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Scorpa SY-250FR 2008 Manual Manual

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  • Page 2 Congratulations! You have just bought a SCORPA SY-250FR 15thA. Welcome in the family of the SCORPA‟s customers. This motorbike is the fruit of the experience of the high level of trial and of advanced technology. As all products of our range, it benefits from the expertise of our suppliers and from the high level of quality in the manufacturing of our motorbikes, which is well known in the world of trial.
  • Page 5 The user manual takes part in the bike and must be given to the new owner in case the bike is sold. SCORPA is always working to develop and to improve its products, so that you could find a few...

  • Page 6: Table Of Contents

    CONTENTS SECURITY ..................................4 DESCRIPTION OF THE VEHICLE ..........................4 ................................4 DENTIFICATION ..................................5 IGHT SIDE ..................................5 EFT SIDE ..............................6 ANDLE BAR CONTROLS CONTROLS AND INSTRUMENTS ..........................6 ..........................6 ONTROLS AND ELECTRIC SWITCHES 3.1.1 Engine circuit breaker .............................. 6 3.1.2 Speedometer ................................
  • Page 7 6.8.4 Fitting of the rear wheel ............................29 ................................... 30 IRES 6.9.1 Check of the conditions and of the treads depth of the tires ................... 30 6.9.2 Pieces of information about the tires ........................30 6.10 ............................... 31 HE SPOKE WHEEL 6.11 ..............................

  • Page 8: Security

    As a consequence, the vehicle has to be maintained in the best work order. That is exactly the same for the rider. SCORPA recommends you to respect the laws of the country where you are riding, not to ride under the influence of alcohol or of drugs. To be in a great form, without extreme fatigue, can allow you a safe driving and quick reflexes.

  • Page 9: Right Side

    2.2 Right side Handle bar Fuel tank tag Steering locker Rear light Rear brake Fuel tap Side stand 2.3 Left side Air cleaner case Fork Brake Rear suspension...

  • Page 10: Handle Bar Controls

    2.4 Handle bar controls Speedometer Choke Brake lever Clutch lever Switchers Throttle Left handgrip Tank cap 3 Controls and instruments 3.1 Controls and electric switches 3.1.1 Engine circuit breaker Engine circuit breaker : “ ” Press this button in emergency, like a fall. The effect is to cut the motor. 3.1.2 Speedometer Digital screen Indicator light...

  • Page 11: Light Switches

    3.1.3 Light switches Sidelight Low beam Horn High beam Indicators This part is made up of three controls : Side light / low beam / high beam :  / /  You put the control on “ ” to switch on the high beam, on “ ” to switch on the low beam. The sidelight is shown by the symbol “...

  • Page 12: Mechanical Controls And Indicators

    3.2 Mechanical controls and indicators 3.2.1 Speedometer This part is made up of 4 elements: 1. A speedometer : it indicates the speed you are riding at 2. A odometer : it gives the number of kilometers covered 3. The turn indicators light (look at the previous paragraph) 4.

  • Page 13: Gearshift Lever

    3.2.3 Gearshift lever Lever The gearshift lever is situated on the left side of the bike, at left toes level, when the heel rests on the left rest-foot. The use of the gearshift lever must be done only when the engine is released. That means the clutch lever is pulled towards the handgrip.

  • Page 14: Rear Brake Pedal

    3.2.5 Rear brake pedal Pedal The rear brake pedal is situated on the right side of the bike, at the front of the right foot level, when the heel rests on the right rest-foot. To operate the rear brake, push the pedal towards the ground. Precautions in the rear brake handling As told for the front brake lever, be careful not to operate too strongly the rear brake pedal.

  • Page 15: Antitheft Lock

    3.2.7 Antitheft lock Lock Locking the direction: insert the key in the lock and turn it a quarter of turn towards left. Push it and, while maintaining it pushed, turn it a quarter of turn towards right. Withdraw the key, the direction is locked.

  • Page 16: Fuel

    0,6 L. WARNING: the use of another fuel than this recommended by the manufacturer can cause serious deteriorations on the engine and on the exhaust system. SCORPA will not be responsible for any problem in that case Before each use, check that the quantity of fuel is sufficient.

