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GTS 250
JOYMAX 250
SERVICE MANUAL
FORWARD
CONTENTS
HOW TO USE THIS MANUAL
SERIAL NUMBER

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Table Of Contents

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   Summary of Contents for Sym GTS 250

  • Page 1: Service Manual

    GTS 250 JOYMAX 250 SERVICE MANUAL FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER...

  • Page 2

    Homepage Contents Forward This service manual contains the technical data of each component inspection and repair for the SANYANG LM25W series scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the scooter, LM25W series scooter, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3

    Homepage Contents How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG LM25W series scooter. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4

    Homepage Contents Page Content Index 1-1 ~ 1-16 General Information 2-1 ~ 2-18 Service Maintenance Information 3-1 ~ 3-8 Lubrication System 4-1 ~ 4-14 Fuel System 5-1 ~ 5-10 Engine Removal 6-1 ~ 6-16 Cylinder Head / Valve 7-1 ~ 7-8 Cylinder / Piston 8-1 ~ 8-14 “V”...

  • Page 5

    Home page Contents Serial Number...

  • Page 6: Table Of Contents

    Homepage Contents 1. General Information Symbols and Marks····························1-1 Torque Values ···································· 1-10 General Safety ····································1-2 Troubles Diagnosis···························· 1-12 Service Precautions ···························1-3 Lubrication Points ····························· 1-16 Specifications ·····································1-9 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

    To this chapter contents 1. General Information General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you ¡...

  • Page 8: Service Precautions

    To this chapter contents 1. General Information Service Precautions Always use with SANYANG genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-designed parts unsmooth control and premature worn out. for SANYANG ATV may damage the ATV. Rubber parts may become deteriorated when Special tools are designed for remove and old, and prone to be damaged by solvent and oil.

  • Page 9

    To this chapter contents 1. General Information The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if another, be sure they are correctly installed. In the contact surface has any damage.

  • Page 10

    To this chapter contents 1. General Information Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.

  • Page 11

    To this chapter contents 1. General Information When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated...

  • Page 12

    To this chapter contents 1. General Information Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.

  • Page 13

    To this chapter contents 1. General Information 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...

  • Page 14: Specifications

    To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL LM25W Overall Length Front 2165 mm TELESCOPE Suspension System Overall Width Rear 870 mm UNlT SWING Overall Height Front 1380 mm 110 / 90-13 56P Tire Specifications Wheel Base Rear 1495 mm 130 / 70-13 57P...

  • Page 15: Torque Values

    To this chapter contents 1. General Information Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 5 mm bolt¡...

  • Page 16

    To this chapter contents 1. General Information Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle 4.0~5.0 post Lock nut for steering stem 1.0~2.0 Steering top cone race 2.0~3.0 Front wheel axle nut 5.0~7.0 Rear wheel axle nut 11.0~13.0...

  • Page 17: Troubles Diagnosis

    To this chapter contents 1. General Information Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.

  • Page 18

    To this chapter contents 1. General Information B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged 1. Poor fuel supply Engine speed can be Engine speed can not be 2.

  • Page 19

    To this chapter contents 1. General Information C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (Using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...

  • Page 20

    To this chapter contents 1. General Information 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

    To this chapter contents 1. General Information Lubrication Points Acceleration cable/ Front & rear brake lever pivot Seat locker Steering shaft bearing Speedometer gear/ Side stand shaft Main stand shaft Clutch bearing front wheel bearing 1-16...

  • Page 22: Maintenance Information

    Home page Contents 2. Maintenance Information Precautions in Operation······················ 2-1 Cylinder Compression Pressure ·······2-9 Periodical Maintenance Schedule ······· 2-2 Drive Belt·············································2-9 Engine Oil ·············································· 2-3 Steering Handle Top Bearing ············2-10 Engine Oil Strainer Clean ····················· 2-3 Cushion ···············································2-10 Gear Oil ·················································· 2-4 Disk Brake System ·····························2-11 Fuel Lines / Cable··································...

  • 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 1,000 kilometers as a reference which ever comes first.

  • Page 24: Engine Oil

    To this chapter contents 2. Maintenance Information Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 25: Gear Oil

    To this chapter contents 2. Maintenance Information Gear Oil Oil inspection bolt Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine. Gear Oil Change Remove oil inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained.

  • Page 26: Air Cleaner

    To this chapter contents 2. Maintenance Information Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Adjustment nut Air Cleaner Air Cleaner Element Remove 8 screws from the air cleaner cover and then remove the cover.

  • Page 27: P.c.v. System

    Valve clearance (IN)¡ G 0.1±0.02 mm. Valve clearance (EX)¡ G 0.15±0.02 mm. Loosen fixing nut and turn the adjustment nut for adjustment. Caution Re-check the valve clearance after tightened the fixing nut. Special tool: Tappet adjuster SYM-9001200-08 SYM-9001200-09 SYM-9001200-10 Special tool: Tappet adjuster wrench SYM-9001200...

  • Page 28

    To this chapter contents 2. Maintenance Information Carburetor Idle Speed Adjustment Ignition coil cable Caution Inspection & adjustment for idle speed have ● to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be ●...

  • Page 29: Ignition System

    To this chapter contents 2. Maintenance Information Ignition System Caution C.D.I ignition system is set by manufacturer ● so it can not be adjusted. Ignition timing check procedure is for ● checking whether CDI function is in normal or not. Remove right side cover.

  • Page 30: Cylinder Compression Pressure

    To this chapter contents 2. Maintenance Information Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove luggage box and central cover Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.

  • Page 31: Steering Handle Top Bearing

    To this chapter contents 2. Maintenance Information Steering Handle Top Bearing Caution Check all wires and cables if they are ● interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.

  • Page 32: Disk Brake System

    To this chapter contents 2. Maintenance Information Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.

  • Page 33

    To this chapter contents 2. Maintenance Information Brake Lining Wear Lining The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc. Caution It is not necessary to remove brake hose when replacing the brake lining.

  • Page 34: Brake Light Switch/starting Inhibitor

    To this chapter contents 2. Maintenance Information Brake Light Switch/Starting Inhibitor Stop switch Switch The brake lamp switch is to light up brake lamp as brake applied. Make sure that electrical starter can be operated only under brake applying. Headlight Beam Distance Turn on main switch Headlight beam adjustment.

