Sym Euro 100 Service Manual Download

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CRANKCASE/CRANKSHAFT

9-3

Crankcase Disassembly

Remove the crankcase bolts.

Install the crankcase puller onto the right
crankcase with two (2) bolts, 6mm, as the
diagram shown.
Disassemble the right crankcase.

Crankshaft Removal

As the diagram show with 3 special bolts to
install the specified service tool onto the left
crankcase.
Remove the crankcase.

Caution

Do not use iron hammer to knock out the
crankshaft.

Remove crankshaft bearing with bearing puller.
Remove the right and left side oil seals.

Caution

Replace the oil seal with new one as
removing the crankshaft.

Right crankcase

Crankcase puller

Outer bearing puller

Crankcase puller

Bolts

Shaft protection collar

Left crankcase

This chapter Contents

Summary of Contents for Euro 100

Page 1: ...SERVICE MANUAL Forward Contents How To Use This Manual Mechanism Illustrations 50 100 50 100...

Page 2: ...rvice Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the motorcycle JET 50 100 and JET Euro 50 100 serie...

Page 3: ...rves the rights to make changes at any time without prior notice and without incurring any obligation whatever Without written consent by SANYANG can not copy any part of this manual There are 4 butto...

Page 4: ...ER PISTON 5 6 1 6 4 ALTERNATOR 6 7 1 7 14 V TYPE BELT DRIVING SYSTEM KICK STARTER 7 8 1 8 6 FINAL DRIVING MECHANISM 8 9 1 9 6 CRANKCASE CRANKSHAFT 9 10 1 10 10 FUEL SYSTEM 10 11 1 11 12 BRAKE SYSTEM 1...

Page 5: ...l light Helmet hook Fuel tank cap Engine number Storage box Muffler Battery Fuses C D I Eng Oil tank cap Light Starter switch High Low beam Turn signal Horn switch Air cleaner Frame number Front turn...

Page 6: ...light Helmet hook Fuel tank cap Engine number Storage box Muffler Battery Fuses C D I Eng Oil tank cap Light Starter switch High Low beam Turn signal Horn switch Air cleaner Frame number Front turn s...

Page 7: ......

Page 8: ...use SAE 20 JASO FC class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil MAX 2 serial oils Grease King Mate G 3 is recommended Gear oil King...

Page 9: ...gine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution y Battery emits explosive gases flame is strictly prohi...

Page 10: ...em z Never bend or twist a control cable to prevent stiff control and premature worn out z Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts be...

Page 11: ...ufacturer 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 z Remove residues of the old gasket or sealant before reinst...

Page 12: ...EAR Type Gasoline Clutch Centrifugal dry type Installation and arrangement Horizontal below center incline FORMAN PERCE Transmission C V T Fuel Used Unleaded 92 95 Speedometer 0 90 km hr Cycle Cooling...

Page 13: ...GEAR Type Gasoline Clutch Centrifugal dry type Installation and arrangement Horizontal below center incline FORMAN PERCE Transmission C V T Fuel Used Unleaded 92 95 Speedometer 0 120 km hr Cycle Cool...

Page 14: ...2 4 3 0 kg m 12 mm Bolt nut 5 0 6 0 kg m 10 mm Flange bolt nut 3 5 4 5 kg m The torque values listed in below table are for more important tighten torque values Please see above standard values for no...

Page 15: ...onnection 2 6 1 2 Nut for exhaust 2 8 3 3 Brake hose bolts 2 10 3 5 Brake caliper mounting bolts 2 8 3 1 Brake cushion guide bolts 2 6 1 8 Brake cushion guide bolts cap 2 6 1 0 Brake drain valve 1 6 0...

Page 16: ...or tube if they contact a sharp edge or corner Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses far away from the exhaust pipes an...

Page 17: ...Winker switch Speedometer Headlight switch Starter switch Throttle cable Headlight Rear brake cable Speedometer cable Throttle cable Main switch Regulator Resistor Horn Front brake hose Speedometer c...

Page 18: ...brake cable Fuel unit cord Fuel filter Speedometer cable Rear brake cable Front brake hose Throttle cable Fuel unit Winker relay Front brake hose Rear brake cable Speedometer cable Throttle cable Fro...

Page 19: ...NERAL INFORMATION 1 12 Fuel filter Battery C D I UNIT Fuse Purge control valve Oil control cable Fuel hose Fuel pump Vacuum hose Oil hose Rear brake cable Carburetor Oil lever switch This chapter Cont...

Page 20: ...ow 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 clo...

Page 21: ...scoloration Fouled and discoloration No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 1 Malfunction of CDI 2 Malfunction o...

Page 22: ...retor O ring 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or short circuit in spark plug leads 6 Malfunction of main switch 1 Insufficie...

Page 23: ...ulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damage 7 Transmission gear worn out or burned Engine running and misfire as motorcycle initial for...

Page 24: ...rication Points Engine suspension bushing Seat lock Rear wheel bearing Steering shaft bearing Speedometer gear front wheel bearing Side stand shaft Main stand shaft Throttle cable Front rear brake lev...

Page 25: ...1 GENERAL INFORMATION 1 18 Note This chapter Contents...

