Sym GTS 250 Manuals

Sym GTS 250 Manuals

Manuals and User Guides for Sym GTS 250. We have 4 Sym GTS 250 manuals available for free PDF download: Service Manual, User Manual

Sym GTS 250 Service Manual

Sym GTS 250 Service Manual (248 pages)

Brand: Sym | Category: Scooter | Size: 30.43 MB

Table of Contents

2. Maintenance Information

20
- Service Manual
  1
- Service Precautions
  6
- Specifications
  12
- Torque Values
  13
- Lubrication Points
  19
- Table of Contents
  20
- Maintenance Information
  20
- Periodical Maintenance Schedule
  21
- Engine Oil
  22
- Engine Oil Strainer Clean
  22
- Gear Oil
  23
- Fuel Lines / Cable
  23
- Air Cleaner
  24
- P.C.V. System
  25
- Valve Clearance
  25
- Carburetor Idle Speed Adjustment
  26
- Ignition System
  27
- Spark Plug
  27
- Cylinder Compression Pressure
  28
- Drive Belt
  28
- Steering Handle Top Bearing
  29
- Cushion
  29
- Disk Brake System
  30
- Brake Light Switch/Starting Inhibitor
  32
- Switch
  32
- Headlight Beam Distance
  32
- Wheel / Tire
  32
- Battery
  33
- Nuts, Bolts Tightness
  33
3. Lubrication System

38
- Lubrication System
  38
- Precautions in Operation
  39
- Troubleshooting
  39
- Engine Oil
  40
- Engine Oil Strainer Clean
  40
- Oil Pump
  41
- Gear Oil
  44
4. Fuel System

46
- Fuel System
  46
- Precautions in Operation
  47
  - Fuel System
    47
- Trouble Diagnosis
  48
- Carburetor Remove / Install
  49
- Vacuum Chamber
  49
- Air Cut-Off Valve
  51
- Automatic By-Starter
  52
- Float Chamber
  53
- Adjustment of Idle Speed
  55
- Fuel Tank
  56
- Fuel Pump
  58
- Air Cleaner
  59
5. Removal & Installation of Engine

60
- Engine Removal
  60
- Engine Removal
  61
- Engine Hanger
  65
- Rear Fork
  66
- Removal of Engine Bush
  68
- Installation of Engine
  69
6. Cylinder Head / Valve

70
- Cylinder Head / Valve
  70
- Precautions in Operation
  71
- Troubleshooting
  72
- Cylinder Head Removal
  73
- Cylinder Head Disassembly
  75
- Cylinder Head Inspection
  77
- Valve Stem Replacement
  79
- Valve Seat Inspection and Service
  80
- Cylinder Head Reassembly
  82
- Cylinder Head Installation
  83
- Valve Clearance Adjustment
  85
7. Cylinder / Piston

86
- Cylinder / Piston
  86
- Precautions in Operation
  87
- Trouble Diagnosis
  87
- Cylinder and Piston Removal
  88
- Piston Ring Installation
  91
- Cylinder Installation
  92
- Piston Installation
  92
8. V-Belt Driving System

94
- Mechanism Diagram
  94
- Maintenance Description
  95
- Trouble Diagnosis
  95
- Left Crankcase Cover
  96
- Drive Belt
  98
- Drive Face
  100
- Clutch Outer/Driven Pulley
  103
9. Final Driving Mechanism

108
- Final Driving Mechanism
  108
- Precautions in Operation
  109
- Trouble Diagnosis
  109
- Disassembly of Final Driving Mechanism
  110
- Inspection of Final Driving Mechanism
  111
- Bearing Replacement
  112
- Re-Assembly of Final Driving Mechanism
  115
10. Alternator / Starting Clutch

116
- Alternator
  116
- Precautions in Operation
  117
- Right Crankcase Cover Removal
  118
- AC.G. Set Removal
  119
- Right Cover Bearing
  119
- Flywheel Removal
  120
- Starting Clutch
  121
- AC.G. Flywheel Installation
  123
- AC.G. Set Installation
  124
- Right Crankcase Cover Installation
  124
11. Crankcase / Crank