  • Page 17: Fuel Tap

    3.3.3 Fuel tap Its aim is to control the flow of fuel from the fuel tank to the carburettor, as the rider wants it to be regulated. This tap contains a filter, which role is to hold back the particles which could damage the engine.

  • Page 18: Check Before Use

    (bad weather or acts of vandalism for example). The damaging of parts which take part in the security can have very serious consequences. SCORPA recommends you to check visually those sensitive spots. If necessary, a more detailed check is naturally advocated. In case you have any doubt, do not hesitate to get in touch with your dealer.
  • Page 19 Clutch Check the functioning Check of the play of the lever Adjustment if necessary Chain Check of the tension. Adjustment if necessary. Check of the condition. Lubrication if necessary : Motul Chain lub Off Road Wheels and Check of the condition. tyres Check of the depth of the treads.

  • Page 20: Instructions And Advice Before Starting The Bike

    5 Instructions and advice before starting the bike WARNING Before using the SY-250FR 15thA, it is recommended to familiarise yourself with the engine and verify all of the functional commands in a non-hazardous area. When in doubt, refer to the SY-250FR 15thA manual and if need be your local dealer.

  • Page 21: Start ( When The Engine Is Already Warm)

    5.2 Start ( when the engine is already warm) The process is the same as this with a cold engine, but you do not have to use the choke here. 5.3 Gear change The gearbox allows you to control the power transmitted to the rear wheel. That is very useful for the hill starts, the accelerations, the hills and the bends…...

  • Page 22: Engine Lapping

    The running-it is complete. You also can use the bike in the normal conditions, which are given in this manual. WARNING: If a problem appears during the lapping, SCORPA recommends submitting the matter to your dealer as soon as possible.

  • Page 23: Maintenance And Little Fixing

    6 Maintenance and little fixing A good motorbike rider is first and foremost expected to worry about the security. Those precautions begin by taking care about the „active security‟. That means that the rider has to respect the indications given in this manual about the checks, the maintenance, the adjustments and lubrications. The different checks are listed in the paragraph which title is „CHECK LIST BEFORE USE‟.
  • Page 24 • Check the free length and the tilt  Valve springs • Replace  • Check for scratches and wear   Valve lifters • Replace  • Inspect the camshaft surface   Camshafts • Replace  • Check for wear on the teeth and Timing chain sprockets, for damage...
  • Page 25 • Adjust lever position and pedal Brakes height • Lubricate pivot point • Check brake disc surface   • Check fluid level and leakage • Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts • Replace pads ...
  • Page 26 • Replace Engine oil • Check the level of oil and the lack     of oil leak • Replace   Oil filter • Lube  Moving parts • Check routing and connection Accelerator cable and and play ...

  • Page 27: Spark Plug Check

    Bad adjustments, the heat and all the deposits can all damage the spark plug. For this bike, SCORPA recommends to use the following NGK R CR 8E...

  • Page 28: Engine Oil

    2. Clean the joint surface and the spark plug thread. 3. Put the spark-plug in the cylinder-head. Then begin to tighten it with the hand, in order not to damage the head cylinder tapping (direction A). Tighten the spark plug thanks to torque wrench: the recommended torque is : 17,5 Nm (1,75 m.kgf).

  • Page 29: Oil Change

    6.4.2 Oil change 1. Start the engine and let it warm up for a few minutes, and after that switch it off. 2. Put an oil change tray under the oil drain plug. It will help you to collect the old oil. 3.

  • Page 30: Carburetor Adjustment

    6.6 Carburetor adjustment The carburetor is one of the essential parts for the functioning of the engine, in order to have the best performances, and to increase the engine reliability. It needs to be very precisely adjusted, preferably by a professional especially trained and tooled. 6.6.1 Tuning engine The air/fuel mixture will vary depending on atmospheric conditions.
  • Page 31 Effects of the setting parts on the throttle valve opening Valve throttle Pilot screw Fully open Main screw Closed Jet needle Pilot system The FLATCR carburettor is manufactured with a pilot screw. The pilot screw adjustment rangdes from fully closed throttle (don‟t tighten) to 3 turn open throttle. Maint jet Jet needle hole Pilot jet...

