Sym MB10A7-A series Service Manual
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Sym MB10A7-A series Service Manual

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Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com
Symba 100
Service Manual
FOREWORD
CONTENTS
HOW TO USE THIS MANUAL
MECHANICAL LAYOUT

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Table of Contents
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Summary of Contents for Sym MB10A7-A series

  • Page 1 Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Symba 100 Service Manual FOREWORD CONTENTS HOW TO USE THIS MANUAL MECHANICAL LAYOUT...
  • Page 2 Foreword This service manual contains the technical data of each component inspection and repair for the SANYANG MB10A7-A series motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment”, providing technician with service guidelines. Copyright reserved.

  • Page 3: Maintenance Information

    How to Use This Manual This service manual describes basic information of individual parts and system inspection & service for SANYANG MB10A7-A series motorcycle. In addition, please refer to the manual contents for detailed information for the model year. The first chapter covers general information and troubleshooting.

  • Page 4: Table Of Contents

    Homepage Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contents Page Content Index 1-1 ~ 1-24 General Information / Troubleshooting 2-1 ~ 2-20 Maintenance Information 3-1 ~ 3-16 Fuel System 4-1 ~ 4-20 Clutch / Transmission / Lubrication System 5-1 ~ 5-10 AC Generator / Starting Clutch 6-1 ~ 6-6...
  • Page 5 Homepage Contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanical Layout Rear Brake Pedal Kick Starter Winker Relay Engine Oil Dipstick Battery / Fuse / CDI / Regulator Rectifier RR. Winker Meter Fuel Tank Cap Horn / Start Motor Main Switch Headlight Ignition Coil...

  • Page 6: Symbols And Marks

    Homepage Contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Symbols and Marks ·················· 1-1 Engine Torque Values··············· 1-10 General Safety ··························· 1-2 Frame Torque Values················ 1-11 Service Precautions·················· 1-3 Troubleshooting ························ 1-12 Specifications···························· 1-9 Cable & Wire Routing················ 1-19 Torque Reference Values ·········...

  • Page 7: General Safety

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area.

  • Page 8: Service Precautions

    Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information Service Precautions Always use with SANYANG genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-genuine parts for unsmooth control and premature worn out.
  • Page 9 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com The length of bolts and screws for assembly, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if another;...
  • Page 10 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly.
  • Page 11 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com When separating a connector, it locker has to Insert the terminal completely. be unlocked first. Then, conduct the service Check if the boot covers the terminal. operation.
  • Page 12 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components when routing tape or tube if they contact a sharp edge or the harness.
  • Page 13 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Use sand paper to clean connector Do not let the wire harness been twisted when pins/terminals if rust is found. And then installation. continue the connection operation. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive...

  • Page 14: Specifications

    To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Specifications Manufacturer SANYANG Model MB10A7-A Overall Length 1910 mm Front TELESCOPIC Suspension System Overall Width 690 mm Rear SWING ARM Overall Height 1055 mm Front 2.50-17 38L...

  • Page 15: Torque Reference Values

    To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Torque Reference Values The torque values listed in above table are for more important tighten torque values. Please see standard values for those not listed in the table. Standard Torque Values for Reference Tighten Torque Tighten Torque...

  • Page 16: Frame Torque Values

    To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Frame Torque Values Torque Value Thread Dia. Item Remarks Q’ty (mm) (kgf-m) (N-m) 3.0~3.5 29~35 Handlebar luck bolt 4.0~4.5 39~49 Handlebar post locknut 25.4 6.0~8.0 59~78 Steering stem locknut...

  • Page 17: Troubleshooting

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Possible causes Loosen carburetor drain bolt to check if there is gasoline carburetor inside the 1.
  • Page 18 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Possible causes Try gradual acceleration and check engine speed 1.
  • Page 19 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (Using ignition lamp) 1. Incorrect ignition timing (malfunction Normal Abnormal of CDI or AC alternator)
  • Page 20 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 1. General Information D. Engine runs sluggish (High speed) Check and adjustment Fault condition Probable causes Check ignition timing 1. Malfunction of CDI Normal Abnormal 2. Malfunction of AC alternator Check fuel supplying...
  • Page 21 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com E. Starter Motor Malfunction 1. Starter Motor doesn’t rotate Fault condition Possible causes Check and adjustment Pull the brake handle or step on the braking pedal 1.
  • Page 22 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 2. Starting Motor rotates slowly or spins without engagement with crankshaft Fault condition Possible causes Check and adjustment Check the battery circuit by activating turning signal 1.
  • Page 23 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com F. Abnormal Engine Noise Fault condition Possible causes Rocker arm noise 1. Excessive valve clearance 2. Worn rocker arm 3. Worn camshaft Piston slapping 1.

  • Page 24: Cable & Wire Routing

    To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cable & Wire Routing Right handlebar switch wire Left handlebar switch wire Front brake switch wire Left winker wire Right winker wire Handlebar right side wire band Headlight wire Left winker wire Right winker wire...
  • Page 25 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Handlebar All cable & wire harness Apply grease 5~7g to Clamp 2 the inside part of After clamp 1 is ready, clamp handlebar post all cable and wire harness.) 50mm Clamp 1...
  • Page 26 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Front brake cable Speedometer cable Push the wire clamp when the wires are at right place. Make sure all cables and wires go through wire grommet Throttle cable and main wire harness should be placed between the left air cleaner...
  • Page 27 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Secondary air pipe and winker relay wire should be clamped. Located on the relay stay PCV drain pipe and carburetor drain pipe should go through the hole of body cover stay.
  • Page 28 To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Taillight wire, rear winker wire should be clamped. Fuel level gauge wire should be clamped Rear winker wire should be clamped Rear winker wire should go through winker stay hole.