126
- General Information
  127
- Trouble Diagnosis
  127
- Disassembly of Crankcase
  128
- Crankshaft Inspection
  129
- Assembly of Crankcase
  131
12. Cooling System

134
- Cooling System
  134
- General Information
  135
- Trouble Diagnosis
  135
- Trouble Diagnosis for Cooling System
  136
- Change of Coolant
  138
- Radiator
  139
- Water Pump
  141
- Thermostat
  145
  - Body Cover
    145
13. Body Cover

148
- Body Cover
  148
- Maintenance
  149
- Handle Cover
  150
- Front Cover
  151
- Meter Panel
  153
- Inner Box
  154
- Side Cover
  156
- Front under Spoiler
  157
- Rear Carrier
  157
- Luggage Box
  158
- Rear Body Cover
  159
- Floor Panel
  160
- Front Fender
  160
- Rear Fender
  161
14. Brake System

162
- Brake System
  162
- Maintenance Description
  163
- Trouble Diagnosis
  164
- Disk Brake System Inspection
  165
- Adding Brake Fluid
  166
- Brake Fluid Replacement / Air-Bleed
  167
- Rear Brake Caliper
  169
- Brake Disk
  170
- Master Cylinder
  170
15. Steering / Front Wheel / Front Cushion

174
- Operational Precautions
  175
- Trouble Diagnosis
  175
- Steering Handle
  176
- Front Wheel
  178
- Front Cushion
  181
- Steering Stem
  182
16. Rear Wheel / Rear Fork / Rear Cushion

184
- Operational Precaution
  185
- Trouble Diagnosis
  185
- Muffler
  186
- Rear Wheel
  186
- Rear Fork
  188
- Rear Cushion
  189
17. Electrical System

190
- Electrical System
  190
- Maintenance Data
  191
- Technical Specification
  191
- Trouble Diagnosis
  192
  - Charging System
    195
- Starting System
  200
- Meters
  202
- Light / Bulb
  204
- Switch / Horn
  208
- Fuel Unit
  210
- Cooling Fan Thermo Switch
  211
- Thermo Sensor
  212
- Water Temperature Meter
  212
  - Electrical Diagram
    214
  - Roll over Sensor
    231
  - Fuel Injector
    235

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Sym GTS 250 Service Manual

Sym GTS 250 Service Manual (227 pages)

Scooter

Brand: Sym | Category: Scooter | Size: 7.11 MB

Table of Contents

1. General Information

6
- Service Manual
  1
- Table of Contents
  6
- Symbols and Marks
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  15
- Troubles Diagnosis
  17
- Lubrication Points
  21
2. Maintenance Information

22
- Maintenance Information
  22
- Periodical Maintenance Schedule
  23
- Engine Oil
  24
- Engine Oil Strainer Clean
  24
- Fuel Lines / Cable
  25
- Gear Oil
  25
- Air Cleaner
  26
- P.C.V. System
  27
- Valve Clearance
  27
- Ignition System
  29
- Spark Plug
  29
- Cylinder Compression Pressure
  30
- Drive Belt
  30
- Cushion
  31
- Steering Handle Top Bearing
  31
- Disk Brake System
  32
- Brake Light Switch/Starting Inhibitor
  34
- Headlight Beam Distance
  34
- Switch
  34
- Wheel / Tire
  34
- Battery
  35
- Nuts, Bolts Tightness
  35
- Special Tools List
  36
  - Lubrication System
    40
  - Oil Pump
    43
4. Fuel System

48
- Fuel System
  48
- Fuel System
  49
- Carburetor Remove / Install
  51
- Vacuum Chamber
  51
- Air Cut-Off Valve
  53
- Automatic By-Starter
  54
- Float Chamber
  55
- Adjustment of Idle Speed
  57
- Fuel Tank
  58
- Fuel Pump
  60
- Air Cleaner
  61
5. Removal & Installation of Engine

