Sym Joyride125 Service Manual
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Sym Joyride125 Service Manual

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  • Page 1 HOW TO USE THIS FORWARD CONTENTS MANUAL SERVICE MANUAL...
  • Page 2 FORWARD Homepage Contents This service manual contains the technical data of each component inspection and repair for the Sanyang JOYRIDE 125/150/200 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.
  • Page 3 How to Use This Manual Homepage Contents This service manual describes basic information of different system parts and system inspection & service for Sanyang JOYRIDE 125/150/200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 CONTENTS Homepage Contents Page Content Index 1-1 ~ 1-16 GENERAL INFORMATION 2-1 ~ 2-12 MAINTENANCE INFORMATION 3-1 ~ 3-6 LUBRICATION SYSTEM 4-1 ~ 4-9 FUEL SYSTEM 5-1 ~ 5-6 ENGINE REMOVAL 6-1 ~ 6-14 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14 V-BELT DRIVING SYSTEM/FOOT STARTER 9-1 ~ 9-8...
  • Page 5 MODEL ILLUSTRATION Homepage Contents REG/REC. Start MAG. switch Winker relay Fuel pump Battery IG. coil Radiator Fuses / C.D.I. Horn Spark plug Seat catch A Fuel tank Seat catch B Fuel tank cap Frame number Gear oil drain plug Engine number ENG.

  • Page 6: Table Of Contents

    Homepage Contents 1. GENERAL INFORMATION Symbols and marks………………….1-1 Torque values……………………….1-8 General safety…………………………1-2 Cables and harness routing………1-10 Service precautions………………….1-3 Troubleshooting…………………….1-11 Specifications…………………………1-5 Lubrication points…………………..1-15 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    1. GENERAL INFORMATION 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 you have to run your engine in a closed area, be strictly prohibited.

  • Page 8: Service Precautions

    1. GENERAL INFORMATION Service Precautions Always use with Sanyang genuine parts and Rubber parts may become deteriorated when recommended oils. Using non-designed parts old, and prone to be damaged by solvent and for Sanyang motorcycle may damage the oil. Check these parts before installation to motorcycle.
  • Page 9 1. GENERAL INFORMATION The length of bolts and screws for assemblies, The ends of rubber hoses (for fuel, vacuum, cover plates or boxes is different from one or coolant) should be pushed as far as they another, be sure they are correctly installed. can go to their connections so that there is In case of confusion, Insert the bolt into the enough room below the enlarged ends for...

  • Page 10: Specifications

    1. GENERAL INFORMATION Specifications Make SANYANG MODEL LA12W Overall Length 2010 mm Front TELESCOPIC FORK Suspension System Overall Width 760 mm Rear UnlT SWING Overall Height 1155 mm Front 110 / 80-12 61L Tire Specifications Wheel Base 1440 mm Rear 130 / 70-12 64L DlSK (ψ273mm)
  • Page 11 1. GENERAL INFORMATION Specifications Make SANYANG MODEL LA15W Overall Length 2010 mm Front TELESCOPIC FORK Suspension System Overall Width 760 mm Rear UNlT SWING Overall Height 1155 mm Front 110 / 80-12 61L Tire Specifications Wheel Base 1440 mm Rear 130 / 70-12 64L DlSK (ψ273mm)
  • Page 12 1. GENERAL INFORMATION Specifications Make SANYANG MODEL LA18W Overall Length 2010 mm Front TELESCOPIC FORK Suspension System Overall Width 760 mm Rear UNlT SWING Overall Height 1155 mm Front 110 / 80-12 61L Tire Specifications Wheel Base 1440 mm Rear 130 / 70-12 64L DlSK (ψ273mm)

  • Page 13: Torque Values

    1. GENERAL INFORMATION Torque values Thread Dia. Torque Value Item Q’ty Remarks (mm) (Kgf-m) Cylinder head bolt 2.0-2.4 Valve clearance adjust nut Apply oil to thread 0.7-1.1 Spark plug 1.0-1.4 L. Crankcase cover bolts 1.1-1.5 Crankcase bolts 0.8-1.2 Oil drain bolt 1.1-1.5 Oil strainer cap 1.3-1.7...
  • Page 14 1. GENERAL INFORMATION Standard Torque Values for Reference Type Torque value kgf-m 5 mm Bolt, Nut 0.45 - 0.6 6 mm Bolt, Nut 0.8 - 1.2 8 mm Bolt, Nut 1.8 - 2.5 10 mm Bolt, Nut 3.0 - 4.0 12 mm Bolt, Nut 5.0 - 6.0 5 mm Screw...

  • Page 15: Cables And Harness Routing

    1. GENERAL INFORMATION Cables and harness routing Note the following when routing cables and wire harnesses: • A loose wire, cable or harness may cause safety hazard. After clamping, check each wire to make sure it is secured. • Do not squeeze wires against the weld or its clamp.

  • Page 16: Troubleshooting

    1. GENERAL INFORMATION Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt 1. No fuel in fuel tank to check if there is gasoline 2. Check if the pipes, fuel tank to carburetor inside the carburetor and intake vacuum, are clogged.
  • Page 17 1. GENERAL INFORMATION Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged Engine speed can be Engine speed can not be 2.
  • Page 18 1. GENERAL INFORMATION 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 generator) Adjust the air screw of carburetor Good Poor...
  • Page 19 1. GENERAL INFORMATION . CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged 3. Driving pulley spring broken Engine can be started but 4. Clutch lining broken motorcycle can not be driving 5.

  • Page 20: Lubrication Points

    1. GENERAL INFORMATION LUBRICATION POINTS Engine suspension bushing Throttle cable/ Front & rear brake lever pivot Seat lock Steering shaft bearing Speedometer gear/ front Rear wheel bearing wheel bearing Main stand shaft Side stand shaft To this chapter contents 1-15...
  • Page 21 1. GENERAL INFORMATION NOTES: To this chapter contents 1-16...

  • Page 22: Maintenance Information

    Homepage Contents 2. MAINTENANCE INFORMATION Brake system hose......2-8 Precautions in operation ....2-1 Brake fluid........2-8 Periodical maintenance schedule......... 2-2 Filling out brake fluid ....2-8 Fuel Lines........2-3 Air bleed operation......2-9 Acceleration operation....2-3 Added brake fluid ......2-9 Air cleaner........

  • Page 23: Periodical Maintenance Schedule

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

  • Page 24: Fuel Lines

    2. MAINTENANCE INFORMATION FUEL LINES Fuel pump Filler hole Remove trunk. Remove side cover. Remove central cover. Remove body frame cover. Remove pedal. Remove front glove box. Check all lines, and replace it when they are deterioration, damage or leaking. Warning Fuel hose Fuel tank...

