Sym SYM series Manuals

Manuals and User Guides for Sym SYM series. We have 2 Sym SYM series manuals available for free PDF download: Manual, Service Manual

Sym SYM series Manual

Sym SYM series Manual (179 pages)

Brand: Sym | Category: Scooter | Size: 21.14 MB

Table of Contents

General Information/Trouble Diagnosis
1
Symbols and Marks
1
Carbon Monoxide
2
Gasoline
2
General Information/Trouble Diagnosis
2
- General Safety
  2
- Used Engine Oil
  2
- Service Precautions
  3
- Specifications
  9
- Torque Values (Engine)
  10
- Standard Torque Values for Reference
  11
- Torque Values (Frame)
  11
- Engine Hard to Start or Can Not be Started
  12
- Troubles Diagnosis
  12
- Engine Run Sluggish
  13
- Engine Runs Sluggish
  14
- Engine Runs Sluggish (High Speed)
  14
- Clutch, Driving and Driving Pulley
  15
- Lubrication Points
  16
- A.C. Generator/Starting Clutch
  17
- Mechanism Diagram
  17
- General Information
  18
- Precautions in Operation
  18
- Specification
  18
- Torque Value
  18
- A.C. Generator Removal
  19
- Right Crankcase Cover Removal
  20
- Starting Clutch
  21
- Starting Clutch Inspection
  21
- Starting Clutch Removal
  21
- Starting Clutch Installation
  23
- Flywheel Installation
  24
- Mounted Coil Set Installation
  24
- Right Crankcase Cover Installation
  24
- Crankcase/Crankshaft
  26
- Engine Noise
  27
- Operational Precautions
  27
Trouble Diagnosis
27
Disassembly of Crankcase
28
Bearing Inspection
30
Crankshaft Inspection
30
Assembly of Crankcase
31
- Body Cover
  33
- Body Covers Disassemble Sequence
  34
- Maintenance Information
  34
  - Handle Cover
    35
  - Front Cover
    36
  - Front Inner Box
    37
  - Body Cover/Rear Center
    38
  - Cover/Rear Fender
    38
  - Front Center Cover
    40
  - Luggage Box
    40
  - Floor Panel
    41
  - Side Cover
    42
  - Under Cover
    42
  - Brake
    43
  - Front Disc Brake System
    43
  - Rear Drum Brake System
    44
  - Disc Brake
    46
  - Hard Operation of Brake Lever
    46
  - Soft Brake Lever
    46
  - Trouble Diognosis
    46
  - Brake Fluid Add
    47
  - Hydraulic Brake System Inspection
    47
  - Brake Fluid Replacement/Air-Bleed
    48
  - Brake Caliper
    49
  - Brake Lining Replacement
    49
  - Brake Disc Inspection
    50
  - Brake Master Cylinder
    50
  - Brake Drum
    53
  - Brake Lining
    53
  - Drum Brake-Drum
    53
  - Brake Panel
    54
  - Front Brake Panel
    55
  - Rear Brake Panel
    55
  - Steering/Front Wheel/Front Shock Absorber
    56
  - Front Wheel Wobbling
    57
  - Hard Steering Stem
    57
  - Soft Front Suspension
    57
  - Steering Stem off Center
    57
  - Steering Handle
    58
  - Disc Brake Type
    59
  - Front Wheel
    59
  - Wheel Axle
    60
  - Wheel Rim
    60
  - Front Fork/Steering Column
    64
  - Front Shock Absorber
    64
  - Rear Wheel/Rear Shock Absorber
    66
  - Braking Noise
    67
  - Poor Brake Performance
    67
  - Rear Wheel Wobbling
    67
  - Shock Absorber too Soft
    67
  - Exhaust Muffler
    68
  - Rear Wheel
    68
  - Rear Shock Absorber
    69
  - Electrical Equipment
    70
  - Charging System
    71
  - Ignition System
    71
  - Starting System
    71
  - Charging System Failure
    73
  - Intermittent Power Supply
    73
  - Low Voltage
    73
  - No Power Supply
    73
  - Charging Wire Diagram
    74
  - Current Leakage Inspection
    74
  - Voltage Check
    76
  - Charging Voltage/Current Inspection
    77
  - Main Wire Circuit Inspection
    78
  - Voltage Regulator Check
    78
  - Voltage Regulator Inspection
    78
  - Alternator Charging Coil
    79
  - Alternator Lighting Coil
    79
  - Resistor Check
    79
  - CDI Unit
    80
  - Ignition System Circuit
    80
  - Ignition Coil
    81
  - Primary Coil Check
    81
  - Spark Plug Confirmation
    81
  - Pulse Generator
    82
  - Secondary Coil
    82
  - Starter Magnetic Switch Inspection
    83
  - Starting Circuit
    83
  - Meter
    84
  - Starting Motor Removal
    84
  - Headlight Bulb Replacement
    86
  - Light/Bulbs
    86
  - Front Turn Signal Lamp Bulb Replacement
    87
  - Main Switch/Horn
    88
  - Handle Switch
    89
  - Headlight Switch
    89
  - High/Low Beam Switch/ Seat Open
    89
  - Starting Switch
    89
  - Brake Light Switch
    90
  - Horn
    90
  - Turn Signal Light Switch
    90
  - Fuel Unit
    91
  - Wiring Diagram
    92
  - Periodical Maintenance Schedule
    94
  - Cleaning the Oil Strainer
    95
  - Engine Oil Capacity
