Sym JD05W Manuals

Manuals and User Guides for Sym JD05W. We have 1 Sym JD05W manual available for free PDF download: Service Manual

Sym JD05W Service Manual

Sym JD05W Service Manual (165 pages)

Brand: Sym | Category: Scooter | Size: 4 MB

Table of Contents

Table of Contents
4
Mechanism Illustrations
5
General Information/Trouble Diagnosis
7
- Symbols and Marks
  7
- General Safety
  8
- Carbon Monoxide
  8
- Gasoline
  8
- Battery
  8
- Service Precautions
  9
- Specifications
  12
Lubrication System
12
- Torque Values (Engine)
  13
- Standard Torque Values for Reference
  14
- Torque Values (Frame)
  14
- Engine Hard to Start or Can Not be Started
  15
- Troubles Diagnosis
  15
- Engine Run Sluggish (Speed Does Not Pick Up, Lack of Power)
  16
- Engine Runs Sluggish (Especially in Low Speed and Idling)
  17
- Engine Runs Sluggish (High Speed)
  17
- Clutch, Driving and Driving Pulley
  18
- Lubrication Points
  19
- Crankcase/Crankshaft
  20
- Engine Noise
  21
- Maintenance Information
  21
- Torque Values
  21
- Troubleshooting
  21
- Crankcase Disassembly
  22
- Crankshaft Removal
  22
- Crankshaft Inspection
  23
- Crankcase Installation
  24
- Body Cover
  26
- Body Covers Disassemble Sequence
  27
- Handle Cover
  28
- Front Cover
  29
- Front Inner Box
  30
- Body Cover/Rear Center Cover/Rear Fender
  31
- Floor Panel
  33
- Front Center Cover
  33
- Luggage Box
  33
- Side Cover
  34
- Under Cover
  35
- Brake System
  36
- Disc Brake System
  36
- Rear Drum Brake System
  37
- Precautions in Operation
  38
- Brake Noise
  39
- Hard Operation of Brake
  39
- Soft Brake Lever
  39
- Tight Brake
  39
- Hydraulic Disc Brake
  40
- Recommended Brake Fluid
  40
- Disc Brake -Air Bleed
  41
- Brake Pad Replacement
  42
- Disc Brake - Caliper
  42
- Front Brake
  42
- Brake Disc
  44
- Disc Brake - Master Cylinder
  44
- Master Cylinder Removal
  44
- Master Cylinder Assembly
  45
- Master Cylinder Inspection
  45
- Rear Drum Brake
  47
- Steering / Front Wheel / Front Cushion
  50
- Hard to Steer
  51
- Soft Cushion
  51
- The Front Wheel Wobbling
  51
- The Steering Handle Is Tilted
  51
- Steering Handle
  52
- Front Wheel
  54
- Bearings Replacement
  55
- Inner Bearing Puller
  55
- Front Cushion
  57
- Steering Stem
  58
- Rear Wheel / Rear Cushion
  60
- Cushion too Soft
  61
- Poor Brake Performance
  61
- Rear Wheel Wobbling
  61
- Rear Wheel
  62
- Brake Disc Removal / Install
  63
- Rear Cushion
  64
- Electrical Equipment
  66
- Charging System
  67
- Ignition System
  67
- Precautions in Operation
  67
  - Starting System
    67
  - Intermittent Power Supply
    69
  - Low Voltage
    69
  - No Power Supply
    69
- Trouble Diagnosis
  69
- Charging System
  70
  - Charging Wire Diagram
    70
  - Current Leakage Inspection
    70
  - Voltage Check
    72
  - Charging Voltage/Current Inspection
    73
  - Control Charging Voltage
    73
  - Specified Charging Current
    73
  - Main Wire Circuit Inspection
    74
  - Voltage Regulator Check
    74
  - Voltage Regulator Inspection
    74
  - Alternator Charging Coil
    75
  - Alternator Lighting Coil
    75
  - Resistor Check
    75
  - CDI Unit
    76
  - Ignition System Circuit
    76
  - Ignition Coil
    77
  - Spark Plug Confirmation
    77
  - Pulse Generator
    78
  - Secondary Coil
    78
  - Remove the Luggage Box
    79
  - Starter Magnetic Switch Inspection
    79
  - Starting Circuit
    79
- Starting System
  79
  - Starter Motor Pinion
    80
  - Starter Motor Pinion Inspection
    80
  - Armature Inspection
    81
  - Starter Motor Re-Assembly/Installation
    81
  - Starter Motor Removal/Disassembly
    81
  - Oil Level Switch
    82
  - Carburetor Heater
    83
  - Fuel Unit
    84
  - Lights
    85
- Meter
  86
- Lights/Bulbs
  88
  - The Headlight Beam Adjustment
    88