  • Page 25: Air Cleaner

    2. MAINTENANCE INFORMATION AIR CLEANER Remove trunk. Remove side cover. Remove 8 screws from the air cleaner cover and then remove the cover. Caution Air cleaner element contains a paper made filter so do not try to clean it. CRANKCASE VENTILATION Separat Separato o o o r r r r Separat...

  • Page 26: Valve Clearance

    2. MAINTENANCE INFORMATION VALVE CLEARANCE Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T”...

  • Page 27: Carburetor Idling Speed Adjustment

    2. MAINTENANCE INFORMATION CARBURETOR IDLING SPEED ADJUSTMENT 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 done after engine is being warm up. (It is enough that operates engine from stop to Idle adjustment running for 10 minutes.)

  • Page 28: Cylinder Compression Pressure

    2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor. Caution Rotate the engine until the reading in the gauge no more increasing.

  • Page 29: Brake System (Front/Rear Disk Brake)

    2. MAINTENANCE INFORMATION BRAKE SYSTEM (FRONT/REAR 10〜 〜 〜 〜 20mm DISK BRAKE) (3/8〜 〜 〜 〜 3/4 in) Free play of front/rear brake: 10~20 mm BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil. Brake hose BRAKE FLUID Check brake fluid level in the brake fluid LOWER...

  • Page 30: Air Bleed Operation

    2. MAINTENANCE INFORMATION AIR BLEED OPERATION Drain valve Air bubble Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses. Caution Before closing the air bleed valve, do not release the brake lever.

  • Page 31: Brake Lamp Switch/Starting Inhibitor Switch

    2. MAINTENANCE INFORMATION Remove brake lining bolt. Lining Take out the lining. Caution In order to maintain brake power balance, the brake lining must be replaced with one set. Lining bolt BRAKE LAMP SWITCH/STARTING Master INHIBITOR SWITCH cylinder The brake lamp switch is to light up brake lamp as brake applied.

  • Page 32: Side Stand

    2. MAINTENANCE INFORMATION SIDE STAND Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly. Make sure that side stand is no bending or deformation.

  • Page 33: Wheel/Tire

    2. MAINTENANCE INFORMATION WHEEL/TIRE Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails, stones or other materials. Appointed tire pressure Tire size Front tire Rear tire Tire Load for pressure as under 90 cold engine (Kg/cm²)

  • Page 34: Lubrication System

    3. LUBRICATION SYSTEM Homepage Contents Precautions in operation ....3-2 Oil pump disassembly ....3-4 Troubleshooting ......3-2 Oil pump inspection...... 3-5 Engine oil ........3-3 Oil pump re-assembly....3-5 Engine oil strainer clean ....3-3 Oil pump installation..... 3-6 Oil pump removal ......

  • Page 35: Precautions In Operation

    Gear oil Disassembly: 110 c.c. Change: 100 c.c. Oil viscosity SEA 10W-30 (Recommended King serial oils) Gear oil Gear oil viscosity SEA 85W-140 (Recommended SYM Hypoid gear oils) Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Clearance between outer rotor and body 0.15~0.20...

  • Page 36: Engine Oil

    3. LUBRICATION SYSTEM 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 37: Oil Pump Removal

    3. LUBRICATION SYSTEM Oil Pump Removal Remove generator and starting gear. Remove snap ring and take out oil pump driving chain and sprocket. Torque value: 0.8~1.2 Kg-m Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then BOLT×...

  • Page 38: Oil Pump Inspection

    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 Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner...

  • Page 39: Oil Pump Installation

    3. LUBRICATION SYSTEM Install the oil pump cover and fixing pin properly SCREW× × × × 1 Tighten screw Make sure that oil pump shaft can be rotated freely. Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value: 0.8~1.2 Kg-m Make sure that oil pump shaft can be rotated freely.

  • Page 40: Gear Oil

    3. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil.
  • Page 41 3. LUBRICATION SYSTEM NOTES To this chapter contents...

  • Page 42: Fuel System

    Homepage Contents 4. FUEL SYSTEM Precautions in operation ....4-2 Float chamber........ 4-7 Trouble diagnosis ......4-3 Installation of carburetor ....4-8 Air cut-off valve ......4-4 Adjustment of pilot screw..... 4-8 Auto by-starter....... 4-4 Fuel tank ........4-9 Carburetor removal ....... 4-5 Air cleaner........

  • Page 43: Precautions In Operation

    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 44: Trouble Diagnosis

    4. FUEL SYSTEM TROUBLE DIAGNOSIS Poor engine start No fuel in fuel tank Clogged fuel tube Too much fuel in cylinder No spark from spark plug(malfunction of ignition system) Clogged air cleaner Malfunction of auto by-starter Malfunction of throttle operation Malfunction of purge control valve Stall after started Malfunction of auto by-starter...

  • Page 45: Air Cut-Off Valve

    4. FUEL SYSTEM AIR CUT-OFF VALVE Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve. Vacuum value: 420~500 mm-Hg Pump compressed air from air pump to air vent hose.

  • Page 46: Auto By-Starter

    4. FUEL SYSTEM AUTO BY-STARTER Screw ×1 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. 10Ω Ω Ω Ω (Measured after engine stopped for more than 10 minutes) Replace the auto starter with a new one if resistance value exceeds standard.

  • Page 47: Carburetor Removal

    4. FUEL SYSTEM Carburetor removal Throttle cable Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove air cut-off valve hose. Remove fuel pipe, vacuum hose. Disconnect automatic by-starter connectors. Release the clamp strip of carburetor isolation.
  • Page 48 4. FUEL SYSTEM Installation Piston Needle seat Spring Install needle, spring and needle seat to vacuum piston. Needle Install vacuum piston to carburetor body and align the indent on the diaphragm. Install compress spring. Install vacuum chamber cover and tighten 2 Screw ×2 screws.

  • Page 49: Float Chamber

    4. FUEL SYSTEM FLOAT CHAMBER Float Screw ×3 Disassembly Remove 4 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.

  • Page 50: Installation Of Carburetor

    4. FUEL SYSTEM Assembly Pilot screw Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking fuel level Caution •...

  • Page 51: Adjustment Of Pilot Screw

    4. FUEL SYSTEM Adjustment of pilot screw Throttle cable adjust nut Caution ˙Pilot 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 main stand must be used to support the motorcycle to perform the adjustments.

  • Page 52: Fuel Tank

    4. FUEL SYSTEM FUEL TANK Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear bracket (2 bolts). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 bolts).

  • Page 53: Air Cleaner

    4. FUEL SYSTEM AIR CLEANER Open the seat. Loosen the clamp strip of air cleaner. Remove left cover (2 screws). Remove mounting bolts for crankcase and gear box (2 bolts). Remove air cleaner cap (8 screws). Remove air cleaner set (4 screws). Caution Screw ×8 The air cleaner element is made of paper so do...