    95
  - Lubrication System
    95
  - Oil Change
    95
  - Fuel Filter
    96
  - Fuel Pipe
    96
  - Fuel System
    96
  - Gear Oil
    96
  - Air Cleaner
    97
  - Throttle Valve Operation
    97
  - Crankcase Ventilation
    98
  - Valve Clearance Adjustment
    98
  - Carburetor Idle Speed Adjustment
    99
  - Emission Adjustment in Idle Speed
    99
  - Valve Clearance Inspection and Adjustment
    99
  - Ignition Timing
    100
  - Spark Plug
    100
  - Clutch Pad
    101
  - Cylinder Copmression Pressure
    101
  - Driving Belt
    101
  - Driving System
    101
  - Steering System
    102
  - Suspension System
    102
  - Air Bleed Operation
    103
  - Brake Fluid
    103
  - Brake System Hose
    103
  - Filling out Brake Fluid
    103
  - Added Brake Fluid
    104
  - Brake Lining Wear
    104
  - Brake Confiramtion
    105
  - Drum Brake System
    105
  - Rear Brake Free Play
    105
  - Appointed Tire
    106
  - Appointed Tire Pressure
    106
  - Wheel/Tire
    106
  - Battery Cables Removal
    107
  - Battery Removal
    107
  - Headlight Adjustment
    107
  - Nuts, Bolts Tighteness
    107
  - Dirty Oil
    109
  - Low Engine Oil Level
    109
  - Low Oil Pressure
    109
- Lubrication System
  109
  - Cleaning Engine Oil Strainer
    110
  - Engine Oil
    110
  - Oil Pump Disassembly
    111
  - Oil Pump Removal
    111
  - Oil Pump Inspection
    112
  - Oil Pump Re-Assembly
    112
  - Oil Pump Installation
    113
  - Gear Oil Replacement
    114
- Fuel System
  116
  - Mixture too Lean
    117
  - Poor Engine Start
    117
  - Rough Idle
    117
  - Stall after Started
    117
  - Carburetor Removal
    118
  - Vacuum Chamber
    118
  - Air Cut-Off Valve
    120
  - Auto By-Starter
    121
  - Valve Inspection
    121
  - Float Chamber
    122
  - Checking Fuel Level
    123
  - Idle Speed Adjustment
    123
  - Installation of Carburetor
    123
  - Standard Turns
    123
  - Fuel Tank Installation
    124
  - Fuel Tank Removal
    124
  - Fuel Unit Installation
    124
  - Fuel Unit Removal
    124
  - Air Cleaner Element Cleaning
    125
  - Removal of Engine
    126
  - Engine Removal
    128
  - Pressing in
    131
  - Pressing out
    131
  - Suspension Bushing
    131
  - Engine Suspension Frame
    132
  - Engine Suspension Nut
    133
  - Installation of Engine
    133
  - Rear Shock Absorber Bolt
    133
  - Rear Wheel Axle Nut
    133
  - Cylinder Head/Valve
    134
- Cylinder Head/Valve
  135
  - Camshaft Removal
    137
  - Camshaft Inspection
    138
  - Cylinder Head Disassembly
    139
  - Cylinder Head Removal
    139
  - Cylinder Head Inspection
    140
  - Valve Spring Free Length
    140
  - Valve Guide
    141
  - Valve Guide Replacement
    141
  - Valve Stem
    141
  - Valve Seat Inspection and Service
    142
  - Valve Seat Grinding
    143
  - Valve Seat Inspection
    143
  - Valve Seat Width
    143
  - Cylinder Head Reassembly
    144
  - Cylinder Head Installation
    145
  - Cylinder/Piston
    147
- Cylinder/Piston
  148
  - Engine Overheat
    148
  - Knock or Noise
    148
  - Low or Unstable Compression Pressure
    148
  - Smoking in Exhaust Pipe
    148
  - Cylinder Removal
    149
  - Disassemble the Piston Rings
    151
  - Piston Removal
    151
  - Piston Ring Installation
    153
  - Cylinder Installation
    154
  - Piston Installation
    154
  - V-Belt Driving System/Kick Starter Arm
    155
  - Engine Can be Started but Motorcycle Can Not be Moved
    156
  - Insufficient Horsepower or Poor High Speed Performance
    156
  - Shudder or Misfire When Driving
    156
  - Installation of the Left Crankcase Cover
    157
  - Left Crankcase Cover
    157
- V" Type Belt Driving System/Kick Starter Arm
  157
  - Driving Pulley Install
    162
  - Clutch/Driven Pulley
    163
  - Clutch Lining
    164
  - Driven Pulley
    164
  - Driven Pulley Bearing Inspection
    164
  - Driven Pulley Spring
    164
  - Clutch Block Replacement
    165
  - Replacement of Driven Pulley Bearing
    166
  - Installation of Clutch/Driven Pulley
    167
  - Final Driving Mechanism
    168
- Final Driving Mechanism
  169
  - Gear Oil Leaks
    169
  - Noise
    169
  - Disassembly of Final Driving Mechanism
    170
  - Inspection of Final Driving Mechanism
    170
  - Bearing Replacement
    171
  - Re-Assembly of Final Driving Mechanism
    173
- Electrical Equipment
  176
- Wiring Diagram
  176
- Table of Contents
  177
- Mechanism Illustrations
  178