  • Page 32: Play Of The Valves

    The richness of the air-fuel mixture with the throttle open ¼ or less can be set by adjusting the pilot jet. Jet needle groove position adjustment Adjusting the jet needle position affects the acceleration when the throttle is 1/8 to ¾ open. Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly.

  • Page 33: Front Wheel Fitting

    6.8.2 Front wheel fitting 1. Lift the wheel up within the two front fork arms, and make sure the brake disk is situated within the brake pads. 2. Thread the wheel axle through the two front fork arm and the wheel hub. 3.

  • Page 34: Tires

    The front and rear tires are preferably from the same manufacturer, with the same structure, with the aim to improve the road holding. Here are the different tires which are homologated for the SCORPA SY-250FR 15thA : FRONT : Mark...

  • Page 35: The Spoke Wheel

    6.10 The spoke wheel The normal functioning of the bike, its reliability and the security depend on the following precautions: Before each use, check the lack of cracks on the rims Check the spoke tightening and tighten it again if necessary as explained in the dedicated paragraph.

  • Page 36: Setting

    6.11.2 Setting 1. Loosen the rear wheel axle. 2. To tighten the chain, turn the left eccentric clockwise (c) and the right one anticlockwise. On the contrary, to release the chain turn the right eccentric clockwise (c) and the left one anticlockwise, then push the wheel towards the front of the bike, until the eccentrics lean on their stop on the swinging arm again.

  • Page 37: Adjustment Of Handlebar

    6.12.2 Adjustment of handlebar front position rear position There are 2 settings; . To make this, it‟s necessary to make a reversal position of lower holder handlebar (eccentric holder handle bar). Front position: The holder handlebars are positioned at the front of the upper triple clamp. Rear position: The holder handlebars are positioned at the rear of the upper triple clamp.

  • Page 38: Brakes

    6.14 Brakes WARNING The new plates must be ground, so that the brake provides optimal proportioning and best deceleration. For that, make about thirty accelerations until approximately 30km/h, and slow down gradually until the total stop. 6.14.1 Adjustment of the brake levers loose Adjustment screw Lock...

  • Page 39: Pad Wear Control

    6.14.3 Pad wear control Take care to check the brake pads wear, in accordance to the frequency given by the „List of the regular maintenance and lubricating : Make sure that the thickness of the brake pads lining is sufficient. It must not be less than 1mm. Otherwise, make the pads replaced by your dealer and your brakes adjusted.

  • Page 40: Brake Fluid Change

    The check of the brake fluid level must be operated when the top of the fluid tanks is horizontal, with the aim not to alter the level measurement. The filling up has to be operated with the recommended brake fluid: Motul Brake Fluid DOT 5.1, and the same type as this of the fluid of the circuit, to avoid the risk of chemical reaction.

  • Page 41: Side Stand

    6.16 Side stand Side stand Just as for the levers, the functioning of the side stand has to be checked before each use. In fact, a bad functioning can prevent the side stand from folding up. If the stand does not totally fold up, it can make the driving very dangerous.

  • Page 42: Front Suspension

    6.17 Front suspension 6.17.1 Inspection Fork surfaces and dust seals must be clean. If there is an oil leakage, fork seal should be replaced before riding the bike. Check the fork by locking the front brake and pushing on the handlebar. You should try factory settings before attempting any adjustments.

  • Page 43: Front Fork And Steering

    Pre-loader adjuster Lock nut Rebound adjuster WARNING Uncontrolled landings after jumps may damage the shock leading to possible health and life danger The bike is manufactured with the following settings: The length of the spring (not installed) is 150 mm The rear shock absorber is manufactured with an adjustment of 7 mm, providing a spring length of 143 +/- 1.5 mm The maximal adjustment limit is 15 mm, providing a spring length of 135 mm...

