Sym LM25W Series Manuals

Manuals and User Guides for Sym LM25W Series. We have 2 Sym LM25W Series manuals available for free PDF download: Service Manual

Sym LM25W Series Service Manual

Sym LM25W Series Service Manual (227 pages)

Scooter

Brand: Sym | Category: Scooter | Size: 7.11 MB

Table of Contents

1. General Information

6
- Service Manual
  1
- Table of Contents
  6
- Symbols and Marks
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  15
- Troubles Diagnosis
  17
- Lubrication Points
  21
2. Maintenance Information

22
- Maintenance Information
  22
- Periodical Maintenance Schedule
  23
- Engine Oil
  24
- Engine Oil Strainer Clean
  24
- Fuel Lines / Cable
  25
- Gear Oil
  25
- Air Cleaner
  26
- P.C.V. System
  27
- Valve Clearance
  27
- Ignition System
  29
- Spark Plug
  29
- Cylinder Compression Pressure
  30
- Drive Belt
  30
- Cushion
  31
- Steering Handle Top Bearing
  31
- Disk Brake System
  32
- Brake Light Switch/Starting Inhibitor
  34
- Headlight Beam Distance
  34
- Switch
  34
- Wheel / Tire
  34
- Battery
  35
- Nuts, Bolts Tightness
  35
- Special Tools List
  36
  - Lubrication System
    40
  - Oil Pump
    43
4. Fuel System

48
- Fuel System
  48
- Fuel System
  49
- Carburetor Remove / Install
  51
- Vacuum Chamber
  51
- Air Cut-Off Valve
  53
- Automatic By-Starter
  54
- Float Chamber
  55
- Adjustment of Idle Speed
  57
- Fuel Tank
  58
- Fuel Pump
  60
- Air Cleaner
  61
5. Removal & Installation of Engine

62
- Engine Removal
  62
- Engine Removal
  63
- Engine Hanger
  67
- Rear Fork
  68
  - Removal of Engine Bush
    70
  - Installation of Engine
    71
6. Cylinder Head / Valve

72
- Cylinder Head / Valve
  72
- Precautions in Operation
  73
- Troubleshooting
  74
- Cylinder Head Removal
  75
- Cylinder Head Disassembly
  77
- Cylinder Head Inspection
  79
- Valve Stem Replacement
  81
- Valve Seat Inspection and Service
  82
- Cylinder Head Installation
  85
- Valve Clearance Adjustment
  87
7. Cylinder / Piston

88
- Cylinder / Piston
  88
- Precautions in Operation
  89
- Trouble Diagnosis
  89
- Cylinder and Piston Removal
  90
- Piston Ring Installation
  93
  - Piston Installation
    94
  - Cylinder Installation
    94
8. V-Belt Driving System

96
- Maintenance Description
  97
- Trouble Diagnosis
  97
- Left Crankcase Cover
  98
- Drive Belt
  100
  - Drive Face
    102
  - Clutch Outer/Driven Pulley
    105
9. Final Driving Mechanism

110
- Final Driving Mechanism
  110
- Precautions in Operation
  111
- Trouble Diagnosis
  111
- Inspection of Final Driving Mechanism
  113
  - Bearing Replacement
    114
  - Re-Assembly of Final Driving Mechanism
    117
10. Alternator / Starting Clutch

118
- Alternator
  118
- Precautions in Operation
  119
- Right Crankcase Cover Removal
  120
- AC.G. Set Removal
  121
- Right Cover Bearing
  121
- Flywheel Removal
  122
- Starting Clutch
  123
- AC.G. Flywheel Installation
  125
- AC.G. Set Installation
  126
- Right Crankcase Cover Installation
  126
11. Crankcase / Crank

128
- General Information
  129
- Trouble Diagnosis
  129
- Disassembly of Crankcase
  130
- Crankshaft Inspection
  131
- Assembly of Crankcase
  133
12. Cooling System

136
- Cooling System
  136
- General Information
  137
- Trouble Diagnosis
  137
- Trouble Diagnosis for Cooling System
  138
- Change of Coolant
  140
  - Radiator
    141
  - Water Pump
    143
  - Thermostat
    147
  - Body Cover
    147
13. Body Cover

