SANYANG INDUSTRY CO. SYM Service Manual Download Page 1

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SERVICE MANUAL

Summary of Contents for SYM

Page 2: ...of the motorcycle are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice This manual that contains all data illustration indication and specifications is based on current production information SYM reserves the right to make changes at any time without notice and without incurring any obligation whate...

Page 3: ...ction and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance The third to the eleventh chapters cover engine and driving systems The twelfth to fifteenth chapters are contained the parts set of assembly body The sixteenth chapter is electrical equipment The seventh chapter is for wiring diagram Please see index of content for...

Page 4: ...LINDER HEAD VALVE 6 CYLINDER PISTON 7 V TYPE BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 BODY COVER 12 BRAKE SYSTEM 13 STEERING FRONT WHEEL FRONT SHOCK ABSORBER 14 REAR WHEEL SUSPENSION 15 ELECTRICAL EQUIPMENT 16 ELECTRICAL DIAGRAM 17 SPECIAL TOOL 18 ...

Page 5: ...er Air cleaner Gear oil filling bolt Oil level Tail light Front turn signal light Fuel tank Fuel unit High Low beam Seat open turn signal horn Head light Position light Rear turn signal light Engine number engine oil draining bolt Ignition coil Frame number Meter A C Generator Start magnetic switch Horn REG REC RR turning signal light Winker relay Engine control switch ...

Page 6: ... Limits to use SAE 10W 30 API SH CD class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Gear oil Limits to use SAE 85W 140 class oil Warranty will not cover the damage that caused by not apply with the limited gear oil Grease King Mate G 3 is recommended Locking sealant Apply sealant medium strength sealant should be used unless otherwise specified Oil...

Page 7: ...se serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist y If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a ...

Page 8: ...tion to O rings or oil seals because most cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent stiff control and premature worn out y Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary y When loosening a component w...

Page 9: ...d fill the groove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal y Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage y The ends of rubber hoses for fuel vacuum or coolant ...

Page 10: ...ry negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark y After service completed make sure all connection points is secured Battery positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables y Make sure that the battery post caps are located in properly after the b...

Page 11: ...y Check if any wire loose y Check if the connector is covered by the twin connector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loose y Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up y Secure wires and wire harnesses to the frame with respective wire bands at the designat...

Page 12: ...ther pull too tight nor have excessive slack y Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied y Secure the rubber boot firmly as applying it on wire harness y Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace them y Never...

Page 13: ... adjacent or surrounding parts in all steering positions y Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction y With sand paper to clean rust on connector pins terminals if found And then conduct connection operation later Do you know how to set the instrument to its measurement position and the in...

Page 14: ...ction GEAR Type 4 STROKE ENGINE Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Deceleration equipment Transmission V belt Fuel Used Unleaded 93 95 Speedometer 0 80 km hr Cycle Cooling 4 stroke forced air cooled Horn 80 112 dB A Bore 37 0 mm Muffler Expansion Pulse Type Stroke 46 0 mm Exhaust Pipe Position and Direction Right side and Backward Cylinder Num...

Page 15: ...t 1 12 3 5 4 5 Gear oil draining plug 1 8 1 0 1 5 Gear oil filling bolt 1 8 1 0 1 5 Oil pump flat screw 2 6 0 8 1 2 Left crankcase cover bolts 10 6 0 8 1 2 Camshaft chain tensioner pivot 1 6 0 8 1 2 Hex socket bolt Camshaft chain adjuster bolts 2 6 1 0 1 4 Cooling fan bolts 4 6 0 8 1 2 Cooling fan cover bolt 2 6 0 7 1 1 RR brake shoe anchor fixing nut 1 8 1 5 2 0 Shroud A B 2 6 0 8 1 2 Start clutc...

Page 16: ...ont brake disc mounting bolts 4 10 4 0 4 5 Front brake clipper mounting bolts 2 10 3 1 3 5 Drum brake arm bolts front rear 2 6 0 8 1 2 Engine suspension bracket bolts 2 10 4 5 5 5 On frame side Engine connection bolt 1 10 4 5 5 5 On engine side Main standard nut 1 10 3 5 4 5 Foot starting lever bolt 1 6 1 6 1 8 Air cleaner bolts 2 6 1 0 1 4 The torque values listed in above table are for more impo...

Page 17: ...w the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged 1 Malfunction of spark plug 2 Spark plug foul 3 Malfuncti...

Page 18: ...tion No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel level too low in carburetor 6 Fuel nozzle clogged in carburetor 1 Malfunction of CDI 2 Malfunction of AC alternator 1 Cylinder piston ring worn out 2 Cylinder gasket leaked 3 Sand hole in compression parts 4 Valve deterioration 5 Seized piston ring 1 Remove for...

Page 19: ...uel cup Check if carburetor clogged 1 Incorrect ignition timing malfunction of CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation gasket 2 Carburetor lock loose 3 Poor intake gasket 4 Poor carburetor O ring 5 Vacuum hose crack 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or sho...

Page 20: ...ion 2 Driving disk damaged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance 1 Driving belt worn out or deformation 2 Balance weight roller worn out 3 Drivin...

Page 21: ...ION TROUBLE DIAGNOSIS SYM 1 16 LUBRICATION POINTS Acceleration cable Front rear brake lever pivot Steering shaft bearing Seat lock Speedometer gear Front wheel bearing Side stand shaft Main stand shaft Rear wheel bearing ...

Page 22: ...GHT ADJUSTMENT 2 15 NUTS BOLTS TIGHTEN 2 15 PRECAUTIONS IN OPERATION Specification Fuel Tank Capacity 4 80L capacity 800 c c Engine Oil change 650 c c capacity 180 c c Transmission Gear oil change 170 c c Clearance of throttle valve 2 6 mm Spark plug A7RC Gap 0 6 0 7 mm F Mark in idling speed Before TDC 13º 1700 rpm Full timing advanced Before TDC 27º 8000 rpm Idling speed 2100 100 rpm Cylinder co...

Page 23: ...nt C Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 These marks in the schedule are emission control items ...

Page 24: ...assembly 800cc Change 650cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen wash it off with suitable solvent recommended using compressed air Check O ring for damage replace if necessary Reinstall st...

