Sym Jet Sport X S50 Service Manual
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Sym Jet Sport X S50 Service Manual

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SERVICE MANUAL
S50/R50/SR50

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Summary of Contents for Sym Jet Sport X S50

  • Page 1 Forward How to use this manual Model illustration Contents SERVICE MANUAL S50/R50/SR50...
  • Page 2 “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the scooters, Jet Sport X S50 / R50 / SR50 series, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3: General Information

    This service manual describes basic information of different system parts and system inspection & service for SANYANG Jet Sport X S50 / R50 / SR50 series scooters. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Home page Contents Page Content Index 1-1 ~ 1-18 General Information 2-1 ~ 2-14 Service Maintenance Information 3-1 ~ 3-6 Lubrication System 4-1 ~ 4-10 Fuel System 5-1 ~ 5-6 Engine Removal 6-1 ~ 6-4 Cylinder Head / Cylinder / Piston 7-1 ~ 7-14 A.C.
  • Page 5 Home page Contents Model illustration Jet Sport X S50 / R50 / SR50 Series ENG. Stop / Starter switch Fuel tank cap Rear turn signal Taillight Rear turn signal Front turn signal Helmet hook High & Low beam / Passing / Turn signal / Horn switch Battery / Fuses / C.D.I.
  • Page 6 Home page Contents 1. General Information Symbols and Marks ····················· 1-1 Torque values······························· 1-7 General Safety······························ 1-2 Cables and Harness Routing ······ 1-9 Service Precautions····················· 1-3 Troubleshooting··························· 1-13 Specifications······························· 1-6 Lubrication Points ······················· 1-20 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
  • Page 7 This chapter Contents 1. General Information General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed • Battery emits explosive gases; flame is area. Run your engine in an open area, if you strictly prohibited.
  • Page 8 1. General Information Service Precautions • Rubber parts may become deteriorated when • Always use with SANYANG genuine parts and old, and prone to be damaged by solvent and recommended oils. Using non-designed parts oil. Check these parts before installation to for SANYANG scooter may damage the make sure that they are in good condition, scooter.
  • Page 9 1. General Information • • The length of bolts and screws for assemblies, The ends of rubber hoses (for fuel, vacuum, or cover plates or boxes is different from one coolant) should be pushed as far as they can another, be sure they are correctly installed. In go to their connections so that there is enough case of confusion, Insert the bolt into the hole room below the enlarged ends for tightening...
  • Page 10 1. General Information...

  • Page 11: Lubrication System

    1. General Information Specifications Make SANYANG MODEL Jet Sport X 50 series Overall Length 1840 mm Front Telescopic Fork Suspension System Overall Width 690 mm Rear Unit Swing Overall Height 1120 mm Front 120 / 70 – 12 Tire Specifications Wheel Base 1275 mm Rear...
  • Page 12 1. General Information Torque values Standard Torque Values for Reference Type Torque value Type Torque value 5 mm Bolt, nut 0.45 ~ 0.6kgf-m 5 mm Screw 0.35 ~ 0.5kgf-m 6 mm Screw, flange bolt 6 mm Bolt, nut 0.8 ~ 1.2kgf-m 0.7 ~ 1.1kgf-m (SH Type) 8 mm Bolt, nut...
  • Page 13 1. General Information Frame Thread Dia. Torque Value Item Q’ty Remarks (mm) (kgf-m) Mounting nut for handle 4.0~5.0 Steering stem lock nut 25.4 1.0~2.0 Steering top cone race 25.4 0.2~0.3 Front cushion bolts 2.4~3.0 Front wheel axle nut 5.0~7.0 Air cleaner bolts 1.0~1.4 Brake master cylinder mounting bolts 1.0~1.4...
  • Page 14 1. General Information Cables and Harness Routing Note the following when routing cables and wire harnesses: • A loose wire, cable or harness may cause safety hazard. After clamping, check each wire to make sure it is secured. • Do not squeeze wires against the weld or its clamp.
  • Page 15 1. General Information Headlight Winker switch switch Speedometer High/low beam switch Starter switch Horn switch Front brake Rear brake lamp lamp switch switch Throttle cable Speedometer cable Front brake cable Rear brake cable Headlight Throttle cable Winker relay Main switch Regulator Horn Resistor...
  • Page 16 1. General Information Speedometer cable Front brake hose Rear brake cable Throttle cable Winker relay Fuel unit Rear brake cable Throttle cable Front brake hose Rear brake cable Throttle cable Fuel unit cord Front brake hose Fuel pump Speedometer cable Fuel filter 1-11...
  • Page 17 1. General Information Battery Fuse Purge control valve Oil control cable C.D.I. UNIT Fuel hose Fuel pump Carburetor Fuel filter Rear brake cable Oil hose Vacuum hose Oil lever switch 1-12...
  • Page 18 1. General Information Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.
  • Page 19 1. General Information 1-14...
  • Page 20 1. General Information B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not 3.
  • Page 21 1. General Information 1-16...
  • Page 22 1. General Information C. Engine runs sluggish (especially in low speed and idling) Fault condition Probable causes Check and adjustment Check ignition timing (using ignition lamp) 1. Incorrect ignition timing (malfunction of Normal Abnormal CDI or AC generator) Adjust the air screw of carburetor Good Poor...
  • Page 23 1. General Information 1-18...
  • Page 24 1. General Information E. CLUTCH, DRIVING AND DRIVING PULLEY PROBABLE CAUSES FAULT CONDITION 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be driving 4. Clutch ling broken 5.
  • Page 25 1. General Information Lubrication Points Throttle cable/ Front & rear brake lever pivot Seat catch Steering shaft bearing Main stand shaft Side stand shaft Rear wheel bearing Speedometer gear/ front wheel bearing 1-20...
  • Page 26 1. General Information Note: 1-21...
  • Page 27 Home page Contents 2. Service Maintenance Information General Information ······························ 2-1 Transmission Oil··································· 2-10 Periodical Maintenance Schedule········ 2-2 Spark Plug ············································· 2-10 Air Cleaner ············································· 2-3 Control Cable Lubrication···················· 2-11 Fuel Lines ·············································· 2-3 Driver Belt·············································· 2-11 Fuel Filter ··············································· 2-4 Ignition Timing ······································...