  • Page 44: Check Of The Steering

    WARNING : if the functioning or the progressiveness of the front fork is not satisfactory, make it inspect by your dealer, and replace it if there is a serious problem. 6.19.3 Check of the steering It might happen that the steering bearings are loose or damaged. Then they may cause serious dysfunction in the steering.

  • Page 45: Replacement Of The Indicators Bulbs

    If any important operation has to occur, it is strongly recommended to confide it to your dealer, who is especially trained therefore. Moreover, le replacement of the defective parts has to be operated with SCORPA‟s parts, which ensure the best reliability and performances. Those are parts which have been jointly designed especially for your vehicle.

  • Page 46: Compression

    6.21.2 Compression Kick-start the bike The engine compression is sufficient Loss of compression Check the ignition Make the bike inspect by your dealer 6.21.3 Ignition Remove the spark plug Check the electrodes damp Wipe with a dry duster Make it check by your dealer Adjust the electrodes distance Turn an half of the throttle Then kick-start...

  • Page 47: Put In Conformity For A Road Use

    7 Put in conformity for a road use 7.1 Install the homologated exhaust pipe Remove the air cleaner case (see « air cleaner case removal »). Remove the carburetor (see « carburetor removal ») Unscrew the racing exhaust pipe fixing nut and bolt. Remove the racing exhaust pipe.

  • Page 48: Install The Electrical Wiring

    To fix the magnet: - Unscrew one of the fixing bolt of the rear brake disc - Put the washer against the disk, then put the magnet - Screw the fixing bolt of the rear brake disc Sensor magnet 7.3 Install the electrical wiring - Remove the fuel tank: (see «...
  • Page 49 Put the homologated electrical wiring like a picture. Homologated Electrical Wiring passage - Put the head light homologated - Connect the front direction light with the homologated electrical wiring: black with black/White- blue with white/Blue-red with white. - Connect the front brake indicator...
  • Page 50 - Connect the rear brake indicator - Install the license plate bracket - Install the license plate bracket (long 150 millimeters between the wheel axle and the left higher fixing bolt). - Install the fixing plate of the bracket - Screw the 5 bolts. - Connect the two electrical lugs of the rear light with homologated electrical wiring.

  • Page 51: Care And Storing Of The Bike

    - Fix the direction lights generator unit to the bolt and nut like picture. - Connect the direction lights generator unit. - Fix the horn. Fixing - Connect the horn. Horn head light Direction Light Generator - Install head light on inner tubes and screw the fixing bolt on the speedometer bracket 8 Care and storing of the bike 8.1 Care The lack of coachwork exposes almost all parts of the bike to the stresses of the surroundings.

  • Page 52: Cleaning

    Moto Wash Motul. It is forbidden to use acid or basic chemicals. SCORPA strongly advise against high pressure or vapour cleaners. In fact an important amount of water could infiltrate joints, bearings, electric components or the airbox. The bike is only expected to work in atmospheric and ground humidity.
  • Page 53 A. Remove the spark plug and its cap B. Pour about 3 centilitres of engine oil in the spark plug hole. C. Operate several times and very slowly the kick-start in order to spread the oil everywhere in the engine. D.
  • Page 55 1 Design features Model name SY-250FR 15THA Engine oil : Motul 10W40 300V 100 % synthesis Type Dimensions -10 à 30°C: SAE 10W/30 Overall length 2060 mm -10 à 40°C: SAE 10W/40 Overall width 845 mm -0 à 40°C: SAE 15W/40 Overall height 1175 mm -5 à...
  • Page 56 Brakes Electrical Front Ignition system Type Single disc, Operation Right hand Liquid Identification number Motul Brake Fluid DOT 4 Rear Type Adhesive plate Type Single disc, Position Steering column of the frame Operation Right foot Liquide Huile Motul Brake Fluid DOT 4 Suspension Front Type...
  • Page 58 CONTENTS GLOSSARY ..................................4 RADIATOR ..................................5 ..............................5 ADIATOR REMOVAL ............................5 ADIATOR INSTALLATION ............................6 EVEL OF COOLING LIQUID CAMSHAFTS ................................. 7 ............................7 YLINDER HEAD COVER ................................8 AMSHAFTS ..............................9 EMOVAL POINTS 3.3.1 Camshafts ................................9 ................................
  • Page 59 7.2.4 Friction plate ..............................45 7.2.5 Clutch plate ............................... 45 7.2.6 Push lever shaft ..............................45 7.2.7 Push rod ................................46 ..........................46 SSEMBLY AND INSTALLATION 7.3.1 Push lever shaft ..............................46 7.3.2 Clutch ................................47 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ..........50 ..............................
  • Page 60 AC MAGNETO ................................75 12.1 ..............................76 EMOVAL POINTS 12.1.1 Rotor ................................76 12.2 ................................76 NSPECTION 12.2.1 AC Magneto ..............................76 12.2.2 Woodruff key ..............................76 12.3 ..........................77 SSEMBLY AND INSTALLATION 12.3.1 AC Magneto ..............................77 CRANKCASE AND CRANKSHATF ........................79 13.1 ............................

