Sym Orbit Manuals

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

SYM Orbit Service Manual

SYM Orbit Service Manual (177 pages)

Symply50

Brand: SYM | Category: Scooter | Size: 5.22 MB

Table of Contents

Table of Contents
4
Mechanism Illustrations
5
Special Tools
6
General Information/Trouble Diagnosis
8
Maintenance Information
24
- Periodical Maintenance Schedule
  25
- Lubrication System
  26
- Engine Oil Capacity
  26
- Oil Change
  26
- Oil Viscosity
  26
- Fuel System
  27
- Fuel Pipe
  27
- Fuel Filter
  27
- Gear Oil
  27
- Air Cleaner
  28
- Throttle Valve Operation
  28
- Valve Clearance Adjustment
  29
- Valve Clearance Inspection and Adjustment
  30
- Carburetor Idle Speed Adjustment
  30
- Ignition Timing
  31
- Ignition System
  31
- Spark Plug
  31
- Driving System
  32
- Driving Belt
  32
- Clutch Pad
  32
- Cylinder Compression Pressure
  32
- Steering System
  33
- Suspension System
  33
- Front Shock Absorber
  33
- Rear Shock Absorber
  33
- Front Disc Brake System
  34
- Brake System Hose
  34
- Brake Fluid
  34
- Air Bleed Operation
  34
- Added Brake Fluid
  35
- Brake Lining Wear
  35
- Brake Confirmation
  36
- Drum Brake System
  36
- Rear Brake Free Play: (Drum Brake Type)
  36
- Wheel/Tire
  37
- Brake Light Switch
  37
- Battery Removal
  38
- Battery Cables Removal
  38
- Headlight Adjustment
  38
- Nuts, Bolts Tightness
  38
- Lubrication System Diagram
  39
- Lubrication System - Operational Precautions
  40
- Lubrication System Trouble Diagnosis
  40
- Engine Oil
  41
- Cleaning Engine Oil Strainer
  41
- Oil Pump Removal
  42
- Oil Pump Inspection
  43
- Oil Pump Re-Assembly
  43
- Oil Pump Installation
  44
- Gear Oil Level Inspection
  45
- Gear Oil Replacement
  45
- Fuel System Diagram
  46
- Fuel System - Precautions in Operation
  47
- Fuel System Specification
  47
- Fuel System Trouble Diagnosis
  48
- Poor Engine Start
  48
- Stall after Started
  48
- Mixture too Lean
  48
- Carburetor Removal
  49
- Vacuum Chamber Removal
  49
- Vacuum Chamber Installation
  50
- Accelerate Pump Removal and Installation
  51
- Auto By-Starter Inspection
  52
- Auto By-Starter Removal and Installation
  52
- Float Chamber
  53
- Idle Speed Adjustment
  54
- Fuel Tank Removal
  55
- Air Cleaner Removal and Installation
  56
- Engine Removal
  57
- Engine Diagram
  57
- Engine Specification
  58
Engine Removal
59
- Removal of Engine Suspension Bushing
  62
- Engine Suspension Frame Removal and Installation
  63
- Installation of Engine
  64
- Cylinder Head/Valve Diagram
  65
- Cylinder Head/Valve Specification
  66
- White Smoke
  67
- Low Compression Pressure
  67
- High Compression Pressure
  67
- Cylinder Head/Valve Troubleshooting
  67
- Camshaft Removal
  68
- Camshaft Inspection
  69
- Disassembly of Camshaft Holder
  69
- Inspection of Camshaft Holder
  69
- Cylinder Head Removal
  70
- Cylinder Head Disassembly
  71
- Cylinder Head Inspection
  72
- Valve Guide Replacement
  73
- Valve Seat Inspection and Service
  74
- Valve Seat Grinding
  74
- Cylinder Head Reassembly
  76
- Camshaft Installation
  77
- Cylinder Head Installation
  77
- Valve Clearance Adjustment
  78
- Cylinder/Piston Diagram
  79
- Cylinder/Piston Specification
  80
- Cylinder/Piston Trouble Diagnosis
  80
- Cylinder Removal
  81
- Cylinder Inspection
  82
- Piston Removal
  83
- Disassemble the Piston Rings
  83
- Piston Ring Installation
  85
- Piston Installation
  86
- Cylinder Installation
  86
- V-Belt Driving System/Kick Starter Arm/Starter Clutch
  87
- V-Belt Driving System/Kick Starter Arm/Starter Clutch Specification
  88
- Left Crankcase Cover Removal
  89
- Installation of the Left Crankcase Cover
  89
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch
89
- Driving Belt Inspection
  90
- Driving Belt Removal
  90
- Driving Belt Installation
  91
- Install the Starter Clutch
  91
- Sliding Pulley Removal
  92
- Sliding Pulley Inspection
  93
- Sliding Pulley Installation
  93
- Driving Pulley Installation
  94
- Clutch/Drive Pulley Disassembly
  95
- Driven Pulley Spring
  96
- Driven Pulley Check
  96
- Driven Pulley Bearing Inspection
  96
- Clutch Block Replacement
  97
- Replacement of Driven Pulley Bearing
  98