Page 25: ...lue 0 8 1 2 kgf m Transmission oil capacity 180 c c 170 c c for change Recommended genuine SYM HYPOID gear oil SAE 85W 140 Fuel System Fuel Pipe Remove luggage box side cover center cover body frame cover and pedal as well as front inner box Check all pipes and replace it when they are deterioration damage or leaking Warning Fuel filter Remove the side cover Remove fuel pipe from the fuel filter R...

Page 26: ...ration is smooth Check throttle valve cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play 2 6 mm Adjustment can be done in either ends Secondary adjustment is conducted from top side Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment nut Fixing nut Adjustment ...

Page 27: ...shaft in clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TDC position in the compression stroke Caution When always riding in rainy area or full throttle position maintenance period must be shorted The depos...

Page 28: ...aust sampling muffler of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value within standard Emission stan...

Page 29: ...e these components if malfunction of these parts are found SPARK PLUG Appointed spark plug A7RC Remove luggage box Remove body side cover Remove front center cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug gap 0 6 0 7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Screw the park plug into the plug ...

Page 30: ... head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit above 17 5 mm Clutch pad Start the motorcycle and gradually increase th...

Page 31: ... scratched or leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scratched or leaking Replace damaged and non repairable components Park the motorcycle with main stand Start engine and let the rear wheel rotate after increased engine rpm Check engine for any ...

Page 32: ...fluid contents inside the brake system hoses AIR BLEED OPERATION Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution Before closing the air bleed valve do not release the brake lever y In order to maintain brake fluid in the reservoir in horizontal position do no...

Page 33: ... Pry out the brake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance It is not necessary to remove brake hose when replacing the brake lining Do not operate the brake lever after the clipper removed to avoid clipping the brake lining In order to mai...

Page 34: ...Free play 10 20 mm Adjust the free play by turning the front brake adjustment nut if necessary BRAKE CONFIRAMTION Caution y After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked y Pull the brake lever and make sure that the wear limit marks of brake ling on the both front rear brake arm are closer and touch to the marks If so replace the bra...

Page 35: ...ck if tire surface is ticked with nails stones or other materials Check if tire surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspection or depth gauge y Replace the tire if tire tread dent or unusual wearing out y The tire should be replaced if the wear limit mark is in visible Measure tire thread depth from tire center surface Repl...

Page 36: ...ght Then tighten the adjustment screw after the beam height in proper position Caution NUTS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check all fixing pins snap rings hose pipe clamps and wire holders for security y To adjust the headlight beam follows related regulations y Impr...

Page 37: ...TIONS 3 2 TROUBLE DIAGNOSIS 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 7 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lubrication Inner passage Connecting rod Oil pump Oil strainer Crankshaft ...

Page 38: ...d Limit Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5kgf m Engine oil filter screen cap 1 0 2 0kgf m Gear oil drain bolt 1 0 1 5kgf m Gear oil filling bolt 1 0 1 5kgf m Oil pump fixing screws 0 8 1 2kgf m TROUBLE DIAGNOSIS Low engine oil level z Oil leaking z Valve guid...

Page 39: ... tighten it Torque value 3 5 4 5 kgf m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it Torque value 1 0 2 0 kgf...

Page 40: ...the pump axle can be rotated freely Remove the oil pump driving gear nut Remove the oil pump Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit below 0 12 mm Check clearance between inner and outer rotors Limit below 0 12 mm Check clearance between rotor side face and pump body Limit below 2 0 mm pump driving gear nut ...

Page 41: ...e indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw Oil Pump Installation Install according to the reverse procedure of removal outer rotor inner rotor Oil pump body Oil pump cover Drive shaft Fixing pin ...

Page 42: ... oil level too low Standard quantity 180 cc Replacement 170 cc Gear Oil Replacement Remove the gear oil filling bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it with new one Torque Value 1 0 1 5 kgf m Add new gear oil 170 c c from the gear oil filling hole and then install the gear oil filling...

Page 43: ...ROUBLE DIAGNOSIS 4 3 CARBURETOR REMOVAL 4 4 VACUUM CHAMBER 4 4 ACCELERATE PUMP 4 6 AUTO BY STARTER 4 7 FLOAT CHAMBER 4 8 INSTALLATION OF CARBURETOR 4 9 IDLE SPEED ADJUSTMENT 4 9 FUEL TANK 4 10 AIR CLEANER 4 11 MECHANISM ILLUSTRATION Carburetor Fuel strainer Fuel tank cap Fuel unit ...

Page 44: ...lue Fuel valve tightening nut 1 5 2 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level gauge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline z Do not bend or twist throttle valve cable Damaged cable will make unstable driveability z When disassembling ...

Page 45: ...dle speed z Malfunction of carburetor z Dirty fuel Intermittently misfire as acceleration z Malfunction of ignition system Late ignition timing z Malfunction of ignition system z Malfunction of carburetor Power insufficiency and fuel consuming z Fuel system clogged z Malfunction of ignition system Mixture too lean z Clogged fuel injector z Vacuum piston stick and closed z Malfunction of float valv...

Page 46: ...ase the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress spring and vacuum piston throttle valve cable clamp strip of isolator vacuum hose Vacuum piston compress spring vacuum hose auto b...

Page 47: ...piston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm z Note direction as installing the piston set because wrong direction of the piston cab not be installed z Align the indent of vacuum diaphragm with the carburetor body fuel needle seat injector needle Piston spring piston fuel needle spr...

Page 48: ... arm from the carburetor Remove 3 mounting screws and remove the float chamber cover Remove 3 mounting screws and remove the float chamber cover Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation direction Screws 2 Accelerate pump drive arm ...

Page 49: ...it clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing plate screw and then remove the plate and auto by starter from carburetor Valve inspection Check if auto by starter and valve needle for damage or wear out Installation Install auto by starter to the ca...

Page 50: ...or body passages with compressed air In case of worn out or dirt the float needle valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float needle valve must be replaced with a new one z Take care not to damage jets and adjust screw z Before removing adjustment screw turn it all the way down and note the number of turns z Do ...

Page 51: ...screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO value fluctuated repeat the procedures described above for adjusting to standard value Set the adjustment screw in according to number of turns noted before it was removed z Check again to ensure flo...