  • Page 28: Periodical Maintenance Schedule

    25. Carbon cleaning for cylinder ☆ head, cylinder, and piston head, and exhaust system. Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition. Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement...

  • Page 29: Air Cleaner

    Soap Clean Limit to use SAE 20 JASO FC class engine oil; otherwise, SYM is no responsible for the warranty. Recommended engine oil: MAX-2 serial oils. Squeeze out remaining oil Squeeze oil out...

  • Page 30: Fuel Filter

    This chapter Contents 2. Service Maintenance Information Fuel Filter Remove the luggage box. Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking. Fuel filter Engine Oil Line Remove the body cover.

  • Page 31: Oil Pump Control Cable

    This chapter Contents 2. Service Maintenance Information Oil Pump Control Cable Caution To adjust the oil pump control cable after adjusted the throttle grip play. Remove the luggage box. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body.

  • Page 32: Tire

    This chapter Contents 2. Service Maintenance Information Tire Caution Tire pressure should be checked when cold. Check tire for cracks, damage, nail, or other object stuck in tread. Recommended tire and tire pressure Front: Rear: Tire size 120 / 90 - 10 130 / 90 - 10 Tire pressure 1.75...

  • Page 33: Disc Brake System Hose

    This chapter Contents 2. Service Maintenance Information Disc Brake System Hose Make sure that the brake hose is corrosion or damage, and also check the system for leaking. Brake Fluid: Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit.
  • Page 34 This chapter Contents 2. Service Maintenance Information Loosen the guide pin bolts. Front brake Remove the front wheel shaft bolt. Take out the front wheel. Lining guide bolts Remove brake caliper mounting bolt and then remove the brake caliper. Caution Caliper bolt Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.

  • Page 35: Steering System

    This chapter Contents 2. Service Maintenance Information Steering System Caution The control cables cannot interfere with the rotation of steering handle. Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut.

  • Page 36: Transmission Oil

    This chapter Contents 2. Service Maintenance Information Transmission Oil Oil level check bolt Leak Check if the transmission is leak. Draining bolt Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.

  • Page 37: Control Cable Lubrication

    This chapter Contents 2. Service Maintenance Information Control Cable Lubrication Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the Tooth face cables thoroughly. Belt width Driver Belt Remove left crankcase cover. Check if the belt is crack or worn out. Replace the belt if necessary.

  • Page 38: Carburetor Idle Speed Adjustment

    This chapter Contents 2. Service Maintenance Information Carburetor Idle Speed Adjustment Pilot screw Caution Inspection & adjustment for idle speed have to be performed after all parts in engine had been adjusted in specification. Idle speed check and adjustment have to be done after engine is being warned up.

  • Page 39: Headlight Adjustment

    This chapter Contents 2. Service Maintenance Information Headlight Adjustment Turn the headlight- adjustment bolt for adjustment its light beam. Caution Higher Lower Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance. Headlight adjustment bolt 2-13...

  • Page 40: Special Tool Manual

    2. Service Maintenance Information Special Tool Manual R/L. Crankcase disassemble Name Name R/L. Crank puller Name R. Crank shaft puller tool No. SYM-1120100-G5 No. SYM-1130000-L No. SYM-1130000-R L. Crankshaft install bush Name R. Crankshaft install bush Name Extension bush SYM-1130031(long) No.
  • Page 41 2. Service Maintenance Information No. SYM-9121600 No. SYM-9120200 No. SYM-9125500 2-15...
  • Page 42 2. Service Maintenance Information (6301) (6204) (6203/6004UZ) Name Bearing driver 6301 Name Bearing driver Ø17mm Name Bearing driver 6204 SYM-9610000 No. SYM-9620000 No. SYM-9110400 Name Inner bearing puller Name Inner bearing puller Name Outer bearing puller SYM-6204020 No. SYM-6204022 No. SYM-6204001...
  • Page 43 Home page Contents 3. Lubrication System Lubrication System Diagram················ 3-1 Oil Pump Removal ································· 3-3 Precautions In Operation······················ 3-2 Oil Pump Installation ····························· 3-3 Lubricant ················································ 3-2 Oil Pump/Oil Tube Air Bleeding············ 3-4 Trouble Shooting ·································· 3-2 Oil Tank ·················································· 3-5 Lubrication System Diagram Oil lever switch Oil tank...

  • Page 44: Precautions In Operation

    This chapter Contents 3. Lubrication System Precautions in Operation Be careful not let dirt enters into engine or oil hoses when removing or installing the oil pump. If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation.

  • Page 45: Oil Pump Removal

    This chapter Contents 3. Lubrication System Oil Pump Removal Adjustment nut 1 bolt Mounting nut Caution Before removing the oil pump, clean the oil pump and crankcase. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control Control cable cable, and remove the control cable.

  • Page 46: Oil Pump/Oil Tube Air Bleeding

    This chapter Contents 3. Lubrication System Oil Pump/Oil Tube Air Bleeding Oil output tube Control cable Caution The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that causes serious engine damage.

  • Page 47: Oil Tank

    This chapter Contents 3. Lubrication System Oil Tank 1 bolt Removal Remove the luggage box and seat. Remove the right / left side covers, right / left rear side covers, center cover, rear carrier, body covers, rear fender and rear inner fender. (Refer to chapter 11) Remove the battery and battery case (1 bolt).
  • Page 48 This chapter Contents 3. Lubrication System Notes:...

  • Page 49: Fuel System

    Home page Contents 4. Fuel System Maintenance Information ······················4-2 Flaot Level Inspection ·························· 4-7 Troubleshooting ····································4-2 Carburetor Installation·························· 4-7 Throttle Valve ·········································4-3 Reed Valve············································· 4-7 Carburetor Remove ·······························4-4 Fuel Pump·············································· 4-8 Auto By-Starter ······································4-4 Air Cleaner············································· 4-9 Float/Float Valve/Jet······························4-6 Throttle valve cable Vacuum tube Fuel output tube Carburetor...