  • Page 35: Battery

    To this chapter contents 2. Maintenance Information Battery Open the inner box lid. Loosen screw & remove the battery cover Battery cable remove¡ G Disconnect the cable negative terminal (-), then the cable positive terminal (+) Remove the battery from the motorcycle.¡ C If there is some rust on battery posts, clean it with steel brush Install the battery in the reverse procedures of...

  • Page 36: Special Tools List

    SYM-1471110/20 L. Crank shaft puller Tappet adjusting wrench Tappet adjusting NAME NAME NAME SYM-1130000-HMA H9A SYM-9001200 SYM-9001200-08 09 10 R. crank case bearing 6201 Left crankshaft & oil seal Rocker arm shaft disassemble NAME NAME NAME assembles tool assembly socket.

  • Page 37

    Steering head top thread Bearing driver HK1516 Bearing puller 6205 NAME NAME NAME wrench SYM-9100200-HMA RB1 SYM-5320010 SYM-9100400 HMA RAI 6205 HK1516 Right crankcase cover bearing Air operated bearing puller Oil seal driver 34*52*5 NAME NAME NAME 6201 puller SYM-9614000-HMA RB1 6201...

  • Page 38

    2. Maintenance Information Drive shaft & oil seal (25*40*8) Bearing driver 6205 Bearing puller 6303 NAME NAME NAME socket SYM-9615000-6205 SYM-9120200-HMA SYM-6303000-HMA H9A 6303 (Ø22mm) (Ø30mm) Bearing driver 6201 Crankcase bush puller Crankcase bush puller NAME NAME NAME SYM-9614000-6201 SYM-1120310...

  • Page 39

    To this chapter contents 2. Maintenance Information Note: 2-18...

  • Page 40: Lubrication System

    Home page Contents 3. Lubrication System Mechanism Diagram ······························ 3-1 Engine Oil Strainer Clean ······················ 3-3 Precautions in Operation ······················ 3-2 Oil Pump ················································· 3-4 Troubleshooting ···································· 3-2 Gear Oil ··················································· 3-7 Engine Oil ··············································· 3-3 Mechanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route...

  • Page 41

    SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 180c.c. Change: 170c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) Unit: Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Oil pump Clearance between outer rotor and body 0.15~0.20...

  • Page 42

    To this chapter contents 3. Lubrication System Engine Oil Turn off engine, and park the scooter in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 43: Oil Pump

    To this chapter contents 3. Lubrication System Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) ¡ C Clip Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.

  • Page 44

    To this chapter contents 3. Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Pins...

  • Page 45

    To this chapter contents 3. Lubrication System Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value¡ G 0.1~0.3kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Install oil pump drive chain and sprocket, and Clip...

  • Page 46

    To this chapter contents 3. Lubrication System Gear Oil Gear oil join bolt Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m Make sure that the drain bolt washer can be re-used.

  • Page 47

    To this chapter contents 3. Lubrication System Notes:...

  • Page 48: Fuel System

    Home page Contents 4. Fuel System Mechanism Diagram ......4-1 Automatic by-starter......4-7 Precautions in Operation....4-2 Float Chamber........4-8 Trouble Diagnosis.......4-3 Adjustment of Idle Speed....4-10 Carburetor Remove / Install ....4-4 Fuel Tank ..........4-11 Vacuum Chamber........4-4 Fuel Pump ..........4-13 Air Cut-off Valve ........4-6 Air Cleaner..........4-14 Mechanism Diagram Carburetor Inlet pipe...

  • Page 49: Fuel System

    To this chapter contents 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 off throttle cable. Damaged throttle cable will make unstable drive-ability. 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 50

    To this chapter contents 4. Fuel System Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system )

  • Page 51: Carburetor Remove / Install

    To this chapter contents 4. Fuel System Carburetor Remove / Install Removal Remove luggage box. Drain out fuel in the float chamber. Throttle cable Fuel pipe Disconnect the fuel hose, vacuum hose. Disconnect the auto by-start and heater couplers. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor.

  • Page 52

    To this chapter contents 4. Fuel System Remove fuel needle seat, spring, and injector Piston Needle seat Needle needle. Inspection Check if the vacuum piston and needle for wear out, crack or other damage. Check if the diaphragm for damage or crack. Caution Do not damage vacuum diaphragm.

  • Page 53: Air Cut-off Valve

    To this chapter contents 4. Fuel System Air Cut-off Valve 2 screws Removal Removal the throttle cable seat (2 screws) Remove the screws (2 screws) of the air cut-off 2 screws valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack.

  • Page 54: Automatic By-starter

    To this chapter contents 4. Fuel System Automatic by-starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter. Resistance value: Max. 10£ [ (Measured after engine stopped for more than 10 minutes) Replace the automatic by-starter with a new one if resistance value exceeds standard.

  • Page 55: Float Chamber

    To this chapter contents 4. Fuel System Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. 3 screws Remove the fuel level plate, float pin, float and 1 screw Float float valve. Main jet Slow jet Inspection Float pin Float Check float valve and valve seat for damage,...

  • Page 56

    To this chapter contents 4. Fuel System Air adjustment screw Assembly Install main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution Set the air adjustment screw in according to number of turns noted before it was removed. Float 1 screw Install the float valve, float, and float pin.

  • Page 57: Adjustment Of Idle Speed

    To this chapter contents 4. Fuel System Adjustment of Idle Speed Throttle cable adjustment nuts Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the scooter to perform the adjustments.

  • Page 58: Fuel Tank

    To this chapter contents 4. Fuel System Fuel Tank Fuel unit coupler Fuel unit removal Remove the left and right side covers. Open seat and remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the foot pedal (please refer to chapter 13 for these components above.) 4 bolts Remove fuel unit coupler, and then remove fuel...

  • Page 59

    To this chapter contents 4. Fuel System Remove fuel tank upper bolts (2 bolts). 2 bolts Remove fuel tank under bolt (1 bolt). 1 bolt Remove fuel tank. Installation Install the fuel tank in the reverse order of removal. 4-12...

  • Page 60: Fuel Pump

    To this chapter contents 4. Fuel System Fuel Pump Clamp Inspection Remove the left side cover and floor panel side cover. Warm up the engine and adjust idle speed. Remove fuel hose from carburetor and then wait for 5 minutes. Measure the output of fuel pump.