  • Page 54: Engine Removal

    5. ENGINE REMOVAL Homepage Contents Precautions in Operation....5-1 Engine Mounting Bracket Installation ........5-6 Removal of Engine ......5-2 Engine Installation ......5-6 Removal of Engine Mounting Bracket ........... 5-5 PRECAUTIONS IN OPERATION General Information The engine has to be supported with special service tools that can be lifted or adjustable. The following parts can be serviced as engine mounted on frame.

  • Page 55: Engine Removal

    5. ENGINE REMOVAL Removal of Engine Open seat cushion. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear bracket (2 bolts). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 screws).
  • Page 56 5. ENGINE REMOVAL Remove fuel pipe, vacuum tube and throttle valve wire from carburetor. Loosen the screw of air cleaner duct strip, and then remove the duct. Remove water hose from water pump. Water hose Remove the thermo-sensor wires. Water pump Remove the muffler (3 bolts, 2 nuts).
  • Page 57 5. ENGINE REMOVAL Remove brake hose bracket (1 bolt). Bolt × × × × 1 1 1 1 Remove rear brake callipper (2 bolts). Caution Do not operate brake lever after the clipper removed to avoid clipping the brake lining. Bolt ×...
  • Page 58 5. ENGINE REMOVAL Loosen the mounting screw of left crankcase duct, Screw and then remove the duct. Remove the mounting bolts (2 bolts) of air cleaner. Bolt × × × × 2 Bolt × × × × 1 1 1 1 Remove the lower mounting bolt of left shock absorber.
  • Page 59 5. ENGINE REMOVAL Check if engine mounting bracket bushing and Bush cushion rubber for damage. Engine Mounting Bracket Installation Install engine onto engine mounting bracket. Install engine mounting bracket bolts & nuts and then tighten the nuts. Bolt × × × × 1 1 1 1 Engine Installation Check if the bushings of engine suspension parts and shock absorber for damage.

  • Page 60: Cylinder Head/Valve

    Homepage Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ....... 6-1 Valve stem replacement ....6-8 Precautions in Operation....6-2 Valve seat inspection and service ..6-9 Cylinder Head Removal ....6-4 Cylinder head reassembly....6-11 Cylinder Head Disassembly ... 6-6 Cylinder head Installation ....6-12 1.0~1.4 kgf-m 0.7~1.1 kgf-m 2.0~2.4 kgf-m...

  • Page 61: Precautions In Operation

    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 Limit Compression pressure...
  • Page 62 6. CYLINDER HEAD/VALVE TOOLS Special service tools Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor Troubleshooting Engine performance will be effected 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 Valve •...

  • Page 63: Cylinder Head Removal

    6. CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Vacuum tube Clamp strip Remove cushion and body center cover. Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator. Remove 1 bolt of thermostat and then remove Thermostat bolt the thermostat.
  • Page 64 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from Nuts Insulator bolt cylinder head side cover, and then remove 4 nuts and washers from cylinder head upper side. Cylinder head mounting bolts Remove the cylinder head. Remove 2 bolts of carburetor insulator and then take the insulator out.

  • Page 65: Cylinder Head Disassembly

    6. CYLINDER HEAD/VALVE CYLINDER HEAD DISASSEMBLY Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts. Then, remove the cap. Remove the rocker arm pin stopper plate, and then screw a 5mm bolt into the rocker arm pin. Finally, remove the pin and the rocker arm.
  • Page 66 6. CYLINDER HEAD/VALVE INSPECTION CYLINDER HEAD Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.5 mm Valve spring free length Measure the free length of intake and exhaust valve springs.

  • Page 67: Valve Stem Replacement

    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 68: 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 69 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 (0.04 in) Caution Make sure that all roughness and uneven faces had been ground.

  • Page 70: Cylinder Head Reassembly

    6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. CYLINDER HEAD REASSEMBLY Intake valve Lubricate valve stem with engine oil, and then insert the valve into valve guide.

  • Page 71: Cylinder Head Installation

    6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts. Carburetor insulator Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole. Then, insert the rocker arm pin.
  • Page 72 6. CYLINDER HEAD/VALVE Install cylinder head. Tighten 4 nuts and washers on the cylinder Insulator mounting bolt Nuts head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover. Torque value: 2.0~2.4 kgf-m Install and tighten spark plug Torque value: 2.0~2.4 kgf-m Caution This model is equipped with more...
  • Page 73 6. CYLINDER HEAD/VALVE Vacuum Clamp strip hose Install carburetor insulator onto carburetor and tighten clamp strip bolt. Install the vacuum hose of carburetor insulator. Remove the intake valve adjustment hole cap Start engine, and make sure that lubricant flows to cylinder head. Turn off engine after confirmed, and install the intake valve adjustment hole cap.

  • Page 74: Cylinder/Piston

    Homepage Contents 7. CYLINDER/PISTON Mechanism Diagram ..... 7-1 Piston Removal ......7-4 Precautions in Operation....7-2 Piston Ring Installation ....7-6 Trouble Diagnosis ......7-2 Piston Installation ......7-7 Cylinder Removal ......7-3 Cylinder Installation.......7-7 To this chapter contents...

  • Page 75: Precautions In Operation

    7. CYLINDER/PISTON PRECAUTIONS IN OPERATION General Information Both cylinder and piston service can be carried out when engine mounted on frame. Specification LA12W & LA15W & LA18W Item Standard Limit ID ( LA18W not included) 56.995~57.015 57.016 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090...

  • Page 76: Cylinder Removal

    7. CYLINDER/PISTON CYLINDER REMOVAL Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder head. Remove cylinder. Coolant hose Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.

  • Page 77: Piston Removal

    7. CYLINDER/PISTON Check cylinder if warp. Service limit: 0.05 mm PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials 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 78 7. CYLINDER/PISTON Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston. Service Limit: Top ring: 0.50 mm ring: 0.65 mm Measure the outer diameter of piston pin.

  • Page 79: Piston Ring Installation

    7. CYLINDER/PISTON Measure piston outer diameter. Caution The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin. Service limit: LA12W & LA15W: 56.9 mm LA18W: 60.9 mm Compare measured value with service limit to calculate the clearance between piston and cylinder.

  • Page 80: Piston Installation

    7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring. Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as...
  • Page 81 7. CYLINDER/PISTON NOTES To this chapter contents...
  • Page 82 Homepage Contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Mechanism Diagram ..... 8-1 Kick starter ........8-3 Maintenance Description....8-2 Driving belt ........8-5 Trouble Diagnosis ......8-2 Drive face........8-6 Left crankcase cover..... 8-3 Clutch outer/Driven pulley.....8-10 3.5~4.5 kgf-m 5.0~6.0 kgf-m 5.0~6.0 kgf-m To this chapter contents...