  • Page 29: Lubrication Points

    To this chapter contents 1. General Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Lubrication Points Throttle cable / Front brake lever pivot Steering stem bearing Drive chain Speedometer pinion Side stand pivot Main stand pivot Rear axle / Front axle 1-24...

  • Page 30: Maintenance Information

    Homepage Contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation ············ 2-1 Clutch Adjustment ······················· 2-11 Periodical Maintenance Chart ····· 2-2 Drive Chain Adjustment··············· 2-12 Lubrication System······················ 2-3 Steering System ··························· 2-13 Fuel System ·································· 2-4 Suspension System ·····················...

  • Page 31: Periodical Maintenance Schedule

    To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Periodical Maintenance Schedule 1 month or 3 months or 6 months or 1 year or Initial Items every every every every 300KM 1000KM 3000KM 6000KM 12000KM ☆Air filter element...
  • Page 32 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Lubrication System Engine Oil Capacity Caution Turn off engine, and park the motorcycle Upper limit on flat surface with main stand. Check oil level with oil dipstick. (Do not Lower limit screw the dipstick into engine when checking.)
  • Page 33 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Fuel System Vacuum type auto fuel cock Fuel lines Check all fuel lines, and replace when they are deteriorated, damaged or leaking. Caution Gasoline is a highly flammable substance, so any source of fire or spark is strictly prohibited during operation.
  • Page 34 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Air Filter 2 screws on both sides Air filter element Remove the side cover. Remove the air filter duct (1 screw). Remove the air filter cover screw (4 screws). Screw Open the hold clip and remove the air filter cover.
  • Page 35 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Throttle Operation Operate the throttle grip to see if the throttle 2~6 mm cable is going smoothly. If the throttle cable is deteriorated, twisted or damaged, replace it with new part.
  • Page 36 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve Clearance Adjustment 2 bolts Caution The valve clearance should be adjusted when the engine is cold. (Under 35 degrees Celsius) Remove the valve clearance-adjusting cap (2 bolts).Remove the cylinder head side cover (2 bolts).
  • Page 37 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Idle Speed Adjustment Caution All the other configurations should be completed before idle speed adjustment. The engine must be fully warmed before the idle speed adjustment. Use the main stand of the bike, and warm up the engine.

  • Page 38: Spark Plug

    To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Ignition System “F” mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it cannot be adjusted. Ignition timing check procedure is for checking whether CDI function is normal or not.
  • Page 39 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Compression Pressure Spark plug hole Warm up the engine and turn it off. Remove the side cover. Remove the spark plug cap and the spark plug.
  • Page 40 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Clutch Adjustment Gear change pedal free play inspection Slightly step on the gear change pedal to check the free play before clutch disengagement. Free play：10~20 mm 10~20 mm Gear change pedal free play adjustment Adjusting screw...
  • Page 41 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Drive Chain Adjustment Drive chain inspection Place the bike on its main-stand with its 10~20 mm neutral gear. Check the drive chain slack by moving the chain up and down by fingers, and measure the amount of chain slack.
  • Page 42 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Steering Mechanism Locknut Caution Check all wires and cables if they are interfered with the rotation of the steering handle bar. Lift the front wheel off the ground. Turn the handle bar from right to left end and check if turning is smooth.
  • Page 43 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Brake System 10~20mm Front drum brake lever free play inspection Pull the front brake lever slightly, and measure the free play before brake engagement. Free play：10~20 mm Turn the brake adjusting nut to adjust the free play.
  • Page 44 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Tire Check the tire pressure to see if it’s in the specified pressure range. Caution Check the tire pressure when the tire is cold. Specified tire pressure range Tire pressure Front...
  • Page 45 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Battery 2 bolts Ventilation tube Battery removal Remove the right side cover. Unplug the ventilation tube. Remove the battery holder (2 bolts). Remove the〝─〞negative pole first, then remove the〝＋〞positive pole.
  • Page 46 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Headlight Adjustment Start the engine, turn on the headlight. Loosen the headlight lock bolt, move the headlight upward or downward to adjust the headlight beam height. When the proper headlight beam height is reached, tighten the lock bolt.
  • Page 47 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Special Tool Catalog Name Name Valve spring compressor Name Rocker arm shaft disassemble tool Valve remove/ assemble tool SY No. SYM-1445100 SY No. SYM-1471100 SY No.
  • Page 48 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Steering stem locknut remove/ Name Name Steering top cone race wrench Name Universal bearing driver assemble tool SY No. SYM-5320000 SY No. SYM-5320020 SY No. SYM-6204024 Name Inner bearing puller set Name Outer bearing puller Name Electrical gauge...
  • Page 49 To this chapter contents 2. Maintenance Information Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 2-20...

  • Page 50: Troubleshooting ························

    Homepage Contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ···················3-1 Float Chamber / Jet Set ············· 3-7 Precautions in Operation ···········3-2 Carburetor Installation··············· 3-10 Troubleshooting··························3-3 Idle Speed Adjustment ·············· 3-11 Carburetor Removal····················3-4 Fuel Tank ···································· 3-12 Throttle Valve ······························3-6 Air Cleaner ··································...

  • Page 51: Precautions In Operation

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com P recautions 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. Caution 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.

  • Page 52: Troubleshooting

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com T roubleshooting Engine cannot be started Late ignition timing No fuel in fuel tank Malfunction of ignition system Clogged fuel tube Malfunction of carburetor Excessive fuel in cylinder No spark from spark plug (malfunction of Weak engine power...

  • Page 53: Carburetor Removal

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com C arburetor Removal Removal Remove the body side cover. Put a container near the fuel drain screw, and loosen it. Drain all the fuel of the float chamber.