  • Page 50: Maintenance Information

    This chapter Contents 4. Fuel System Maintenance Information Precautions in Operations Warning Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Care must be taken when dealing with gasoline, and always work in a well-ventilated place and strictly prohibit flame.

  • Page 51: Throttle Valve

    This chapter Contents 4. Fuel System Throttle Valve Carburetor upper part Removal Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Inspection Sealed cap Throttle valve spring...

  • Page 52: Carburetor Remove

    This chapter Contents 4. Fuel System Carburetor Remove Remove the rear side cover. Auto by-starter coupler Disconnect the auto by-starter coupler. Carburetor Fuel hose Loosen draining screw and then drain out fuel upper part inside the carburetor. Loosen carburetor upper part and remove 2 bolts carburetor upper part.
  • Page 53 This chapter Contents 4. Fuel System Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes.

  • Page 54: Float/Float Valve/Jet

    This chapter Contents 4. Fuel System Float/Float Valve/Jet Removal Remove the float from carburetor body. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as installation.

  • Page 55: Flaot Level Inspection

    This chapter Contents 4. Fuel System Float Level Inspection Measures float fuel level to have the upper end of float just contact with the float. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Fuel hose Carburetor Installation...

  • Page 56: Fuel Pump

    This chapter Contents 4. Fuel System Inspection Reed valve Reed valve stopper Check the reed valve for damage and its reed strength. Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper.

  • Page 57: Air Cleaner

    This chapter Contents 4. Fuel System Air Cleaner 1 screw Removal/Installation Remove air cleaner and rear inner fender mounting screw. Hose clamp Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner. Install in the reverse order of removal procedures. 2 bolts...
  • Page 58 This chapter Contents 4. Fuel System Notes: 4-10...

  • Page 59: Engine Removal

    Home page Contents 5. Engine Removal Maintenance Information······················ 5-2 Engine installation ······························· 5-6 Engine removal······································ 5-3 5.5~6.5kgf-m 2.4~3.0kgf-m 2.4~3.0kgf-m 5.5~6.5kgf-m 5.5~6.5kgf-m 4.5~5.5kgf-m...
  • Page 60 This chapter Contents 5. Engine Removal Maintenance Information There are parts that require removal of engine for maintenance. ● Crankcase ● Crankshaft Related bolts tightening torque for removal of engine: Engine hanger bolt 5.5~6.5kgf-m Engine hanger bracket bolt 4.5~5.5kgf-m Rear cushion upper mounting bolts 3.5~4.5kgf-m Rear cushion lower mounting bolts 2.4~3.0kgf-m...
  • Page 61 This chapter Contents 5. Engine Removal Engine removal Fuel output tube Spark plug Remove body cover. Remove the spark plug cap from the spark plug. Remove the fuel output and the vacuum tubes from fuel pump. Vacuum tube Control cable Remove the oil control cable from oil pump.
  • Page 62 This chapter Contents 5. Engine Removal Drum type rear brake Remove rear brake cable from engine rear-lower side. Remove brake cable from cable clamp. Rear brake cable Disc type rear brake Remove rear brake caliper (2 bolts) from engine rear-upper side. Remove brake hose from hose clamp.
  • Page 63 This chapter Contents 5. Engine Removal Remove two exhaust pipe connection nuts. Connection nut Remove two bolts beside fan cover and exhaust pipe. 3 bolts Support the engine and then remove cushion Rear cushion lower mounting bolt lower mounting bolt. Remove engine mounting nut and bolt.
  • Page 64 This chapter Contents 5. Engine Removal Engine Hanger Bracket Removal Remove the frame side right and left side bolts of engine hanger bracket. (1 bolt on each side) Disassembly Remove the engine hanger bracket nut and bolt. 2 bolts Disassembly engine hanger bracket A and engine hanger bracket B.

  • Page 65: Cylinder Head / Cylinder / Piston

    Home page Contents 6. Cylinder Head/Cylinder/Piston Maintenance Information ······················6-2 Cylinder Head········································· 6-3 Troubleshooting ····································6-2 Cylinder/Piston······································· 6-5 1.6~2.0kgf-m 1.1~1.7kgf-m...
  • Page 66 This chapter Contents 6. Cylinder Head/Cylinder/Piston Maintenance Information Precautions in Operation The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. Remove all washes from the interfaces of cylinder head, cylinder and crankcase.
  • Page 67 This chapter Contents 6. Cylinder Head/Cylinder/Piston Cylinder Head Fuel output tube Vacuum tube Cylinder Head Removal Removal luggage box, body covers and center cover. Remove fuel pump tubes. Fuel inlet tube 2 nuts Remove spark plug cap. Remove fuel pump bracket (2 nuts). Plug cap Remove vacuum tube and oil pump control cable from engine shield.
  • Page 68 This chapter Contents 6. Cylinder Head/Cylinder/Piston Remove engine shield. 4 bolts Cylinder Head Removal Remove spark plug. Remove the 4 cylinder head bolts and then remove the cylinder head. Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging it. Cleaning Carbon in Combustion Chamber Clean carbon deposit in which built up in combustion chamber with shown chisel.
  • Page 69 This chapter Contents 6. Cylinder Head/Cylinder/Piston Cylinder/Piston Connection nut Remove spark plug cap. Remove fan cover. Remove engine shield. Remove two connection nuts of the exhaust pipe. Remove exhaust muffle mounting bolt, and then remove the exhaust muffler. 3 bolts Cylinder Removal Remove cylinder head.
  • Page 70 This chapter Contents 6. Cylinder Head/Cylinder/Piston Check if cylinder and piston are worn or damaged, and then clean carbon deposit on exhaust opening area as the diagram shown. Caution Do not scratch both the cylinder and the piston. Use a straight edge and a feeler gauge to measure the cylinder head for warp.
  • Page 71 This chapter Contents 6. Cylinder Head/Cylinder/Piston Measure the piston pinhole ID of piston. Service limit: 12.030mm The ID of piston pinhole Measure the OD of piston pin. The OD of piston pin Service limit: 11.970 mm Piston Ring Inspection Measure the end gap of each piston ring. Service limit: 0.40 mm Caution With the piston, push each piston ring into...
  • Page 72 This chapter Contents 6. Cylinder Head/Cylinder/Piston Piston/Cylinder Installation Install the expanding ring into the groove of 2 ring. Align the ring end with the lock pin in the ring groove. Install the top ring and the 2 ring onto the ring groove respective.
  • Page 73 6. Cylinder Head/Cylinder/Piston...
  • Page 74 This chapter Contents 6. Cylinder Head/Cylinder/Piston Lubricate cylinder and piston with two-stroke engine oil. Hold the piston and then install it into cylinder. Caution To avoid to damaging the piston and the cylinder sliding surface. Lock pin 4 bolts Install the cylinder head. Tighten torque: 1.6~2.0kgf-m Connection nut Replace the exhaust pipe washer with new one...
  • Page 75 This chapter Contents 6. Cylinder Head/Cylinder/Piston Note: 6-11...

