User Manuals: Sym JOYMAX 250 Maxi scooter

Manuals and User Guides for Sym JOYMAX 250 Maxi scooter. We have 1 Sym JOYMAX 250 Maxi scooter manual available for free PDF download: Service Manual

Sym JOYMAX 250 Service Manual

Sym JOYMAX 250 Service Manual (248 pages)

Brand: Sym | Category: Scooter | Size: 30 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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