  • Page 83: Maintenance Description

    8. V-BELT DRIVING SYSTEM/KICK STARTER MAINTENANCE DESCRIPTION Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Driving belt and driving pulley must be free of grease. Item Standard value (mm) Limit (mm) Driving belt width 19.000 17.500...

  • Page 84: Left Crankcase Cover

    8. V-BELT DRIVING SYSTEM/KICK STARTER Left crankcase LEFT CRANKCASE COVER cover Left crankcase cover removal Remove body cover. Remove air cleaner (2 bolts). Remove kick starter (1 bolt). Remove L crankcase cover (9 bolts). Kick starter Disassembly of Kick Starter Starter spindle Driven gear Remove snap ring and thrust washer from L...
  • Page 85 8. V-BELT DRIVING SYSTEM/KICK STARTER Starter Reassembly of Kick Starter spindle Install socket, return spring and starter spindle as diagram shown. Install thrust washer and snap ring onto starter spindle. Install kick starter arm temporary. Rotate the arm and then align driven gear with width-tooth on the starter spindle.

  • Page 86: Driving Belt

    8. V-BELT DRIVING SYSTEM/KICK STARTER DRIVING BELT Removal Remove left crankcase cover Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage Universal reduction gear system.

  • Page 87: Drive Face

    8. V-BELT DRIVING SYSTEM/KICK STARTER Drive face Driving belt Driven pulley Drive shaft Install the clutch with universal holder, and then Clutch outer tighten nut to specified torque value. Torque value: 5.0~6.0 kgf-m Universal holder DRIVE FACE Removal Remove left crankcase cover. Universal holder Hold generator flywheel with universal holder, and then remove drive face nut.
  • Page 88 8. V-BELT DRIVING SYSTEM/KICK STARTER Movable drive face Removal Drive face boss Remove movable drive face comp. and driving belt from crankshaft. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable drive face. Movable drive face Weight roller Inspection Weight roller The weight rollers are to press movable drive...
  • Page 89 8. V-BELT DRIVING SYSTEM/KICK STARTER Check if drive face boss is worn or damaged and Movable drive face replace it if necessary. Measure the outer diameter of movable drive face, and replace it if it exceed service limit. Service limit: 26.94 mm Drive face boss Measure the inner diameter of movable drive face, and replace it if it exceed service limit.
  • Page 90 8. V-BELT DRIVING SYSTEM/KICK STARTER Install movable drive face comp. onto crankshaft. Movable drive face Drive face Crankshaft boss Driven pulley installation Press down Press driving belt into pulley groove, and then pull the belt onto drive shaft. Driving belt Install driven pulley, washer and nut.

  • Page 91: Clutch Outer/Driven Pulley

    8. V-BELT DRIVING SYSTEM/KICK STARTER CLUTCH OUTER/DRIVEN PULLEY Clutch nut wrench Disassembly Remove driving belt and clutch outer/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 92 8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch lining Measure each clutch weight thickness. Clutch lining Replace it if exceeds service limit. Service limit: 2.0 mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 83.2 mm Free length Driven pulley...
  • Page 93 8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch weight Replacement Spring Driving Remove snap and washer, and then remove 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 Snap ring elasticity.
  • Page 94 8. V-BELT DRIVING SYSTEM/KICK STARTER Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Clipper Remove inner bearing. Caution Outer bearing If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 95 8. V-BELT DRIVING SYSTEM/KICK STARTER Installation of Clutch OUTER/Driven Oil seal Pulley 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. Movable driven Oil seal Install the guide pin and guide pin roller.

  • Page 96: Final Driving Mechanism

    Homepage Contents 9. FINAL DRIVING MECHANISM Mechanism Diagram ..... 9-1 Inspection of Final Driving Mechanism ........9-3 Precautions in operation ....9-2 Bearing Replacement ....9-4 Trouble Diagnosis ......9-2 Re-assembly of Final Driving Disassembly of Final Driving Mechanism ........9-6 Mechanism........9-3 To this chapter contents...

  • Page 97: Precautions In Operation

    9. FINAL DRIVING MECHANISM Precautions in operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4 kg-m Tools Special tools Bearing (6203/6004UZ) driver Bearing (6204) driver Bearing (6301) driver Oil seal (27*42*7) driver...

  • Page 98: Disassembly Of Final Driving Mechanism

    9. FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover. Remove gasket and dowel pin. 7 bolts Remove drive shaft. Remove final driving gear and shaft. Remove countershaft and gear.

  • Page 99: Bearing Replacement

    9. FINAL DRIVING MECHANISM Check bearings on gear box. 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 tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 100 9. FINAL DRIVING MECHANISM Remove oil seal, and then remove final shaft bearing from left crankcase. Install new final shaft bearing. Press the bearing in with hydraulic presser. Tool: Bearing (6203/6004UZ) driver Oil seal (27*42*7) driver Press out the driving shaft from gear box cover. Bearing puller Using bearing protector as operation.

  • Page 101: Re-Assembly Of Final Driving Mechanism

    9. FINAL DRIVING MECHANISM Install a new final shaft bearing onto gear box cover. Tool: Bearing (6203/6004UZ) driver Press the bearing in with hydraulic presser. Install the driving shaft onto gear box cover and then place it to proper position. Apply with grease onto new oil seal lip, and then install the oil seal.
  • Page 102 9. FINAL DRIVING MECHANISM Install dowel pin and new gasket. dowel Gasket Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4 kgf-m Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase. Install rear wheel. Add gear oil.
  • Page 103 9. FINAL DRIVING MECHANISM NOTES To this chapter contents...

  • Page 104: Alternator/Starting Clutch

    Homepage Contents 10. ALTERNATOR/STARTING CLUTCH Precautions in Operation....10-2 Starting Clutch .......10-4 Right Crankcase Cover Removal . 10-3 Flywheel Installation ......10-7 A.C.G. Set Removal ....... 10-3 A.C.G. Set Installation....10-7 Flywheel Removal ......10-3 Right Crankcase Installation..10-7 1.0~1.4 kgf-m 5.0~6.0 kgf-m 0.8~1.2 kgf-m To this chapter contents 10-1...

  • Page 105: Precautions In Operation

    10. ALTERNATOR/STARTING CLUTCH Precautions in Operation General information • Refer to chapter 5: Engine removal and installation • Refer to chapter 16: The troubleshooting and inspection of alternator • Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm)

  • Page 106: Right Crankcase Cover Removal

    10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 7 bolts Remove 7 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. A.C.G. Set Removal 2 bolts Remove 2 mounted bolts from pulse generator and then remove it. Remove 3 screws from right crankcase cover and A.C.G.