Page 26: ...Muffle 2 13 Cylinder Compression Pressure Test 2 13 Headlight Adjustment 2 14 General Information Specification Model Item JET 50 JET 100 Tire dimension Front 120 70 12 Rear 130 70 12 Tire pressure a...

Page 27: ...Emission check in Idling I I 20 Idle speed check I I 21 Fuel lines I I 22 Throttle operation I I 23 Engine bolt tightening I I 24 Engine screw torque I 25 Carbon cleaning for cylinder head cylinder pi...

Page 28: ...ap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover Limit to use SAE 20 JASO FC class engine oil otherwise...

Page 29: ...the fuel line for leaking Engine Oil Line Remove the body cover Check the engine oil line and replace damaged parts Remove the filling pipe from the oil pump and drain oil into a cleaning container Lo...

Page 30: ...le grip play Remove the body cover Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump body Loosen the adjustment nut of the oil pump con...

Page 31: ...or un even wear Caution Wear indicator is distributed on average along the wall rubber for check Battery Open the seat Loosen two screws of battery cap and then remove the cap Check if the battery ter...

Page 32: ...r Free play 10 20 mm 3 8 3 4 in Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution After brake adjustment it has to check the brake operation to mak...

Page 33: ...ot operate the brake lever after the cap had been removed Otherwise the brake fluid will spread out if operated the lever z Do not mix non compatible brake fluid together Brake Lining Wear Rear Drum B...

Page 34: ...clipping the brake lining Pry out the brake lining with a flat driver if lining is clipped Remove brake lining bolt Take out the lining Tighten Torque Mounting bolt 2 9 3 5 kgf m Pin bolt 1 5 2 0 kgf...

Page 35: ...ive ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be re...

Page 36: ...e spark plug seat z Remove the spark plug z Visually inspect the spark plug electrodes for wear z The center electrode should have square edges and side electrode should have a constant thickness Repl...

Page 37: ...move the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is cor...

Page 38: ...d remove the spark plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 0 1 kg cm2 Probable causes for low comp...

Page 39: ...e headlight for adjustment its light beam Tighten the headlight mounting bolt after adjusted Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for...

Page 40: ...utions In Operation 3 2 Lubricant 3 2 Trouble Shooting 3 2 Oil Pump Removal 3 3 Oil Pump Installation 3 3 Oil Pump Oil Tube Air Bleeding 3 4 Oil Tank 3 5 Lubrication System Diagram Oil pump Oil output...

Page 41: ...ply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage z Recommended Oil MAX 2 oil z Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil...

Page 42: ...Check if pump body is damaged z Check if pump gear is damaged z Check for oil leaking Caution The oil pump can not be disassembled Oil Pump Installation Install the oil pump onto the crankcase Cautio...

Page 43: ...l with oil Then install the tube onto oil pump z Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted ai...

Page 44: ...cover Remove the rear fender Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil switch wire of the oil indicator Remove the mounting bolt on the oil tank u...

Page 45: ...3 LUBRICATION SYSTEM 3 6 NOTES This chapter Contents...

Page 46: ...l of engine for maintenance z Crankcase z Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt 5 0kgf m Engine bracket bolt 6 0kgf m Rear shock absorber upper mounting b...

Page 47: ...control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire connectors of auto by starter and ACG Remove the upper part of the carburetor from its upper side R...

Page 48: ...ting bolts 2 bolts Support the engine and then remove shock absorber lower mounting bolt Remove two exhaust pipe connection nuts Remove two bolts beside fan cover and exhaust pipe Mounting bolt Shock...

Page 49: ...upper mounting bolts Rear shock absorber lower mounting bolts Exhaust pipe connection nut Muffle mounting bolt 5 0kgf m 4 0kgf m 2 7kgf m 1 2kgf m 3 3kgf m Perform the following inspection and adjust...

Page 50: ...5 CYLINDER HEAD CYLINDER PISTON 5 1 Maintenance Information 5 2 Troubleshooting 5 2 Cylinder Head 5 3 Cylinder Piston 5 5 5 Home page Contents...

Page 51: ...14 030 Piston pin OD 11 994 12 000 11 970 13 994 14 000 13 970 Clearance between piston and piston pin 0 002 0 014 0 030 0 002 0 014 0 030 Piston ring end gap 0 100 0 250 0 400 0 100 0 250 0 400 Pist...

Page 52: ...oval Remove the 4 cylinder head bolts and then remove the cylinder head Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging it Cleaning Carbon In Combustion Chamber Cle...

Page 53: ...nd by 2 3 sequences Tighten torque 1 0 kgf m Install spark plug Tighten torque 1 4 kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut...

Page 54: ...ece and then push piston pin out the piston Caution y Do not damage or scratch the piston y Do not apply with lateral force to connecting rod y Do not let piston pin snap ring falling into crankcase P...

Page 55: ...ndition Service limit JET 50 39 050mm JET 100 51 050mm Measure the OD of piston at the 7 mm from the bottom of the piston Service limit JET 50 38 935 mm JET 100 50 935 mm Calculate the clearance betwe...