  • Page 61: Air Cleaner

    To this chapter contents 4. Fuel System Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Remove the air cleaner (3 bolts). Installation Install the tank in the reverse order of removal. 2 bolts 8 screws 1 bolt...

  • Page 62: Engine Removal

    Home page Contents 5. Removal & Installation of Engine Operational Precautions····················· 5-1 Rear Fork ·············································· 5-7 Engine Removal ·································· 5-2 Removal of Engine Bush····················· 5-9 Engine Hanger ····································· 5-6 Installation of Engine··························· 5-10 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.

  • Page 63: Engine Removal

    To this chapter contents 5. Removal & Installation of Engine Engine Removal Open inner box cover. Remove battery cover (1 screw). Remove the battery negative (-) cable. Remove the battery positive (+) cable. Positive Negative Open the seat. Remove the luggage box (6 bolts, 2 screws). (Refer to chapter 13) Remove right and left side covers (4 screws on each side.).

  • Page 64

    To this chapter contents 5. Removal & Installation of Engine Remove the generator power wire and pulse Couplers of the generator and generator connector. pulse generator Remove the starter motor wire. Starter motor wire Remove engine blow-by pipe. Engine blow-by pipe Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor.

  • Page 65

    To this chapter contents 5. Removal & Installation of Engine Remove the air cleaner connection bolts (2 bolts). Remove the air cleaner. 2 bolts Remove the exhaust muffler (3 bolts, 2 nuts). 2 nuts 3 bolts Drain out coolant, and remove coolant inlet hose. Drain bolt Inlet hose Remove the coolant inlet hose and thermo-sensor...

  • Page 66

    To this chapter contents 5. Removal & Installation of Engine Remove rear brake hose clamp and rear brake caliper. Brake hose clamp 2 bolts Rear axle nut 2 bolts Remove the right rear cushion lower bolt (1 bolt). Remove the rear fork bolts (2 bolts). Remove the rear wheel axle nut (1 nut).

  • Page 67: Engine Hanger

    To this chapter contents 5. Removal & Installation of Engine With a bracket to support the engine to prevent Frame side bolt from it damage by falling down as removing the engine. Remove frame side engine hanger bolts (each side 1 bolt), and then remove engine. Engine side bolt Engine Hanger Removal...

  • Page 68: Rear Fork

    Drive the bearing out of the rear fork. Bearing installation Install new rear axle bearing and baring puller into rear fork. Special Service Tools: Rear fork bearing puller SYM-6303000-6303 6303 bearing puller Install the washer of the 6303 bearing puller. 6303 bearing puller washer...

  • Page 69

    5. Removal & Installation of Engine Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Bearing puller Use screw driver holder bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing.

  • Page 70: Removal Of Engine Bush

    Place the detent section of the bush remover toward the bush, and drive both the pressing ring and bolt in to press the bush out. Special Service Tools: Crankcase bush remover/presser SYM-1120310 Crankcase bush remover/presser SYM-1120320 Pressing In Place the flat section of the remover toward the bush, and then drive the bush, pressing ring, and bolt in to install the bush.

  • Page 71: Installation Of Engine

    To this chapter contents 5. Removal & Installation of Engine Installation of Engine Install the engine according to the reversing order of removal. Caution Note both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose. Route all cables and wires in accordance with the routine layout.

  • Page 72: Cylinder Head / Valve

    Home page Contents 6. Cylinder Head / Valve Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10 Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11 Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13 Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-14 Cylinder Head Disassembly···············...

  • Page 73: Precautions In Operation

    To this chapter contents 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 rocker arm. Cylinder head service can be carried out when engine is in frame. Specification Item Standard...

  • Page 74: Troubleshooting

    To this chapter contents 6. Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1.

  • Page 75: Cylinder Head Removal

    To this chapter contents 6. Cylinder Head / Valve Cylinder Head Removal Remove engine. (Refer to chapter 5) Tensioner bolts Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.

  • Page 76

    To this chapter contents 6. Cylinder Head / Valve Remove the side cover mounting blots of cylinder 3 bolts head, and then take out the side cover. Remove left crankcase cover, and turn the Timing mark Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position.

  • Page 77: Cylinder Head Disassembly

    Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.

  • Page 78

    To this chapter contents 6. Cylinder Head / Valve Remove valve cotters, spring retainers, springs Inlet valve Inner spring Spring retainer and valves. Exhaust valve Cotter Outer spring Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.

  • Page 79: Cylinder Head Inspection

    To this chapter contents 6. Cylinder Head / Valve Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.05 mm Camshaft Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm...

  • Page 80

    To this chapter contents 6. Cylinder Head / Valve Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: Inner spring 35.20 mm Outer spring 36.90 mm Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure &...

  • Page 81: Valve Stem Replacement

    To this chapter contents 6. Cylinder Head / Valve Valve Stem Replacement Heat up cylinder head to 100~150 ¢ J with heated Valve guide driver 5.0mm plate or toaster. Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it.

  • Page 82: Valve Seat Inspection And Service

    To this chapter contents 6. Cylinder Head / Valve Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.

  • Page 83

    To this chapter contents 6. Cylinder Head / Valve Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.

  • Page 84

    Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.

  • Page 85: Cylinder Head Installation

    To this chapter contents 6. Cylinder Head / Valve Install camshaft into cylinder head. 2 bolts Cam shaft setting plate Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head.

  • Page 86

    To this chapter contents 6. Cylinder Head / Valve Install cylinder head side cover (3 bolts). 3 bolts Tensioner bolts Install thermostat (2 bolts). Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt.

  • Page 87: Valve Clearance Adjustment

    To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment 4 bolts Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover. Remove the cylinder head side cover. 3 bolts Timing mark Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position.

  • Page 88: Cylinder / Piston

    Home page Contents 7. Cylinder / Piston Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7 Trouble Diagnosis································ 7-2 Cylinder Installation ························· 7-7 Cylinder and Piston Removal ············· 7-3 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m...

  • Page 89: Precautions In Operation

    To this chapter contents 7. Cylinder / Piston Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit¡ G mm Item Standard Limit 70.995~71.015 71.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston...

  • Page 90: Cylinder And Piston Removal

    To this chapter contents 7. Cylinder / Piston Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.

  • Page 91

    To this chapter contents 7. Cylinder / Piston Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.

  • Page 92

    To this chapter contents 7. Cylinder / Piston Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.