  • Page 54: Throttle Valve

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the carburetor top cover by turning it Top cover counterclockwise. Remove the top cover, throttle cable, and throttle valve. Throttle valve Loosen the clamp from the air cleaner side and remove the pipe.
  • Page 55 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com T hrottle Valve Disassembly Compress the throttle spring and disassemble the throttle cable, and the spring. Turn the jet needle seat counterclockwise to remove the jet needle and the seat from the throttle valve.
  • Page 56 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com F loat Chamber / Jet Set Remove 2 mounting screws and remove float chamber cover. Warning Please fill the gasoline in float chamber into the fuel tank. 2 screws Float pin Remove the float pin.
  • Page 57 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cleaning Main jet Remove the main jet, main jet seat and slow jet. Slow jet Remove the air adjusting screw. Caution Be careful not to damage jets and adjusting screw.
  • Page 58 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Assembly Before assembling, please blow the fuel passages with compressed air. Assemble the air adjusting screw. Caution Please assemble the air adjusting screw ● with the same setting circles as removal.
  • Page 59 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Fuel level inspection Caution Check the float valve and float for proper installation. To get the correct reading, position the fuel level gauge in the way that float chamber face is vertical to the main jet.
  • Page 60 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com I dle Speed Adjustment Air adjusting screw Idle adjusting screw Caution Air-screw was set at factory, so no adjustment is needed. For easy installation, count the number of circles it takes to screw the air-screw to the bottom.

  • Page 61: Fuel Tank

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com F uel Tank Fuel tank removal Remove the license plate bracket (2 bolts). 2 bolts 1 bolt 1 screw Remove the rear right / left winkers, and the rear fender (1 bolt, 1 screw).
  • Page 62 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the right body cover, and remove Vacuum operated automatic fuel cock the battery. Fuel outlet tube Remove the fuel outlet pipe and the vacuum pipe from the Vacuum operated automatic fuel cock.

  • Page 63: Air Cleaner

    To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com A ir Cleaner 4 screws for both sides Air filter element Remove the body cover. Loosen the air duct clamp (1 screw). Remove the air cleaner cover screws. 1 screw Open the air cleaner lock clip and remove the air cleaner cover.
  • Page 64 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Fuel vapor recycle tube Air cleaner removal Remove the body cover. Remove the air cleaner connecting tube and the fuel vapor recycle tube. 1 clamp Air cleaner duct band Loosen the air cleaner duct band, and remove the air cleaner ducts (both sides).
  • Page 65 To this chapter contents 3. Fuel System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 3-16...

  • Page 66: Engine Oil

    Homepage Contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ....4-1 Clutch Removal ......4-6 Mechanism Diagram ....4-2 Clutch Inspection ......4-8 Precautions in Operation .... 4-3 Clutch Installation ......4-9 Troubleshooting......

  • Page 67: Mechanism Diagram

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram Shift drum retainer Shift drum stopper Shift drum stopper spring Shift drum plate Shift drum cam Bearing 6805 Shift fork Clutch lifter plate Cam plate spring Shift drum pin guide...

  • Page 68: Precautions In Operation

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation： General Information This chapter covers the engine oil pump and the oil replacement. The disassembly of the clutch and the shifting linkage is covered. All these operations can be done while the engine is still on the motorcycle.

  • Page 69: Troubleshooting

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Troubleshooting Engine oil level too low Clutch slips during acceleration Oil leakage Worn clutch plate Worn valve guide or stem seal Weak clutch spring Worn piston ring ike trembles...
  • Page 70 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Engine Oil Turn off the engine, and park the motorcycle on flat surface with main stand. Check the oil level with the oil dipstick. Do not screw the dipstick in while checking.

  • Page 71: Clutch Removal

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Clutch Removal 8 bolts Drain the engine oil. Remove the footrest, exhaust pipe and kick-starter. Remove the right crankcase cover (8 bolts). Remove the clutch lift plate, ball retainer and Clutch ball retainer clutch cam plate spring.
  • Page 72 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Open the location foot of the lock washer. Anti-loose nut Remove the anti-loose locknut. Remove the flexible washer, lock washer and the whole clutch assembly.

  • Page 73: Clutch Inspection

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the clutch drive plate screws (4 4 screws screws) and disassemble the clutch drive plate from the clutch outer. Clutch damper spring Remove the clutch spring.

  • Page 74: Clutch Installation

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Clutch plate inspection Use a feeler gauge to measure the warp of each clutch plate. Service limit：0.2mm Clutch outer inspection Check the clutch outer to see if any cracks or damage can be found.
  • Page 75 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Reinstall the clutch set ring. Clutch set ring Assemble the clutch assembly to the Anti-loose locknut crankshaft. Put the anti-loose lock washer first and then the flexible washer.
  • Page 76 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the clutch cam plate side spring, ball retainer, and clutch lifter plate onto the clutch cam plate. Install the right crankcase cover (8 bolts). 8 bolts Reinstall the kick starter, gear shift pedal, footrest and exhaust pipe.
  • Page 77 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Gear Shift Linkage Mechanism Gear shift linkage mechanism removal Remove the gear shift pedal (1 bolt). 1 bolt Drain out the engine oil. Remove the footrest, kick starter and exhaust pipe.
  • Page 78 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Pull out the gear shift spindle and gear shift arm. Gear shift spindle Remove the shift drum pin guide and gear Shift drum pin guide shift drum pins.
  • Page 79 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Check the shift drum stopper and stopper spring for wear or damage. Check the shift drum cam for wear or damage. Check the shift drum plate and shift drum pin for wear or damage.
  • Page 80 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the shift drum plate and shift drum pin Shift drum plate onto the gear shift drum. Install the gear shift spindle and gear shift Claw of gear shift arm arm.