  • Page 76: A.c. Generator

    Home page Contents 7. A.C. Generator Maintenance Information ············7-2 Generator Installation·················· 7-4 Generator Removal······················7-3 3.5~4.5kgf-m...
  • Page 77 The maintenance service of A.C. generator can be carried out directly on the scooter. Please refer to Chapter 15 for the relative A.C. generator inspection. Torque value: Flywheel 3.5~4.5kgf-m Special Service Tools: Flywheel puller SYM-3110A01 Universal holder SYM-2210100 Coil resistance value for the A.C. generator Earth 50~200 0.2~0.8 0.2~0.8...
  • Page 78 10mm flanged nut Hold flywheel with universal holder. Support the flywheel and the remove the 10 mm nut on the flywheel. Special tool: Universal holder SYM-2210100 Universal holder Remove the flywheel with flywheel puller. Special tool: Flywheel puller SYM-3110A01 Flywheel puller...
  • Page 79 This chapter Contents 7. A.C. Generator Disconnect generator wire coupler and pulse coil Generator coupler coupler. Pulse coil coupler Remove the pulse coil and generator coil bolts (4 bolts), and then take out the generator assembly. Caution Care to be taken for not damaging the generator coil.
  • Page 80 Home page Contents 8. "V" Type Belt Drive System/Kick-Starter Maintenance Information ·····················8-3 Drive Belt··············································8-6 Trouble Shooting ·································8-3 Movable Driven Pulley·························8-7 Left Crankcase Cover ··························8-4 Clutch/Driven Pulley ····························8-11 Reassembly Of Kick Starter ················8-5 Installation Of The Left Crankcase Cover ·······························································8-5 5.0~6.0kgf-m 3.5~4.5kgf-m 5.5~6.5kgf-m...
  • Page 81 8. "V" Type Belt Drive System/Kick-Starter...

  • Page 82: Maintenance Information

    ID of movable driven face 33.000 34.060 ID: Inner Diameter OD: Outer diameter Torque Values: Special Service Tools Movable drive face 5.5~6.5kgf-m Clutch spring compressor SYM-2301000 Driven pulley plate 5.0~6.0kgf-m Clutch nut wrench SYM-9020200 Clutch outer 3.5~4.5kgf-m Universal holder SYM-2210100 Inner bearing puller...

  • Page 83: Left Crankcase Cover

    This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Left Crankcase Cover Left crankcase cover removal Remove rear left body side cover. Remove air cleaner (2 bolts). Remove kick-start arm (1 bolt). Remove left crankcase cover (9 bolts). 9 bolts Return spring Disassembly of Kick Starter Remove snap clip and thrust washer from left...

  • Page 84: Reassembly Of Kick Starter

    This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Reassembly of Kick Starter Kick starter spindle Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Return spring Width-tooth Driven gear Install kick-starter lever temporary.

  • Page 85: Drive Belt

    Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer. Special tool: Universal holder SYM-2210100 Caution Using special tools for tightening or loosening the nut. Universal holder Fixed rear wheel or rear brake will damage reduction gear system.
  • Page 86 Clutch/driven pulley Clutch outer Hold the clutch outer, and then tighten nut to specified torque value. Special tool: Universal holder SYM-2210100 Torque value: 3.5~4.5kgf-m Movable Drive Face Universal holder Removal Remove fan cover and fan. Remove left crankcase cover.
  • Page 87 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Removal Drive face boss Movable drive face Remove movable drive face set and drive belt from crankshaft. Crankshaft Ramp plate Remove ramp plate. Movable drive face Remove weight rollers from movable face. Weight roller Weight roller Inspection...
  • Page 88 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Check if movable drive face boss is worn or Movable drive face damage and replace it if necessary. Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit.
  • Page 89 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Install movable drive face assembly onto Drive face boss Movable drive face crankshaft. Crankshaft Drive belt Drive Face Installation Press down Press drive belt into pulley groove, and then pull the belt on to crankshaft. Universal holder Install drive face, washer and nut.

  • Page 90: Clutch/Driven Pulley

    Remove drive belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Special tool: Clutch spring compressor SYM-2301000 Clutch nut wrench SYM-9020200 Clutch spring Caution compressor Do not press the compressor too much.
  • Page 91 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Clutch weight Clutch weight Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 82.5 mm Free length Driven pulley...
  • Page 92 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Clutch Block Replacement Spring Drive plate Remove clip and washer, and then remove clutch weight and spring from drive plate. Caution Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity.
  • Page 93 This chapter Contents 8. "V" Type Belt Drive System/Kick-Starter Install snap clip and mounting plate onto lock pin. Snap clip Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clip Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 94 Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench. Special tool: Clutch spring compressor SYM-2301000 Clutch nut wrench SYM-9020200 Remove the clutch spring compressor. Torque value: 5.0~6.0kgf-m Clutch spring...
  • Page 95 8. "V" Type Belt Drive System/Kick-Starter 8-16...