  • Page 93: Piston Ring Installation

    To this chapter contents 7. Cylinder / Piston Piston Ring Installation Clean up piston top, ring groove, and piston surface. 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 94: Piston Installation

    To this chapter contents 7. Cylinder / Piston Piston Installation IN mark Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve. Install new piston pin clip. Clip end gap Caution Do not let the opening of piston pin clip align with the piston cutout.

  • Page 95

    To this chapter contents 7. Cylinder / Piston Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.¡...

  • Page 96

    Home page Contents 8. V-Belt Driving System Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-5 Maintenance Description ···················· 8-2 Drive Face·············································8-7 Trouble Diagnosis ······························· 8-2 Clutch Outer / Driven Pulley················8-10 Left Crankcase Cover ························· 8-3 Mechanism Diagram 5.0~6.0kgf-m 8.5~10.5kgf-m 5.0~6.0kgf-m...

  • Page 97: Maintenance Description

    Weight of weight roller 17.700~18.300 17.200 Torque value Special Service Tools Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000 Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002 Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder:...

  • Page 98: Left Crankcase Cover

    To this chapter contents 8. V-Belt Driving System Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (8 bolts) Remove 2 dowel pin and gasket. 8 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.

  • Page 99

    If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Bearing replacement Remove bearing with special service tools Special tools: Inner bearing puller SYM-6204022 Install bearing with special service tools. Special tools: Right crank case bearing 6201 assembles tool SYM-9614000-HMA 6201...

  • Page 100: Drive Belt

    To this chapter contents 8. V-Belt Driving System Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool¡ G universal holder Hold clutch outer with universal holder, and Universal holder Bearing stay collar remove nut, bearing stay collar and clutch outer.

  • Page 101

    To this chapter contents 8. V-Belt Driving System Installation Caution Pull out driven face to avoid it closing. ● Driven face Cannot oppress friction plate comp in order to ● avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.

  • Page 102: Drive Face

    To this chapter contents 8. V-Belt Driving System Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Movable drive face Remove movable drive face comp and drive face boss from crankshaft.

  • Page 103

    To this chapter contents 8. V-Belt Driving System Inspection The weight rollers are to press movable drive face Weight roller by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged.

  • Page 104

    To this chapter contents 8. V-Belt Driving System With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Install movable drive face comp.

  • Page 105: Clutch Outer/driven Pulley

    To this chapter contents 8. V-Belt Driving System Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.

  • Page 106

    To this chapter contents 8. V-Belt Driving System Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.400 mm Free length Driven pulley...

  • Page 107

    To this chapter contents 8. V-Belt Driving System Clutch weight Replacement Remove snap ring and washer, and then remove Spring Driving plate clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.

  • Page 108

    To this chapter contents 8. V-Belt Driving System Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.

  • Page 109

    To this chapter contents 8. V-Belt Driving System Installation of Clutch Outer/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face.

  • Page 110: Final Driving Mechanism

    Home page Contents 9. Final Driving Mechanism Mechanism Diagram ···························· 9-1 Inspection of Final Driving Mechanism · 9-4 Precautions in Operation ···················· 9-2 Bearing Replacement ······························ 9-5 Trouble Diagnosis ······························· 9-2 Re-Assembly of Final Driving Mechanism ··································································· 9-8 Disassembly of Final Driving Mechanism ·······························································...

  • Page 111: Precautions In Operation

    Oil quantity: 180 c.c. (170 c.c. when replacing) Torque value Gear box cover 2.6~3.0kgf-m Special tools Bearing (6205) driver SYM-9615000-6205 Bearing (6205) puller SYM-9100400 HMA RA1 6205 Bearing (6203) driver SYM-9620000 Drive shaft & oil seal (25*40*8) socket SYM-9120200-HMA Bearing (HK1516) driver SYM-9100200-HMA HK1516 Bearing (6204) driver...

  • Page 112

    To this chapter contents 9. Final Driving Mechanism Disassembly of Final Driving Mechanism Remove the rear wheel. Remove the clutch. Drain out gear oil from gear box. Loosen 7 bolts and remove gear box cover bolts. 7 bolts Remove the gear box cover. Remove the gasket &...

  • Page 113: Inspection Of Final Driving Mechanism

    To this chapter contents 9. Final Driving Mechanism Inspection of Final Driving Mechanism Check if the drive shaft are burn, wear or damage and replace it if necessary. Caution If remove the drive shaft from the gear box upper side, then its bearing has to be replaced.

  • Page 114: Bearing Replacement

    SYM-6204001 Shaft protector SYM-6204010 Remove final shaft bearing and counter shaft bearing from left crankcase using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Inner bearing puller Caution Never install used bearings. Once bearing removed, it has to be replaced with new one.

  • Page 115

    Gear box cover side Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Inner bearing puller Remove oil seal, and then remove final shaft bearing from gear box cover using following tools.

  • Page 116

    Apply with grease onto final shaft oil seal. Install the oil seal into gear box cover. Special tool: Oil seal driver 34*52*5 SYM-9125500-HMA Oil seal driver...

  • Page 117: Re-assembly Of Final Driving Mechanism

    Drive shaft and seal install socket Mechanism Install drive shaft. Special tool: Drive shaft puller SYM-2341110- HMA RB1 Drive shaft socket & oil seal driver (25*40*8) SYM-9120200-HMA Clutch nut wrench SYM-9020200 Drive shaft puller Apply with grease onto drive shaft oil seal.

  • Page 118: Alternator

    Home page Contents 10. Alternator / Starting Clutch Mechanism Diagram ···························10-1 Flywheel Removal ······························ 10-5 Precautions in Operation ···················10-2 Starting Clutch···································· 10-6 Right Crankcase Cover Removal ······10-3 AC.G. Flywheel Installation ··············· 10-8 AC.G. Set Removal ·····························10-4 AC.G. Set Installation ························· 10-9 Right Cover Bearing ···························10-4 Right Crankcase Cover Installation ··...

  • Page 119: Precautions In Operation

    5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.8~2.2kgf-m Special tools AC.G. flywheel puller SYM-3110000-HMA Left crank case cover 6201 bearing puller SYM-9614000-HMA RB1 6201 Inner bearing puller SYM-6204022 Universal holder SYM-2210100 10-2...