  • Page 81: Oil Pump Removal / Inspection

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Oil Pump Removal / Inspection Primary drive gear Drain out the engine oil. Remove the footrest and exhaust pipe. Remove the kick starter (1 bolt). Remove the right crankcase cover (8 bolts) and clutch assembly.
  • Page 82 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the oil pump cover and washer (3 3 screws screws). Oil pump inspection Check the clearance between the oil pump and outer rotor.

  • Page 83: Oil Pump Assembly / Installation

    To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Oil Pump Assembly / Installation 3 screws Assemble the inner and outer rotor into the oil pump body. Install the oil pump drive shaft. Install the oil pump cover and washer (3 screws).
  • Page 84 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the oil pump (3 screws). Oil pump drive gear Torque value：0.4~0.6kgf-m Install the oil pump drive gear onto the crankshaft and make the teeth of oil pump drive gear and driven gear coordinate.
  • Page 85 To this chapter contents 4. Lubrication / Clutch / Transmission Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 4-20...
  • Page 86 Homepage Contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram····················· 5-1 AC. Generator Stator Removal········ 5-3 Precautions in Operation ············· 5-2 AC. Generator / Starting Clutch ······ 5-6 Mechanism Diagram Starter motor Starter clutch gear 1.0~1.4kgf-m Starter clutch outer body...
  • Page 87 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation General information For engine troubleshooting and inspection, refer to the first chapter. For starting Motor repairing process and cautions, refer to Chapter 13. Specification Measurement unit：mm Item...
  • Page 88 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com ACG Stator Replacement Rubber cover Stator replacement Remove the body cover. Disconnect the ACG coupler. Disconnect the gear change switch coupler. Remove the gear shift pedal (1 bolt).
  • Page 89 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the foreign objects and gasket residue on the interface of crankcase and cover. Remove the pulse coil (2 screws) and ACG 2 screws stator (2 bolts).
  • Page 90 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rubber seal ACG stator assembly Assemble the ACG stator (2 bolts) and pulse coil (2 screws). Assemble the stator wire correctly onto the left crankcase cover with the rubber seal.
  • Page 91 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com ACG Flywheel / Starting One-way Clutch ACG flywheel / starting clutch removal Remove the flywheel / starting one-way clutch with flywheel puller. Special tool：...
  • Page 92 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Check the starter reduction gear and shaft for any wear or damage. Measure the inner diameter of starter reduction gear. Service limit： Inner diameter：Under 13.02 mm Measure the exterior diameter of starter reduction gear shaft.
  • Page 93 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Starter clutch disassembly Roller spring Remove the starter clutch inner-hexagon bolts. Spring cap Separate the starter clutch outer body and the clutch outer cover.
  • Page 94 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 2 screws Flywheel / starter clutch installation Install the starter reduction gear shaft (2 bolts). Install the starter reduction gear and cir clip. Cir clip Install the ACG flywheel, starter clutch and starter clutch gear (1 locknut).
  • Page 95 To this chapter contents 5. AC. Generator / Starting Clutch Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Assemble the stator wire correctly onto the left Rubber seal crankcase cover with the rubber seal. Install the left crankcase cover (7 bolts). 7 bolts Torque value：1.5~2.0kgf-m Install the left crankcase rear cover (2 bolts).

  • Page 96: Engine Removal

    Homepage Contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation ···········6-1 Engine Intallation ························6-5 Engine Removal ··························6-2 Precautions in Operation General information During maintenance of a removed engine, you need to use an adjustable rack or cart to ●...
  • Page 97 To this chapter contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Engine Removal Drain the engine oil. Engine oil drain bolt Remove the right body cover. 2 bolts Ventilation pipe Remove the battery ventilation pipe. Remove the battery cable, first negative then positive pole.
  • Page 98 To this chapter contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the spark plug cap. Cord clamp Spark plug cap Remove the high tension cord from the cord clamp. Remove the step bar (4 bolts). 4 bolts Remove the exhaust pipe (3 locknuts) 2 locknuts...
  • Page 99 To this chapter contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the PCV breather tube. PCV breather pipe Remove the PCV drain pipe from the drain pipe clamp. PCV drain pipe Remove the inlet pipe lock bolts. 2 bolts Sleeve nut Rear wheel axle nut...
  • Page 100 To this chapter contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Use a rack to hold the engine. 2 nuts Remove the engine locknuts. Pull out the engine holding bolts and remove the engine. Engine Installation Install the engine in the reversed procedure of removal Caution...
  • Page 101 To this chapter contents 6. Engine Removal Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note:...
  • Page 102 Homepage Contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ···················7-1 Valve ············································ 7-8 Precautions in Operation ···········7-2 Valve Seat Inspection & Refacing ····················································· 7-12 Troubleshooting··························7-3 Cylinder Head Assembly ··········· 7-15 Cylinder Head ······························7-4 Cylinder Head Installation ·········...

  • Page 103: Precautions In Operation

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation General information This chapter includes the repair information of the cylinder head, valve, camshaft, and valve rocker arm. The repairing of Cylinder head can be proceeded when the engine is still on the frame. Specification Measurement unit: mm Specification...

  • Page 104: Troubleshooting

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Troubleshooting Engine performance will be affected by troubles on cylinder-head perimeter parts. The trouble usually can be determined or by performing cylinder compression test or judging the abnormal noise.
  • Page 105 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Head AICV tube Cylinder head disassembly Remove the AICV pipe and spark plug cap on the right side of engine. Spark plug cap 2 locknuts Remove the exhaust pipe (3 locknuts).
  • Page 106 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the cam chain tensioner lifter (2 2 bolts bolts). Remove the cam chain tensioner lock bolt. Cam chain tensioner lock bolt Remove the cam chain sprocket (2 bolts).
  • Page 107 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the cylinder head (4 locknuts). 4 locknuts Clean up residues from the matching surfaces of cylinder and cylinder head Caution Don’t damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase when...

