Sym HD200 Manuals

Sym HD200 Manuals

Manuals and User Guides for Sym HD200. We have 2 Sym HD200 manuals available for free PDF download: Service Manual, Owner's Manual

Sym HD200 Service Manual

Sym HD200 Service Manual (211 pages)

Brand: Sym | Category: Motorcycle | Size: 6.27 MB

Table of Contents

1. General Information

6
- Table of Contents
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
  - Lubrication System
    14
- Specifications
  15
- Torque Values
  16
- Troubles Diagnosis
  18
- Parts to be Greased
  22
2. Maintenance Information

24
- Periodical Maintenance Schedule
  25
- Fuel Lines / Cable
  26
  - Maintenance Information
    26
- Air Cleaner
  27
- Spark Plug
  27
- Valve Clearance
  28
- Carburetor Idle Speed Adjustment
  29
- Cylinder Compression Pressure
  30
- Ignition System
  30
- Brake System (Front Disk Brake)
  31
- Drive Belt
  31
- Brake Light Switch/Starting Inhibitor
  33
- Clutch Disc Wear
  33
- Headlight Beam Distance
  33
- Switch
  33
- Cushion
  34
- Nuts, Bolts Tightness
  34
- Side Stand
  34
- Steering Handle Top Bearing
  35
- Wheel/Tire
  35
- Special Tools List
  36
3. Lubrication System

40
- Lubrication System
  40
- Precautions in Operation
  41
- Troubleshooting
  41
- Engine Oil
  42
- Engine Oil Strainer Clean
  42
- Oil Pump
  43
- Gear Oil
  46
4. Fuel System

48
- Fuel System
  48
- Precautions in Operation
  49
  - Fuel System
    49
- Trouble Diagnosis
  50
- Carburetor Removal
  51
- Vacuum Chamber
  51
- Air Cut-Off Valve
  53
- Auto By-Starter
  54
- Float Chamber
  55
- Fuel Tank
  57
- Air Cleaner
  58
5. Engine Removal

60
- Engine Removal
  60
- Removal of Engine
  61
- Engine Hanger Removal
  64
- Removal of Engine Hanger Bush
  65
- Engine Hanger Installation
  66
- Engine Installation
  66
6. Cylinder Head/Valve

68
- Cylinder Head/Valve
  68
- Precautions in Operation
  69
- Troubleshooting
  70
- Cylinder Head Removal
  71
- Cylinder Head Disassembly
  73
- Cylinder Head Inspection
  74
- Valve Stem Replacement
  75
- Valve Seat Inspection and Service
  76
- Cylinder Head Reassembly
  78
- Cylinder Head Installation
  79
- Valve Clearance Adjustment
  81
7. Cylinder/Piston

82
- Cylinder/Piston
  82
- Precautions in Operation
  83
- Trouble Diagnosis
  83
- Cylinder Removal
  84
- Piston Removal
  85
- Piston Ring Installation
  87
- Cylinder Installation
  88
- Piston Installation
  88
8. V-Belt Driving System/Kick Starter

90
- Maintenance Description
  91
- Trouble Diagnosis
  91
- Left Crankcase Cover
  92
- Driving Belt
  93
  - Drive Face
    95
  - Clutch Outer/Driven Pulley
    98
    
    Final Driving Mechanism
    104
    
    Bearing Replacement
    108
10. Alternator/Starting Clutch

114
- Alternator
  114
- Precautions in Operation
  115
- A.C.G. Set Removal
  116
- Flywheel Removal
  116
- Right Crankcase Cover Removal
  116
- Starting Clutch
  117
- A.C.G. Set Installation
  120
- Flywheel Installation
  120
- Right Crankcase Cover Installation
  120
11. Crankcase / Crank

122
- General Information
  123
- Trouble Diagnosis
  123
- Disassembly of Crankcase
  124
- Crankshaft Inspection
  126
- Assembly of Crankcase
  127
12. Cooling System

130
- Cooling System
  130
- General Information
  131
- Trouble Diagnosis
  131
- System Test
  134
- Radiator
  135
- Water Pump
  137
- Thermostat
  141
13. Body Cover

144
- Maintenance
  145
- Front Cover
  146
- Handle Front Cover
  147
- Handle Rear Cover
  148
- Side Cover
  149
- Front under Spoiler
  150
- Luggage Box
  151
- Rear Carrier
  152
- 13. Body Cover
  153
- Inner Box
  154
- Floor Panel
  155
- Front Fender
  156
- Center Fender
  158
- Rear Fender
  158
14. Brake

160
- Mechanism Diagram-Rear Drum Brake
  161
- Maintenance Description
  162
- Trouble Diagnosis
  163
- Disk Brake System Inspection
  164
- Adding Brake Fluid
  165
- Brake Fluid Replacement / Air-Bleed
  166
- Disk Brake-Caliper
  167
- Brake Disk
  168
- Disk Brake - Master Cylinder
  168
- Rear Drum Brake
  171
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 Cushion
    188
17. Electrical System

190
- Electrical System
  190
- Maintenance Data
  191
- Technical Specification
  191
- Trouble Diagnosis
  192
- Battery
  193
- Charging System
  194
- Ignition System
  197
- Starting System
  199
- Meters
  200
- Light / Bulb
  201
- Switch / Horn
  203
- Fuel Unit
  206
- Cooling Fan Thermo Switch
  207
- Thermo Unit
  208
- Water Temperature Meter
  208
  - Electrical Diagram
    210

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Sym HD200 Owner's Manual

Sym HD200 Owner's Manual (33 pages)

LH12W Series LH18W Series

Brand: Sym | Category: Scooter | Size: 1.52 MB

Table of Contents

Contents
4
Control Location
6
Before Riding
7
Safe Riding
8
Riding
9
Use Genuine Spare Parts
9
Use of each Component
10
Gauges
10
Operation of Ignition Switch
11
Use Od Buttons
12
Safety Helmet Hook
13
Seat Lock
13
Luggage Box
14
Fuel Tank Cap
14
Brake
14
Important Points and Cautions for Starting Engine
15
The Best Way to Ride off
16
The Control of Throttle Valve Handle
16
Parking Method
16
Inspection and Maintenance before Riding
17
Routine Inspection
17
Engine Oil Inspection and Change
17
Inspection of Fuel Level
18
Transmission Oil Inspection and Change
18
Oil Filter Cleaning
18
Inspection and Adjustment of Brake Free Play
19
Disk Brake Inspection
20
Leak, Damaged, Looseness of Brake Line
20
Checking Front Brake Lining
20
Checking Oil Quantity in Brake Oil Reservoir
20
Throttle Valve Handle Clearance Adjustment
21
Tire Inspection
21
Steering Handle Front Shock Absorbers Inspection
22
Rear Cushion Hardness Setting
22
Checking for Fuel Leakage
22
Checking the Lubrication of Body's Various Mechanisms
22
Inspection and Maintenance of Battery
23
Checking and Changing Fuses
24
Checking the Turn Signal Lights and Horns
24
Checking the Headlight and Tail Light
24
Checking the Brake Light
25
Checking the Spark Plug
25
A Reference Table for Anti-Freeze Concentration Percentages
25
Cooling System Inspection
26
Replenishment of Coolant
26
Checking the Air Cleaner
27
Abnormal Condition or a Trouble
28
CDI Electrical Ignition System
28
Suggestions on Engine Fuel
28
Transmission Oil
28
Cautions for Riding Scooter
29
Periodical Maintenance
30
Specification
31

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