  • Page 120: Right Crankcase Cover Removal

    To this chapter contents 10. Alternator / Starting Clutch Right Crankcase Cover Removal Remove left side cover. Remove seat and luggage box (Refer chapter 13) Remove the exhaust muffler (3 bolts, 2 nuts). 2 nuts 3 bolts Drain out the engine oil and coolant (refer chapter Remove coolant hoses.

  • Page 121: Ac.g. Set Removal

    Replace it if necessary. Remove the bearing 6201with inner bearing puller. Special tool: Inner bearing puller SYM-6204022 Inner bearing puller Install the bearing 6201 bearing with special tool. Special tool: Right crankcase cover bearing 6201 presser SYM-9614000-HMA RB1 6201 Inner bearing presser 10-4...

  • Page 122: Flywheel Removal

    Installs shaft protector onto the crank shaft. Special tool: Shaft protector Shaft protector Reduction gear Remove starter reduction gear and shaft. Pull out flywheel with AC.G. flywheel puller. Special tool: AC.G. Flywheel puller SYM-3110000-HMA Flywheel puller Remove flywheel and starting driven gear. 10-5...

  • Page 123: Starting Clutch

    To this chapter contents 10. Alternator / Starting Clutch Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 25.050 mm OD: 42.100 mm Check the starting reduction gear and shaft for wear or damage.

  • Page 124

    To this chapter contents 10. Alternator / Starting Clutch Remove the starting gear Loosen 3 starting clutch socket bolts from one way clutch and remove one way clutch. 3 bolts Push out the roller set and check each roller for wear or damage.

  • Page 125: Ac.g. Flywheel Installation

    Install starting driven gear onto one way clutch. Align the key on crankshaft with the flywheel Groove groove, and then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Torque value: 5.0~6.0kgf-m Special tool: Universal Holder SYM-2210100 10-8...

  • Page 126: Ac.g. Set Installation

    To this chapter contents 10. Alternator / Starting Clutch AC.G. Set Installation 3 screws Install the AC.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator.

  • Page 127

    To this chapter contents 10. Alternator / Starting Clutch Notes: 10-10...

  • Page 128

    Home page Contents 11. Crankcase / Crank Mechanism Diagram ··························11-1 Disassembly of Crankcase················ 11-3 General Information ···························11-2 Crankshaft Inspection ······················· 11-4 Trouble Diagnosis ······························11-2 Assembly of Crankcase····················· 11-6 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 0.8~1.2kgf-m 11-1...

  • Page 129: General Information

    1.2~1.6kgf-m Special tools R/L. crank disassemble tool SYM-1120000-HMA H9A L. crank shaft bearing puller SYM-9100100 Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Crank shaft puller SYM-1130000-HMA H9A Outer bearing puller SYM-6204001 Inner bearing puller SYM-6204022 Clutch nut wrench...

  • Page 130: Disassembly Of Crankcase

    Hold left crank shaft puller nut by clutch nut wrench, and turn the shaft puller to press out crank shaft from left crankcase. Special tool: Crank case disassemble SYM-1120000-HMA H9A L. Crank shaft puller SYM-1130000-HMA H9A Clutch nut wrench SYM-9020200...

  • Page 131: Crankshaft Inspection

    To this chapter contents 11. Crankcase / Crank Remove crankshaft and wave washer from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping.

  • Page 132

    Check the inner ring to see it links firmly on the bearing. Crank bearing If any roughness, noise and loose linkage are Out bearing puller detected, replace the bearing with new one. Caution The bearing shall be replaced in pair. Special tool: Outer bearing puller SYM-6204001 11-5...

  • Page 133: Assembly Of Crankcase

    Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Crank shaft install socket Turn in the crank shaft puller spiral tooth to the left crank shaft. Special tool: L. Crank shaft puller SYM-1130000-HMA H9A Crank shaft puller 11-6...

  • Page 134

    To this chapter contents 11. Crankcase / Crank Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft into left crankcase. Crank shaft puller Put wave washer onto right crank bearing. Caution Right flank the wave washer piece certainly must install.

  • Page 135

    Install the oil seal in the left crankcase with special Oil seal driver tool. Special tool: Crank shaft install socket & oil seal driver SYM-2341110- HMA RB1 Setting plate Tensioner Install the cam chain tensioner & and tighten the bolts.

  • Page 136: Cooling System

    Home page Contents 12. Cooling System Mechanism Diagram ··························· 12-1 Change of coolant································ 12-5 General Information ···························· 12-2 Radiator ················································ 12-6 Trouble Diagnosis ······························· 12-2 Water Pump ·········································· 12-8 Trouble Diagnosis for Cooling System Thermostat ··········································· 12-12 ······························································ 12-3 Mechanism Diagram Radiator filler cap Reserve tank Reserve tank inlet pipe...

  • Page 137: General Information

    For water pump rotor 1.0~1.4kgf-m Tools Requirement Special tools Water pump bearing driver (6901): SYM-9100100 Water pump oil seal driver (Inner): SYM-9120500-H9A Water pump mechanical seal driver: SYM-1721700-H9A Inner bearing puller: SYM-6204020 Trouble Diagnosis The engine temperature is too high...

  • Page 138: Trouble Diagnosis For Cooling System

    To this chapter contents 12. Cooling System Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.

  • Page 139

    To this chapter contents 12. Cooling System Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12¡ ÷ 0V)? temperature gauge over 3 checks? E-2.

  • Page 140: Change Of Coolant

    Stop the engine. Add coolant to proper level if necessary. Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unclear trade mark refrigerant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% 12-5...

  • Page 141: Radiator

    To this chapter contents 12. Cooling System Check reserve tank Open the inner box lid. Check the liquid level in the reservoir. Add coolant to proper level if too low. Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in the cooling system the refrigerant backflow floods.

  • Page 142

    To this chapter contents 12. Cooling System Disconnect the couplers for the thermo switch and Thermo switch coupler fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Engine coolant inlet pipe Cooling fan coupler Remove reserve tank coolant inlet pipe.

  • Page 143: Water Pump

    To this chapter contents 12. Cooling System Water Pump Check water pump seal / cooling system divulges inspection Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.

  • Page 144

    To this chapter contents 12. Cooling System Check any wear and damage of the mechanical Mechanical seal seal and inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Water pump mechanical seal driver Replacement of Mechanical Seal Remove the inside bearing by inner bearing puller.

  • Page 145

    To this chapter contents 12. Cooling System Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Install a new outside bearing to the right Water pump bearing crankcase cover.

