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 59: Engine Removal

    5. REMOVAL OF ENGINE ENGINE REMOVAL pulse generator Open the seat. connector Remove the luggage box assembly (4 bolts ). Remove the body cover . Generator Remove the power connector of auto by- Auto by-start connector connector start. Remove the generator connector and pulse generator connector.
  • Page 60 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 61 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 62 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 63 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 64 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 65: 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 66 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 67 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 68 6. CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head bolts and then remove the cylinder head (4 bolts). A.I. 4 bolts Loosen the bolt of camshaft chain adjuster bolt and remove O-ring.
  • Page 69 6. CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Camshaft Service Limit bearing IN: Replacement when less than 25.29 mm EX: Replacement when less than 25.12 mm Inspect the camshaft bearing for looseness or wear out.
  • Page 70 6. CYLINDER HEAD/VALVE Measure the valve rocker arm I.D. Service Limit: Replace when it is above 10.100 mm Measure the active O.D. of the valve rocker arm shaft and valve rocker arm. Service Limit: Replace when it is above 9.910 mm Calculate the clearance between the rocker arm shaft and the rocker arm.
  • Page 71 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts dowel pins from cylinder head left side cover. Remove cylinder head gasket and 2 dowel pins. Remove chain plate. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution Do not damage the matching surfaces of cylinder and cylinder head.

  • Page 72: Cylinder Head Inspection

    6. CYLINDER HEAD/VALVE CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack. Measure cylinder head flat with a straightedge and flat feeler gauge. Service limit: 0.05mm Valve spring free length Measure the free length of intake and exhaust valve springs.
  • Page 73 6. CYLINDER HEAD/VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.

  • Page 74: Valve Seat Inspection And Service

    6. CYLINDER HEAD/VALVE VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 75 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm Caution Make sure that all roughness and uneven faces had been grinded.

  • Page 76: Cylinder Head Reassembly

    6. CYLINDER HEAD/VALVE After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded. Valve cotters CYLINDER HEAD REASSEMBLY Valve stem Lubricate valve stem with engine oil, and oil seal Valve spring then insert the valve into valve guide.
  • Page 77 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Cylinder head gasket Lock pins Install the lock pins and new cylinder head gasket onto the cylinder head. Install the camshaft chain plate. Chain plate Install the cylinder head. CAMSHAFT INSTALLATION Assemble the camshaft holder. 5mm blot Install the exhaust valve rocker arm set onto the camshaft holder showing “EX”...

  • Page 78: Valve Clearance Adjustment

    6. CYLINDER HEAD/VALVE Install the lock pins. Install the camshaft holder, gasket and nut onto the cylinder head. Tighten the cylinder head nuts. (4 nuts) At first, tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.

  • Page 79: Cylinder/Piston

    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 80 7. CYLINDER/PISTON PRECAUTIONS IN OPERATION General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification unit: mm Item Standard Limit 39.00 ¡ 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 81 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 82 7. CYLINDER/PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.

  • Page 83: Piston Removal

    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 84 7. CYLINDER/PISTON 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 85: Piston Ring Installation

    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 86: Piston Installation

    7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Install new piston pin snap ring. Piston pin Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 87 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 5.0~6.0kgf-m 3.5~4.5kgf-m 0.8~1.2kgf-m...
  • Page 88 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 89: 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 90 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 91 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 92 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SLIDING PULLEY Starter clutch driving pulley REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Remove the sliding pulley fixing nut and Crankshaft Sliding pulley remove the driving belt from the sliding...
  • Page 93 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 94 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 Install siding pulley assembly onto crankshaft.
  • Page 95 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 96 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 97 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 98 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 99 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 100: 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 2.6~3.0 kgf-m...
  • Page 101 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: 110 c.c. (100 c.c. when Gear oil filling bolt 1.0~1.5 kgf-m replacing) Tools...
  • Page 102 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 103 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 104 9. FINAL DRIVING MECHANISM Driving shaft Press out the driving shaft from the 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 105 Install the driving pulley, belt and left crankshaft cover. Install the rear wheel. 7 bolts Filling bolt Add gear oil. Recommended usage gear oil : SYM HYPOID GEAR OIL (SAE 85W-140) (110 cc: standard capacity) (100 cc: when replacement) Draining bolt...
  • Page 106 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 107: 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 108: 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 109: 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 110 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 111: 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 1.5~2.0 kgf-m 11-1...
  • Page 112 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 113 11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 1 bolt Remove the 1 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 114 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 115 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 116 11. CRANKCASE/CRANKSHAFT ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.
  • Page 117 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 118: Body Cover