  • Page 61: Glossary

    1 Glossary...

  • Page 62: Radiator

    2 Radiator 2.1 Radiator removal Remove the fuel tank cover, the cleaner case (refer to “side covers removal”). Remove the fuel tank and the side covers (refer to “fuel tank removal”). Unscrew the water pump hose collar. Unscrew the radiator cap. Take out the water pump hose and keep the liquid cooler.

  • Page 63: Level Of Cooling Liquid

    Fill the radiator with liquid cooler. Screw the cap. Install the fuel tank, the side covers (refer to “fuel tank installation”). Install the fuel tank, the air cleaner case cover (refer to “side covers installation”) 2.3 Level of cooling liquid WARNING: this operation must be done when the engine is cold.

  • Page 64: Camshafts

    3 Camshafts 3.1 Cylinder head cover...

  • Page 65: Camshafts

    3.2 Camshafts...

  • Page 66: Removal Points

    3.3 Removal points 3.3.1 Camshafts...

  • Page 68: Inspection

    3.4 Inspection 3.4.1 Camshafts...

  • Page 70: Camshaft Sprocket

    3.4.2 Camshaft sprocket 3.4.3 Decompression system 3.4.4 Timing chain tensioner...

  • Page 71: Assembly And Installation

    3.5 Assembly and installation 3.5.1 Camshaft...

  • Page 74: Cylinder Head

    4 Cylinder head 4.1 Removal points...

  • Page 75: Inspection

    4.2 Inspection...

  • Page 76: Assembly And Installation

    4.3 Assembly and installation 4.3.1 Cylinder head...

  • Page 77: Valves And Valves Springs

    5 Valves and valves springs...

  • Page 78: Removal Points

    5.1 Removal points 5.1.1 Valve lifter and valve cotter...

  • Page 79: Inspection

    5.2 Inspection 5.2.1 Valves...

  • Page 83: Valve Spring

    5.2.2 Valve spring 5.2.3 Valve lifter...

  • Page 84: Valve Clearance Inspection And Adjustment

    5.3 Valve clearance inspection and adjustment...

  • Page 89: Assembly And Installation

    5.4 Assembly and installation 5.4.1 Valve and valve spring...

  • Page 91: Cylinder And Piston

    6 Cylinder and piston...

  • Page 92: Removal Points

    6.1 Removal points 6.1.1 Piston and piston ring...

  • Page 93: Inspection

    6.2 Inspection 6.2.1 Cylinder and piston...

  • Page 95: Piston Ring

    6.2.2 Piston ring...

  • Page 96: Piston Pin

    6.3 Piston pin...

  • Page 97: Assembly And Installation

    6.4 Assembly and installation 6.4.1 Piston ring and piston...

