Sym Joyride 200i EVO Manuals

Manuals and User Guides for Sym Joyride 200i EVO. We have 1 Sym Joyride 200i EVO manual available for free PDF download: Service Manual

Sym Joyride 200i EVO Service Manual

Sym Joyride 200i EVO Service Manual (275 pages)

Brand: Sym | Category: Scooter | Size: 25.02 MB

Table of Contents

1. General Information

6
- Table of Contents
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  10
- Torque Values
  14
- Cables and Harness Routing
  16
- Troubleshooting-Carburetor Model
  17
- Troubleshooting-Efi Model
  21
- Lubrication Points
  25
2. Maintenance Information

26
- Periodical Maintenance Schedule
  27
  - Maintenance Information
    27
- Fuel Lines
  28
- Throttle Operation
  28
- Air Cleaner
  29
- Spark Plug
  29
- Valve Clearance
  30
- Ignition System
  31
- Cylinder Compression Pressure
  32
- Drive Belt
  32
- Brake Fluid
  33
- Brake Hose
  33
- Brake System (Front/Rear Disk Brake)
  33
- Filling out Brake Fluid
  33
- Add Brake Fluid
  34
- Air Bleed Operation
  34
- Brake Lining
  34
- Brake Light Switch
  35
- Clutch Weight
  35
- Headlight Beam Distance
  35
- Front / Rear Cushion
  36
- Nut, Bolts Tightness
  36
- Side Stand
  36
- Wheel / Tire
  37
3. Lubrication System

38
- Lubrication System
  38
- Precautions in Operation
  39
- Troubleshooting
  39
- Engine Oil
  40
- Engine Oil Strainer Clean
  40
- Oil Pump Disassembly
  41
- Oil Pump Removal
  41
- Oil Pump Inspection
  42
- Oil Pump Reassembly
  42
- Oil Pump Installation
  43
- Gear Oil
  44
4. Fuel System

46
- Fuel System
  47
- Precautions in Operation
  47
- Trouble Diagnosis
  48
- Air Cut-Off Valve
  49
- Auto By-Starter
  50
- Carburetor Removal
  51
- Vacuum Chamber
  51
- Float Chamber
  53
- Installation of Carburetor
  54
- Adjustment of Pilot Screw
  55
- Fuel Tank
  56
- Air Cleaner
  57
5. Fuel Injection System

58
- Fuel Injection System
  58
- Efi System Introduction
  59
- Efi System Components
  60
- Efi System Location
  61
- Efi System Component Description
  62
  - Fuel Pump
    63
  - Ignition Coil
    63
  - Ect Sensor
    64
- Efi System Circuit
  65
- Precautions in Operation
  66
- Troubleshooting
  67
- Procedure
  68
- Fuel Lines
  72
- Ignition System
  73
- Crankshaft Position Sensor
  74
- Engine Temperature Sensor / T-Map Sensor
  75
- Air By-Pass Valve
  76
- Fuel Injector
  76
- Fuel Pump
  76
- Fuel Unit
  77
- Fuel Tank
  80
  - Fuel Tank Removal
    80
- Air Cleaner
  81
- Efi Troubleshooting & Solution
  82
- Replacement Procedure
  83
6. Engine Removal

114
- Engine Removal-Carburetor Model
  115
- Engine Removal-Efi Model
  119
- Engine Hanger
  124
- Engine Hanger Rubber Bush
  125
- Engine Installation
  126
- Engine Removal
  126
7. Cylinder Head / Valve

128
- Cylinder Head / Valve
  128
- Precautions in Operation
  129
  - Cylinder Head/Valve
    129
- Cylinder Head Removal
  131
- Cylinder Head Disassembly
  133
  - Inspection
    134
- Valve Seat Inspection
  136
- Cylinder Head Reassembly
  138
- Cylinder Head Installation
  139
8. Cylinder / Piston