Page 52: ...der of removal Cautions FUEL TANK REMOVAL Open the seat Remove the rear carrier 3 bolts Remove the luggage box and the double seat 4 bolts Remove the left right body cover Disconnect the fuel unit connector Remove the fuel pipe fuel filter Remove the fuel tank 2 bolts Fuel Tank Installation Install the tank in the reverse order of removal z Do not bend the float arm of fuel unit z Do not fill out ...

Page 53: ...eaner Installation Install the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With compressed air to clean dirty around the element Replace it if it is too dirty to clean Cautions The air cleaner element is made of paper so do not soap it into water or wash it with water air filter strap bolts 2...

Page 54: ... DIAGRAM 5 1 OPERATIONAL PRECAUTIONS 5 2 ENGINE REMOVAL 5 3 REMOVAL OF ENGINE SUSPENSION BUSHING 5 6 ENGINE SUSPENSION FRAME 5 7 INSTALLATION OF ENGINE 5 8 MECHANISM DIAGRAM 3 5 4 5kgf m 2 4 3 0kgf m 4 5 5 5kgf m 4 5 5 5 kgf m 4 5 5 5kgf m ...

Page 55: ...k driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Specification Disassemble 800 c c Engine Oil Capacity Replacement 650 c c Disassemble 180 c c Gear Oil Capacity Replacement 170 c c Torque Values Engine suspension bolt frame side 4 5 5 5kgf m Engine suspension nut engine side 4 5 5 5kgf m Bolt of rear shock absorber upper connection 3 5 4 5kgf m Bolt of rea...

Page 56: ...ody cover Remove the power connector of auto by start Remove the generator connector and pulse generator connector Remove the starter motor wire on the Starter magnetic switch Remove the spark plug cap Spark plug cap Starter magnetic switch Auto by start connector Generator connector pulse generator connector ...

Page 57: ...nd throttle valve cable from the carburetor Loose the strap screw of the air cleaner guide and remove the air cleaner guide Remove the exhaust muffler Bolts 2 Nuts 2 Remove the rear wheel Nut 1 Remove the air cleaner connection bolts 2 bolts Nut 1 2 bolts Bolts 2 ...

Page 58: ... Remove the engine suspension nut and bolt engine side and then remove the engine Caution Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so y With a bracket to support the engine to prevent from it damage by falling down as removing the engine Engine suspension bolt nut Bushing Strap screw of guide Brake cable nut Rear shock a...

Page 59: ...ress the bushing out and replace it with new one Engine suspension bushing Φ28mm Rear shock absorber bushing Φ20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pressing ring and bolt in to press the bushing out Pressing In Place the flat section of the remover toward the bushing and then drive the bushing pressing ring and bolt in to install th...

Page 60: ...move the left side bolt of engine suspension frame Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame Engine suspension frame nut Torque Value 4 5 5 5 kgf m Bolt of engine suspension frame left side ...

Page 61: ... Engine suspension nut Torque Value 4 5 5 5kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5kgf m lower 2 4 3 0kgf m Rear wheel axle nut Torque Value 11 0 13 0kgf m y Notice both feet and hands safety for squeezing as engine installation y Do not bent or squeeze each wires or hose y Route all cables and wires in accordance with the routine layout Engine suspension nut 1 Rear shock absorber l...

Page 62: ...NDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD INSPECTION 6 8 VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLATION 6 13 VALVE CLEARANCE ADJUSTMENT 6 14 MECHANISM DIAGRAM 0 7 1 1 kgf m 1 0 1 4 kgf m 0 8 1 2 kgf m 0 8 1 2 kgf m 0 8 1 2 kgf m ...

Page 63: ... 10 015 10 10 Rocker arm OD of valve rocker arm shaft 9 972 9 987 9 910 Intake 4 975 4 99 4 90 OD of valve stem Exhaust 4 955 4 97 4 90 ID of Guide 5 000 5 015 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 030 0 057 0 100 Outer 35 25 Valve Free length of valve spring Inner 32 26 32 56 Torque Value Cylinder head cover bolt 0 8 1 2kgf m Cylinder head bolt LH 0 8 1 2...

Page 64: ...on y Poor sealing on valve seat y Improper spark plug installation 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder surface 3 Piston y Piston ring worn out High compression pressure y Too much carbon deposit on combustion chamber or piston head Noise y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Cam chai...

Page 65: ...stem hose from the cylinder head Remove the cylinder head cover 4 bolts and then remove the cylinder head cover Loosen the bolt of camshaft chain adjuster in a counter clockwise motion for release adjuster Removed cam chain adjustment bolt And then removed the chain adjuster bolts 2 Removed cylinder head side cover 4 bolts bolts Chain adjuster Cylinder head side cover ...

Page 66: ... on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Remove camshaft sprocket bolt bolt 2 Remove the cam sprocket and cam chain Removed the bolts of the left side of the cylinder head between cylinder head and cylinder bolt 2 Removed cylinder head fixed nut nuts 4 TDC mark Bolts 2 Bolts 2 Nuts 4 ...

Page 67: ...YM 6 6 Remove cylinder head Caution DISASSEMBLY CYLINDER HEAD Remove the fixed bolt 1 then remove the camshaft Remove the valve rocker arm shaft Remove the valve rocker arm Loosen the nuts diagonally by 2 3 sequences Camshaft ...

Page 68: ... Clean residues and foreign materials on cylinder head matching surface Caution CAMSHAFT INSPECTION Inspect cam lobe height for damaged Service Limit IN Replacement when less than 25 57 mm EX Replacement when less than 25 41 mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Camshaft bearing Do not over compressed valve springs Avoiding weake...

Page 69: ...ulate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack Measure cylinder head flat with a straightedge and flat feeler gauge Service limit below 0 05mm Valve spring free length Measure the free length of intake and exhaust valve springs Standard 35 250 mm The narrow pit...

Page 70: ...rrect it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too Caution Valve guide replacement Heat up cylinder head to 100 150 with heated plate or toaster Caution Before measuring the valve guide clean carbon deposits with reamer If clearance between valve stem and valve guide exceeded service limit check whether the new clearanc...