  • Page 107: Starting Clutch

    10. ALTERNATOR/STARTING CLUTCH Hold flywheel with flywheel holder, and then remove flywheel nut. Tool: Multi-functional holder Pull out flywheel with A.C.G. flywheel puller. Tool: A.C.G. Flywheel puller Starting Clutch Removal Remove starting driven gear. Remove mounting plate, starter reduction gear, and the shaft.
  • Page 108 10. ALTERNATOR/STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the starting clutch gear. Service Limit: ID: 20.1 mm OD: 42.10 mm Check the starting reduction gear and shaft for wear or damage.
  • Page 109 10. ALTERNATOR/STARTING CLUTCH Remove the rollers, spring caps, and springs of Springs clutch on the one way clutch that located on the Rollers back of flywheel. Check each roller and plug for wear or damage. Install rollers, plugs and springs. Spring cap Installation Install the components in the reverse...

  • Page 110: Flywheel Installation

    10. ALTERNATOR/STARTING CLUTCH Flywheel Installation Insert the pin onto crankshaft. Make sure that there is no other material stock on it. If so, clean it up. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut.
  • Page 111 10. ALTERNATOR/STARTING CLUTCH NTOES To this chapter contents 10-8...

  • Page 112: Crankshaft/Crankcase

    Homepage Contents 11. CRANKSHAFT/CRANKCASE General information ......11-2 Crankshaft..........11-5 Trouble diagnosis ........11-2 Assembly of crankcase......11-6 Disassembly of crankcase....11-3 1.2~1.6 kgf-m 1.0~1.5 kgf-m 1.5~3.0 kgf-m 0.8~1.2 kgf-m 11-1 To this chapter contents...

  • Page 113: General Information

    11. CRANKSHAFT/CRANKCASE General information Operational precautions • This Section concerns disassembly of the crankcase for repair purpose. • Remove following components before disassembling crankcase. ―Engine Section 5 －Cylinder head Section 6 －Cylinder and piston Section 7 －Drive pulley and driven pulley Section 8 －AC generator/Start driven gear Section 10...

  • Page 114: Disassembly Of Crankcase

    Caution • Care should be taken not to damage the contact surfaces. R/L. crank disassemble tool Refer to chapter 18: Special tools Special tool : R/L. crank case R/L. crank disassemble/install tool disassemble tool SYM-1120000-H9A 11-3 To this chapter contents...
  • Page 115 11. CRANKSHAFT/CRANKCASE Remove crankshaft 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 116: Crankshaft

    If any roughness, noise and loose linkage are detected, replace the bearing with new one. Caution • The bearing shall be replaced in pair. Special tool : outer bearing puller SYM-6204010 Outer bearing puller 11-5 To this chapter contents...

  • Page 117: Assembly Of Crankcase

    11. CRANKSHAFT/CRANKCASE Assembly of crankcase Install a new bearing onto the left crankcase. Special tool : left crank shaft bearing driver SYM-9100200-H9A R/L. crank case disassemble/install tool SYM-1120000-H9A Crank shaft puller Left crank shaft bearing driver SYM-11130000-H9A Clutch nut wrench...
  • Page 118 11. CRANKSHAFT/CRANKCASE Crank shaft puller R/L. crank case disas. / install tool Clutch nut wrench Crank shaft puller R/L. crank case disas. / install tool Install new dowel pin and new gasket. Install the right crankcase onto the left crankcase. Tighten seven bolts on the crankcase.
  • Page 119 Clean the crankshaft with clean solvent. Special tool : Oil seal driver (25*40*8) SYM-9121600 Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. Tensioner Install the tensioner and tighten the bolts.

  • Page 120: Cooling System

    Homepage Contents 12. COOLING SYSTEM General Information ...... 12-2 Radiator .......... 12-5 Trouble Diagnosis ......12-3 Water Pump........12-6 System Test ........12-4 Temperature sensor ...... 12-10 Change of coolant ......12-4 Thermostat ........12-11 12-1 To this chapter contents...

  • Page 121: General Information

    12. COOLING SYSTEM General Information General Warning: ˙While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. Refill the radiator with distilled water or specified additives.

  • Page 122: Trouble Diagnosis

    12. COOLING SYSTEM Trouble Diagnosis The engine temperature is too high The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to closed. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The filler cap of the radiator malfunction.

  • Page 123: System Test

    12. COOLING SYSTEM System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low.

  • Page 124: Radiator

    12. COOLING SYSTEM Removing the reserve tank filler cap. ˙Check the liquid level in the reservoir. Add coolant to proper level if too low. ˙Reinstall the reserve tank filler cap. Reserve tank filler cap Radiator Removal Remove the front guard, check for any leakage from weld seam.

  • Page 125: Water Pump

    12. COOLING SYSTEM Bolt × × × × 1 Loosen the hose clamp and remove the upper water hose. Disconnect the connectors for the thermostat and fan motor. Loosen the hose clamp and remove the lower water hose. Disconnect the horn. Loosen four screws and air duct.
  • Page 126 12. COOLING SYSTEM Removal of water pump Remove the water hose. Loosen three bolts and remove the pump cover. Loosen 9 bolts and remove the right cover. Take off the gasket and dowel pin. Turn pump rotor clockwise and remove. Caution The rotor is provided with left turn thread.
  • Page 127 12. COOLING SYSTEM Replacement of Mechanical Seal Drive the mechanical seal and inner seal out of the right crankcase. Tools required Water pump bearing driver Caution Replace a new mechanical seal after removing bearing driver Install the new inner seal onto the right crankcase.
  • Page 128 12. COOLING SYSTEM Mount the water pump shaft and the inner Bearing bearing to the right crankcase cover. Install the circlip to hold the inner bearing. Water pump shaft Install water pump rotor Washer Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal.

  • Page 129: Temperature Sensor

    12. COOLING SYSTEM Install the right crankcase cover.(bolt × 9) Install the dowel pin and new gasket. Install the water pump cover with three bolts. Temperature sensor Please refer to chapter 17 for inspection of temperature sensor. Removal Remove the body cover. Drain out the coolant.

  • Page 130: Thermostat

    12. COOLING SYSTEM Thermostat Temperature sensor Removal Remove the rear cover. Drain out the coolant. Disconnect the cable from the thermostat. Remove the water hose from the thermostat holder. Remove the air vent hose from the holder. Remove the holder and lock bolt from the cylinder head.
  • Page 131 12. COOLING SYSTEM Technical Data Valve begins to open 71 ~ 80℃ Valve stroke 3.5 ~ 4.5 mm at 80℃ Installation Install in reverse order of removal. Caution Always use a new oil ring and apply a coat of grease on it before installing. Refill the specified coolant as necessary.
  • Page 132 Homepage Contents 13. BODY COVERS Mechanical Illustration....13-1 Side Cover ........13-7 Maintenance........13-2 Body Cover........13-8 Steering Handlebar Guard .... 13-3 Central Cover .........13-9 Front Guard........13-4 Foot Rest ........13-10 Front Lower Spoiler ...... 13-5 Inner Cover ........13-11 Luggage Box........13-6 Front Fender........13-12 Body Overview Back seat COMP.