  • Page 96: Final Driving Mechanism

    Home page Contents 9. Final Driving Mechanism Maintenance Information ···················· 9-2 Inspection of Final Driving Mechanism ································································9-6 Troubleshooting ·································· 9-2 Bearing Replacement ···························9-7 Disassembly of Final Driving Mechanism ······························································ 9-3 Re-Assembly of Final Driving Mechanism ································································9-8 Bearing 6004UU Oil seal 27x x x x 42x x x x 7 Bearing 6201 Bearing 6203 Bearing 6201...

  • Page 97: Maintenance Information

    Outer type bearing puller SYM-6204010 Final shaft oil seal installer SYM-9125500 Drive shaft oil seal installer SYM-9120200 Bearing driver 6201 SYM-9610001 Bearing driver 6203/6004UZ SYM-9620000 R. Crank shaft puller SYM-1130000-R L. Crank shaft install bush SYM-1130010 Extension bush SYM-1130031 (long) Extension bush...
  • Page 98 This chapter Contents 9. Final Driving Mechanism Disassembly of Final Driving Oil filling hole Mechanism Remove driven pulley Remove oil drain bolt and filling bolt. Drain gear oil out from gearbox. Oil draining hole Remove muffler and rear wheel. Rear wheel nut 7 bolts Remove gearbox cover mounting bolts from the clutch side (7 bolts).
  • Page 99 Drive shaft is pulled out with it’s bearing, then remove the bearing with bearing puller and shaft protector. Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010 Remove drive shaft oil seal and bearing from left crankcase. Oil seal...
  • Page 100 Drive shaft is pulled out with it’s bearing, then Outer bearing puller remove the bearing with bearing puller and shaft protector. Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010 Remove drive shaft oil seal and bearing from left crankcase. Oil seal...

  • Page 101: Inspection Of Final Driving Mechanism

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

  • Page 102: Bearing Replacement

    Bearing Replacement Inner bearing puller Remove gearbox bearing from left crankcase and gearbox cover using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Caution Never install used bearings. Once bearing removed, it has to be replaced with new one.

  • Page 103: Re-Assembly Of Final Driving Mechanism

    Install drive shaft. With the special service tools to install drive shaft by through the bearing. Special tool: R. Crank shaft puller SYM-1130000-R L. Crank shaft install bush SYM-1130010 Extension bush SYM-1130031 (long) Extension bush SYM-1130032 (short) R. Crank shaft puller Apply with grease onto drive shaft oil seal.
  • Page 104 9. Final Driving Mechanism...

  • Page 105: Crankcase / Crankshaft

    Home page Contents 10. Crankcase/Crankshaft Maintenance Information ·····················10-2 Crankshaft Removal ···························· 10-3 Troubleshooting ···································10-2 Crankshaft Inspection ························· 10-4 Crankcase Disassembly ······················10-3 Crankcase Installation························· 10-5 1.0~1.5kgf-m Apply liquid gasket 10-1...

  • Page 106: Maintenance Information

    R. Crank shaft puller SYM-1130000-R R. Crank shaft install bush SYM-1130020 L. Crank shaft puller SYM-1130000-L L. Crank shaft install bush SYM-1130010 Extension bush SYM-1130031 (long) 20x31x7 Oil seal driver SYM-9120200 Bearing driver6204 SYM-9110400 Torque Values: Crankcase bolt 1.0~1.5kgf-m Troubleshooting Engine noise 1.

  • Page 107: Crankcase Disassembly

    Install the crankcase puller onto the right disassemble tool crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase. Special Tools: Crankcase disassemble tool SYM-1120100-G5 Right crankcase Crankcase Crankshaft Removal disassemble tool As the diagram show with 2 special bolts to install the specified service tool onto the left crankcase.

  • Page 108: Crankshaft Inspection

    This chapter Contents 10. Crankcase/Crankshaft Crankshaft Inspection Measure the clearance of connecting rod big end. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.

  • Page 109: Crankcase Installation

    Special Tools: L. Crank shaft install bush L. Crank shaft puller SYM-1130000-L L. Crank shaft install bush SYM-1130010 Extension bush SYM-1130031 (long) Apply liquid gasket Apply liquid gasket and dowel pin onto the interface of left crankcase. Dowel pin 10-5...
  • Page 110 Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil. Special Tools: R. Crank shaft puller SYM-1130000-R R. Crank shaft install bush SYM-1130020 Install the bolts and tighten them. Torque value: 1.0~1.5kgf-m 7 Bolts R.