  • Page 98: Cylinder

    6.5 Cylinder...

  • Page 99: Clutch

    7 Clutch...

  • Page 101: Removal Points

    7.1 Removal points 7.1.1 Clutch boss 7.2 Inspection 7.2.1 Clutch housing and boss 7.2.2 Primary driven gear...

  • Page 102: Clutch Spring

    7.2.3 Clutch spring 7.2.4 Friction plate 7.2.5 Clutch plate 7.2.6 Push lever shaft...

  • Page 103: Push Rod

    7.2.7 Push rod 7.3 Assembly and installation 7.3.1 Push lever shaft...

  • Page 104: Clutch

    7.3.2 Clutch...

  • Page 107: Oil Filter Element, Water Pump And Right Crankcase Cover

    8 Oil filter element, water pump and right crankcase cover...

  • Page 109: Removal Points

    8.1 Removal points 8.1.1 Impeller shaft 8.1.2 Oil seal...

  • Page 110: Inspection

    8.2 Inspection 8.2.1 Oil delivery pipe 8.2.2 Impeller shaft 8.2.3 Impeller shaft gear 8.2.4 Bearing...

  • Page 111: Oil Seal

    8.2.5 Oil seal 8.3 Assembly and installation 8.3.1 Oil seal 8.3.2 Impeller shaft...

  • Page 112: Right Crankcase Cover

    8.3.3 Right crankcase cover...

  • Page 113: Kickstarter Crank

    8.3.4 Kickstarter crank...

  • Page 114: Water Pump Housing

    8.3.5 Water pump housing 8.3.6 Oil filter element...

  • Page 115: Balancer

    9 Balancer...

  • Page 116: Removal Points

    9.1 Removal points 9.1.1 Balancer shaft drive gear and balancer shaft driven gear 9.1.2 Balancer 9.2 Inspection 9.2.1 Primary drive gear, balancer shaft drive gear and balancer shaft driven gear...

  • Page 117: Balancer

    9.2.2 Balancer...

  • Page 118: Assemblage Et Installation

    9.3 Assemblage et installation 9.3.1 Balancer shaft drive gear and balancer shaft drive gear...

  • Page 119: Oil Pump

    10 Oil pump...

  • Page 121: Inspection

    10.1 Inspection 10.1.1 Oil pump...

  • Page 122: Assembly And Installation

    10.2 Assembly and installation 10.2.1 oil pump...

  • Page 124: Kick Shaft And Shift Shaft

    11 Kick shaft and shift shaft...

  • Page 126: Removal Points

    11.1 Removal points 11.1.1 Kick shaft assembly 11.1.2 Shift guide and shift lever assembly 11.1.3 Segment 11.2 Inspection 11.2.1 Kick shaft and ratchet wheel...

  • Page 127: Kick Gear, Kick Idle Gear And Ratchet Wheel

    11.2.2 Kick gear, kick idle gear and ratchet wheel 11.2.3 Shift shaft 11.2.4 Shift guide and shift lever assembly 11.2.5 Stopper lever...