  • Page 146

    To this chapter contents 12. Cooling System Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and Water pump rotor tighten. Torque Value: 1.0~1.4kgf-m Caution The rotor is left thread.

  • Page 147: Thermostat

    To this chapter contents 12. Cooling System Thermostat Thermo sensor Please refer to chapter 17 for inspection of thermo unit. Removal Remove the luggage box and body cover. Drain out the coolant. Remove the thermostat cover. (2 bolts) 2 bolts Remove the thermostat.

  • Page 148

    To this chapter contents 12. Cooling System Place the thermostat into heated water to check its operation. Caution Whenever the thermostat and the thermometer are in contact to the wall of heated water container, the reading displayed is incorrect. If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change,...

  • Page 149

    To this chapter contents 12. Cooling System Notes: 12-14...

  • Page 150: Mechanism Diagram

    Home page Contents 13. Body Cover Mechanism Diagram ···························13-1 Front under Spoiler···························· 13-10 Maintenance ········································13-2 Rear Carrier ········································ 13-10 Handle Cover·······································13-3 Luggage Box ······································ 13-11 Front Cover ·········································13-4 Rear Body Cover································ 13-12 Meter Panel··········································13-6 Floor Panel ········································· 13-13 Inner Box ·············································13-7 Front Fender·······································...

  • Page 151: Maintenance

    To this chapter contents 13. Body Cover Maintenance Body covers disassemble sequence: R/L. Handle covers Wind screen garnish Luggage box & seat Handle upper cover Wind screen Rear carrier Front fender Meter visor R/L body cover Front cover Rear fender R/L.

  • Page 152

    To this chapter contents 13. Body Cover Handle Cover Remove Loosen the 2 screws from handle upper cover front end. 2 screws Loosen the 2 screws from handle upper cover rear end. Remove right and left handle side cover. 2 screws Remove the handle upper cover cap.

  • Page 153: Front Cover

    To this chapter contents 13. Body Cover Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Each side 2 screws Loosen 8 screws from the wind screen and remove the wind screen. 8 screws Loosen 4 screws from the meter visor and remove the meter visor.

  • Page 154

    To this chapter contents 13. Body Cover Loosen 2 bolts from the front cover under side. 2 bolts Loosen 2 screws and 2 bolts from the front cover upper side. Each side 1 screw Each side 1 bolt Disconnect the headlight, foggy light and winker Headlight coupler light couplers.

  • Page 155

    To this chapter contents 13. Body Cover Meter Panel Right side Left side Remove Remove wind screen garnish, wind screen, meter visor and front cover. Remove reserve tank cap. Loosen 4screws from right & left side of the meter panel. 4 screws Loosen 2 screws from in side of meter panel.

  • Page 156: Inner Box

    To this chapter contents 13. Body Cover Inner Box Reserve tank Remove Remove wind screen garnish, wind screen, meter visor, front cover, meter panel, R/L side cover and front under spoiler. Loosen 1 screw from reserve tank stay. 1 screw 1 screw 1 screw Loosen 1 screw from fuse box and remove it.

  • Page 157

    To this chapter contents 13. Body Cover Remove the filler pipe cover. Loosen 3 screws of the filler pipe. 3 screws Loosen 2 bolts from inner box under side. Each side 1 bolt Loosen 2 bolts from inside of the inner box. Disconnect the hazard light and foggy light switch couplers.

  • Page 158: Side Cover

    To this chapter contents 13. Body Cover Side Cover Remove Loosen 2 screws from the side cover side end. 2 screws Loosen 2 screws from the side cover upper end. 2 screws Remove the side cover. Installation Install in reverse order of removal procedures. 13-9...

  • Page 159

    To this chapter contents 13. Body Cover Front under Spoiler Each side 1 bolt Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover and R/L side cover. Loosen 2 screw and 2 bolts from the front under spoiler upper end.

  • Page 160: Luggage Box

    To this chapter contents 13. Body Cover Luggage Box 2 screws Remove Open the seat. Loosen 2 screws from the luggage box rear cover. Disconnect the luggage box light and switch coupler. Remove the luggage box rear cover. 2 bolts Loosen 2 bolts from luggage box front side 4 bolts Loosen 4bolts from luggage box rear side.

  • Page 161: Rear Body Cover

    To this chapter contents 13. Body Cover Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel. Each side 1 screw Loosen right and left side screws from rear side of the body cover. Each side 1 screw Disconnect the tail light coupler.

  • Page 162: Front Fender

    To this chapter contents 13. Body Cover Floor Panel Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover, R/L side cover, front under spoiler, inner box, luggage box and body cover. Loosen 4 bolts and 2 screws from floor panel. Each side 2 bolts Remove floor panel.

  • Page 163: Rear Fender

    To this chapter contents 13. Body Cover Rear Fender Loosen 4 bolts from rear fender. Each side 1 bolt 2 bolts Remove the rear fender. Installation Install in reverse order of removal procedures. 13-14...

  • Page 164: Brake System

    Home page Contents 14. Brake System Mechanism Diagram ···························· 14-1 Brake fluid replacement / Air-bleed·· 14-6 Maintenance Description ···················· 14-2 Front Brake Caliper···························· 14-7 Trouble Diagnosis ······························· 14-3 Rear Brake Caliper ····························· 14-8 Disk Brake System Inspection············ 14-4 Brake Disk ·········································· 14-9 Adding Brake Fluid······························...

  • Page 165: Maintenance Description

    To this chapter contents 14. Brake System Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.

  • Page 166: Trouble Diagnosis

    To this chapter contents 14. Brake System Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8.

  • Page 167: Disk Brake System Inspection

    To this chapter contents 14. Brake System Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.

  • Page 168: Adding Brake Fluid

    To this chapter contents 14. Brake System Adding Brake Fluid Front brake master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.

  • Page 169: Brake Fluid Replacement / Air-bleed

    To this chapter contents 14. Brake System Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay valve the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.

  • Page 170: Front Brake Caliper

    To this chapter contents 14. Brake System Front Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.

  • Page 171: Rear Brake Caliper

    To this chapter contents 14. Brake System Rear Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.

  • Page 172: Brake Disk

    To this chapter contents 14. Brake System Brake Disk 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: Front brake disk 2.5 mm Micrometer...