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Sym SYM series Service Manual

Sym SYM series Service Manual (176 pages)

Brand: Sym | Category: Motorcycle | Size: 5.17 MB

Table of Contents

Table of Contents
4
Special Tool
6
General Information/Trouble Diagnosis
8
- Specifications
  16
- Lubrication Points
  23
Maintenance Information
24
- Periodical Maintenance Schedule
  25
- Air Cleaner
  28
- Spark Plug
  31
Lubrication System
39
Engine Oil
41
Fuel System
46
- Trouble Diagnosis
  48
- Carburetor Removal
  49
- Idle Speed Adjustment
  54
- Removal of Engine
  58
Engine Removal
59
Cylinder Head/Valve
65
- Camshaft Removal
  68
- Cylinder Head Inspection
  72
- Valve Clearance Adjustment
  78
Cylinder/Piston
79
- Cylinder Removal
  81
- Piston Removal
  83
- Piston Ring Installation
  85
- Piston Installation
  86
- Cylinder Installation
  86
- Left Crankcase Cover
  89
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch
89
Final Driving Mechanism
100
Generator/Starting Clutch
107
Flywheel Installation
109
Crankcase/Crankshaft
111
Body Cover
118
Brake Fluid Replacement
133
Brake System
133
- Brake Caliper
  134
- Brake Pad
  138
Steering/Front Wheel/Front Shock Absorber
141
- Steering Handle
  143
- Front Shock Absorber
  148
Rear Wheel/Suspension
152
Electrical Equipment
154
- Charging System
  155
- Ignition System
  155
- Starting System
  155
- Alternator Charging Coil
  163
- Pulse Generator
  166
- Handle Switch
  173
- Fuel Unit
  175

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