  • Page 133: Maintenance

    13. BODY COVERS Maintenance Body covers disassemble sequence: Front cover Front handle cover Luggage box / seat Rear carrier Rear Handle cover Front fender Rear center cover Front under spoiler Speedometer cover Left / right side cover Speedometer cover Rear center cover Center cover Left / right side cover Inner box...
  • Page 134 13. BODY COVERS Steering Handle Cover Screw x 4 Disassembly Loosen 5 screws from both sides and rear. Screw x 1 Disengage the buckle from the slot, take off the Screw x 2 front cover of the handlebar and loosen two screws.

  • Page 135: Front Guard

    13. BODY COVERS Front Cover Disassembly Loosen two lock bolts. Bolt Screw x 4 Loosen four screws on the lower part of the front cover. Take off four screws that hold the front luggage Screw x 4 carrier (Screw x 4). Disconnect the connectors for the head lamp and the direction lamps.
  • Page 136 13. BODY COVERS Front Under Spoiler Disassembly Loosen six screws that hold the front inner box. Screw x 6 Loosen two screws that lock up the front under Screw x 2 spoiler. (Screw x 2) Loosen one screw at the back of the under spoiler.

  • Page 137: Luggage Box

    13. BODY COVERS Luggage Box Bolt x 6 Disassembly Lift up the seat saddle Loosen six bolts inside the luggage box. (Bolt x 6) Loosen one hook screw on the center cover (Screw x 1) Screw x 1 Hold the front end of the luggage box and lift it upward to take off from the frame Assembly In reverse order of the disassembly.

  • Page 138: Side Covers

    13. BODY COVERS Side Covers Disassembly Loosen four screws and take of the rear center cover. (Screw x 4). Screw x 4 Loosen six screws and remove two side covers from the frame (Screw x 3 for each cover). Screw x 1 Screw x 1 Screw x 2 Assembly...

  • Page 139: Body Cover

    13. BODY COVERS Body Cover Disassembly Loosen three bolts and remove the rear grip. (Bolt x 3). Bolt x 3 Loosen two bolts from the rear frame. (Bolt x 2) Bolt x 2 Loosen two screws that link the central guard Screw x 2 and the body cover (Screw x 2).
  • Page 140 13. BODY COVERS Center Cover Disassembly Remove the hook and screw from the center cover (Screw x 1). Screw x 1 Loosen four screws and take off the center cover from the frame (Screw x 4). Screw x 4 Assembly In reverse order of the disassembly as described above.
  • Page 141 13. BODY COVERS Floor Panel Screw x 4 Disassembly Loosen four screws (Screw x 4). Loosen four front bolts (Bolt x 4). Bolt x 4 Loosen two bolts under the saddle (Bolt x 2). Bolt x 2 Loosen four screws under the saddle (Screw x Screw x 4 Remove the floor panel.

  • Page 142: Inner Cover

    13. BODY COVERS Inner cover Disassembly Take off four screws from the speedometer cover (Screw x 4). Disconnect the cable and connector of the speedometer. Loosen two bolts from under speedometer (Screw x 2). Remove the speedometer and speedometer cover. Bolt x 2 Screw x 4 Bolt x 1...

  • Page 143: Front Fender

    13. BODY COVERS Front Fender Screw x 4 Disassembly Loosen four screws from the front fender (Screw x 4). Lift the front fender upward and disengage the front shock absorber to remove the front fender. Assembly In reverse order of the disassembly as described above.

  • Page 144: Brake

    Homepage Contents 14. BRAKE Illustration - Front Disc Brake Hydraulic Disc brake ......... 14-5 System ............14-1 Air Bleed ............ 14-6 Illustration - Rear Disc Brake Brake Calliper .......... 14-6 System ............14-2 Brake Disc ..........14-7 Maintenance Description .......14-3 Brake Master Cylinder....... 14-7 Trouble Diagnosis ........14-4 Front Disc Brake System 3.5 kgf-m...

  • Page 145: System

    14. BRAKE Rear Disk Brake System 3.5 kgf-m 0.55 kgf-m 4.5 kgf-m To this chapter contents 14-2...

  • Page 146: System

    14. BRAKE 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 calliper 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 147 14. BRAKE Trouble Diagnosis Master cylinder Holder Soft brake lever Alignment 1. Air inside the hydraulic system point 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disc 7. Low brake fluid 8.

  • Page 148: Hydraulic Disc Brake

    14. BRAKE Hydraulic Disc Brake Master cylinder Close the drain valve of the hydraulic Lower disc brake. Plate level Replace the brake fluid. Diaphragm Before the brake fluid reservoir is removed, turn Upper the handle so that the brake fluid reservoir level becomes horizontal, then remove the brake fluid reservoir.

  • Page 149: Air Bleed

    14. BRAKE Drain valve Air bubble Air Bleed 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. CAUTION • Do not release the brake lever before the drain valve is closed. •...
  • Page 150 14. BRAKE Brake Disc Inspection Brake Visually check the brake disc for wear or disc break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel.

  • Page 151: Master Cylinder Inspection

    14. BRAKE Master Master Cylinder Inspection cylinder Check the master cylinder for damage or 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.
  • Page 152 14. BRAKE Install the rubber cap into the groove correctly. Master cylinder Place the master cylinder onto handlebar, and install the master cylinder seat and its bolts. Alignment The “UP” mark on the seat should face upward. point Align the master cylinder seat with the alignment point on the handlebar.
  • Page 153 14. BRAKE Notes 14-10 To this chapter contents...

  • Page 154: Steering/Front Wheel/Front Brake

    Homepage Contents 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Mechanical Illustration....15-1 Front Wheel ........15-6 Operational Precautions ....15-2 Front Brake........15-9 Trouble Diagnosis ......15-2 Front Shock Absorber ....15-10 Steering Handlebar ....... 15-3 Front Fork/Steering .......15-11 2.4~3.0 kgf-m 4.0~5.0 kgf-m 1.0~2.0 kgf-m 0.2~0.3 kgf-m 2.4~3.0 kgf-m 0.15~0.3 kgf-m...

  • Page 155: Operational Precautions

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Operational Precautions General Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of the tire. Torque Values Nut for the front wheel axle 10.0 ~ 12.0 kgf-m Nut for the steering shaft 4.0 ~ 5.0 kgf-m Lock nut for the steering shaft...