62
- Engine Removal
  62
- Engine Removal
  63
- Engine Hanger
  67
- Rear Fork
  68
  - Removal of Engine Bush
    70
  - Installation of Engine
    71
6. Cylinder Head / Valve

72
- Cylinder Head / Valve
  72
- Precautions in Operation
  73
- Troubleshooting
  74
- Cylinder Head Removal
  75
- Cylinder Head Disassembly
  77
- Cylinder Head Inspection
  79
- Valve Stem Replacement
  81
- Valve Seat Inspection and Service
  82
- Cylinder Head Installation
  85
- Valve Clearance Adjustment
  87
7. Cylinder / Piston

88
- Cylinder / Piston
  88
- Precautions in Operation
  89
- Trouble Diagnosis
  89
- Cylinder and Piston Removal
  90
- Piston Ring Installation
  93
  - Piston Installation
    94
  - Cylinder Installation
    94
8. V-Belt Driving System

96
- Maintenance Description
  97
- Trouble Diagnosis
  97
- Left Crankcase Cover
  98
- Drive Belt
  100
  - Drive Face
    102
  - Clutch Outer/Driven Pulley
    105
9. Final Driving Mechanism

110
- Final Driving Mechanism
  110
- Precautions in Operation
  111
- Trouble Diagnosis
  111
- Inspection of Final Driving Mechanism
  113
  - Bearing Replacement
    114
  - Re-Assembly of Final Driving Mechanism
    117
10. Alternator / Starting Clutch

118
- Alternator
  118
- Precautions in Operation
  119
- Right Crankcase Cover Removal
  120
- AC.G. Set Removal
  121
- Right Cover Bearing
  121
- Flywheel Removal
  122
- Starting Clutch
  123
- AC.G. Flywheel Installation
  125
- AC.G. Set Installation
  126
- Right Crankcase Cover Installation
  126
11. Crankcase / Crank

128
- General Information
  129
- Trouble Diagnosis
  129
- Disassembly of Crankcase
  130
- Crankshaft Inspection
  131
- Assembly of Crankcase
  133
12. Cooling System

136
- Cooling System
  136
- General Information
  137
- Trouble Diagnosis
  137
- Trouble Diagnosis for Cooling System
  138
- Change of Coolant
  140
  - Radiator
    141
  - Water Pump
    143
  - Thermostat
    147
  - Body Cover
    147
13. Body Cover

150
- Mechanism Diagram
  150
  - Body Cover
    150
- Front under Spoiler
  151
- Maintenance
  151
- Rear Carrier
  151
  - Front Cover
    153
  - Inner Box
    156
  - Side Cover
    158
- Luggage Box
  160
  - Rear Body Cover
    161
- Floor Panel
  161
  - Front Fender
    162
  - Rear Fender
    163
14. Brake System

164
- Brake System
  164
- Maintenance Description
  165
- Trouble Diagnosis
  166
- Disk Brake System Inspection
  167
- Adding Brake Fluid
  168
- Brake Fluid Replacement / Air-Bleed
  169
- Front Brake Caliper
  170
- Rear Brake Caliper
  171
- Brake Disk
  172
- Master Cylinder
  172
15. Steering / Front Wheel / Front Cushion

176
- Operational Precautions
  177
- Steering Handle
  177
- Trouble Diagnosis
  177
- Front Wheel
  180
  - Front Cushion
    183
  - Steering Stem
    184
16. Rear Wheel / Rear Fork / Rear Cushion

186
- Operational Precaution
  187
- Trouble Diagnosis
  187
- Muffler
  188
- Rear Wheel
  188
- Rear Fork
  190
- Rear Cushion
  191
17. Electrical System

192
- Mechanism Diagram
  192
- Maintenance Data
  193
- Technical Specification
  193
- Trouble Diagnosis
  194
  - 17. Electrical System
    196
  - Charging System
    197
  - Starting System
    202
  - Meters
    204
  - Meter Circuit Diagram
    204
  - Light / Bulb
    206
  - Switch / Horn
    210
- Fuel Unit
  212
- Cooling Fan Thermo Switch
  213
- Thermo Sensor
  214
- Water Temperature Meter
  214
  - Emission Control System
    216
  - Control System
    217
  - Control System
    218
  - Catalytic Converting System (CATA)
    219
  - Secondary Air Introduction System
    220
  - Positive Crankcase Ventilation System
    223
  - Inspection Items
    224
  - Countermeasure for Emission Pollutants
    225
  - Electrical Diagram
    226