Page 71: ...d valve seat with a rubber hose or other manual grinding tool Caution Remove the valve and check its contact face Caution y Check if new valve guide is deformation after pressed it in y When pressing in the new valve guide cylinder head still must be kept in 100 150 y Using cutting oil when correcting valve guide with a reamer y Turn the reamer in same direction when it be inserted or rotated y Do...

Page 72: ...h or uneven surface from valve seat Caution Use 32 cutter to cut a quarter upper part out Use 60 cutter to cut a quarter lower part out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width Caution Grind valve seat again if necessary After valve guide had been replaced it has to be grinded with 45 valve seal chamfer cutter to correct its seat face Make...

Page 73: ...o specified width After the valve seat grinded coat valve seat surface with emery and then slightly press the grinded surface Clean up all emery coated onto cylinder and valve after grinded CYLINDER HEAD REASSEMBLY Lubricate valve stem with engine oil and then insert the valve into valve guide Install new valve stem oil seal Install valve springs and retainers Caution The contact surfaces of valve...

Page 74: ...s on the left side of cylinder head With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the flywheel aligns with the mark on crankcase piston is at TDC position Install the cylinder head nuts and tighten it Torque value 2 0 2 4 kgf m Install the cylinder head left side bolt and tighten it Torque value 0 8 1 2 kgf m Install the spark plug and tighten it Torque value 1 ...

Page 75: ...adjuster adjustment hole Caution VALVE CLEARANCE ADJUSTMENT Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the adjustment nut Standard Value IN EX 0 12 0 02mm Especial tool The O ring must be installed into glove T mark B...

Page 76: ... 7 1 MECHANISM DIAGRAM 7 1 PRECAUTIONS IN OPERATION 7 2 TROUBLE DIAGNOSIS 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 MECHANISM DIAGRAM 0 8 1 2kgf m ...

Page 77: ...er 0 025 0 040 0 100 Piston Piston ring ID of piston pin hole 13 002 13 008 13 040 OD of piston pin 12 994 13 000 12 980 Clearance between piston and piston pin 0 002 0 014 0 018 ID of connecting rod small end 13 005 13 020 13 040 TROUBLE DIAGNOSIS Low Or Unstable Compression Pressure z Cylinder or piston ring worn out z Compress pressure to high z Too much carbon deposited in combustion chamber a...

Page 78: ...r to chapter 6 Remove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase 2 bolts camshaft chain adjuster Cylinder ...

Page 79: ...pective in the cylinder Service limit 39 047mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Check Cylind...

Page 80: ...ng the carbon in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Take out the piston rings and place them respective into cylinder below 20mm of cylinder top Measure each piston ring gaps Caution Service Limit Top ring replace if over 0 50mm 2nd ring replace if ...

Page 81: ... the inner diameter of piston pin hole Service Limit 13 040mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 38 970mm Compare measured value with service limit to calculate the clearance between piston and cylinder The measurement position is 10 mm distance from piston bottom side and 90 to piston pin ...

Page 82: ... Place the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston rings can be rotated freely after installed Top groove 2nd groove Oil groove Top ring 2nd ring Oil ring Spacer Side ring Side ring Over 20 mm 120 ...

Page 83: ...ken when installing piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder head gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto adjuster 2 bolts y Do not let the opening of piston pin snap ring align with the opening piston ring y Place a piece of cleaning cloth between piston skirt section and...

Page 84: ...UTCH 8 1 MECHANISM DIAGRAM 8 1 MAINTENANCE DESCRIPTION 8 2 TROUBLE DIAGNOSIS 8 2 LEFT CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 MECHANISM DIAGRAM 3 5 4 5kgf m 5 0 6 0kgf m 5 0 6 0kgf m 0 8 1 2kgf m ...

Page 85: ...OD of driven pulley 33 965 33 985 33 940 ID of sliding pulley 34 000 34 025 34 060 ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 5 0 6 0kgf m Clutch outer nut 5 0 6 0kgf m driving pulley nut 3 5 4 5kgf m Special Service Tools Clutch spring compressor Bearing puller inner type Clutch mounting nut wrench Universal fixture TROUBLE DIAGNOSIS Engine can be started but motorcycle c...

Page 86: ...te on the left crankcase cover screws 6 Remove left side cover plate gasket First put kick starter pedal into the starter shaft After a little rotation remove the drive gear and washer Removed kick starter pedal starter shaft return spring and the thrust washer Check if starter shaft drive gear bushing for wear or damage Replace it with new one if necessary Check the return spring for spring force...

Page 87: ...haft as diagram shown Install kick starter arm temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install thrust washer and socket onto starter shaft Installation of the left crankcase cover Install the left crankcase cover 8 bolts Install front vent tube of left cover and tighten the strap Install kick starter arm 1 bolt Tighten the air cleaner 2 bolts dr...

Page 88: ... same time Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited specification Service Limit 16 80mm Caution Using special service tools for tightening or loosening the nut Fixed rear wheel or rear brake only will damage reduction gear system y Using the genuine parts ...

Page 89: ...stall the clutch with universal fixture and then tighten nut to specified torque value Torque value 3 5 4 5 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily When install the driving belt if there is a arrow mark then the arrow mark must point to rotation motion If not the let...

Page 90: ...riving pulley Remove the sliding pulley fixing nut and remove the driving belt from the sliding pulley Remove the driving belt from the sliding pulley Remove the limited speed bush Remove the bush and remove the sliding pulley from the crankshaft Remove tilt plate Remove weight rollers from sliding pulley Tilt plate Sliding pulley Roller Bush Sliding pulley Limited speed bush Crankshaft Special to...

Page 91: ...ers are wear out or damage Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 57 mm Measure the inner diameter of the sliding pulley Service limit 34 06 mm Measure the inner diameter of the pulley bush Replace it if exceed the service limit Service limit 20 15 mm Assembly Installation Install the weight rollers Install the title plat...

Page 92: ...ut Caution Hold driving pulley with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover The pulley surface has to be free of grease Clean it with cleaning solvent Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent To press down the up down sides of the driving belt can avoid to pressing and dama...

Page 93: ... clutch spring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring oil seal seat from sliding pulley Inspection Clutch outer Measure the inner diameter of clutch outer friction face Replace the clutch outer if exceed service limit Service limit 107 ...

Page 94: ...ts Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bear...