  • Page 108: Camshaft

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve Rocker Arm 4 bolts Valve rocker arm removal Remove the cylinder head right side cover (4 bolts). Rocker arm shaft / camshaft puller Use rocker arm shaft / camshaft puller to pull out the in.

  • Page 109: Valve

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Inner diameter Valve rocker arm inspection Measure the valve rocker arm inner diameter and the contact face for wear or damage. Also check if the oil hole is clogged.
  • Page 110 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Use the valve spring compressor to compress Valve spring compressor the spring, remove the valve cotter, and then take out the spring and spring retainers Special tool：...
  • Page 111 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve stem inspection Check if valve stems are bent, cracked or burnt. Check the operation condition of valve stem in valve guide, and measure the valve stem outer diameter Service limit：In.
  • Page 112 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve guide replacement Heat the cylinder head with heated plate or toaster till the temperature reaches 100~150 ℃. Valve guide remover 5.0mm Caution Do not use flame to heat the cylinder head directly.
  • Page 113 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve Seat Inspection / Refacing Inspection Clean up all carbon deposits on the intake and exhaust valve seats. Apply some red lead paint onto valve contact face.
  • Page 114 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rotate the valve seat cutter clockwise and 4~5kg counterclockwise with 4 to 5 kg pressure in order to fix the uneven part. Caution Apply motor oil to the contact face while grinding it.
  • Page 115 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Use the 45 degree cutter and cut the seat to the proper width. 1.0mm Caution Confirm that all roughness is removed. 45° Grind valve seat again if necessary.

  • Page 116: Cylinder Head Assembly

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Head Assembly Valve cotters Valve stem Lubricate the valve stem with engine oil, and seal then insert the valve into valve guide. Valve spring Install the new valve stem oil seal.

  • Page 117: Cylinder Head Installation

    To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Head Installation Dowel pins Install the cam chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Cam chain guide Gasket Install the cylinder head.
  • Page 118 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rotate the crankshaft counterclockwise to TDC mark “T” match the TDC mark “T”. Install the cam chain sprocket. Timing mark Install the cam chain onto the sprocket and align the timing mark on the sprocket with that of cylinder head.
  • Page 119 To this chapter contents 7. Cylinder Head / Valve Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Valve Clearance Adjustment TDC mark Caution Check and adjust the valve clearance when the engine is cold (below 35°C). Remove the tappet adjusting hole cap, cylinder head side cover, timing-inspecting hole cap, and ACG cap.
  • Page 120 Homepage Contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ···················· 8-1 Piston Removal / Inspection ······· 8-5 Precautions in Operation ············ 8-2 Piston Rings Installation ············· 8-8 Troubleshooting··························· 8-2 Piston Installation ························ 8-9 Cylinder Removal / Inspection ····...

  • Page 121: Precautions In Operation

    To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation General information The engine must be removed from the frame before the repairing of the cylinder and piston. Specification Measurement unit：mm Specification Item Standard...

  • Page 122: Cylinder Removal / Inspection

    To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Removal / Inspection Dowel pins Remove the cylinder head (refer to Chapter Remove the cylinder head gasket and dowel pins. Remove the cam chain guide. Cam chain guide Gasket Remove the cylinder.
  • Page 123 To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Inspection Check the inner diameter of cylinder for any Exhaust side Inlet side wear or damage. Service limit：52.45 mm Calculate the taper and out of round at three levels in X and Y axis.

  • Page 124: Piston Removal / Inspection

    To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Piston Removal / Inspection Cover the holes of crankcase and cam chain with a piece of clean cloth to prevent piston pin clips from falling into the crankcase. Remove piston pin clip with pliers.
  • Page 125 To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Insert the piston ring into the bottom of the cylinder and then push it to the position 20 mm from the cylinder surface. Measure the piston ring end.
  • Page 126 To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Measure the piston outer diameter. Caution Measure the piston outer diameter 90 degrees to the piston pin hole. Service limit：52.25 mm Calculate the clearance between the piston and cylinder.
  • Page 127 To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Piston Rings Assembly Clean up the piston and ring grooves. Install the piston rings onto piston carefully. Place the opening of piston rings as diagram shown. Caution Do not damage the piston and piston rings during installation.

  • Page 128: Piston Installation

    To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Piston Installation Cover the holes of crankcase and cam chain with a piece of clean cloth. Clean out the gasket and residues on the cylinder and crankcase contact face.

  • Page 129: Cylinder Installation

    To this chapter contents 8. Cylinder / Piston Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Cylinder Installation Install dowel pins, new cylinder gasket and o-ring. Dowel pins O-ring Apply some engine oil to the inside of cylinder, piston and piston rings. Install the piston into cylinder carefully.
  • Page 130 Homepage Contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ···················9-1 Crankshaft Inspection ················9-7 Precautions in Operation ···········9-3 Shifting Gear Inspection·············9-8 Troubleshooting··························9-4 Kick Starter ··································9-10 Crankcase Disassembly ·············9-5 Crankcase Inspection ·················9-12 Shifting Gear Disassembly·········9-6 Crankcase Assembly ··················9-13...

  • Page 131: Shifting Gear

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Gear shift mechanism Shift drum retainer Shift drum stopper Shift drum stopper spring Shift drum plate Shift drum cam Counter shaft shift fork Gear shift drum Gear shift fork shaft...

  • Page 132: Precautions In Operation

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation General information This Section concerns disassembly of the crankcase and transmission system for repair purpose.