  • Page 111: Body Cover

    Home page Contents 11. Body Cover Body Overview·····································11-1 Front under Spoiler····························· 11-9 Maintenance Information ····················11-2 Floor Panel··········································· 11-10 Steering Handle Cover ························11-3 Front Inner Box ··································· 11-11 Front Cover ··········································11-5 Front Fender········································ 11-12 Luggage Box········································11-6 Rear Fender ········································· 11-12 Side Covers··········································11-7 Rear Inner Fender ·······························...
  • Page 112 This chapter Contents 11. Body Cover Maintenance Information Body covers disassemble sequence: Handle Front Cover Front Cover Luggage Box / Seat Handle upper Cover Front Wheel Floor Panel Center Cover Handlebar Rear Cover Front Fender Front Inner Cover Left / Right Side Cover Front Inner Spoiler And Left / Right Side Cover Left / Right Rear Side Cover...
  • Page 113 This chapter Contents 11. Body Cover Steering Handle Cover 4 screws Removal Remove 4 screws from the handle rear cover upper. Remove 2 screws from the handle rear cover under. Each side 1 screws 3 screws Remove 3 screws from the handle front cover under.
  • Page 114 This chapter Contents 11. Body Cover Remove 1 screw from the handle rear cover inner. 1 screw Remove handle upper cover. Remove 1 screw from rear by handle rear cover. 1 screw Remove 2 inner screws. Disconnect each switch connectors. 2 Screws Remove speedometer electric cord coupler.
  • Page 115 This chapter Contents 11. Body Cover Front Cover Removal Remove 10 screws from the front inner box and front cover. Each side 5 screws Remove 1 screw from the front cover. Screws Headlight coupler Remove electric cord coupler from the headlight. Remove the front cover.
  • Page 116 This chapter Contents 11. Body Cover Luggage Box Removal Lift up seat cushion. Remove oil tank cap and oil guide rubber. 2 nuts 1 bolt Remove luggage box mounting nuts and bolt (2 nuts & 1 bolt). Hold the luggage box in both front and rear sides by two hands, and then lift up the box to remove it.
  • Page 117 This chapter Contents 11. Body Cover Side Covers Removal Remove 2 screws under side cover front end. 2 screws Remove 2 screws, and then slide the side cover backward so that their hooks are out of slots. Take out the side cover end part and then remove the cover.
  • Page 118 This chapter Contents 11. Body Cover Center Cover Removal Remove 2 screws from center cover. Slide the center cover frontward so that their hooks are out of slots. Take out the center cover end part and then remove the cover. Installation Install in reverse order of removal procedures.
  • Page 119 This chapter Contents 11. Body Cover Front under Spoiler Removal Remove front cover and right / left side covers. Remove front wheel and front fender. Remove 6 screws from the front inner box. Each side 3 screws Remove 2 screws from the front upper part of the front spoiler and the front inner box.
  • Page 120 This chapter Contents 11. Body Cover Floor Panel Removal Remove luggage box, rear carrier, center cover, right & left side cover and body covers. Remove 4 rubber caps. 4 rubber caps Remove the floor panel. (4 bolts) 4 bolts Disassembly Remove 2 screws from right / left center cover and floor panel.
  • Page 121 This chapter Contents 11. Body Cover Front Inner Box Removal Remove the front cover. Remove luggage box, rear carrier, center cover, right & left side cover, body covers, and floor panel. Remove main switch cover. Main switch cover Hook & 1 bolt Remove 1 bolt and hook.
  • Page 122 This chapter Contents 11. Body Cover Front Fender 1 Bolt Speedometer cable Removal Ramoval 1 bolt from left front cushion, and then remove speedometer cable clamp and front brake hose clamp. Front brake hose Ramoval 4 screws form front fender right and left side.
  • Page 123 This chapter Contents 11. Body Cover Rear Inner Fender Removal Ramoval luggage box, rear carrier, body covers and rear fender. Ramoval 2 screws from rear inner fender upper. Each side 1 screw Pull out rear fender front hanger with frame, and then removal rear inner fender.
  • Page 124 This chapter Contents 11. Body Cover Under Cover Removal Remove right and left side cover. Remove 1 bolt and 1 nut from the under cover right side. 1 nut 1 bolt Remove 1 bolt and 1 nut from the under cover left side, and then remove under cover.

  • Page 125: Disc Brake System

    Home page Contents 12. Brake System Disc Brake System ·······························12-1 Disc Brake - Caliper····························· 12-8 Rear Drum Brake System·····················12-2 Brake pad replacement ······················· 12-8 Maintenance Information ·····················12-3 Brake Disc ············································ 12-10 Troubleshooting ···································12-5 Disc Brake - Master Cylinder ·············· 12-10 Hydraulic Disc Brake····························12-6 Rear Drum Brake··································...

  • Page 126: Rear Drum Brake System

    This chapter Contents 12. Brake System Rear Drum Brake System 10.0~12.0kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m 12-2...

  • Page 127: Maintenance Information

    This chapter Contents 12. Brake System Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.
  • Page 128 12. Brake System 12-4...

  • Page 129: Troubleshooting

    This chapter Contents 12. Brake System Troubleshooting Disc Brake Soft brake lever Hard operation of brake Tight brake lever 1. Air inside the hydraulic 1. Dirty brake lining/disc system 2. Poor wheel alignment 1. Blocked brake system 2. Hydraulic system leaking 3.

  • Page 130: Hydraulic Disc Brake

    This chapter Contents 12. Brake System Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir.

  • Page 131: Disc Brake -Air Bleed

    This chapter Contents 12. Brake System Disc Brake -Air Bleed Drain valve Air bubble Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. Caution Do not release the brake lever before the drain valve is closed.

  • Page 132: Disc Brake - Caliper

    This chapter Contents 12. Brake System Disc Brake - Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the Caliper bolt brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper.
  • Page 133 This chapter Contents 12. Brake System Install the new brake pads onto brake caliper. Locking spring Install the brake pad guide pin bolts. Install the brake caliper and tighten the mounting bolts. Torque: 3.3~3.7kgf-m Tighten the lining guide pin bolts. Torque: 1.5~2.0kgf-m Rear brake Loosen the 1 lining guide pin bolt.

  • Page 134: Brake Disc

    This chapter Contents 12. Brake System Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: Front brake disc 3.5mm Rear brake disc...
  • Page 135 This chapter Contents 12. Brake System Install the rubber pad into groove properly. Remove the rubber pad. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary.
  • Page 136 12. Brake System Piston Clip Rubber pad Piston Spring Micrometer Master cylinder Rubber Sub-cup bush Cylinder gauge Cir clip Piston Sub-cup Spring Master cylinder Master cylinder 12-12...
  • Page 137 This chapter Contents 12. Brake System Place the master cylinder onto handlebar, and install the bolts. 2 bolts Install the brake lever, and connect leads to brake Master cylinder light switch. Brake hose Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified Washers torque value.

  • Page 138: Rear Drum Brake

    This chapter Contents 12. Brake System Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
  • Page 139 This chapter Contents 12. Brake System Installation Bolt Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin.
  • Page 140 This chapter Contents 12. Brake System Notes: 12-16...
  • Page 141 Home page Contents 13. Steering / Front Wheel / Front Cushion Maintenance Information ·····················13-2 Front Wheel ·········································· 13-5 Troubleshooting ···································13-2 Front Cushion ······································ 13-9 Steering Handle ····································13-3 Steering Stem······································· 13-10 1.0~1.4kgf-m 4.0~4.5kgf-m 1.0~1.2kgf-m 0.2~0.3kgf-m 2.4~3.0kgf-m 3.1~3.5kgf-m 5.0~7.0kgf-m 13-1...