150
- Mechanism Diagram
  150
  - Body Cover
    150
- Front under Spoiler
  151
- Maintenance
  151
- Rear Carrier
  151
  - Front Cover
    153
  - Inner Box
    156
  - Side Cover
    158
- Luggage Box
  160
  - Rear Body Cover
    161
- Floor Panel
  161
  - Front Fender
    162
  - Rear Fender
    163
14. Brake System

164
- Brake System
  164
- Maintenance Description
  165
- Trouble Diagnosis
  166
- Disk Brake System Inspection
  167
- Adding Brake Fluid
  168
- Brake Fluid Replacement / Air-Bleed
  169
- Front Brake Caliper
  170
- Rear Brake Caliper
  171
- Brake Disk
  172
- Master Cylinder
  172
15. Steering / Front Wheel / Front Cushion

176
- Operational Precautions
  177
- Steering Handle
  177
- Trouble Diagnosis
  177
- Front Wheel
  180
  - Front Cushion
    183
  - Steering Stem
    184
16. Rear Wheel / Rear Fork / Rear Cushion

186
- Operational Precaution
  187
- Trouble Diagnosis
  187
- Muffler
  188
- Rear Wheel
  188
- Rear Fork
  190
- Rear Cushion
  191
17. Electrical System

192
- Mechanism Diagram
  192
- Maintenance Data
  193
- Technical Specification
  193
- Trouble Diagnosis
  194
  - 17. Electrical System
    196
  - Charging System
    197
  - Starting System
    202
  - Meters
    204
  - Meter Circuit Diagram
    204
  - Light / Bulb
    206
  - Switch / Horn
    210
- Fuel Unit
  212
- Cooling Fan Thermo Switch
  213
- Thermo Sensor
  214
- Water Temperature Meter
  214
  - Emission Control System
    216
  - Control System
    217
  - Control System
    218
  - Catalytic Converting System (CATA)
    219
  - Secondary Air Introduction System
    220
  - Positive Crankcase Ventilation System
    223
  - Inspection Items
    224
  - Countermeasure for Emission Pollutants
    225
  - Electrical Diagram
    226

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Sym LM25W Series Service Manual

Sym LM25W Series Service Manual (217 pages)

LM25W Series

Brand: Sym | Category: Scooter | Size: 6.17 MB

Table of Contents

1. General Information

6
- Service Manual
  1
- Table of Contents
  6
- Symbols and Marks
  6
- General Safety
  7
- Service Precautions
  8
- Specifications
  14
- Torque Values
  15
- Troubles Diagnosis
  17
- Lubrication Points
  21
2. Maintenance Information

22
- Maintenance Information
  22
- Periodical Maintenance Schedule
  23
- Engine Oil
  24
- Engine Oil Strainer Clean
  24
- Fuel Lines / Cable
  25
- Gear Oil
  25
  - Gear Oil Change
    25
- Air Cleaner
  26
- P.C.V. System
  27
- Valve Clearance
  27
- Ignition System
  29
- Spark Plug
  29
- Cylinder Compression Pressure
  30
- Drive Belt
  30
- Cushion
  31
- Steering Handle Top Bearing
  31
- Disk Brake System
  32
- Brake Light Switch/Starting Inhibitor
  34
- Headlight Beam Distance
  34
- Switch
  34
- Wheel / Tire
  34
- Battery
  35
- Nuts, Bolts Tightness
  35
- Special Tools List
  36
  - Lubrication System
    40
  - Oil Pump
    43
4. Fuel System

48
- Fuel System
  48
- Fuel System
  49
- Carburetor Remove / Install
  51
- Vacuum Chamber
  51
- Air Cut-Off Valve
  53
- Automatic By-Starter
  54
- Float Chamber
  55
- Adjustment of Idle Speed
  57
- Fuel Tank
  58
- Fuel Pump
  60
- Air Cleaner
  61
5. Removal & Installation of Engine

62
- Engine Removal
  62
- Engine Removal
  63
- Engine Hanger
  67
- Rear Fork
  68
  - Removal of Engine Bush
    70
  - Installation of Engine
    71
6. Cylinder Head / Valve

