Sym JOYMAX 300i Manuals

Manuals and User Guides for Sym JOYMAX 300i. We have 1 Sym JOYMAX 300i manual available for free PDF download: Service Manual

Sym JOYMAX 300i Service Manual

Sym JOYMAX 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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