  • Page 142: Maintenance Information

    3.1~3.5kgf-m Steering stem mounting nut 1.0~1.2kgf-m Top cone race 0.2~0.3kgf-m Special Tools Inner bearing puller SYM-6204022 Bearing driver 6201 Troubleshooting Hard To Steer The Front Wheel Wobbling The steering shaft bolt is too tight. The rim is bent. The steering shaft bearing are damaged...

  • Page 143: Steering Handle

    This chapter Contents 13. Steering / Front Wheel / Front Cushion Steering Handle 2 bolts Removal Remove handle cover and front cover (refer to chapter 11). Remove front brake master cylinder (disc brake) after 2 bolts removed. Remove throttle grip and right handle switch after right handle switch mounting screws removed.
  • Page 144 This chapter Contents 13. Steering / Front Wheel / Front Cushion Remove handle mounting bolt and nut, and then remove the handle. Installation Installs handle and align with bolt hole. Install bolt and nut and then tighten it. Torque value: 4.0~4.5kgf-m Handle mounting nut and bolt Lock pin Apply with grease onto throttle cable and the...

  • Page 145: Front Wheel

    This chapter Contents 13. Steering / Front Wheel / Front Cushion Front Wheel Removal Support body bottom and lift front wheel free of ground with a stand. Remove speedometer cable from speedometer gear box (1 screw). Speedometer cable Remove front wheel axle nut, and then pull out the axle and remove the wheel.
  • Page 146 Bearings replacement Remove 3 bolts and brake disc. Remove left side dust seal, bearing and dist. collar. Special tools Inner bearing puller (SYM-6204020) Dust seal Dist. collar Installation Fill out the block of bearing by grease. Drive the left bearing, dust seal into wheel rim and Bearing install the dist.
  • Page 147 13. Steering / Front Wheel / Front Cushion 13-7...
  • Page 148 This chapter Contents 13. Steering / Front Wheel / Front Cushion Install the brake disc and then tighten the bolts 3 bolts (disc brake). Torque value: 4.0~4.5kgf-m Lubricate the speedometer gear with grease and install the gear into the wheel hub. Align the flange part on the speedometer gear with the slot of wheel hub.

  • Page 149: Front Cushion

    This chapter Contents 13. Steering / Front Wheel / Front Cushion Front Cushion Hose clamp Removal Remove front cover, front fender and front wheel. Remove the caliper mounting bolt and the caliper. Take out the hose from hose clamp. 2 bolts Brake caliper 4 bolts Remove the front cushion upper bolts and the...

  • Page 150: Steering Stem

    This chapter Contents 13. Steering / Front Wheel / Front Cushion Steering Stem Steering stem Removal mounting nut Remove steering handle, front wheel and front cushion. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing.
  • Page 151 This chapter Contents 13. Steering / Front Wheel / Front Cushion Install the steering stem mounting nut and tighten Steering stem mounting nut the nut by means of holding the top cone race body. Torque value: 1.0~1.2kgf-m Install in reverse order of removal procedures. Top cone race 13-11...
  • Page 152 Home page Contents 14. Rear Wheel / Rear Cushion Maintenance Information ····················· 14-2 Rear Wheel ············································14-3 Troubleshooting ··································· 14-2 Rear Cushion·········································14-5 10.0~12.0kgf-m 4.0~4.5kgf-m 10.0~12.0kgf-m 14-1...
  • Page 153 This chapter Contents 14. Rear Wheel / Rear Cushion Maintenance Information Specification Item Standard value (mm) Limit (mm) Rear wheel rim run out — 2.0 (0.08 in) Torque Value Rear cushion upper mounting bolt 3.5~4.5kgf-m Rear cushion lower mounting bolt 2.4~3.0kgf-m Rear wheel nut 10.0~12.0kgf-m...
  • Page 154 This chapter Contents 14. Rear Wheel / Rear Cushion Rear Wheel Connection nuts Remove Remove exhaust pipe nut. (2 connection nuts) Bolts Remove exhaust muffler bolt (3 bolts), then remove the muffler. Shaft nut Remove rear wheel shaft nut and then remove the rear wheel.
  • Page 155 This chapter Contents 14. Rear Wheel / Rear Cushion Brake disc removal / install 4 bolts Remove 4 bolts, and then remove brake disc. Check item refer chapter 12. Install by reverse order of removal procedures. Shaft nut Installation Install the rear wheel and tighten the nut. Tighten torque: 10.0~12.0kgf-m 3 bolts 2 nuts...
  • Page 156 This chapter Contents 14. Rear Wheel / Rear Cushion Upper mounting bolt Rear Cushion Removal Remove luggage box. Remove air cleaner. Remove rear cushion upper & lower bolts. Remove rear cushion. Installation Install the rear cushion. Tighten the upper & lower mounting bolts to specified torque.
  • Page 157 This chapter Contents 14. Rear Wheel / Rear Cushion Note: 14-6...

  • Page 158: Electrical Equipment

    Home page Contents 15. Electrical Equipment Maintenance Information ···················· 15-2 Starting System ································· 15-錯 誤! 尚未定義書籤。 Troubleshooting ·································· 15-3 Oil Level Switch ································· 15-13 Battery ·················································· 15-4 Fuel Unit ············································· 15-15 Charging System ································· 15-6 Switch/Horn········································ 15-16 Ignition System···································· 15-錯 誤! 尚未定義書籤。...

  • Page 159: Maintenance Information

    This chapter Contents 15. Electrical Equipment Maintenance Information Precautions in Operation When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.

  • Page 160: Troubleshooting

    This chapter Contents 15. Electrical Equipment Troubleshooting Charging system does not operate No voltage properly Battery discharged The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor AC.G.

  • Page 161: Battery

    This chapter Contents 15. Electrical Equipment Battery Positive terminal Negative terminal Battery Removal/Installation Turn off main switch. Open seat, remove 2 screws and then open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal.
  • Page 162 This chapter Contents 15. Electrical Equipment Charging Voltage Inspection Connect a tachometer. Digital voltmeter Turn on the headlight to high beam and start the engine. Ammeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Specified Charging Current: 1.2 A / 5000 rpm Control Charging Voltage: 14.0~15.0 V / 5000 Caution...