Page 95: ...f necessary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location Caution Install the spring snap into groove with pliers y Grease or lubricant will damage the clutch block and effect the block s connection capacity Shock absorption rubber Clut...

Page 96: ...bearing Install a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary y Its sealing end should be forwarded to outside as bearing installation y Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser y If the inner bearing equipped with oil seal on one side in the driven pulley then remove the oil seal f...

Page 97: ...n pulley spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with special nut wrench Remove the clutch spring compressor Torque value 5 0 6 0 kg m Install clutch driven pulley and driving belt onto driving shaft Oil seal O ring ...

Page 98: ...DIAGRAM 9 1 OPERATIONAL PRECAUTIONS 9 2 TROUBLE DIAGNOSIS 9 2 DISASSEMBLY OF FINAL DRIVING MECHANISM 9 3 INSPECTION OF FINAL DRIVING MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANISM 9 6 MECHANISM DIAGRAM 2 6 3 0 kgf m ...

Page 99: ...ng puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover 2 6 3 0 kgf m Gear oil drain plug 1 0 1 5 kgf m Gear oil filling bolt 1 0 1 5 kgf m TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved Damaged driving gear Burnt out driving gear Broken driving belt Noise Worn or burnt gear Worn gear Gear oil leaks Excessive g...

Page 100: ... box cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft and the gear are wear or damage Check if the final driving shaft and gear are burn wear or damage 7 bolts final driving shaft final driving gear final driving shaft final driving gear countershaft count...

Page 101: ...wear or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Tool Press the bearing into cover with C type hydraulic presser or bearing installer Never install used bearings Once bearing remo...

Page 102: ...er Bearing protector Install a new driving shaft bearing onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a new final driving shaft bearing onto crankcase Specified tool Press the bearing in with C type hydraulic presser or the bearing installer Apply with some grease onto the lip section of oil seal and th...

Page 103: ... oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 6 3 0 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover Install the rear wheel Add gear oil Recommended usage gear oil SAE 85W 140 180 cc standard capacity 170 cc when replacement dowel pins Filling bolt Draining bolt final driving shaft cou...

Page 104: ...STALLATION 10 4 FLY WHEEL INSTALLATION 10 4 PRECAUTIONS IN OPERATION General information y Refer to chapter 5 Engine removal and installation y Refer to chapter 1 The troubleshooting and inspection of A C generator Torque value Flywheel nut 3 5 4 5kgf m Exhaust muffler bolt 8 mm 3 0 3 6kgf m Oil screen cover 1 0 2 0kgf m Special service tools Flywheel puller Universal fixture ...

Page 105: ...lts 2 nuts Remove the fan shroud 4 bolts Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the 10mm nut on the flywheel Special Service Tools Universal Fixture Flywheel Cooling fan Cooling fan shroud Coil Pulse generator Cable guide Universal fixture Cooling fan Exhaust muffler Cooling fan shroud ...

Page 106: ... Caution RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 8 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase Caution Do not damage the alternator coil Do not damage the connection surfaces Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the ...

Page 107: ...cover 2 bolts Install pulse generator 2 bolts Torque 0 8 1 2kgf m Tie the wire harness hose onto the indent of crankcase Install A C generator connector and pulse generator connector FLYWHEEL INSTALLATION Make sure that there is no magnetic powder If so clean up it Align insert on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel with flywheel holder and tighten i...

Page 108: ... 5 Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Cooling fan 4 bolts Exhaust muffler Cooling fan shroud ...

Page 109: ...RANKSHAFT 11 1 MECHANISM DIAGRAM 11 1 OPERATIONAL PRECAUTIONS 11 2 TROUBLE DIAGNOSIS 11 2 DISASSEMBLY OF CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 0 8 1 2 kgf m 0 7 1 1 kgf m ...

Page 110: ...eplaced Specification Unit mm Item Standard Limit Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Run out Below 0 030 0 10 Torque value Bolts for crankcase 0 8 1 2 kgf m Bolts for cylinder cylinder head 0 7 1 1 kgf m Engine oil draining plug 3 5 4 5 kgf m Bolts for cam chain tensioner 0 8 1 2 kgf m ...

Page 111: ...crankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Remove the cam chain Caution Special Service Tools Crankcase remover set z Never pry out the connection surfaces of crankcases as separating Otherwise the connection surfaces could be damaged and cause oil leaking z It have to separate the cam chain and the drive gear befor...

Page 112: ...s 2 Scrape gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase z Do not damage contact surface of the crankcase z Soap the gasket residues into solvent and the residues will be removed easily z The left and right bearings of crankshaft is to press fit onto the crankshaft ...

Page 113: ...ical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 60 mm 90...

Page 114: ...gasket Install the right crankcase and tighten the crankcase bolts 1 bolts Torque value 0 8 1 2 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution z Do not damage the cam chain as installing the crankshaft z The O ring must be installed into the bolt s groove h...

Page 115: ... 11 7 Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x37x6 Special service tools the oil seal installer 25x37x6 ...

Page 116: ...R COVER 12 8 LUGGAGE BOX 12 8 FLOOR PANEL 12 8 SIDE COVER 12 9 UNDER COVER 12 10 Double Seat Front cover Front handle cover Under cover Luggage box Rear carrier Left side cover Left body cover Front center cover Rear handle cover Floor panel Front under cover FR Inner box RR fender Right side cover Right body cover RR mudguard FR center cover FR Inner lid Top cover ...

Page 117: ...assembly operation y Align the buckles on the guards with slot on the covers y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during assembly Left right side cover Front cover Luggage box Seat Rear carrier Under cover Front Handle cover Rear handle cover Floor panel Rear fender Tail light Front fender Front center co...

Page 118: ...s Removed the left right turn signal light connectors Remove the front handle cover Remove the speedometer cable Remove the rear handlebar cover 3 screws Removed the rear handle cover Installation Install according to the reverse procedure of removal Caution With the clipper to fix the end section of the handlebar cover Do not pull it forcedly to avoid to breaking the hooks turn signal light conne...

Page 119: ...emove the 1 mounting bolt of front cover from the frame Remove the front under cover 4 mounting screws between the front under cover and the frame Remove the 2 mounting screws between the front cover and the left right side cover bolt 1 Top cover screws2 2 Screws1 2 ...

