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Manuals and User Guides for Sym GTS 300i. We have
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Sym GTS 300i manual available for free PDF download: Service Manual
Sym GTS 300i Service Manual (275 pages)
Brand:
Sym
| Category:
Scooter
| Size: 32.11 MB
Table of Contents
Table of Contents
4
Service Manual
1
General Information
3
Table of Contents
4
Serial Number
5
Symbols and Marks
6
General Safety
7
Before Servicing
8
Specifications
14
Torque Values
17
Trouble Diagnosis
19
Lubrication Points
23
2. Maintenance Information
24
Maintenance Information
24
Periodical Maintenance Schedule
25
Engine Oil
26
Engine Oil Strainer Clean
26
Gear Oil
27
Fuel Lines / Cable
27
Air Cleaner
28
P.C.V. System
29
Valve Clearance
29
Spark Plug
30
Cylinder Compression Pressure
31
Drive Belt
31
Steering Handle Top Bearing
32
Cushion
32
Disk Brake System
33
Brake Light Switch / Start Switch
35
Headlight Distance Adjustment
35
Wheel / Tire
35
Battery
36
Nuts, Bolts Tightness
36
Special Tools List
37
3. Lubrication System
42
Lubrication System
42
Precautions in Operation
43
Troubleshooting
43
Engine Oil
44
Engine Oil Strainer Clean
44
Oil Pump
45
Gear Oil
48
Integrated Troubleshooting Procedure
50
Efi System Components
50
Efi System Vehicle Configuration
51
Efi System Operation
52
Efi System Introduction
53
Fuel System
54
System Description
54
Ignition System
55
Sensors / Drives
56
Precautions in Operation
63
Special Tools
63
Efi System Components Description
64
Throttle Body
65
Map Sensor
66
Roll over Sensor
73
Fuel Injector
77
Efi System Circuit
80
ECU Pin Configuration
81
Fuel Injection System
82
Troubleshooting
82
Integrated Troubleshooting Procedure
86
Air Cleaner
89
Efi System Diagnosis Methods
90
Check Light Fault Codes Differentiation
91
Fault Code and Sensors Table
92
Fault Code and Check Light Flashing Lighting Identification Table
93
Efi System Diagnostic Tool - V70
94
Troubleshooting Table
107
Comprehensive Maintenance List
108
5. Removal & Installation of Engine
110
Engine Removal
111
Engine Hanger
117
Rear Fork
118
Engine Bush Removal
120
Engine Installation
121
6. Cylinder Head / Valve
122
Cylinder Head / Valve
122
Precautions in Operation
123
Troubleshooting
124
Cylinder Head Removal
125
Cylinder Head Disassembly
127
Cylinder Head Inspection
129
Valve Stem Replacement
131
Valve Seat Inspection and Service
132
Cylinder Head Reassembly
134
Cylinder Head Installation
135
Valve Clearance Adjustment
137
7. Cylinder / Piston
138
Precautions in Operation
139
Troubleshooting
139
Cylinder / Piston
140
Cylinder / Piston Removal
140
Piston Ring Installation
143
Cylinder Installation
144
Piston Installation
144
8. V-Belt Drive System
146
V-Belt Drive System
146
Precautions in Operation
147
Troubleshooting
147
Left Crankcase Cover
148
Drive Belt
150
Drive Face
152
Clutch Outer / Driven Pulley
155
9. Final Drive Mechanism
160
Final Drive Mechanism
160
Precautions in Operation
161
Troubleshooting
161
Final Drive Mechanism Disassembly
162
Final Drive Mechanism Inspection
163
Bearing Replacement
164
Final Drive Mechanism Reassembly
167
10. AC. Generator / Start Clutch
168
Precautions in Operation
169
Right Crankcase Cover Removal
170
AC. Generator Removal
171
Right Crankcase Cover Bearing
171
Flywheel Removal
172
Start Clutch
173
Flywheel Installation
175
Ac.generator Installation
176
Right Crankcase Cover Installation
176
11. Crankshaft / Crankcase
178
Crankshaft / Crankcase
178
Precautions in Operation
179
Troubleshooting
179
Crankcase Disassembly
180
Crankshaft Inspection
181
Crankcase Assembly
183
12. Cooling System
186
Cooling System
186
Precautions in Operation
187
Troubleshooting
187
Diagnosis for Cooling System
188
Change of Coolant
190
Radiator
191
Water Pump
193
Thermostat
197
Body Cover
197
13. Body Cover
200
Body Cover Mechanism Diagram
200
Maintenance
201
Handle Cover
202
Front Cover
203
Meter Panel
205
Inner Box
206
Side Cover
208
Front under Spoiler
209
Rear Carrier
209
Luggage Box
210
Rear Body Cover
211
Floor Panel
212
Front Fender
212
Rear Fender
213
14. Brake System
214
Brake System
214
Precautions in Operation
215
Troubleshooting
216
Disk Brake System Inspection
217
Adding Brake Fluid
218
Brake Fluid Replacement / Air-Bleed
219
Front Brake Caliper
220
Rear Brake Caliper
221
Brake Disk
222
Master Cylinder
222
15. Steering / Front Wheel / Front Cushion
226
Steering / Front Wheel / Front Cushion
226
Precautions in Operation
227
Troubleshooting
227
Steering Handle
228
Front Wheel
230
Front Cushion
233
Steering Stem
234
16. Rear Wheel / Rear Fork / Rear Cushion
236
Rear Wheel / Rear Fork / Rear Cushion
236
Precautions in Operation
237
Troubleshooting
237
Muffler
238
Rear Wheel
238
Rear Fork
240
Rear Cushion
241
17. Electrical System
242
Electrical System
242
Precautions in Operation
243
Specification
243
Troubleshooting
244
Battery
245
Fuse
246
Charging System
247
Starting System
252
Meter
254
Light / Bulb
256
Switch / Horn
259
Fuel Unit
261
Cooling Fan Thermo Switch
262
Thermo Unit
263
Water Temperature Meter
263
Emission Control System
264
Electrical Diagram
274
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