    12. BODY COVER MAINTENANCE INFORMATION..12-2 BODY COVER/REAR CENTER HANDLE COVER .......12-3 COVER/REAR FENDER ....12-8 FRONT COVER........12-4 FRONT CENTER COVER....12-10 FRONT UNDER COVER ....12-5 LUGGAGE BOX ......... 12-10 FRONT INNER BOX A / B....12-6 FLOOR PANEL ........12-10 Double Seat Rear handle over Rear carrier...
  • Page 119 12. BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Front handle cover Front cover Luggage box & Seat Front handle garnish Inner box A Front center cover Rear carrier Front handle visor Inner box B Rear center cover Rear handle cover Floor panel Left/right body cover Battery cover...
  • Page 120 12. BODY COVER HANDLE COVER screw ¡ Á 1 Removal: Remove 1 lower mounting screw of the handle front cover. Remove the mounting screws (4 screws) between the front handle cover and the rear handle cover. Remove the mounting screws (1screw) between the rear handle cover and the frame.
  • Page 121 12. BODY COVER FRONT COVER 8 screws Removal Remove the 8 mounting screws of front cover from the inner box A. Remove the 2 mounting screws between the front cover and the inner box . 2 screws bolt¡ Á 1 Remove the 1 mounting bolt of front cover from the frame.
  • Page 122 12. BODY COVER 2 screws FRONT UNDER COVER Removal Remove the 2 mounting screws between the inner box B and the floor panel. Remove the 4 mounting screws between the front under cover and the inner box B. 4 screws Remove the 2 mounting bolts between the front under cover and frame.
  • Page 123 12. BODY COVER 8 screws FRONT INNER BOX A Removal Remove the 8 mounting screws of front cover from the inner box A. Remove the screw on the front inner box. 1 bolt Remove the front cover. 1 screw Remove the screw on the main switch. Remove the main switch cover.
  • Page 124 12. BODY COVER 2 screws Remove the 2 mounting screws between the inner box B and the floor panel. Remove the 4 mounting screws between the front under cover and the inner box B. Remove the front inner box A and the front inner box B.
  • Page 125 12. BODY COVER 4 bolts BODY COVER/REAR CENTER COVER/REAR FENDER Removal Open the seat. Remove the luggage box. (4 bolts) 3 bolts Remove the rear carrier. (3 bolts) 2 bolts Remove the 2 mounting bolts of the rear fender. screw Remove the 2 mounting screws between the body cover and the floor panel.
  • Page 126 12. BODY COVER 4 screws Remove the 4 screws between the rear center cover and the left/right body cover. Remove the 4 screws between the rear Screws 2¡ Á 2 fender and the left/right body cover. Screws1¡ Á 2 Remove the 2 screws between the rear fender and the rear center cover.

  • Page 127: Luggage Box

    12. BODY COVER bolt¡ Á 1 FRONT CENTER COVER Removal Remove the luggage box. Remove the front center cover mounting screw. Remove the front center cover mounting bolt. screw¡ Á 1 Front center cover Remove the front center cover. Installation Install the cover according to the reverse procedure of removal.

  • Page 128: Brake System

    13. BRAKE MECHANISM DIAGRAM 13-1 BRAKE CALIPER ......13-7 ........ MAINTENANCE INFORMATION ..13-3 BRAKE DISK ........13-8 TROUBLE DIAGNOSIS ..... 13-4 BRAKE MASTER CYLINDER ... 13-8 HYDRAULIC BRAKE SYSTEM DRUM BRAKE-DRUM ....... 13-11 INSPECTION ........13-5 BRAKE LING ........13-11 BRAKE FLUID REPLACEMENT/ BRAKE PANEL........
  • Page 129 13. BRAKE Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-2...
  • Page 130 13. BRAKE MAINTENANCE INFORMATION Precautions in Operation Caution Installing pad 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 131 13. BRAKE TROUBLE DIAGNOSIS DISK BRAKE Soft brake lever Uneven brake Air inside the hydraulic system Dirty brake pad/disk Hydraulic system leaking Poor wheel alignment Worn master piston Clogged brake hose Worn brake pad Deformed or warped brake disk Poor brake caliper Restricted brake hose and fittings Worn brake pad/disk Low brake fluid...
  • Page 132 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 133: 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 disk. CAUTION The dirty brake pad or disc will reduce the brake performance.
  • Page 134 13. BRAKE BRAKE CALIPER Removal bolts x 2 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. hose bolt Make sure the brake pad condition.
  • Page 135 13. BRAKE BRAKE DISK Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 2.0 mm brake disk micrometer Remove the brake disk from wheel.
  • Page 136 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 137 13. BRAKE master cylinder INSTALLATION mounting Place the master cylinder onto handlebar, seat brake and install the split ring and bolts. The hose “UP” mark on the split ring should face upward. Align the split ring on the master cylinder seat with the alignment point on the handlebar.