  • Page 173

    To this chapter contents 14. Brake System Remove the rubber pad. Remove the cir clip. Cir clip Rubber Remove the piston and the spring. boot Clean the master cylinder with recommended Piston brake fluid. Piston Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.

  • Page 174

    To this chapter contents 14. Brake System Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. 2 bolts Connect brake hoses with 2 new washers.

  • Page 175

    To this chapter contents 14. Brake System Note: 14-12...

  • Page 176

    Contents Home page 15. Steering / Front Wheel / Front Cushion Mechanism Diagram ···························· 15-1 Front Wheel ·········································· 15-5 Operational Precautions ····················· 15-2 Front Cushion ······································ 15-8 Trouble Diagnosis ······························· 15-2 Steering Stem······································· 15-9 Steering Handle ··································· 15-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 2.4~3.0kgf-m...

  • Page 177: Operational Precautions

    Locating screw for the speedometer cable 0.15 ~0.3kgf-m Front cushion upper lock bolt 2.4 ~ 3.0kgf-m Front brake disk 4.0~4.5kgf-m Special Tools Steering handle top thread wrench SYM-5320000¡ B SYM-5321100 Inner bearing puller SYM-6204020 Steering nut wrench SYM-6204010 Driver 32*35mm Driver 42*47mm Trouble Diagnosis...

  • Page 178

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Steering Handle Master cylinder Remove Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake.

  • Page 179

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Loosen 2 bolts from the master cylinder of the rear Master cylinder brake. Remove holder and master cylinder. Holder 2 bolts Loosen left handle switch connecter. Loosen 2 screws from left side handle switch holder.

  • Page 180: Front Wheel

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Wheel 2 screws Loosen 2 bolts from the front brake caliper and remove it Caution Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out.

  • Page 181

    Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) Inner bearing Disassembly puller Remove brake disk (5 bolts). Remove dust seal, bearing and dist collar from left side. Remove dust seal and bearing from right side. Special tools: Inner bearing puller SYM-6204020 15-6...

  • Page 182

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Assembly Dist collar Dust seal Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist. collar. Bearing Install the right side bearing. 6201U Caution Carefully install the bearing in correct and...

  • Page 183: Front Cushion

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Cushion 2 bolts Remove Remove front cover, front under spoiler and front fender. Remove front wheel. Remove front brake caliper. Remove speedometer cable. Speedometer cable 4 bolts Loosen 4 bolts from steering stem.

  • Page 184: Steering Stem

    Remove top cone race and steering stem. Caution Place the steel ball onto a parts container to prevent from missing. Special tools: Steering stem top thread wrench SYM-5320010 Handle stand nut wrench SYM-5321100 Handle stand nut wrench Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats.

  • Page 185

    To this chapter contents 15. Steering / Front Wheel / Front Cushion Lubricate the top cone race seat with grease. Steering lock nut Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turns.

  • Page 186

    Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram ···························16-1 Rear Wheel ········································· 16-3 Operational Precaution ······················16-2 Rear Fork ············································ 16-5 Trouble Diagnosis ······························16-2 Rear Cushion······································ 16-6 Muffler··················································16-3 Mechanism Diagram 11.0~13.0kgf-m 3.5~4.5kgf-m 2.4~3.0kgf-m 4.0~5.0kgf-m 4.0~5.0kgf-m 16-1...

  • Page 187: Operational Precaution

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit...

  • Page 188: Muffler

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Muffler Removal Loosen the 2 nuts from exhaust muffler front side. 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler. Installation Install in reverse order of removal procedures.

  • Page 189

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Remove rear wheel axle nut. 1 nut Remove rear fork and both side collars. Remove the rear wheel. Inspection rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator.

  • Page 190: Rear Fork

    (6303) onto rear fork. Install assembly directs puller bearing puller. Special Service Tools: Rear fork bearing 6303 bearing puller SYM-6303000-HMA H9A 6303 Assembly directs puller SYM-2341110 Use screw driver hold bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing.

  • Page 191: Rear Cushion

    To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Install the bearing lock cir clip. Cir clip Outside collar Bearing (6303UU) Inside collar Rear Cushion Left Upper bolt Removal Remove the luggage box, rear carrier and body covers.

  • Page 192: Mechanism Diagram

    Home page Contents 17. Electrical System Mechanism Diagram ··························· 17-1 Starting System ································· 17-11 Maintenance Data································ 17-2 Meters················································· 17-13 Technical Specification······················· 17-2 Light / Bulb········································· 17-15 Trouble Diagnosis ······························· 17-3 Switch / Horn······································ 17-19 Battery ·················································· 17-4 Fuel Unit ············································· 17-21 Fuse ······················································...

  • Page 193: Maintenance Data

    To this chapter contents 17. Electrical System Maintenance Data Operational precaution 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.) The model of the spark plug and the tightening torque. The ignition timing.

  • Page 194: Trouble Diagnosis

    To this chapter contents 17. Electrical System Trouble Diagnosis No voltage Intermittent power supply Battery discharged The connector of the charging system becomes The cable disconnected loose The fuse is blown Poor connection of the battery cable Improper operation of the main switch Poor connection or short-circuit of the Low voltage discharging system...

  • Page 195

    To this chapter contents 17. Electrical System Battery Removal Loosen 1 screw and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery. Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 196: 17. Electrical System

    To this chapter contents 17. Electrical System Fuse Fuse circuit diagram Fuse box (Headlight) Fuse 20A Headlight (Hi & Lo-beam) Transistor Auto by-starter ignition (Ignition) Fuse 15A Carburetor Meter heater Winker & hazard control unit (Meter & Operate) Fuse 20A Main switch Meter Horn...

  • Page 197: Charging System

    To this chapter contents 17. Electrical System Charging System Charging circuit Main switch Reg. Rec. Fuse 20A AC. G. Fuse 30A Starting relay Battery Black Green Meter charging Yellow Starting motor system lamp Regulator rectifier Inspection (KΩ) ¡ Û ¡ Û ¡...

  • Page 198

    To this chapter contents 17. Electrical System Inspection on AC. Generator coil Remove the luggage box, rear carrier and body covers. Ω Disconnect 3 pin couplers of the generator coil. Connect an ohmmeter to the each terminal end. Ω Check the continuity of the each terminal end, and Ω...

  • Page 199

    To this chapter contents 17. Electrical System Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...