  • Page 133: Troubleshooting

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Troubleshooting Excessive engine noise Worn connecting rod big end Worn crankshaft bearing Worn piston pin or piston pin hole Hard to shift gear Bent shift fork Bent shift fork shaft...

  • Page 134: Crankcase Disassembly

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Crankcase Disassembly Remove the cam chain set plate from the left crankcase (1 bolt). Remove the cam chain. 1 bolt 2 screws Remove the gear change switch (2 screws).

  • Page 135: Shifting Gear Disassembly

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Separate the left crankcase from the right crankcase. Shake the crankshaft gently and remove the crankshaft. Gear shift drum Shift fork Shifting Gear Disassembly Shift fork...

  • Page 136: Crankshaft Inspection

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Crankshaft Inspection Use a feeler gauge to measure left and right clearance of connecting rod big end. Service limit：0.6 mm Measure the clearance of the big end at the vertical directions.

  • Page 137: Shifting Gear Inspection

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Crankcase bearing inspection Clearance Rotate the bearings on the left and right crankcase to check if the bearings rotate Clearance smoothly and silently.
  • Page 138 To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Check the gear shift drum for wear or damage. Disassemble the gears and washers on the main shaft and counter; arrange the gears and washers in order.

  • Page 139: Kick Starter

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Kick Starter Removal / inspection Remove the kick starter guide (2 bolts). Loosen the kick starter spring by rotating the kick starter spindle.
  • Page 140 To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Thrust washer Spindle collar Kick starter spring Kick starter assembly Assemble the kick starter spring, spindle collar and thrust washer to the kick starter spindle.

  • Page 141: Crankcase Inspection

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Crankcase Inspection Check if the oil path on the crankcase is clogged or not. Blow the oil path with compressed air if necessary.

  • Page 142: Crankcase Assembly

    To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Crankcase Assembly Remove the crankcase gasket and dowel pins. Clean the gasket residues off the crankcase contact surface. Caution Do not damage the contact surface of the crankcase.
  • Page 143 To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the crankshaft onto the right crankcase. Install the crankcase gasket and dowel pins. Dowel pins Assemble the left crankcase to the right 7 bolts crankcase.
  • Page 144 To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the cam chain and cam chain set plate (1 bolt). 1 bolt 9-15...
  • Page 145 To this chapter contents 9. Crankshaft / Crankcase / Shifting Gear / Kick Starter Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 9-16...

  • Page 146: Steering / Front Wheel / Front Suspension / Front Brake

    Homepage Contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Mechanism Diagram ················10-1 Front Wheel ······························10-9 Precautions in Operation ········10-2 Front Suspension·····················10-13 Troubleshooting·······················10-3 Steering Stem ···························10-16 Headlight···································10-4 Front Brake Hub ·······················10-19 Speedometer ····························10-5 Front Brake Shoes ···················10-19 Handlebar··································10-6...

  • Page 147: Precautions In Operation

    To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation General information Before removing the front wheel, use a bracket to hold the bottom of engine. Let the front wheel away from the ground and do not let the vehicle topple over.

  • Page 148: Troubleshooting

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Troubleshooting Steering / Front suspension Drum brake Weak brake Hard steering Incorrect brake adjustment Steering stem locknut too tight Worn brake shoe Worn or damaged steering bottom cone Worn wheel hub...

  • Page 149: Headlight

    To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Headlight Removal Remove the front cover (1 bolt). 1 bolt Headlight coupler Disconnect the headlight wire coupler. Remove the headlight lock bolt and the headlight.

  • Page 150: Speedometer

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Speedometer Speedometer coupler Removal Remove the front cover (1 bolt). Disconnect the speedometer wire coupler. 3 screws Remove the speedometer cover (3 screws).

  • Page 151: Handlebar

    To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Handlebar Wire coupler Removal Remove the front cover (1 bolt). Disconnect the speedometer cable, left / right handle switch, winker coupler, brake light switch and headlight coupler.
  • Page 152 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake 2 screws Remove the left handle switch (2 screws). Remove the handle pipe up holder bolt caps. Bolt caps Remove the handle pipe up holder (4 bolts).
  • Page 153 To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Installation Install in the reverse order. Torque value： Handlebar locknut 3.0~3.5kgf-m Location hole Before assembling the handle switch, throttle grip and throttle cable, apply grease to the sliding surface.

  • Page 154: Front Wheel

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Front Wheel Removal Use a bracket to hold the bottom of engine and let the front wheel away from the ground. Remove the speedometer cable from the brake panel Speedometer cable screw...
  • Page 155 To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Bearing Clearance Turn the inner ring of each bearing to check if it rotates smoothly and quietly. Meanwhile, check if the outer ring fits the Clearance wheel hub closely.
  • Page 156 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Apply grease to the inner side of right dust Dust seal seal and install the dust seal to the wheel hub. Gear receiver Check the dust seal inside the brake panel for Dust seal...
  • Page 157 To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the right side collar and push in the Side collar front wheel axle from the right cushion. Assemble the front wheel axle locknut and Axle locknut lock it to the specified torque value.

  • Page 158: Front Suspension

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Front Suspension 2 bolts on each side Removal Remove the front wheel and front brake mechanism. Remove 2 lock bolts from the right / left side of the front fender A.
  • Page 159 To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Front cushion inspection / bearing replacement Scratch Push the fork pipe for several times to check if there is any oil leakage or excessive noise.
  • Page 160 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake 2 fork bolts Front cushion installation Caution Rotate the fork pipe during installation will make it easier to install the fork pipe. Install the fork pipe from the bottom of the front fork.