Sym GTS 250 Service Manual

Sym GTS 250 Service Manual (217 pages)

LM25W Series

Brand: Sym | Category: Scooter | Size: 6.17 MB

Table of Contents

1. General Information

6
- Service Manual
  1
- Table of Contents
  6
- Symbols and Marks
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  15
- Troubles Diagnosis
  17
- Lubrication Points
  21
2. Maintenance Information

22
- Maintenance Information
  22
- Periodical Maintenance Schedule
  23
- Engine Oil
  24
- Engine Oil Strainer Clean
  24
- Fuel Lines / Cable
  25
- Gear Oil
  25
  - Gear Oil Change
    25
- Air Cleaner
  26
- P.C.V. System
  27
- Valve Clearance
  27
- Ignition System
  29
- Spark Plug
  29
- Cylinder Compression Pressure
  30
- Drive Belt
  30
- Cushion
  31
- Steering Handle Top Bearing
  31
- Disk Brake System
  32
- Brake Light Switch/Starting Inhibitor
  34
- Headlight Beam Distance
  34
- Switch
  34
- Wheel / Tire
  34
- Battery
  35
- Nuts, Bolts Tightness
  35
- Special Tools List
  36
  - Lubrication System
    40
  - Oil Pump
    43
4. Fuel System

48
- Fuel System
  48
- Fuel System
  49
- Carburetor Remove / Install
  51
- Vacuum Chamber
  51
- Air Cut-Off Valve
  53
- Automatic By-Starter
  54
- Float Chamber
  55
- Adjustment of Idle Speed
  57
- Fuel Tank
  58
- Fuel Pump
  60
- Air Cleaner
  61
5. Removal & Installation of Engine

62
- Engine Removal
  62
- Engine Removal
  63
- Engine Hanger
  67
- Rear Fork
  68
  - Removal of Engine Bush
    70
  - Installation of Engine
    71
6. Cylinder Head / Valve

72
- Cylinder Head / Valve
  72
- Precautions in Operation
  73
- Troubleshooting
  74
- Cylinder Head Removal
  75
- Cylinder Head Disassembly
  77
- Cylinder Head Inspection
  79
- Valve Stem Replacement
  81
- Valve Seat Inspection and Service
  82
- Cylinder Head Reassembly
  84
- Cylinder Head Installation
  85
- Valve Clearance Adjustment
  87
7. Cylinder / Piston

88
- Cylinder / Piston
  88
- Precautions in Operation
  89
- Trouble Diagnosis
  89
- Cylinder and Piston Removal
  90
- Piston Ring Installation
  93
  - Piston Installation
    94
  - Cylinder Installation
    94
8. V-Belt Driving System

96
- Maintenance Description
  97
- Trouble Diagnosis
  97
- Left Crankcase Cover
  98
- Drive Belt
  100
  - Drive Face
    102
  - Clutch Outer/Driven Pulley
    105
9. Final Driving Mechanism

110
- Final Driving Mechanism
  110
- Precautions in Operation
  111
- Trouble Diagnosis
  111
- Inspection of Final Driving Mechanism
  113
  - Bearing Replacement
    114
  - Re-Assembly of Final Driving Mechanism
    117
10. Alternator / Starting Clutch

118
- Alternator
  118
- Precautions in Operation
  119
- Right Crankcase Cover Removal
  120
- AC.G. Set Removal
  121
- Right Cover Bearing
  121
- Flywheel Removal
  122
- Starting Clutch
  123
- AC.G. Flywheel Installation
  125
- AC.G. Set Installation
  126
- Right Crankcase Cover Installation
  126
11. Crankcase / Crank