Page 120: ...ner box Remove the front cover from the frame Installation Install according to the reverse procedure of removal FRONT INNER BOX Removal Remove the 8 mounting screws of front cover from the inner box A Remove the hook screw bolt from the front inner box 1 bolt Front cover screws 4 2 screws 4 2 ...

Page 121: ...nt inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal BODY COVER REAR CENTER COVER REAR FENDER Removal Open the seat Remove 2 bolts in front of the luggage box Remove 2 bolts in rear of the luggage box Remove the luggage box Remove the rear carrier 3 bolts 2 screws 2 bolts 3 bolts 2 bolts Main switch cover ...

Page 122: ...body cover and the frame Remove the left right side 2 mounting bolts under rear of the body cover between the body cover and the frame Remove the rear fender Remove the left right body cover Installation Install the body cover and rear fender according to the reverse procedure of removal 1 bolt 4 screws Bolts1 2 ...

Page 123: ...n the seat Remove the 4 bolts from the luggage box Remove the luggage box and the double seat Installation Install the luggage box according to the reverse procedure of removal FLOOR PANEL Removal Remove the 4 bolts from the luggage box Remove the luggage box and the double seat Remove the front center cover Remove the 2 bolts between the floor panel and the frame 4 bolts screws 5 Front center cov...

Page 124: ...Install the floor panel according to the reverse procedure of removal SIDE COVER Removal Remove the left right side 2 mounting screws in the front of the side cover Remove the left right side 2 mounting bolts in the rear of the side cover Remove the left right side cover Installation Install the side cover according to the reverse procedure of removal Screws1 2 2 screws Screws1 2 ...

Page 125: ...emove the floor panel Remove the left right side cover Remove the left right side 4 mounting bolts between the under cover and frame Remove the under cover Installation Install the under cover according to the reverse procedure of removal Bolts2 2 ...

Page 126: ...13 3 TROUBLE DIAGNOSIS 13 4 HYDRAULIC BRAKE SYSTEM INSPECTION 13 5 BRAKE FLUID REPLACEMENT AIR BLEED 13 6 BRAKE CALIPER 13 7 BRAKE DISC 13 8 BRAKE MASTER CYLINDER 13 8 DRUM BRAKE DRUM 13 11 BRAKE LING 13 11 BRAKE PANEL 13 12 MECHANISM DIAGRAM Front Disc Brake System 5 0 7 0 kgf m 4 0 4 5 kgf m 0 8 1 0 kgf m 3 3 3 7 kgf m 2 8 3 2 kgf m ...

Page 127: ...13 BRAKE SYM 13 2 MECHANISM DIAGRAM Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m ...

Page 128: ...tem Standard Limit The thickness of front brake 3 50 2 00 Front brake disc eccentricity 0 15 0 30 Master cylinder inner diameter 25 40 IID of front rear brake drums 130 00 131 00 OD of front brake disc 226 00 Thickness of front disc brake As brake ling mark Thickness of front drum brake 2mm or As brake ling mark Thickness of rear brake lining 2mm or As brake ling mark Torque values Bolt for front ...

Page 129: ...ation of brake lever z Blocked brake system z Poor brake caliper z Blocked brake pipe z Seized worn master cylinder piston z Bent brake lever Uneven brake z Dirty brake lining disc z Poor wheel alignment z Clogged brake hose z Deformed or warped brake disc z Restricted brake hose and fittings Tight brake z Dirty brake lining disc z Poor wheel alignment z Deformed or warped brake disc Brake noise z...

Page 130: ...d brake fluid WELLRUN DOT 3 brake fluid CAUTION Brake Fluid Add Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or rubber components when conduct brake system maintenance CAUTION z Do not over the upper level when adding brake fluid and avoid to spilling brake fluid on painted surfaces plastic or rubber c...

Page 131: ...r bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve CAUTION 2 Slowly release the brake lever and wait for a few seconds until it reaches its top position 3 Repeat the steps 1 and 2 until there is no air bubble at the end of the hose Tightly close the dr...

Page 132: ...ter brake lining Compress the brake caliper at first as installation Install the inner brake lining firstly and then install the outer brake lining INSTALLATION Install the brake caliper and tighten the attaching bolts securely Torque 3 3 kgf m CAUTION Tighten the lining guide bolt Torque 1 8 kgf m Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5 kgf m Ref...

Page 133: ...rake master cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder Remove the rubber pad Remove the circlip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Do not let foreign materials enter into the cylinder The whole set of master cylinder piston spring diaphragm and circlip should be replaced after removal z Do not let grea...

Page 134: ... cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master cup Install the circlip CAUTION Install the rubber pad into groove properly z It is necessary to replace the whole set comprising piston spring piston cup and circlip z Make sure there is no dust on a...

Page 135: ...fied torque value Install the brake lever and connect leads to brake lamp switch Connect brake hoses with 2 new washes Tighten the brake hose bolt to the specified torque value Torque value 3 5 kgf m Make sure the hose is installed correctly CAUTION CAUTION Add specified brake fluid and bleed the system and conduct the air bleeding job for the system Improper routing may damage leads hoses or pipe...

Page 136: ...BRAKE LINING Inspection Measure the thickness of the brake lining at three points both ends and center If the thickness is less than specified or if it is contaminated by oil or grease replace as a set Service limit Front 2 0 mm Rear 2 0mm Inhaling dust may cause respiration system disorder even cancer Never use an air hose or a dry brush as to clean the brake parts Grease on brake lining will red...

Page 137: ...llation Slightly grind the brake lining surfaces with sand paper to clean the surfaces Caution BRAKE PANEL Removal Remove the brake arm bolt and then remove the brake arm wear indicator brake return spring and brake cam as well as the oil seal from the brake panel Brake linings must be replaced as a set Braking efficiency will be reduced if brake lining is contaminated by oil or grease Bolt Brake ...

Page 138: ...ner gear of wear indicator and the mark on the brake arm with the indent gear of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2 kgf m REAR BRAKE PANEL Apply a thin cost of grease between the oil seals on the brake cam shaft Install the brake cam Align the mark on the brake arm with the inner gear of the brake cam Tighten the bolts and nuts to specified ...