  • Page 161: Steering Stem

    To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Steering Stem Removal Remove the speedometer, headlight, headlight bracket, steering hand pipe, front wheel, front brake set and front cushion. Remove the steering handle pipe post 1 locknut.
  • Page 162 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Remove the steering upper / bottom ball race by driver and rubber hammer. Remove the steering bottom cone race from the steering stem.
  • Page 163 To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Install the steering stem into the frame. Steering stem locknut Lubricate the steering upper cone race. Counterclockwise 1/2 circle Screw the upper cone race and steering stem locknut to the steering stem till the steering...

  • Page 164: Front Brake Hub

    To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 10. Steering / Front Wheel /Front Suspension / Front Brake Front Brake Hub Removal Remove the front wheel. Clean the wheel hub with vacuum cleaner. Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use compressed air or dry brush to clean brake parts.

  • Page 165: Front Brake Panel

    To this chapter contents 10. Steering / Front Wheel /Front Suspension / Front Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Removal Caution Brake shoes must be replaced with a new pair. Remove the brake shoes from the brake panel.

  • Page 166: Precautions In Operation

    Homepage Contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation ···········11-1 Rear Cushion····························· 11-13 Troubleshooting··························11-2 Rear Fork ··································· 11-14 Rear Wheel···································11-3 Rear Brake Pedal······················· 11-16 Drive Chain / Driven Sprocket / Driven Flange ······························11-8 Precautions in Operation General information...

  • Page 167: Troubleshooting

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Troubleshooting Rear wheel wobbling Insufficient braking performance Distorted rim Incorrect brake adjustment Faulty rear tire Worn brake lining Rear axle not tightened correctly Worn wheel hub Worn brake cam...

  • Page 168: Rear Wheel

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rear Wheel Rear wheel removal Remove the exhaust pipe mounting nuts. 2 mounting nuts Remove the rear fork axle locknut. Remove the exhaust pipe.
  • Page 169 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Loosen the left and right drive chain adjuster nuts. Adjuster nut Loosen the final driven flange locknut. Rear axle locknut Final driven flange locknut Adjuster nut Fix the rear wheel axle and remove the rear...
  • Page 170 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Inspection Rear wheel axle Put the rear axle on a V-block and measure the run out. Service limit：0.2 mm Bearing Clearance Turn the inner ring of each bearing to check if...
  • Page 171 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rear wheel hub Check the rear wheel hub for wear or damage. Replace it if necessary. Measure the inner diameter of the wheel hub. Service limit：111.0mm Caution Rub the wheel hub with #120 sandpaper...
  • Page 172 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rear wheel installation Raised part Location groove Install the rear brake penal into the wheel hub. Align the location grooves on the rear wheel dampers with the raised parts on the final driven flange.

  • Page 173: Driven Flange

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Drive Chain / Drive Sprocket / Final Driven Flange Drive chain / drive sprocket removal Remove the left crankcase rear cover (2 bolts).
  • Page 174 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Drive chain / drive sprocket inspection Drive chain Inspect the drive sprocket teeth for wear or damage. Replace it if it is over worn out. Caution The drive sprocket teeth and drive chain should be checked at the same time.
  • Page 175 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Remove the final driven sprocket from the final driven flange (4 bolts, 4 locknuts). Final driven flange inspection Check the final driven flange and the raised parts for crack or damage.
  • Page 176 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Final driven flange / final driven sprocket installation Install the driven sprocket onto the driven flange. Tighten the locknuts and bend the tongued washers.
  • Page 177 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Drive chain adjustment Left chain adjuster nut Turn the right / left side drive chain adjuster nuts evenly to adjust the drive chain slack to the normal range.

  • Page 178: Rear Cushion

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rear Cushion 1 locknut Removal Remove the rear cushion lower locknut. 1 locknut Remove the rear cushion upper locknut. Remove the rear cushion.

  • Page 179: Rear Fork

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Rear Fork 1 locknut Removal Remove the rear fork pivot locknut. Remove the exhaust pipe, rear wheel, drive chain final driven sprocket, drive chain cases and rear cushions.
  • Page 180 To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Check the rear fork rubber bush for crack or wear. Push out Rear fork rubber bush replacement Push out the rear fork rubber bush. Special tool：...

  • Page 181: Rear Brake Pedal

    To this chapter contents 11. Rear Wheel / Rear Suspension / Rear Brake Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Installation Install in the reverse order of removal. Torque value： Rear fork pivot locknut 3.0~4.0kgf-m Rear brake torque link locknut Rear fork 1.5~2.5kgf-m pivot bolt...

  • Page 182: Mechanism Diagram

    Homepage Contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Mechanism Diagram ················· 12-1 Ignition System ························· 12-11 Precautions in Operation ········· 12-2 Starting System ························· 12-14 Technical Specification ············ 12-3 Light System······························ 12-16 Troubleshooting························ 12-4 Switch / Horn ·····························...

  • Page 183: Precautions In Operation

    To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Precautions in Operation Charging system When removing the battery, the disconnection sequence of cable terminals shall be strictly • observed. (First disconnect the negative cable terminal then the positive cable terminal.) The electrolyte level should be checked carefully.

  • Page 184: Technical Specification

    To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Technical Specification Charging system Item Specification Capacity / Type 12V5Ah / 12N5A Charging rate 0.5A / 5~10hr (Standard) 3A / 1hr (Quick) Battery Specific gravity of electrolyte (20ºC) 1.260~1.280 Fully charged 13.0~13.2V...