128
- General Information
  129
- Trouble Diagnosis
  129
- Disassembly of Crankcase
  130
- Crankshaft Inspection
  131
- Assembly of Crankcase
  133
12. Cooling System

136
- Cooling System
  136
- General Information
  137
- Trouble Diagnosis
  137
- Trouble Diagnosis for Cooling System
  138
- Change of Coolant
  140
  - Radiator
    141
  - Water Pump
    143
  - Thermostat
    147
  - Body Cover
    147
13. Body Cover

150
- Mechanism Diagram
  150
  - Body Cover
    150
- Front under Spoiler
  151
- Maintenance
  151
- Rear Carrier
  151
  - Front Cover
    153
  - Inner Box
    156
  - Side Cover
    158
- Luggage Box
  160
  - Rear Body Cover
    161
- Floor Panel
  161
  - Front Fender
    162
  - Rear Fender
    163
14. Brake System

164
- Brake System
  164
- Maintenance Description
  165
- Trouble Diagnosis
  166
- Disk Brake System Inspection
  167
- Adding Brake Fluid
  168
- Brake Fluid Replacement / Air-Bleed
  169
- Front Brake Caliper
  170
- Rear Brake Caliper
  171
- Brake Disk
  172
- Master Cylinder
  172
15. Steering / Front Wheel / Front Cushion

176
- Operational Precautions
  177
- Steering Handle
  177
- Trouble Diagnosis
  177
- Front Wheel
  180
  - Front Cushion
    183
  - Steering Stem
    184
16. Rear Wheel / Rear Fork / Rear Cushion

186
- Operational Precaution
  187
- Trouble Diagnosis
  187
- Muffler
  188
- Rear Wheel
  188
- Rear Fork
  190
- Rear Cushion
  191
17. Electrical System

192
- Mechanism Diagram
  192
- Maintenance Data
  193
- Technical Specification
  193
- Trouble Diagnosis
  194
  - 17. Electrical System
    196
  - Charging System
    197
  - Starting System
    202
  - Meters
    204
  - Meter Circuit Diagram
    204
  - Light / Bulb
    206
  - Switch / Horn
    210
- Fuel Unit
  212
- Cooling Fan Thermo Switch
  213
- Thermo Sensor
  214
- Water Temperature Meter
  214
  - Electrical Diagram
    216

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Sym GTS 250 User Manual

Sym GTS 250 User Manual (34 pages)

Brand: Sym | Category: Scooter | Size: 1.37 MB

Table of Contents

Safety Information
1
Table of Contents
3
2 Control Location

5
- Vehicle Views
  5
3 Before Riding

6
4 Safe Riding

6
5 Driving

7
6 Use Genuine Spare Parts

7
- Gauges
  8
  - Information of the Gauge Botton
    8
  - Fuel Gauge
    8
7 Use of each Component

8
- Engine Coolant Temperature
  9
- Odometer
  9
- Side Stand Warning Indicator
  9
- Time Setting
  9
- Operation of Ignition Switch
  10
  - Engine Stop Switch
    11
  - Light Switches
    11
  - Seat Open Switch
    11
- Use of Buttons
  11
  - Electrical Starter Button
    12
  - Hazard Switch
    12
  - High/Low Beam Switch
    12
  - Passing Switch
    12
- Engine Control Switch
  13
  - Power Supply Comp
    13
  - Turn Signal Switch
    13
- Goods Hook
  14
- Pillion Step
  14
- Saddle Lock
  14
- Storage Box
  14
- Fuel Tank Cap
  15
- Brake
  16
- Engine Brake
  16
8 Important Points and Cautions for Starting Engine

17
- The Control of Throttle Valve Handle
  18
- Parking Method
  18
9 The Best Way to Drive off

18
- Routine Inspection
  19
- Engine Oil Inspection and Change
  19
10 Inspection and Maintenance before Riding

19
11 When There Is an Abnormal Condition or a Trouble

30
13 Suggestions on Engine Fuel

31
14 Transmission Oil

31
15 Cautions for Riding Scooter

31
- CDI Electrical Ignition System
  31
16 Periodical Maintenance Schedule

32
17 Specification

33

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