  • Page 156: Steering Handlebar

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Steering Handlebar Removal Remove the front handle cover. (Screw ×4) Screw× × × × 1 1 1 1 Screw× × × × 4 Remove the rear handle cover. (Screw ×3) Remove the right switch assembly by loosening two screws.
  • Page 157 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Remove the left switch assembly by loosening two screws. Screw × × × × 2 Bolt× × × × 2 Loosen the lock bolt for the master cylinder of the rear brake. Remove the master cylinder of the rear brake. Loosen the lock bolt for the handle fix bolts.
  • Page 158 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Loosen nuts and locating sleeve from the handlebar. Remove the handlebar. Bolt× × × × 1 1 1 1 Installation In reverse order of the disassembly. Caution Apply grease to the throttle cable end and connect it to the throttle holder.

  • Page 159: Front Wheel

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Bolt× × × × 2 Front Wheel Removal Loosen two screws from the front brake calliper. Remove the front brake calliper. Caution Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out.
  • Page 160 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Wheel rim Place the wheel rim on a rotary rack. Rotate the wheel rim and measure the runout. Service limit: Radial: 2.0 mm Axial: 2.0 mm Disassembly Remove the bushes and dust-proofing oil seal. Insert the bearing puller into the bearing and pull out the bearing.
  • Page 161 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Assembly Assemble in reverse order of disassembly. Apply a coat of grease on the inner side of the dust-proofing oil seal. Install the dust proofing oil seal and the left and right bushes. Installation Insert the wheel axle through the front shock absorber and wheel.

  • Page 162: Front Brake

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Install the speedometer cable. Press the brake pad to open. Install the brake caliper and tighten the lock screw. Torque value: 3.3 kgf-m Front Brake Remove the front wheel. Loosen the lock screws and remove the brake disk.

  • Page 163: Front Shock Absorber

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Front Shock Absorber Removal of front shock absorber Loosen two bolts from the front brake calliper. Remove the front brake calliper and hose. Calliper Bolt× × × × 2 Bolt× × × × 4 Loosen the bolts and remove the front shock absorber.

  • Page 164: Front Fork/Steering

    15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Front Fork/Steering Removal of the front fork Steering lock Remove the following parts: The instrument panel assembly The Steering handlebar The front wheel Use the steering nut wrench to loosen the lock nut from the steering. Steering Tools cone...
  • Page 165 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Use the punch and the drive to press the ball race into the steering shaft end. Tools Driver Punch Use the punch and the driver to press the bottom ball race into the steering shaft end. Tools Driver Punch...
  • Page 166 Homepage Contents 16. REAR WHEEL/REAR BRAKE/REAR CUSHION Mechanical Illustration....16-1 Muffler ..........16-3 Operational Precaution ....16-2 Rear Wheel........16-3 Trouble Diagnosis ......16-2 Rear Cushion......... 16-5 3.5~4.5 kgf-m 2.4~3.0 kgf-m 0.55 kgf-m 3.5 kgf-m 1.8 kgf-m 4.5 kgf-m To this chapter contents 16-1...

  • Page 167: Operational Precaution

    16. REAR WHEEL/REAR BRAKE/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 Run-out of rear rim Radial Axial Thickness of rear brake lining...

  • Page 168: Muffler

    16. REAR WHEEL/REAR BRAKE/REAR CUSHION Muffler Removal Loosen the front lock nuts of the muffler (nut x2). Loosen the lock bolts (bolt x 3). Remove the exhaust pipe. Installation In reverse order of the removal. Caution Replace the front gasket if worn or deformed. Torque Value For lock bolt: 3.2 ~ 3.8 kgf-m...
  • Page 169 16. REAR WHEEL/REAR BRAKE/REAR CUSHION Check any deformation and warping of the brake disc. Allowable limit: 0.3 mm Warning Never contaminate the brake disc with grease. The contaminated brake disc will reduce it performance. The brake disc contains asbestos. Never use air jet to clean it.

  • Page 170: Rear Cushion

    16. REAR WHEEL/REAR BRAKE/REAR CUSHION Align the rear shock absorber with the rocker arms hole; tighten the cushion with bolts. Install the brake calliper and tighten the lock bolts. Install the muffler and tighten the lock bolts. Install the guards and cover in reverse order of removal.
  • Page 171 16. REAR WHEEL/REAR BRAKE/REAR CUSHION Remove an upper bolt from the shock absorber (bolt x 1). Remove the rear shock absorber. Installation In reverse order of removal. Caution The shock absorber must be replaced as a unit. Never disassemble the shock absorber as that would damage the structure.

  • Page 172: Electrical System

    Homepage Contents 17. ELECTRICAL SYSTEM Mechanical Illustration....17-1 Lamp/Bulb ........17-12 Maintenance Data......17-2 Switch/Horn ........17-13 Trouble Diagnosis ......17-3 Fuel Gauge ........17-16 Battery ..........17-4 Thermal Switch.......17-17 Charging System ......17-5 Sensor..........17-18 Ignition System......17-8 Digital meters trouble diagnosis...17-19 Starting System ......17-10 Winker relay Horn Ignition / Seat...

  • Page 173: Maintenance Data

    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 174: Trouble Diagnosis

    17. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate properly Battery discharged The cable disconnected • Burnt fuse The fuse is blown • Poor contact, open or short circuit Improper operation of the main switch • Poor regulator •...

  • Page 175: Battery

    17.ELECTRICAL SYSTEM Battery Removal Loosen four screws and remove the rear cover (screw x 4). Loosen three screws and remove the right body cover (screw x 3). Loosen two nuts and remove the battery guard cover (nut x 2). Disconnect the negative cable terminal first, then the positive cable terminal.

  • Page 176: Charging System

    17.ELECTRICAL SYSTEM Charging System Charging Circuit Main Switch Green Black Yellow Fuse 20A Yellow Yellow Battery Yellow Regulator rectifier Auto by-pass Generator starter Current Leakage Test Current Leakage Inspection Turn the main switch to OFF position, and Battery negative remove the negative cable terminal (-) from the terminal battery.
  • Page 177 17.ELECTRICAL SYSTEM Connect a tachometer. Inspection on Charging Voltage Turn on the headlamp to high beam and start the engine. Caution Accelerate the engine to the specified revolution Before conducting the inspection, be per minute and measure the charging voltage. sure that the battery is fully charged.
  • Page 178 17.ELECTRICAL SYSTEM Inspection on SCR Remove the bumper by loosening four screws (screw x 4). Remove the right side cover by loosening three screws (screw x 3). Disconnect 3P and 4P connectors to remove the SCR. Item Check Points Standard Value Main switch R –...

  • Page 179: Ignition System

    17.ELECTRICAL SYSTEM Ignition System Ignition circuit diagram CDI assembly Green Main switch Black/white Black/yellow Green/ Blue/ white Black/red yellow Green Spark plug Ignition Pulse coil generator Exciting coil C.D.I Assembly Disconnect connectors of the C.D.I assembly. Check the following connectors as indicated in the table at the harness side. Item Points to check Result...
  • Page 180 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: 0.17Ω Ω Ω Ω ± ± ± ± 10% Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.