- Installation of Clutch/Driven Pulley
  99
- Final Driving Mechanism Diagram
  100
- Final Driving Mechanism Specification
  101
- Disassembly of Final Driving Mechanism
  102
- Inspection of Final Driving Mechanism
  102
- Bearing Replacement
  103
- Re-Assembly of Final Driving Mechanism
  105
- AC Generator
  106
Generator/Starting Clutch
107
- Right Crankcase Cover Removal
  108
- Right Crankcase Cover Installation
  109
- Mounted Coil Set Installation
  109
- Flywheel Installation
  109
- Crankcase/Crankshaft Diagram
  111
- Crankcase/Crankshaft - Operating Precautions
  112
- Crankcase/Crankshaft Specification
  112
- Crankcase/Crankshaft Trouble Diagnosis
  112
- Disassembly of Crankcase
  113
- Crankshaft Inspection
  115
- Assembly of Crankcase
  116
- Body Cover Diagram
  118
- Body Covers Disassemble Sequence
  119
- Handle Cover Removal
  120
- Front Cover Removal and Installation
  121
- Front under Cover Removal and Installation
  122
- Front Inner Box a Removal
  123
- Front Inner Box a Installation
  124
- Body Cover/Rear Center Cover/Rear Fender Removal
  125
- Body Cover/Rear Center Cover/Rear Fender Installation
  126
- Front Center Cover Removal and Installation
  127
- Luggage Box Removal and Installation
  127
- Floor Panel Removal and Installation
  127
- Brakes Diagram
  128
- Brake Specifications
  130
- Brake - Precautions in Operation
  130
- Brake Trouble Diagnosis
  131
- Soft Brake Lever
  131
- Uneven Brake
  131
- Poor Brake Performance
  131
- Hydraulic Brake System Inspection
  132
- Brake Fluid Add
  132
- Brake Fluid Replacement/Air-Bleed
  133
Brake System
133
- Brake Caliper Removal and Installation
  134
- Brake Pad Replacement
  134
- Brake Disk Inspection
  135
- Brake Master Cylinder Removal
  135
- Brake Master Cylinder Installation
  137
- Drum Brake-Drum Removal
  138
- Brake Pad Inspection
  138
- Brake Panel Removal and Installation
  139
- Brake Pad Removal and Installation
  139
- Front Brake Panel
  140
- Rear Brake Panel
  140
- Steering/Front Wheel/Front Shock Absorber Diagram
  141
- Steering/Front Wheel/Front Shock Absorber Data
  142
- Steering/Front Wheel/Front Shock Absorber Trouble Diagnosis
  142
- Steering Handle Removal
  143
- Steering Handle Installation
  144
- Front Wheel Removal
  144
- Front Wheel Inspection
  145
- Wheel Rim Check
  145
- Wheel Axle Check
  145
- Bearing Inspection
  146
- Front Shock Absorber Removal and Installation
  148
- Front Fork/Steering Column Removal and Installation
  148
- Rear Wheel/Rear Shock Absorber Diagram
  150
- Rear Wheel/Rear Shock Absorber Specification
  151
- Rear Wheel/Rear Shock Absorber Trouble Diagnosis
  151
- Exhaust Muffler Removal and Installation
  152
- Rear Wheel Inspection
  152
- Rear Wheel Removal and Installation
  152
- Rear Shock Absorber Removal and Installation
  153
- Electrical Equipment Diagram
  154
- Electrical Equipment - Precautions in Operation
  155
- Charging System
  155
- Ignition System
  155
- Starting System
  155
- Electrical Equipment Specifications
  156
- Electrical Equipment Trouble Diagnosis
  157
- Charging System
  158
- Charging Wire Diagram
  158
- Current Leakage Inspection
  158
- Battery Voltage Check
  160
- Battery Charging
  160
- Charging Voltage/Current Inspection (Battery)
  161
- Voltage Regulator Inspection
  162
- Alternator Charging Coil
  163
- Alternator Lighting Coil
  163
- Resistor Check
  163
- Ignition System Circuit
  164
- CDI Unit
  164
- Ignition Coil
  165
- Spark Plug Confirmation
  165
- Primary Coil Check
  165
- Secondary Coil
  166
- Pulse Generator
  166
- Remove the Luggage Box
  167
- Starter Magnetic Switch Inspection
  167
- Starting Circuit
  167
- Starting System
  167
- Starting Motor Removal
  168
- Meter Removal
  168
- Headlight Bulb Replacement
  170
- The Headlight Beam Adjustment
  170
- Front Turn Signal Lamp Bulb Replacement
  171
- Bulbs Replacement of Tail Light/Brake Light/Rear Turn Signal Light
  171
- Main Switch/Horn
  172
- Handle Switch
  173
- Headlight Switch
  173
- Starting Switch
  173
- High/Low Beam Switch/ Passing
  173
- Turn Signal Light Switch
  174
- Fuel Unit
  175
- Wiring Diagram
  176

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