User Manuals: Sym Joyride200 Motorcycle

Manuals and User Guides for Sym Joyride200 Motorcycle. We have 1 Sym Joyride200 Motorcycle manual available for free PDF download: Service Manual

Sym Joyride200 Service Manual

Sym Joyride200 Service Manual (203 pages)

Brand: Sym | Category: Motorcycle | Size: 16 MB

Table of Contents

1. General Information

6
- Table of Contents
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  10
- Torque Values
  13
- Cables and Harness Routing
  15
- Troubleshooting
  16
- Lubrication Points
  20
2. Maintenance Information

22
- Maintenance Information
  22
- Periodical Maintenance Schedule
  23
- Acceleration Operation
  24
- Fuel Lines
  24
- Air Cleaner
  25
- Crankcase Ventilation
  25
- Spark Plug
  25
- Valve Clearance
  26
- Carburetor Idling Speed Adjustment
  27
- Ignition System
  27
- Cylinder Compression Pressure
  28
- Driving Belt
  28
- Brake Fluid
  29
- Brake System (Front/Rear Disk Brake)
  29
- Brake System Hose
  29
- Filling out Brake Fluid
  29
- Added Brake Fluid
  30
- Air Bleed Operation
  30
- Brake Lining Wear
  30
- Brake Lamp Switch/Starting Inhibitor Switch
  31
- Clutch Disc Wear
  31
- Headlamp Beam Distance
  31
- Shock Absorber
  32
- Side Stand
  32
- Steering Handle Top Bearing
  33
- Wheel/Tire
  33
3. Lubrication System

34
- Lubrication System
  34
- Precautions in Operation
  35
- Troubleshooting
  35
- Engine Oil
  36
- Engine Oil Strainer Clean
  36
  - Oil Change
    36
- Oil Pump Disassembly
  37
- Oil Pump Removal
  37
- Oil Pump Inspection
  38
- Oil Pump Re-Assembly
  38
- Oil Pump Installation
  39
- Gear Oil
  40
4. Fuel System

42
- Fuel System
  42
- Precautions in Operation
  43
  - Fuel System
    43
- Trouble Diagnosis
  44
- Air Cut-Off Valve
  45
- Auto By-Starter
  46
- Carburetor Removal
  47
- Vacuum Chamber
  47
- Float Chamber
  49
- Installation of Carburetor
  50
- Adjustment of Pilot Screw
  51
- Fuel Tank
  52
- Air Cleaner
  53
  - Engine Removal
    54
  - Engine Removal
    55
6. Cylinder Head/Valve

60
- Cylinder Head/Valve
  60
- Precautions in Operation
  61
- Cylinder Head Removal
  63
- Cylinder Head Disassembly
  65
- Valve Stem Replacement
  67
7. Cylinder/Piston

74
- Cylinder/Piston
  74
- Precautions in Operation
  75
- Trouble Diagnosis
  75
- Cylinder Removal
  76
- Piston Removal
  77
  - Piston Ring Installation
    79
  - Piston Installation
    80
  - Cylinder Installation
    80
8. V-Belt Driving System/Kick Starter

82
- Maintenance Description
  83
- Trouble Diagnosis
  83
- Kick Starter
  84
  - Driving Belt
    86
  - Drive Face
    87
  - Clutch Outer/Driven Pulley
    91
- Left Crankcase Cover
  84
9. Final Driving Mechanism

96
- Final Driving Mechanism
  96
- Precautions in Operation
  97
- Trouble Diagnosis
  97
  - Final Driving Mechanism
    97
- Disassembly of Final Driving Mechanism
  98
- Inspection of Final Driving Mechanism
  98
- Bearing Replacement
  99
- Re-Assembly of Final Driving Mechanism
  101
10. Alternator/Starting Clutch

104
- Alternator/Starting Clutch
  104
- Precautions in Operation
  105
- A.C.G. Set Removal
  106
- Flywheel Removal
  106
- Right Crankcase Cover Removal
  106
- Starting Clutch
  107
- A.C.G. Set Installation
  110
- Flywheel Installation
  110
- Right Crankcase Installation
  110
11. Crankshaft/Crankcase

112
- Crankshaft/Crankcase
  112
- General Information
  113
- Trouble Diagnosis
  113
  - Service Data
    113
- Disassembly of Crankcase
  114
- Crankshaft
  116
- Assembly of Crankcase
  117
12. Cooling System

120
- Cooling System
  120
- General Information
  121
  - Cooling System
    121
- Trouble Diagnosis
  122
- Change of Coolant
  123
- System Test
  123
- Radiator
  124
- Water Pump
  125
- Temperature Sensor
  129
- Thermostat
  130
13. Body Covers

132
- Maintenance
  133
- Front Guard
  135
- Luggage Box
  137
  - Side Covers
    138
  - Body Cover
    139
- Inner Cover
  142
  - Front Fender
    143
14. Brake

144
- Brake
  144
- System
  145
- Maintenance Description
  146
- System
  146
- Hydraulic Disc Brake
  148
- Air Bleed
  149
- Brake Calliper
  149
- Brake Disc
  149
  - Master Cylinder Inspection
    151
14. Brake Notes

154
- Steering/Front Wheel/Front Brake
  154
- Operational Precautions
  155
- Trouble Diagnosis
  155
- Steering Handlebar
  156
- Front Wheel
  159
  - Front Brake
    162
  - Front Shock Absorber
    163
  - Front Fork/Steering
    164
16. Rear Wheel/Rear Brake/Rear Cushion

166
- Operational Precaution
  167
- Trouble Diagnosis
  167
- Muffler
  168
- Rear Wheel
  168
- Rear Cushion
  170
17. Electrical System

172
- Electrical System
  172
- Maintenance Data
  173
  - Technical Specification
    173
- Trouble Diagnosis
  174
- Battery
  175
- Charging System
  176
- Ignition System
  179
- Starting System
  181
- Lamp/Bulb
  183
- Switch/Horn
  184
- Fuel Gauge
  187
- Thermal Switch
  188
- Sensor
  189
- Digital Meters Trouble Diagnosis
  190
  - How to Use Special Tools
    195
  - Special Tools
    195
  - Crank Case / Transmission Oil Seal Driver
    198
  - AC.G. Flywheel Puller
    199
  - Valve Cotter Remover / Install Driver
    199
  - Crank Case Bush Puller
    201
  - Wiring Diagram
    202

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