Page 139: ...ISM DIAGRAM 14 1 PRECAUTIONS IN OPERATION 14 2 TROUBLE DIAGNOSIS 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT SHOCK ABSORBER 14 9 FRONT FORK STEERING COLUMN 14 9 MECHANISM DIAGRAM 3 1 3 5kgf m 1 0 2 0kgf m 0 2 0 3kgf m 4 0 5 0kgf m 5 0 7 0kgf m 2 4 3 0kgf m ...

Page 140: ...0kgf m Tools Special service tools Steering column wrench Bearing remover Inner type bearing remover Attachment 32 35 mm Attachment 42 47 mm Steering column nut wrench Steering column top cone ring nut wrench TROUBLE DIAGNOSIS Hard steering stem y Over tightening of steering stem lock nut y Broken steering stem steel ball and cone bearing seat y Insufficient tire pressure Steering stem off center ...

Page 141: ... Remove acceleration handlebar screw and then remove the handlebar acceleration cable and handlebar cover seat Remove the rear brake lever nut and screw then take out the rear brake cable Remove the brake lever seat bolt and then remove the seat Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder Screw Bolts x 2 Master cylinder Split rin...

Page 142: ...arts when installing the acceleration handlebar seat acceleration handlebar and acceleration cable FRONT WHEEL Removal Disc Brake type Support body bottom and lift front wheel free of ground Remove the bolts and disconnect speedometer cable from the gear box Remove the wheel axle nut and pull out the axle Then remove the front wheel Caution Do not operate the front brake lever to avoid to pressing...

Page 143: ...n V blocks and measure the run out Service limit 0 2 mm Wheel Rim Place the wheel onto a rotated bracket Turn the wheel with hand and measure its wobble value with a dial gauge Service limit Radial 2 0 mm Axial 2 0 mm Disassembly Disc type Remove 3 hex socket bolts and brake disc Wheel axle ...

Page 144: ...eck if the outer collar is tightly connected to the wheel hub If the bearing do not turn smoothly or if they are too loose in the races or damaged then remove and replace the bearings with new ones Caution Installation Install the bearing according to the reverse procedure of removal Apply some grease into the bearing seat of the wheel hub Install the left bearing onto the seat Install the bearing...

Page 145: ... the front wheel side collar Apply with some grease on both side of the speedometer gear oil seal and then install the seal y Do not install used bearing and replace the bearing once it has been removed y Do not the bearing in tile motion when installing This two example will to louse the bearing Dust seal Wheel side collar Speedometer gear dust seal Bearing Bearing Bearing spacer DISC BRAKE ...

Page 146: ...rt on the speedometer gear with the slot of shock absorber stopper Disc Brake Install the front wheel axle from right shock absorber side Install the wheel axle nut and tighten it to specified torque value Torque value 11 0 13 0kgf m Connect the speedometer cable to the speedometer gear box Contaminated brake lining will reduce brake performance so the brake lining brake drum and disc must be free...

Page 147: ...rk Installation Install the shock absorbers according to the reverse procedure of removal Align the shock absorber top edge with the top end level of the front fork when installing the front shock absorber onto the front fork Then tighten the nut Torque value 2 4 3 0kgf m FRONT FORK STEERING COLUMN Removal Firstly remove the handlebar front wheel front brake set and front shock absorbers Remove th...

Page 148: ...t with the top bearing seat no clearance Note return 1 2 turn and then tighten the top cone race to specified torque tighten the race around 1 4 3 8 turn more Torque value 0 2 0 3kgf m Caution Install the steering column nut and lock the top cone race Then tighten the nut Torque value 1 0 2 0kgf m Install the bearing seat according to the reverse procedure of removal Caution Do not damage the fram...

Page 149: ...15 1 MECHANISM DIAGRAM 15 1 PRECAUTIONS IN OPERATION 15 2 TROUBLE DIAGNOSIS 15 2 EXHAUST MUFFLER 15 3 REAR WHEEL 15 3 REAR SHOCK ABSORBER 15 4 MECHANISM DIAGRAM 0 8 1 2kgf m 3 0 3 6kgf m 11 0 13 0kgf m 1 0 1 4kgf m 2 4 3 0kgf m 3 5 4 5kgf m ...

Page 150: ...ck absorber lower mount bolt 2 4 3 0kgf m Exhaust muffler connection nut 1 0 1 4kgf m Exhaust muffler connection bolt 3 0 3 6kgf m TROUBLE DIAGNOSIS Rear wheel wobbling z bend wheel rim z poor tire z loosen wheel shaft Shock absorber too soft z insufficient shock absorber spring force Braking Noise z worn brake lining z brake drum deformation z improperly brake panel installation z unparalleled br...

Page 151: ...t 1 0 1 4kgf m REAR WHEEL Inspection Measure wheel rim wobbling Service limit Radial 2 0mm Axial 2 0mm If the wheel rim wobbling out of the specification except resulted from the wheel rim deformation it might be loosen or worn final driving shaft bearing or bend deformed driving shaft Removal Remove the rear inner mudguard Bolt x 1 Remove the exhaust muffler bracket bolts x 3 Remove the rear disk...

Page 152: ... the upper nut of the rear shock absorber bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution Torque values Rear shock absorber lower mount bolt 2 4 3 0 kgf m Rear shock absorber upper mount bolt 3 5 4 5 kgf m The rear shock absorber has to be replaced with one set and can not be replaced by unauthorized persons...

Page 153: ... SYSTEM 16 11 STARTING SYSTEM 16 14 METER 16 15 LIGHTS BULBS 16 17 SWITCH 16 19 FUEL UNIT 16 22 MECHANISM DIAGRAM Spark plug Fuel unit Ignition coil Main switch Starter magnetic switch Light starter switch Horn turn signal light high low beam Front stop switch Rear stop switch Auto by star REG REC C D I Battery fuse box Winker relay Horn ...

Page 154: ...lyte and then charged to prolong the battery s life span z Please check electrical device according to the procedure of diagnosis chart z Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage current regulator will be damaged The ignition switch must be turned OFF ...

Page 155: ...istance 20 5W5Ω 4 5 5 5Ω Resistor Resistance 20 30W7 5Ω 7 0 8 0Ω Ignition System Item Specification Standard A7RC Recommended usage Hot type A8RC Cold type A6RC Spark plug Spark plug gap 0 6 0 7 mm Primary 0 21 10 Ω With plug cap 7 6 10 KΩ Ignition coil resistance 20 Secondary Without plug cap 3 1 10 KΩ F Mark Before TDC 13 1700 rpm Before TDC 28 4000 rpm Ignition timing Timing advanced character ...