  • Page 200

    To this chapter contents 17. Electrical System Ignition System Ignition circuit diagram Side stand Main switch Power relay switch Fuse 20A Engine stop Resistor switch Thermo switch Ignition coil Fuse 15A Transistor ignition Heater Battery AC. G. Auto by start White Black Blue...

  • Page 201

    To this chapter contents 17. Electrical System Inspection on ignition coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Standard resistance: 0.17±10% Ω Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.

  • Page 202: Starting System

    To this chapter contents 17. Electrical System Starting System Starting circuit diagram Main switch Front brake switch Fuse 20A Brake light Rear brake switch Fuse 20A Start relay Battery Start switch Start motor Side stand switch SB/O Engine stop relay White Black Blue...

  • Page 203

    To this chapter contents 17. Electrical System Disconnect the positive cable of the starter motor. Disconnect the coupler of the relay. Connect an ohmmeter to the large terminal end. Connect the yellow/red cable to the battery positive terminal and the green/yellow cable to the battery negative terminal.

  • Page 204: Meters

    To this chapter contents 17. Electrical System Meters Meter circuit diagram Meter (Ignition) Fuse 15A Turn right indicator Main switch Fuse 20A Turn left indicator Charge High beam indicator indicator REG. REC. Side stand warning light Eng. temperature indicator Thermo sensor Battery Foggy right indicator Fuel indicator...

  • Page 205

    To this chapter contents 17. Electrical System Removal of meter Remove wind screen garnish, wind screen, meter visor, front cover, meter visor. (Refer chapter 13) Disconnect the coupler of the speedometer, and take off the meter panel and meter. Meter coupler 4 screws Loosen 4 screws from meter panel.

  • Page 206: Light / Bulb

    To this chapter contents 17. Electrical System Light / Bulb Headlight and foggy light circuit diagram (Headlight) White Fuse 15A Black Blue Green Brown Position & meter illumination light Lo-beam light Lo-beam relay Light switch Beam switch Hi-beam light Hi-beam relay Main switch Fuse 20A Passing switch...

  • Page 207

    To this chapter contents 17. Electrical System Replacement headlight bulbs Coupler 1 screw Remove wind screen garnish, wind screen, meter visor, front cover. (Refer chapter 13) Disconnect the rubber sleeve and the terminal coupler from the headlight. Loosen 1 screw from the headlight bulb setting stay.

  • Page 208

    To this chapter contents 17. Electrical System Replacement the front winker light and Front winker light foggy light bulb Remove wind screen garnish, wind screen, meter visor, front cover. (Refer chapter 13) Foggy light Foggy light bulb Front winker light bulb Disconnect the rubber sleeve and turn the foggy light bulb seat in C.C.W.

  • Page 209

    To this chapter contents 17. Electrical System Replacement the meter bulbs Remove the meter board waterproofing rubber. Illumination bulb Indicator bulb Uses the “-“ screw driver turn the indicator bulb seat in C.C.W. direction, and take out the indicator bulb. Uses the round nose pliers turn the illumination bulb seat in C.C.W.

  • Page 210: Switch / Horn

    To this chapter contents 17. Electrical System Switch / Horn 2 blots Main switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below BAT1 BAT2 Position LOCK Main switch coupler Wire Color Black Blake...

  • Page 211

    To this chapter contents 17. Electrical System Left handle switch High and low beam switch Remove the handle cover and front cover. Disconnect the coupler of left handle switch. Check the continuity between two points as indicated in the table below High and low beam switch Position Horn switch...

  • Page 212: Fuel Unit

    To this chapter contents 17. Electrical System Fuel Unit Fuel unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove right & left side cover. Remove the body cover Remove the floor panel. Disconnect the coupler of the fuel unit. Loosen 4 bolts from fuel unit and remove it.

  • Page 213: Cooling Fan Thermo Switch

    To this chapter contents 17. Electrical System Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.

  • Page 214: Thermo Sensor

    To this chapter contents 17. Electrical System Thermo Sensor Thermo sensor Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (£ [ ) 134~149 47.5~57.0 26~29 14.8~17.2 Caution Wear gloves and goggles when performing this test.

  • Page 215

    To this chapter contents 17. Electrical System Note: 17-24...

  • Page 216: Emission Control System

    Home page Contents 18. Emission Control System Names of Mechanisms in the Emission Secondary Air Introduction System ··· 18-5 Control System······································ 18-1 Positive Crankcase Ventilation System Function of Mechanisms in the Emission (P.C.V.) ·················································· 18-8 Control System······································ 18-1 Inspection Items··································· 18-9 Fuel Evaporative Emission Control System Countermeasure for Emission Pollutants (E.E.C.) ···················································...

  • Page 217: Control System

    To this chapter contents 18. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) Construction: Reduce HC to pollute air. To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Automatic control Vapor hose...

  • Page 218: Control System

    To this chapter contents 18. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge...

  • Page 219: Catalytic Converting System (cata)

    To this chapter contents 18. Emission Control System Catalytic Converting System (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.

  • Page 220: Secondary Air Introduction System

    To this chapter contents 18. Emission Control System Secondary Air Introduction System Construction Secondary air filter Carburetor Intake valve Flesh air Vacuum hose Engine Cylinder head Reed valve Flesh air Mixture gas First burn exhaust Exhaust valve Purged exhaust gas Air injection cut valve Vacuum Exhaust pipe...

  • Page 221

    To this chapter contents 18. Emission Control System 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject cut valve (AICV). b. System hose leakage. c. abnormal ignition timing. d. lean mixture gas. e. abnormal fuel supply. Rich Exhaust Gas: a.

  • Page 222

    To this chapter contents 18. Emission Control System Warm-up test: Start engine. Remove the air injection filter. Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet Reed valve Air filter Secondary air inject Exhaust muffler...

  • Page 223: Positive Crankcase Ventilation System

    To this chapter contents 18. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Exhaust pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.

  • Page 224: Inspection Items

    To this chapter contents 18. Emission Control System Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1.

  • Page 225: Countermeasure For Emission Pollutants

    To this chapter contents 18. Emission Control System Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2) Clean the carburetor Keep the CO value in 1.5~4.5% (note 3) by adjusting...

  • Page 226: Electrical Diagram

    Home page Contents 19. Electrical Diagram 19-1...

  • Page 227

    Home page Contents 19. Electrical Diagram Note: 19-2...

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