  • Page 163: Charging System

    This chapter Contents 15. Electrical Equipment Charging System Fuse 15A Black Green Main switch REG. REC. Yellow Pink Fuse 15A Battery Auto by- starter AC. Generator Regulator rectifier Inspection Regulator rectifier coupler Check the each pins of coupler on the regulator rectifier.
  • Page 164 This chapter Contents 15. Electrical Equipment Regulator rectifier Inspection Black Green ∞ ∞ ∞ ∞ Pink 2.8M 522.1 1.5M 1.7M 2.7M 522.1 1.5M 1.7M 1.5M 29.2M 29.2M 1.6M 26.3M 26.3M 2.7M If the resistance values are abnormal among the pins, replace the regulator rectifier. Yellow Caution If the probe is touched by finger, then the...

  • Page 165: Ignition System

    This chapter Contents 15. Electrical Equipment Ignition System DC. CDI. Unit To tachometer Main switch Fuse 15A Ignition Coil AC. Generator Pulse Generator ENG. Stop switch Battery Ignition Coil Inspection Remove lower side cover. Remove ignition coil wire pins. Ignition Coil Measure the primary coil resistance.
  • Page 166 This chapter Contents 15. Electrical Equipment Remove the plug cap, and measure its negative (-) terminal for the secondary coil resistance. Resistance : 3.1~3.2KΩ Ω Ω Ω (A)→ → → → (C) Electrical System Circuit Inspection Pulse Generator Remove luggage box. Disconnect pulse generator coil coupler.

  • Page 167: Starting System

    This chapter Contents 15. Electrical Equipment Starting System Brake light Main switch Stop switch Starter relay Start switch Starter motor Battery Starter Relay Inspection Starter relay Remove battery box and then remove starter relay. Connect both the green/yellow (-) and the Starter relay yellow/red (+) pins to battery posts directly.
  • Page 168 This chapter Contents 15. Electrical Equipment Starter Motor Pinion Removal/Installation Starter motor pinion holder Remove left crankcase cover and drive face. Remove starter motor pinion holder, and then remove starter motor pinion. Install the starter motor pinion in reverse order of removal.
  • Page 169 This chapter Contents 15. Electrical Equipment Starter Motor Removal/Disassembly Starter motor Remove body cover. Remove bolt and oil pump control cable. Disconnect starter motor harness coupler. Remove 2 bolts for separation starter motor and gasket. Remove 2 bolts for disassembly the starter motor. 2 bolts Armature Inspection Check the armature for discoloration or other...

  • Page 170: Oil Level Switch

    This chapter Contents 15. Electrical Equipment Oil Level Switch Troubleshooting Fuse Main switch If the oil level in oil tank is in specified level, but the oil level indicator still goes on. 1. Remove luggage box. 2. Disconnect oil level switch wire, and turn the main switch to ON position.
  • Page 171 This chapter Contents 15. Electrical Equipment Carburetor Heater Power filter Thermo switch Main switch Fuse 15A To REG. REC. Carburetor heater Battery AC. Generator Removal/Installation Wire pins Remove luggage box, rear carrier and body cover. Remove carburetor heater wire pins. Remove carburetor heater.

  • Page 172: Fuel Unit

    This chapter Contents 15. Electrical Equipment Fuel Unit 2 nuts Removal/Installation Remove 4 bolts and floor panel. Remove floor plate (2 nuts). Remove fuel tank heat guard. Heat guard Disconnect fuel unit coupler from front wheel side. Turns the fuel unit retain plate in counter-clockwise direction and then remove the fuel unit retain plate.

  • Page 173: Switch/Horn

    This chapter Contents 15. Electrical Equipment Switch / Horn Remove handle covers and front cover. Check continuity on each switch. Main switch cap The connected circles with a line are that they should be in continuity. Main Switch Wire color Black LOCK Replacement of main switch...
  • Page 174 This chapter Contents 15. Electrical Equipment Left handle switch Passing switch Remove the front cover. Disconnect the coupler of left handle switch. Check the continuity between two points as High / low beam indicated in the table below switch Turn signal light switch Wire color Orange Gray...
  • Page 175 This chapter Contents 15. Electrical Equipment Lights Tail & stop light Stop switch Position light Meter illuming light Hi beam indicate light Headlight (Hi-beam) Headlight beam switch Main switch Headlight (Lo-beam) Right winker indicate light Winker relay Right winker light Winker switch Fuse 15A Left winker light...
  • Page 176 This chapter Contents 15. Electrical Equipment Bulb Replacement Position light Headlight/position light Remove front cover. Headlight Remove the headlight bulb set coupler. Headlight coupler Turn the set in counter-clockwise direction, and then remove the bulb. Replace with new bulb if necessary. Specification: Headlight bulb 12V 35W (H8)
  • Page 177 This chapter Contents 15. Electrical Equipment Front winker light Remove 9 screws and then remove handle front cover (refer to chapter 11). Turn the front winker light set in counter-clockwise direction, and then remove the front winker light bulb seat. Push and turn the bulb in counter-clockwise direction, and then remove the bulb.
  • Page 178 This chapter Contents 15. Electrical Equipment Tail light / Brake light Taillight coupler Remove taillight coupler. Remove body cover, rear carrier, rear fender and taillight assembly. (Refer chapter 11) 1 screw Remove 1 screw from taillight upper side. Remove 4 screws and then remove taillight 4 Screws assembly.
  • Page 179 This chapter Contents 15. Electrical Equipment Meter indicator light Rubbers Remove steering handle front cover. Remove winker and hi-beam indicator light rubber. Winker indicator light bulb Turn the bulb seat in counter-clockwise direction and then remove, and then take out the bulb seat from the bottom of instrument panel.

  • Page 180: Electrical Diagram

    Home page Contents 16. Electrical Diagram 16-1...
  • Page 181 Home page Contents 16. Electrical Diagram Notes: 16-2...

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