  • Page 128: Assembly And Installation

    11.3 Assembly and installation 11.3.1 Segment 11.3.2 Stopper lever...

  • Page 129: Shift Guide And Shift Lever Assembly

    11.3.3 Shift guide and shift lever assembly...

  • Page 130: Shift Shaft

    11.3.4 Shift shaft 11.3.5 Kick shaft assembly...

  • Page 131: Kick Idle Gear

    11.3.6 Kick idle gear...

  • Page 132: Ac Magneto

    12 AC Magneto...

  • Page 133: Removal Points

    12.1 Removal points 12.1.1 Rotor 12.2 Inspection 12.2.1 AC Magneto 12.2.2 Woodruff key...

  • Page 134: Assembly And Installation

    12.3 Assembly and installation 12.3.1 AC Magneto...

  • Page 136: Crankcase And Crankshatf

    13 Crankcase and crankshatf...

  • Page 138: Crankcase Bearing

    13.1 Crankcase bearing...

  • Page 139: Removal Points

    13.2 Removal points 13.2.1 Crankcase...

  • Page 140: Crankshaft

    13.2.2 Crankshaft 13.2.3 Crankcase bearing 13.3 Inspection 13.3.1 Timing chain and timing chain guide...

  • Page 141: Crankcase

    13.3.2 Crankcase 13.3.3 Crankshaft...

  • Page 142: Oil Strainer

    13.3.4 Oil strainer 13.3.5 Oil delivery pipe 2 13.4 Assembly and installation 13.4.1 crankcase bearing...

  • Page 143: Cranshaft

    13.4.2 Cranshaft...

  • Page 146: Transmission

    14 Transmission...

  • Page 147: Removal Points

    14.1 Removal points 14.1.1 Transmission 14.2 Inspection 14.2.1 Gears...

  • Page 148: Bearing

    14.2.2 Bearing 14.2.3 Shift fork, shift cam and segment...

  • Page 149: Assembly And Installation

    14.3 Assembly and installation 14.3.1 Transmission...

  • Page 152: Carburetor

    15 Carburetor Pump Fixing collar cable Accelerator cable Starter cable Carburetor 15.1 Carburettor removal Remove the fuel tank cover, the air cleaner case and the side covers (see ”side covers removal”). Remove the air cleaner case (see ”air cleaner case removal”). Unscrew the carburettor fixing collar on the pipe.
  • Page 154 CONTENTS GLOSSARY ..................................4 PLASTICS ................................... 5 ..............................6 IDE COVERS REMOVAL ............................6 IDE COVERS INSTALLATIONS FUEL TANK ..................................7 ........................7 UEL TANK AND SIDE COVERS REMOVAL ....................... 7 UEL TANK AND SIDE COVERS INSTALLATION AIR CLEANER CASE ................................ 8 ............................
  • Page 155 CLUTCH CONTROL ............................... 23 15.1 ............................23 LUTCH CONTROL REMOVAL 15.2 ..........................23 LUTCH CONTROL INSTALLATION SIDE STAND AND FOOTREST ............................. 24 16.1 ........................24 IDE STAND AND FOOTRESTS REMOVAL 16.2 ....................... 24 IDE STAND AND FOOTRESTS INSTALLATION FRAME ....................................25 17.1 ...............................

  • Page 156: Glossary

    1 Glossary Lubricate with grease. Lubricate with copper grease. Use hard locking agent. Use soft locking agent. Tightening torque. 6 N.m...

  • Page 157: Plastics

    2 Plastics...

  • Page 158: Side Covers Removal

    2.1 Side covers removal 2.2 Side covers installations Unscrew the fuel tank cover upper bolt. Install the silencer side covers.   Remove the cover. For each side, screw the 2 silencer side covers   Unscrew the air cleaner case cover bolt. bolts.

  • Page 159: Fuel Tank

    3 Fuel tank 3.1 Fuel tank side covers 3.2 Fuel tank side covers removal installation Remove the fuel tank cover (see “side cover Install the cock with a new seal.   removal”) Screw the 2 cock bolts.  Remove the fuel tank, dismounting the fuel Install the side covers.

  • Page 160: Air Cleaner Case

    4 Air cleaner case 4.1 Air cleaner case removal 4.2 Air cleaner case installation Remove the fuel tank cover, the air cleaner Install the air cleaner filter.   case and the side covers (see “side cover Install the air cleaner case. ...

  • Page 161: Exhaust Pipe

    5 Exhaust pipe 5.1 Exhaust pipe removal 5.2 Exhaust pipe installation Remove the air cleaner case (see « air cleaner Place the exhaust pipe (put a new seal).   case removal »). Screw the exhaust pipe fixing nut and bolt. ...

  • Page 162: Muffler

    6 Muffler 6.1 Muffler removal 6.2 Muffler installation Lubricate the graphite seals. Remove the fuel tank cover, the air cleaner   Joint the silencer to the exhaust pipe. case cover, the side covers and the rear fender  Screw the 4 bolts fixing the silencer to the ...

  • Page 163: Front Wheel

    7 Front wheel 7.1 Front wheel removal 7.2 Front wheel installation To take out the disc protection (see “front Lubricate the front wheel axle and lubricate   brake removal”). the threading with copper grease. Unscrew the 2 bottom fork axle bolts, disc Place the front wheel (with the disc between ...