  • Page 138: Brake Pad

    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 139 13. BRAKE Removal front brake cam Caution Brake pads must be replaced as a set. brake spring Remove brake shoes from the brake panel by pulling out the brake pads with two hands. Installation Apply a thin coat of grease to the brake cam anchor pin «...
  • Page 140 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 141: 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..... 14-8 TROUBLE DIAGNOSIS......14-2 FRONT FORK/STEERING COLUMN 14-8 STEERING HANDLE......14-3 MECHANISM DIAGRAM 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 3.1~3.5kgf-m 2.4~3.0kgf-m 11.0~13.0kgf-m 14-1...
  • Page 142 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 143 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE Acceleration handlebar seat REMOVAL screw Remove handle front & rear covers and the front cover (refer to chapter 12). Brake lever screw Brake lever nut Master cylinder Remove the 2 bolts of the brake master Seat cylinder, and then take out the master cylinder and the split ring.
  • Page 144 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a wrench to hold the handlebar bolt and then remove the nut. Bolt Take out the handlebar after removed the bolt. Installation Install the handlebar according to the reverse procedure of removal. Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat, acceleration handlebar, and acceleration cable.
  • Page 145 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 146 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Bearing Inspection Turn the inner race of bearing with fingers. The bearing should be turn smoothly. Also check if the outer collar is tightly connected to the wheel hub. If the bearing do not turn smoothly, or if they are too loose in the races, or damaged, then, remove and replace the bearings with new ones.
  • Page 147 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Installation Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc or speedometer gear box. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake disc must be free of grease.

  • Page 148: 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 149 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 150 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 151 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 152 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 153 15. REAR WHEEL/REAR SHOCK ABSORBER REAR SHOCK ABSORBER Removal Remove the left & right covers. (screws x 8) Remove the luggage box. (bolts x 4, nuts x 2, screw x 1) Remove the rear carrier. (bolts x 3) Remove the body cover (bolts x2) Remove the air cleaner bolts (bolts x2) Remove the lower nut of the rear shock absorber (bolt x 1)

  • Page 154: Electrical Equipment

    16. ELECTRICAL EQUIPMENT MECHANISM DIAGRAM ....16-1 STARTING SYSTEM ......16-14 PRECAUTIONS IN OPERATION ..16-2 METER ..........16-15 SPECIFICATION ........16-3 LIGHTS/BULBS ........16-17 TROUBLE DIAGNOSIS......16-4 MAIN SWITCH/HORN ......16-19 CHARGING SYSTEM......16-5 FUEL UNIT .........16-22 IGNITION SYSTEM ......16-11 MECHANISM DIAGRAM High & low beam/Passing/turn signal light/Horn Front/Rear stop switch Main switch...

  • Page 155: 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 156 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 157 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 158 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 159 16. ELECTRICAL EQUIPMENT Battery Battery cover Removal Remove the 4 screws on the battery cover. (Screws x 4). CAUTION 4 screw Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind.
  • Page 160 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 161 16. ELECTRICAL EQUIPMENT digital voltmeter Charging Voltage/Current ammeter Inspection Caution Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.0 V. If undercharged, the current changes dramatically. While starting the engine, the starter motor draws large amount of current from Fuse ends...
  • Page 162 Do not touch the probe of multi-meter by White fingers, then the resistance values will be incorrect because there is some resistance existence in human body. To use the multi-meter recommended by Yellow Green SYM. Otherwise, the measured resistance might be different. 16-9...
  • Page 163 16. ELECTRICAL EQUIPMENT Alternator charging coil Ignition light coil connector connector Caution The check of alternator charging coil and illumination coil can be done when the Pulse generator alternator is mounted on engine. connector Check Remove the 3P connector of the alternator. Measure the resistance between the white wire on the alternator and frame ground with Charging coil...
  • Page 164 16. ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit green Blue /yellow green Black/ yellow Black Pluser spark plug Engine start control switch green Blue/yellow Blue/yellow black/yellow Black green C.D.I. unit green Ignition coil CDI UNIT Removal Remove the right body cover, then the C.D.I. unit can be removed from the frame.
  • Page 165 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 166 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 167 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 168 16. ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the right side cover. (screws x3) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the starting motor power wire. Remove the starting motor mounting bolts and motor.
  • Page 169 16. ELECTRICAL EQUIPMENT Remove the rear handle cover. Remove the meter mounting screws. Take out the meter. Speedomete High Beam Indicator Turn Right Turn Left Signal Signal Indicator Indicator Fuel meter Odometer Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components.
  • Page 170 16. ELECTRICAL EQUIPMENT LIGHT/BULBS Headlight Bulb Replacement Rear the screw of the front cover. Rear the front cover. Disconnect the headlight wire connector. Press down the bulb spring locker and then remove the locker with turning it left motion. Remove the bulb. Replace the bulb with new one if necessary.
  • Page 171 16. ELECTRICAL EQUIPMENT Front Turn Signal Lamp Bulb Front turn Replacement signal light Remove the front handle cover. Remove the wire connector of the turn signal light. the wire connector of Pull out the bulb and replace it with new one. the turn signal light (12V 5W) Installation...
  • Page 172 16. ELECTRICAL EQUIPMENT Remove the tail light assembly. The tail light assembly Replace the bulbs of the tail light, brake light tail light & brake light turn signal light (12V 5W/21W) Replace the bulbs of the turn signal light (12V/10W). Installation Install the bulb in reverse order of removal.
  • Page 173 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 174 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 175: 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 R.R. center cover. Disconnect the fuel unit wire connector. Caution Do not damage or bend the float arm as removing.

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