Page 156: ...C D I z alternator is out of work Engine does not crank smoothly z Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch z Secondary coil circuit Poor ignition coil Poor spark plug Poor high tension cable Current leakage in the spark plug cap z Incorrect ignition timing Poor alternator Improper installation of the pulse sensor Poor C D I Starting System S...

Page 157: ...t may indicate a short circuit Allowable current leakage Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit z In the current leakage test set the current range at larger scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse z Do not turn the main switc...

Page 158: ...ort connect positive terminal at first and next negative terminal z Electrolyte diluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind In case of being spread flush with great quantity of water immediately and then send to hospital z When clothes is spread by electrolyte it will contact with skin So it must flush with great quantity water to tak...

Page 159: ...clean grease z Strictly keep flames away from a charging battery z The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires z Turn the charger s switch OFF at first before or after charging to prevent from sparks created on the connectors and explosion z To charge a battery must be based on the battery s ampere hour showed on label z Quick charge ...

Page 160: ... battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not z The replacement battery is aged and does not have enough capacity z Battery used do not have enough electricity or is over charged z The fuse of the ammeter is blown z The ammeter is improperly connected 3 The charging current is normal but the voltage is not z The fuse of the voltmeter is ...

Page 161: ...ured value is abnormal check the abnormal wire circuit If components are good it could be a poor wire circuit If all items are in good condition then replace the voltage regulator If main wire circuit check is in normal and there is no loose in the pins of voltage regulator connector then measure the resistance between the connector of voltage regulator Voltage Regulator Check Unit Ω Multi meter M...

Page 162: ...r Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 1Ω 20 Replace the alternator lighting coil if the measured value exceeds standard Resistor check Remove the front cover Measure the resistance between the resistor wire green black and frame ground Standard 5Ω 5W 4 5 5 5 green black Standard 7 5Ω 30W 7 0 8 0 pink The check of alternato...

Page 163: ...on at each terminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200Ω Primary Black yellow green 0 21Ω 10 Green high voltage cable w o cap 3 5KΩ Ignition Coil Secondary Green high voltage cable w cap 7 12KΩ CDI UNIT Black red green main switch spark plug Ignition coil C D I unit Pulse green black yellow Blue yellow Black white Blue yellow green...

Page 164: ... terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to black yellow side Min voltage Above 95 V Caution Primary coil check Disconnect the primary coil connector and check the resistance between primary coil terminals Standard 0 21Ω 10 Ω at 20 Primary coil i...

Page 165: ...d and the measured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution Check Remove body cover Remove the pulse generator connector Measure the resistance between blue yellow terminal on engine side and frame ground Standard 140 20Ω 20 Replace the alternator if the meas...

Page 166: ...ositive connection and starting motor wires from the starter magnetic switch large pin Remove the power control connector of the Starter magnetic switch Connect a Ohmmeter between the Starter magnetic switch large pins Connect the green yellow wire to battery positive terminal and yellow red to battery negative terminal Check the continuity between the Starter magnetic switch large pins If it is n...

Page 167: ...emove the luggage box Remove the starting motor power wire Remove the starting motor mounting bolts and motor Starting Motor Installation Install the motor in reverse order of removal METER Removal Remove the front handle cover Remove the speedometer cable Remove the front cover Remove the power connector of the meter Bolts x2 Meter connector Meter speedometer cable ...

Page 168: ...rse order of removal Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components High Beam Indicator Fuel meter Odometer Speedometer Turn Right Signal Indicator Turn Left Signal Indicator Odometer Trip kilometer Speedometer Turn Left Signal Indicator High Beam Indicator Fuel meter Turn Right Signal Time meter ...

Page 169: ...has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment bolt located under the headlight Caution z Do not touch the bulb surface with fingers because the bulb will create hot spot so that let it be burnt It has to be package with cloth or wear glove as installing z Wipe the bul...

Page 170: ...f removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the taillight left right turn light lens Remove the tail light assembly Replace the bulbs of the tail light brake light 12V 5W 21W Replace the bulbs of the turn signal light 12V 10W Installation Install the bulb in reverse order of removal the wire connector of the turn signal light tail light brake...

Page 171: ...nect main switch leads connector Check connector terminals for continuity color Location Black Red green green OFF ON LOCK Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the main switch Install a new main switch and tighten the bolts bolts x2 main switch connector terminals main switch bolts x 2 ...

Page 172: ...cation Yellow red green FREE High Low beam switch passing color Location blue white brown white White green passing Horn switch color Location Black Light green FREE headlight switch starting switch turn signal switch High Low beam switch passing horn switch brown brown white yellow red green headlight switch Starting switch yellow pink yellow brown white Black white Horn switch Light green High L...

Page 173: ...ow wire on the brake light switch should be in continuity when operating the brake lever If the switch damaged replace it with new one Horn Remove the front cover Connect the light blue wire on the horn to the battery positive terminal and the green wire to the battery negative terminal Then the horn should sound Replace it if necessary Sky blue gray turn signal light switch orange ...

Page 174: ...7 5 107 5Ω F full 4 10Ω DOWN empty Connect the fuel unit to the main harness Turn the main switch ON position Move the float arm in UP DOWN and then check if the fuel unit indication needle is in correct position Caution Float arm position Indicator needle UP full E empty DOWN empty F full Installation Install the fuel unit in reverse order of removal Do not damage or bend the float arm as removin...

Page 175: ......

Page 176: ...R NO SYM 9020100 PURPOSE REMOVE ONE WAY CLUTCH FIX NUT ITEM BEARING DISASSEMBLER NO SYM 6202Z 6204 PURPOSE REMOVE THE BEARING ITEM UNIVERSAL HOLDER NO SYM 2210100 PURPOSE HOLD THE MDF CLUTCH OUTER ITEM CLUTCHSPRING COMPRESSOR NO SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH ITEM CLUTCH NUT WRENCH NO SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT ...

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SANYANG INDUSTRY CO. SYM, Service Manual

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