142
- Cylinder / Piston
  142
- Precautions in Operation
  143
- Troubleshooting
  143
- Cylinder Removal
  144
- Piston Removal
  145
  - Piston Ring Installation
    147
    
    Piston Installation
    148
    
    Cylinder Installation
    148
9. V-Belt Drive System

150
- V-Belt Drive System
  150
- Precautions in Operation
  151
- Troubleshooting
  151
  - Left Crankcase Cover
    152
- Drive Belt
  154
  - Drive Face
    155
  - Clutch Outer / Driven Pulley
    159
10. Final Drive Mechanism

164
- Final Drive Mechanism
  164
- Precautions in Operation
  165
- Troubleshooting
  165
- Final Drive Mechanism Inspection
  166
- Bearing Replacement
  167
- Final Drive Mechanism Reassembly
  169
11. AC. Generator / Start Clutch

172
- Precautions in Operation
  173
- AC. Generator Removal
  174
- Flywheel Removal
  174
- Right Crankcase Cover Removal
  174
- Start Clutch
  175
- AC. Generator Installation
  178
- Flywheel Installation
  178
- Right Crankcase Cover Installation
  178
12. Crankshaft / Crankcase

180
- Crankshaft / Crankcase
  180
- Troubleshooting
  181
  - Service Data
    181
- Crankcase Disassembly
  182
- Crankshaft Inspection
  184
  - Crankcase Assembly
    185
13. Cooling System

188
- Cooling System
  188
- General Information
  189
  - Technical Specification
    189
- Troubleshooting
  190
- Coolant Change
  191
- System Test
  191
- Radiator
  192
- Water Pump
  193
- Temperature Sensor
  197
  - Body Cover
    197
- Thermostat
  198
14. Body Cover

200
- Body Cover
  200
- Maintenance
  201
- Steering Handle Cover
  202
- Front Cover
  203
- Wind Screen
  203
- Meter Cover
  204
- Front under Spoiler
  205
- Side Cover
  205
- Luggage Box
  206
- Rear Carrier
  206
- Body Covers / Rear Fender
  207
- Center Cover
  207
- Floor Panel
  208
- Under Cover
  208
- Front Fender
  209
- Inner Cover
  209
- Rear Fender
  209
15. Brake System

210
- Rear Brake System Diagram
  211
- Maintenance Description
  212
- Troubleshooting
  213
- Hydraulic Disc Brake
  214
- Air Bleed
  215
- Brake Caliper
  215
- Brake Disk Inspection
  216
- Brake Master Cylinder
  216
  - Master Cylinder Inspection
    217
15. Brake System Notes

220
- Steering / Front Wheel / Front Cushion
  220
- Precautions in Operation
  221
- Troubleshooting
  221
  - Steering Handlebar
    222
- Front Wheel
  225
  - Front Cushion
    229
  - Front Fork / Steering Stem
    230
17. Muffler / Rear Wheel / Rear Cushion

232
- Muffler / Rear Wheel / Rear Cushion
  232
- Precautions in Operation
  233
- Troubleshooting
  233
  - Muffler
    234
  - Rear Wheel
    234
- Rear Cushion
  236
Homepage 18. Electrical System

238
- Electrical System
  238
- Battery
  239
- Charging System
  239
- Ignition System
  239
  - Voltage Inspection
    241
- Precautions in Operation
  239
- Starting System
  247
  - Starter Motor Removal
    248
  - Starter Motor Installation
    248
- Meter
  249
- Light / Bulb
  250
- Switch / Horn
  255
- Fuel Unit
  257
- Thermo Switch
  258
- Thermo Guage
  259
  - Special Tools List
    260
    
    19. Special Tools
    261
    
    Crank Case / Transmission Oil Seal Driver
    264
    
    AC.G. Flywheel Puller
    268
  - Valve Cotter Remover / Install Driver
    268
  - Crank Case Bush Puller
    270
  - Wiring Diagram
    272
- Thermo Unit
  259

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