Sym Track Runner 200 Manuals

Manuals and User Guides for Sym Track Runner 200. We have 1 Sym Track Runner 200 manual available for free PDF download: Service Manual

Sym Track Runner 200 Service Manual

Sym Track Runner 200 Service Manual (221 pages)

Brand: Sym | Category: Offroad Vehicle | Size: 5.67 MB

Table of Contents

Table of Contents

4
- Track Runner
  2
- General Information
  3
- General Safety
  7
- Service Precautions
  8
- Lubrication System
  14
  - Specifications
    16
  - Torque Values
    17
  - Troubles Diagnosis
    19
  - Parts to be Greased
    24
- Specifications
  14
2. Maintenance Information

26
- Maintenance Information
  26
- Periodical Maintenance Schedule
  27
- Acceleration Operation
  28
- Air Cleaner
  28
- Fuel Lines
  28
- Spark Plug
  28
- Valve Clearance
  29
- Carburetor Idle Speed Adjustment
  30
- Cylinder Compression Pressure
  31
- Ignition System
  31
- Drive Belt
  32
- Drive Chain
  32
- Brake System (Disk Brake)
  33
- Brake Light Switch/Starting Inhibitor
  34
- Switch
  34
- Clutch Disc Wear
  35
- Cushion
  35
- Headlight Beam Distance
  35
- Nuts, Bolts Tightness
  36
- Steering Handle
  36
- Wheel/Tire
  36
- Special Tools List
  37
3. Lubrication System

40
- Precautions in Operation
  41
- Troubleshooting
  41
- Engine Oil
  42
- Engine Oil Strainer Clean
  42
- Oil Pump
  43
- Gear Oil
  46
4. Fuel System

48
- Fuel System
  48
  - Precautions in Operation
    49
  - Trouble Diagnosis
    50
  - Carburetor Remove / Install
    51
  - Air Cut-Off Valve
    52
  - Throttle Valve
    53
  - Float Chamber
    54
  - Adjustment of Idle Speed
    56
  - Fuel Tank
    57
  - Air Cleaner
    58
- Engine Removal
  60
  - Engine Installation
    64
6. Cylinder Head/Valve

66
- Cylinder Head/Valve
  66
  - Precautions in Operation
    67
  - Troubleshooting
    68
  - Cylinder Head Removal
    69
  - Cylinder Head Disassembly
    71
  - Cylinder Head Inspection
    72
  - Valve Stem Replacement
    73
  - Valve Seat Inspection and Service
    74
  - Cylinder Head Reassembly
    76
  - Cylinder Head Installation
    77
  - Valve Clearance Adjustment
    79
7. Cylinder/Piston

80
- Cylinder/Piston
  80
  - Precautions in Operation
    81
  - Trouble Diagnosis
    81
  - Cylinder Removal
    82
  - Piston Removal
    83
  - Piston Ring Installation
    85
  - Piston Installation
    86
  - Cylinder Installation
    86
8. V-Belt Driving System/Kick Starter

88
- Maintenance Description
  89
- Trouble Diagnosis
  89
- Left Crankcase Cover
  90
- Kick Starter
  91
  - Drive Belt
    92
  - Drive Face
    94
  - Clutch Outer/Driven Pulley
    97
9. Final Driving Mechanism

102
- Final Driving Mechanism
  102
  - Mechanism Diagram - Transmission
    103
  - Trouble Diagnosis
    104
  - Inspection of Mission Mechanism
    107
  - Bearing Replacement
    109
  - Re-Assembly of Final Driving
    111
  - Mechanism
    111
10. Alternator/Starting Clutch

114
- Alternator
  114
  - Precautions in Operation
    115
  - Right Crankcase Cover Removal
    116
  - A.C.G. Set Removal
    116
  - Flywheel Removal
    116
  - Starting Clutch
    117
  - Flywheel Installation
    120
  - A.C.G. Set Installation
    120
  - Right Crankcase Cover Installation
    120
11. Crankcase / Crank

122
- General Information
  123
- Trouble Diagnosis
  123
- Disassembly of Crankcase
  124
- Crankshaft Inspection
  126
- Assembly of Crankcase
  127
12. Cooling System

130
- Cooling System
  130
  - General Information
    131
  - Trouble Diagnosis
    131
  - System Test
    134
  - Radiator
    135
  - Water Pump
    137
  - Thermostat
    141
13. Body Cover

144
- Body Cover
  144
  - Maintenance
    145
  - Handle Front Cover
    146
  - Handle Protect Cover
    146
  - Front Center Cover
    146
  - Rear Center Cover
    147
  - Rear Carrier
    147
  - Rear Fender
    148
  - Front Fender
    150
  - Footrest
    152
14. Front Brake & Front Wheel

154
- Maintenance Description
  155
- Trouble Diagnosis
  156
- Front Wheel
  157
- Front Wheel Hub
  157
- Disk Brake System Inspection
  160
- Adding Brake Fluid
  161
- Brake Fluid Replacement / Air-Bleed
  162
- Front Brake Caliper
  163
- Brake Disk
  164
- Front Brake Master Cylinder
  164
15. Steering / Suspension

168
- Operational Precautions
  169
- Trouble Diagnosis
  169
- Steering Handle
  170
- Steering Shaft
  173
- Steering Tie-Rod
  174
- Knuckle
  175
- Front Cushion
  176
- Suspension Arm
  177
- Toe-In
  178
16. Rear Brake & Rear Wheel & Rear Cushion

180
- Maintenance Description
  181
- Trouble Diagnosis
  182
- Rear Wheel
  183
- Rear Wheel Shaft Connecter
  183
- Rear Wheel Axle
  184
- Disk Brake System Inspection
  188
- Adding Brake Fluid
  189
- Brake Fluid Replacement / Air-Bleed
  190
- Rear Brake Caliper
  191
- Brake Disk
  192
- Rear Brake Master Cylinder
  192
- Rear Cushion
  196
17. Electrical System

198
- Electrical System
  198
- Maintenance Data
  199
  - Charging System
    202
  - Starting System
    207
- Light / Bulb
  210
- Switch / Horn
  213
- Fuel Unit
  216
- Cooling Fan Thermo Switch
  217
- Water Temperature Indicator Light
  218
- Electrical Diagram
  220

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