  - Bulbs Replacement of Tail Light/Brake
    89
  - Front Turn Signal Lamp Bulb Replacement
    89
  - Main Switch/Horn
    90
  - Handle Switch
    91
  - Headlight Switch
    91
  - High/Low Beam Switch/ Passing
    91
  - Starting Switch
    91
  - Brake Light Switch
    92
  - Horn
    92
  - Turn Signal Light Switch
    92
- Fuel Unit
  93
- Wiring Diagram
  94
- Special Tool
  95
- Service Maintenance Information
  96
- General Information
  96
- Periodical Maintenance Schedule
  97
- Air Cleaner
  98
- Fuel Lines
  98
- Fuel Filter
  99
- Engine Oil Line
  99
- Battery Removal
  100
- Oil Pump Control Cable
  100
- Tire
  101
- Recommended Tire and Tire Pressure
  101
- Rear Drum Brake Free Play
  101
- Disc Brake System Hose
  102
- Brake Fluid
  102
- Filling out Brake Fluid
  102
- Air Bleed Operation
  102
- Brake Lining Wear
  103
- Brake Pad Wear
  103
- Steering System
  104
- Suspension
  104
- Front Shock Absorber
  104
- Rear Shock Absorber
  104
- Recommended Plug
  105
- Leak
  105
- Spark Plug
  105
- Transmission Oil
  105
- Control Cable Lubrication
  106
- Driver Belt
  106
- Ignition Timing
  106
- Throttle Valve Operation
  106
- Carburetor Idle Speed Adjustment
  107
- Cylinder Compression Pressure Test
  107
- Compression Pressure
  107
- Headlight Adjustment
  108
- Nuts, Bolts Tighteness
  108
- Lubrication System
  109
- Lubrication System Diagram
  109
- Piston Seized
  110
- Too Much Smoke, Carbon in Spark Plug
  110
- Over Heat
  110
- Lubricant
  110
- Oil Pump Removal
  111
- Oil Pump Installation
  111
- Oil Pump/Oil Tube Air Bleeding
  112
- Oil Tube/Oil Pump
  112
- Oil Tube Air Bleeding
  112
- Oil Tank
  113
Fuel System
115
- Precautions in Operations
  116
- Engine Cannot be Started
  116
- Stall after Started
  116
- Lean Mixture
  116
- Throttle Valve
  117
- Auto By-Starter
  118
- Carburetor Remove
  118
- Auto By-Starter Removal/Installation
  119
- Float/Float Valve/Jet
  120
- Float Level Inspection
  121
- Carburetor Installation
  121
- Reed Valve
  121
Engine Removal
124
- Engine Hanger Bracket
  129
- Engine Installation
  129
Cylinder Head/Cylinder/Piston
130
- Compression Pressure too Low/Difficult to Start/Rough Idling
  131
- Piston Noise
  131
- Piston Ring Noise
  131
- Compression Pressure too High/Overheat/Knock
  131
- Cylinder Head Removal
  132
- Cylinder Head Installation
  133
- Cleaning Carbon in Combustion Chamber
  133
- Cylinder Head Inspection
  133
- Cylinder/Piston
  134
- Cylinder Removal
  134
- Piston Removal
  134
- Piston Ring Removal
  134
- Piston Ring Inspection
  136
- Connecting Rod Inspection
  136
- Piston/Cylinder Installation
  137
- A.C. Generator
  139
- Coil Resistance Value for the A.C. Generator
  140
- AC. Generator
  140
- Generator Removal
  141
- Generator Installation
  142
- "V" Type Belt Drive System/Kick-Starter
  143
- Engine Can be Started but Motorcycle Cannot be Moved
  144
- Shudder or Misfire When Drive
  144
- Insufficient Horsepower or Poor High-Speed Performance
  144
- Left Crankcase Cover
  145
- Left Crankcase Cover Removal
  145
- Disassembly of Kick Starter
  145
- Inspection of Kick Starter
  145
- Reassembly of Kick Starter
  146
- Installation of the Left Crankcase Cover
  146
- Drive Belt
  147
- Movable Drive Face
  148
- Drive Face Installation
  151
- Clutch/Driven Pulley
  152
- Clutch Outer
  152
- Driven Pulley Bearing Inspection
  153
- Driven Pulley Spring
  153
- Driven Pulley
  153
- Clutch Weight
  153
- Clutch Block Replacement
  154
- Replacement of Driven Pulley Bearing
  155
- Installation of Clutch/Driven Pulley
  156
Final Driving Mechanism
157
- Engine Can be Started but Scooter Cannot be Moved
  158
- Noise
  158
- Gear Oil Leaks
  158
- Disassembly of Final Driving Mechanism
  159
Special Tool
160

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