72
- Cylinder Head / Valve
  72
- Precautions in Operation
  73
- Troubleshooting
  74
- Cylinder Head Removal
  75
- Cylinder Head Disassembly
  77
- Cylinder Head Inspection
  79
- Valve Stem Replacement
  81
- Valve Seat Inspection and Service
  82
- Cylinder Head Reassembly
  84
- Cylinder Head Installation
  85
- Valve Clearance Adjustment
  87
7. Cylinder / Piston

88
- Cylinder / Piston
  88
- Precautions in Operation
  89
- Trouble Diagnosis
  89
- Cylinder and Piston Removal
  90
- Piston Ring Installation
  93
  - Piston Installation
    94
  - Cylinder Installation
    94
8. V-Belt Driving System

96
- Maintenance Description
  97
- Trouble Diagnosis
  97
- Left Crankcase Cover
  98
- Drive Belt
  100
  - Drive Face
    102
  - Clutch Outer/Driven Pulley
    105
9. Final Driving Mechanism

110
- Final Driving Mechanism
  110
- Precautions in Operation
  111
- Trouble Diagnosis
  111
- Inspection of Final Driving Mechanism
  113
  - Bearing Replacement
    114
  - Re-Assembly of Final Driving Mechanism
    117
10. Alternator / Starting Clutch

118
- Alternator
  118
- Precautions in Operation
  119
- Right Crankcase Cover Removal
  120
- AC.G. Set Removal
  121
- Right Cover Bearing
  121
- Flywheel Removal
  122
- Starting Clutch
  123
- AC.G. Flywheel Installation
  125
- AC.G. Set Installation
  126
- Right Crankcase Cover Installation
  126
11. Crankcase / Crank

128
- General Information
  129
- Trouble Diagnosis
  129
- Disassembly of Crankcase
  130
- Crankshaft Inspection
  131
- Assembly of Crankcase
  133
12. Cooling System

136
- Cooling System
  136
- General Information
  137
- Trouble Diagnosis
  137
- Trouble Diagnosis for Cooling System
  138
- Change of Coolant
  140
  - Radiator
    141
  - Water Pump
    143
  - Thermostat
    147
  - Body Cover
    147
13. Body Cover

150
- Mechanism Diagram
  150
  - Body Cover
    150
- Front under Spoiler
  151
- Maintenance
  151
- Rear Carrier
  151
  - Front Cover
    153
  - Inner Box
    156
  - Side Cover
    158
- Luggage Box
  160
  - Rear Body Cover
    161
- Floor Panel
  161
  - Front Fender
    162
  - Rear Fender
    163
14. Brake System

164
- Brake System
  164
- Maintenance Description
  165
- Trouble Diagnosis
  166
- Disk Brake System Inspection
  167
- Adding Brake Fluid
  168
- Brake Fluid Replacement / Air-Bleed
  169
- Front Brake Caliper
  170
- Rear Brake Caliper
  171
- Brake Disk
  172
- Master Cylinder
  172
15. Steering / Front Wheel / Front Cushion

176
- Operational Precautions
  177
- Steering Handle
  177
- Trouble Diagnosis
  177
- Front Wheel
  180
  - Front Cushion
    183
  - Steering Stem
    184
16. Rear Wheel / Rear Fork / Rear Cushion

186
- Operational Precaution
  187
- Trouble Diagnosis
  187
- Muffler
  188
- Rear Wheel
  188
- Rear Fork
  190
- Rear Cushion
  191
17. Electrical System

192
- Mechanism Diagram
  192
- Maintenance Data
  193
- Technical Specification
  193
- Trouble Diagnosis
  194
  - 17. Electrical System
    196
  - Charging System
    197
  - Starting System
    202
  - Meters
    204
  - Meter Circuit Diagram
    204
  - Light / Bulb
    206
  - Switch / Horn
    210
- Fuel Unit
  212
- Cooling Fan Thermo Switch
  213
- Thermo Sensor
  214
- Water Temperature Meter
  214
  - Electrical Diagram
    216

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