  • Page 181: Starting System

    17.ELECTRICAL SYSTEM Starting System Starting Circuit Diagram Main switch Main fuse 20A Main fuse 10A Rear brake Starter relay switch Starter motor Starter switch Yellow/red Green/yellow Inspection on Starter Relay Remove the luggage box assembly. Open the main switch Press the brake Push down the starter switch If a sound of “Looh Looh”...
  • Page 182 17.ELECTRICAL SYSTEM Removal of Starter motor bolt× 2 Remove the rear cover (screw x 4). Remove the right body cover (screw x 3). Remove the battery cover (nut x 2). Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove the luggage box.

  • Page 183: Lamp/Bulb

    17.ELECTRICAL SYSTEM Lamp/Bulb Replacing Bulb for Headlamp Loosen the front cover (bolt x 2, screw x 8). Headlamp assembly Front cover Disconnect the terminal connector and the Headlamp screw × × × × 4 rubber sleeve from the headlamp. terminal Remove the bulb spring holder and the bulb.

  • Page 184: Switch/Horn

    17.ELECTRICAL SYSTEM Replacing Bulb of Number Plate Lamp Screw× × × × 2 Remove the rear cover (screw x 4). Remove the lamp lens (screw x 2). Winker light screw × × × × 2 screw Replacing bulbs of Tail light, Brake light, and Tail / brake bulb Rear winker light Remove the rear cover (screw x 4).
  • Page 185 17.ELECTRICAL SYSTEM Replacement of Main Switch Bolt×2 Disconnect the connector of the main switch and loosen the lock bolts (bolt x 2). Remove the main switch. Install the new main switch and tighten the lock bolts (bolt x 2). Steering Handlebar Switch Remove the front handlebar guard (bolt x 2, screw x 8).
  • Page 186 17.ELECTRICAL SYSTEM Winker light Seat open switch(LA18W) ● ● FREE PUSH OFF SEAT ● ● OPEN ● ● Wire Color Black Purple Light Wire Color Gray Orange blue Passing switch(LA12W & LA15W) Horn switch BAT4 BAT3 FREE FREE ● ● PASSING ●...

  • Page 187: Fuel Gauge

    17.ELECTRICAL SYSTEM Fuel Gauge Fuel gauge connector Open the seat. Remove the luggage box (bolt x 6, screw x 1). Remove the rear carrier (bolt x 3). Remove the rear carrier seat (bolt x 2). Remove the rear center cover (screw x 4). Remove the left and right rear foot rest (bolt x1).

  • Page 188: Thermal Switch

    17.ELECTRICAL SYSTEM Thermal Switch The thermal 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 switch, the fan motor should operate.

  • Page 189: Sensor

    17.ELECTRICAL SYSTEM Sensor Remove the sensor. Hang the sensor in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2 Sensor Sensor Caution Wear gloves and goggles when performing this test.

  • Page 190: Digital Meters Trouble Diagnosis

    17.ELECTRICAL SYSTEM Gauges Water Fuel Indicator Speedometer temperature Fuel Warning Indicator Turn Signal Turn Signal Indicator Indicator High Beam Indicator Alarm set button Odometer set b tt Water temperature Fuel gauge Gauge Odometer Digital meters trouble diagnosis 1. The meter doesn’t indicate 2.The monitor indicates but doesn’t work: Check if the main switch is ON Turn off the main switch then turn...
  • Page 191 17.ELECTRICAL SYSTEM NOTES: 17-20 To this chapter contents...
  • Page 192 Crank case bush puller .......18-10 H9A ENG. REMOVE. ASSEMBLY. ADJUSTER SPECIAL TOOLS LIST CRANK SHAFT BRG. FIXING NAME NAME NAME R/L. CRANK DISASS. TOOL CRANK SHAFT PULLER SOCKET SYM-1120000-H9A SYM-1130000-H9A SYM-9100210-H9A PRICE USD 14.53 PRICE USD 5.96 PRICE USD 8.94 (6204) (6301) NAME...
  • Page 193 18. SPECIAL TOOLS (27*42*7) WATER PUMP MECHANICL SEAL NAME NAME NAME AC.G. FLYWHEEL PULLER OIL SEAL DRIVER DRIVER SYM-1721700-H9A SYM-3110A00 SYM-9125500 PRICE USD 3.72 PRICE USD 7.82 PRICE USD 7.82 (25*40*8) (20*32*6) NAME NAME NAME OIL SEAL DRIVER OIL SEAL DRIVER...
  • Page 194 18. SPECIAL TOOLS VALVE COTTER REMOVE & NAME NAME NAME VALVE SPRING COMPRESSOR UNIVERSAL HOLDER ASSEMBLY TOOL SYM-1471100 SYM-1471110/20 SYM-9001210 PRICE USD 16.02 PRICE USD 8.19 PRICE USD 17.88 (ψ ψ ψ ψ 30mm) (ψ ψ ψ ψ 22mm) RR CUSHION ADJUSTING...

  • Page 195: How To Use Special Tools

    18. SPECIAL TOOLS How to use special tools: R/L. CRANK CASE PISASS TOOL Disassemble the Install the left crank Install the crankshaft crankcase case bearing 18-4 To this chapter contents...
  • Page 196 18. SPECIAL TOOLS BEARING DRIVER 18-5 To this chapter contents...
  • Page 197 18. SPECIAL TOOLS WATER PUMP WATER PUMP OIL SEAL DRIVER BEARING DRIVER BEARING (6901) INNER OIL SEAL MECHANICL SEAL 18-6 To this chapter contents...

  • Page 198: Crank Case / Transmission Oil Seal Driver

    18. SPECIAL TOOLS (Seal from transmission side install) CRANK CASE / TRANSMISSION OIL SEAL DRIVER OIL SEAL (25*40*8) OIL SEAL (20*32*6) OIL SEAL (25*42*7) 18-7 To this chapter contents...

  • Page 199: Ac.g. Flywheel Puller

    18. SPECIAL TOOLS VALVE COTTER REMOVE / AC.G. FLYWHEEL PULLER INSTALL DRIVER 18-8 To this chapter contents...
  • Page 200 18. SPECIAL TOOLS OUTER BEARING PULLER INNER BEARING PULLER 18-9 To this chapter contents...

  • Page 201: Crank Case Bush Puller

    18. SPECIAL TOOLS (ψ ψ ψ ψ 30mm) (ψ ψ ψ ψ 22mm) CRANK CASE BUSH PULLER / DRIVER REMOVER INSTALL To this chapter contents 18-10...

  • Page 202: Wiring Diagram

    Homepage Contents 19. WIRING DIAGRAM 19-1...
  • Page 203 19. WIRING DIAGRAM Homepage Contents 19-2...

This manual is also suitable for:

Joyride150Joyride200Joyride 100

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