  • Page 185: Troubleshooting

    To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Troubleshooting Charging system Ignition system No battery voltage No spark Poor spark plug Battery discharged The cable is poorly connected, open or The cable disconnected short-circuited The fuse is blown ~between AC.
  • Page 186 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Charging System Battery Removal Remove the right side cover (1 bolt). Remove the battery fix bracket (2 bolts). Pull out the battery. Disconnect the negative terminal wire first and then the positive terminal.
  • Page 187 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Battery voltage inspection Use the digital voltmeter or multi meter to measure the battery voltage. Voltage Fully charged：13.0~13.2V (20°C) Insufficiently charged：Below 12.3V (20°C) Charging Remove the battery cell caps.
  • Page 188 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Connect a tachometer. Charging voltage / current inspection Turn on the headlight to high beam and start the engine. Digital voltmeter Accelerate the engine to the specified Ampere meter revolution per minute and measure the charging voltage.
  • Page 189 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Current leakage test Inspection Turn off the main switch. Negative terminal Disconnect the negative terminal wire from the battery. Connect ammeter between battery negative terminal and negative terminal wire (as shown at left picture).
  • Page 190 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Charging circuit Black Main switch Light switch Regulator rectifier Blue Yellow Green White 白 Green / Brown Pink Black Green Green Battery License Taillight light Headlight Regulator rectifier inspection...
  • Page 191 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com If the readings measured are not normal, check parts in the circuit. If the parts are normal, then trouble is in the wiring. If there is nothing wrong with parts and wiring, replace the regulator rectifier.
  • Page 192 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 12. Electrical System Ignition System Ignition circuit Main Switch C.D.I. B / Y B / W AC. Generator Spark plug Ignition coil inspection Primary winding Remove the front seat and fuel tank. Measure the resistance between the terminals of the primary winding.
  • Page 193 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Pulse coil inspection White Green Black / Red Disconnect the AC. Generator 6 pin coupler. Measure the resistance between the terminal Blue / Yellow and terminal Green. Standard value：110Ω±10% Caution Coil does not need to be removed from...
  • Page 194 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Spark plug inspection Check the sparking condition. If the sparking condition is not proper or the spark plug electrode is contaminated, replace it with new one. Caution Be extremely careful to carry out the sparking condition inspection.
  • Page 195 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Starting System Starting circuit diagram Main switch Fuse 7A Brake light Green / Yellow Brake switch Black Starter relay Starter switch Yellow / Red Red / White Green Green...
  • Page 196 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Starter motor removal 1 nut Disconnect the starter motor wire. 2 bolts Remove the starter motor (2 lock bolts). Starter motor inspection Connect the battery positive terminal and starter motor power terminal.
  • Page 197 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Light System Light circuit diagram Hi beam indicator Regulator rectifier Light switch Headlight Green Blue White Resistor White Yellow Pink Green Brown Meter light Green Black Gear switch...
  • Page 198 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Headlight bulb replacement Remove the headlight lock screw. 1 screw Pull out the headlight set. Press the headlight bulb seat and rotate it counterclockwise to remove it. Remove the headlight bulb and replace it if Headlight bulb seat necessary.
  • Page 199 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Winker bulb replacement 1 screw Remove the winker lens lock screw. Pull out the hook and remove the winker lens. Hook Rubber seal Press the winker bulb slightly and rotate it clockwise.
  • Page 200 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Taillight / brake light / license light removal 2 bolts Remove the pillion seat and rear cushion upper locknuts. Remove the luggage carrier (2 bolts). 1 bolt for each side Remove the winker lock bolts and disconnect the wire coupler.
  • Page 201 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Disconnect the taillight wire coupler. Coupler 2 locknuts Remove the taillight (2 locknuts). Specification： Taillight / Brake light 12V LED Caution Taillight / Brake light are LED type; it needs to be replaced as a set.
  • Page 202 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Switch / Horn Main switch Inspection Turn the main switch cover counterclockwise and remove the cover. Remove the body cover. Main switch cover Disconnect the main switch coupler. Main switch coupler Check the circuit between two points as Black...
  • Page 203 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Right handle switch 1 bolt Remove the front cover (1 bolt). Right handle switch coupler Disconnect the right handle switch coupler. Check the circuit between two points as indicated in the table below.
  • Page 204 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Left handle switch 1 bolt Remove the front cover (1 bolt). Disconnect the left handle switch couplers. Left handle switch coupler Check the circuit between two points as indicated in the table below.
  • Page 205 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Brake switch Rear brake switch While grasp the brake lever firmly, the terminals of black and green/yellow of the brake should have continuity. Replace the switch if damaged. Front brake switch Horn Coupler...
  • Page 206 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Fuel Unit Fuel unit inspection Remove the fuel unit (3 screws). Check the washer for deformation or damage; replace it with new one if necessary. 3 screws Measure the fuel unit electrical resistance.
  • Page 207 To this chapter contents 12. Electrical System Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 12-26...

  • Page 208: Emission Control System

    Home page Contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Names of Mechanism in the Emission Secondary Air Introduction System · 13-5 Control System··································· 13-1 Positive Crankcase Ventilation System Function of Mechanism in the Emission (P.C.V.) ················································...
  • Page 209 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) Construction: Reduce HC to pollute air. To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose...
  • Page 210 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank...
  • Page 211 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Catalytic Converting System (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO gases.
  • Page 212 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Secondary Air Introduction System Construction Secondary air filter Carburetor Intake valve Flesh air Vacuum hose Engine Cylinder head Reed valve Flesh air Mixture gas First burn exhaust Exhaust valve Purged exhaust gas...
  • Page 213 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject cut valve (AICV). b. System hose leakage. c. abnormal ignition timing. d. lean mixture gas. e.
  • Page 214 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Warm-up test: Start engine. Remove the air injection filter. Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet...
  • Page 215 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Exhaust pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil...
  • Page 216 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage.
  • Page 217 To this chapter contents Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 13. Emission Control System Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2)

  • Page 218: Electrical Diagram

    Homepage Contents 14. Electrical Diagram Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 14-1...

  • Page 219: Electrical Diagram

    Homepage Contents 14. Electrical Diagram Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Note: 14-2...

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