  • Page 164: Rear Wheel

    8 Rear wheel 8.1 Rear wheel removal Rear wheel installation Unscrew the rear wheel nut. Place the rear wheel (and the chain).   Remove the right eccentric. Install the left eccentric on the axle.   Remove the rear wheel axle. Lubricate the axle.

  • Page 165: Front Brake

    9 Front brake...

  • Page 166: Front Brake Control Removal

    9.1 Front brake control removal Front brake control installation Unscrew the two front brake calliper. To install the hose : screw the pipe portion bolt   To take out the disc : remove the front wheel to the master cylinder after changing the ...

  • Page 167: Rear Brake

    10 Rear brake...

  • Page 168: Rear Brake Control Removal

    10.1 Rear brake control removal 10.2 Rear brake control installation Remove the rear wheel (see “rear wheel To install the hose : screw the pipe portion bolt   removal”). to the master cylinder after changing the Remove the rear brake calliper. washer seals, then screw the pipe portion bolt ...

  • Page 169: Steering

    11 Steering...

  • Page 170: Handle Crowns Removal

    11.1 Handle crowns removal 11.2 Handle crowns installation Remove the fork (see « fork removal »). Lubricate the lower steering bearing.   Unscrew the 2 handle upper holders fixing Install the upper handle crown in the steering.   bolts.

  • Page 171: Fork

    12 Fork 12.1 Fork removal 12.2 Fork installation Remove the front wheel (see « front wheel Install correctly the inner tube (the upper line   removal »). should be just visible at the top of the upper Unscrew the 2 front calliper fixing bolts and crown).

  • Page 172: Oil Change, Fork Of Left Side

    12.3 Oil change, fork of left side Open fork 1. Remove the front fork cap bolt 2. Leave spacer and spring 3. Return the fork to empty oil. Front fork cap bolt 4. For completely empty oil of the fork, move several time inner tube and Spacer damper rod...

  • Page 173: Swing Arm

    13 Swing arm 13.1 Swing arm removal 13.2 Swing arm installation Remove the rear wheel (see « rear wheel Install the chain cover and the fixing bolts.   removal »). Screw the chain cover nut and bold (use soft ...

  • Page 174: Shock Absorber

    14 Shock absorber 14.1 Rear shock absorber removal 14.2 Rear shock absorber installation Remove the air cleaner case (see « air cleaner Place the absorber.   case removal »). Screw the absorber lower fixing bolt.  Unscrew and take out the absorber upper Place and hold up the swing arm.

  • Page 175: Clutch Control

    15 Clutch control 15.1 Clutch control removal 15.2 Clutch control installation Remove the air cleaner case (see « air cleaner To install the hose : screw the pipe portion bolt   case removal »). to the master cylinder after changing the Remove the fuel tank (see «...

  • Page 176: Side Stand And Footrest

    16 Side stand and footrest 16.1 Side stand and footrests removal 16.2 Side stand and footrests installation Unscrew the side stand bracket bolts.  Remove the side stand bracket.  Place the side stand on the bracket and put  Unscrew the side stand axle nut.

  • Page 177: Frame

    17 Frame...

  • Page 178: Engine Removal

    17.1 Engine removal 17.2 Engine installation Unscrew the 2 guard engine rear fixing bolts. Install the main frame on the engine.   Unscrew the 2 guard engine front fixing nuts. Place the 2 frame fixing bolts and place the ...
  • Page 180 CONTENTS ELECTRICAL ..................................2 ................................2 IRING DIAGRAM ................................3 PARK GAP TEST ....................3 EADS AND IGNITION COIL CONNECTION INSPECTION ............................4 GNITION COIL INSPECTION...

  • Page 181: Electrical

    1 Electrical 1.1 Wiring diagram...

  • Page 182: Spark Gap Test

    1.2 Spark gap test 1.3 Leads and ignition coil connection inspection...

  • Page 183: Ignition Coil Inspection

    1.4 Ignition coil inspection...

This manual is also suitable for:

2008 sy-250fr 15tha

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