Page 56: ...in in the ring groove Install the top ring and the 2nd ring onto the ring groove respective Caution The top ring and the 2nd ring can not be changeable each other Push the rings into ring groove and t...

Page 57: ...onto the interfaces of cylinder and crankcase Place a new gasket onto the crankcase Make sure that the piston ring aligns with the lock pin in piston ring groove Caution Make sure that all rings in th...

Page 58: ...6 ALTERNATOR 6 1 Maintenance Information 6 2 Alternator Removal 6 3 Alternator Installation 6 4 6 3 8 kgf m Home page Contents...

Page 59: ...Please refer to Chapter 15 for the relative alternator inspection Torque value Flywheel 3 8 kgf m Tool General tool Rotor puller Universal holder Coil resistance value for the A C alternator JET 50 1...

Page 60: ...n cover Remove four bolts and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel Remove the flywheel with rotor puller...

Page 61: ...Caution Connect the alternator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove Caution z Clean dirt and metal pieces inside the flywhe...

Page 62: ...Information 7 2 Trouble Shooting 7 2 Left Crankcase Cover 7 3 Reassembly Of Kick Starter 7 4 Installation Of The Left Crankcase Cover 7 4 Drive Belt 7 5 Movable Driven Pulley 7 6 Clutch Driven Pulley...

Page 63: ...driven face 33 000 34 060 ID Inner Diameter OD Outer diameter Torque Values Movable drive face 3 8 kgf m Driven pulley 5 5 kgf m Clutch outer 3 8 kgf m Special Service Tools Clutch spring compressor...

Page 64: ...r Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection of kick Starte...

Page 65: ...mporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Installation Of The Left Cr...

Page 66: ...clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diag...

Page 67: ...tighten nut to specified torque value Torque value 3 8 kgf m Movable Drive Face Removal Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Remove...

Page 68: ...le driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wear out or damage Replace it if necessary Measure...

Page 69: ...m Measure the inner diameter of drive face and replace it if it exceed service limit Service limit 20 120 mm Reassembly Installation Install weight rollers Install ramp plate Apply with grease 4 5g to...

Page 70: ...Install drive face washer and nut Caution y Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to specifie...

Page 71: ...nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven pulley an...

Page 72: ...r diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is d...

Page 73: ...amage or deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch...

Page 74: ...lace new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Install new inner bearing Caution y Its sealing end should be forwarded to outside...

Page 75: ...tch 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 specifi...

Page 76: ...8 1 Maintenance Information 8 2 Troubleshooting 8 2 Disassembly of Final Driving Mechanism 8 3 Inspection of Final Driving Mechanism 8 4 Bearing Replacement 8 4 Re Assembly of Final Driving Mechanism...

Page 77: ...500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6204 SYM 9110400 Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 L crank puller SYM 1130000 L L crank shaft install...

Page 78: ...then remove the cover from the rear wheel side Remove final gear final shaft and counter gear counter shaft Remove the drive shaft from left crankcase Caution y The bearing must be replaced when remov...

Page 79: ...l Inner type bearing puller Re Assembly Of Final Driving Mechanism Re assemble the gearbox cover and left crankcase with special tools Special tool Gear Box Cover Final shaft bearing Bearing driver 62...

Page 80: ...new gasket and lock pin Install gearbox cover Install clutch driven pulley assembly Install driven pulley drive belt and left crankcase side cover Install body cover Install rear wheel Fill out specif...

Page 81: ...8 FINAL DRIVING MECHANISM 8 6 Notes This chapter Contents...

Page 82: ...ANKSHAFT 9 1 Maintenance Information 9 2 Troubleshooting 9 2 Crankcase Disassembly 9 3 Crankshaft Removal 9 3 Crankshaft Inspection 9 4 Crankcase Installation 9 5 9 Apply liquid gasket 1 0 kgf m Home...

Page 83: ...by using the specified service tools The old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil seal has to be replaced with new on...

Page 84: ...special bolts to install the specified service tool onto the left crankcase Remove the crankcase Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with bearing pulle...

Page 85: ...ons as diagram show Service limit 0 04 mm Place the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Service limit A 0 10 mm B 0 10 mm Check the crankshaft bear...

Page 86: ...al tool Install new bearing into left crankcase Install crankshaft onto the left crankcase Install left crankshaft puller and install bush onto crankshaft Screw the left crankshaft puller onto cranksh...

Page 87: ...crank shaft install bush install new oil seal into the right crankcase Its installation depth is 4mm as the diagram shown With the specified tool to install a new oil seal onto the left crankcase to...

Page 88: ...e 10 4 Auto By Starter 10 4 Float Float Valve Jet 10 6 Flaot Level Inspection 10 7 Carburetor Installation 10 7 Reed Valve 10 7 Fuel Pump 10 8 Air Cleaner 10 9 10 Fuel tank Fuel unit Fuel filter Vacuu...

Page 89: ...level 8 8 1 0mm Air screw opener 1 3 8 Idle speed 2000 100 rpm 2100 100 rpm Throttle handle free play 2 6 mm Troubleshooting Engine can not be started 1 No fuel in fuel tank 2 Fuel can not reach to ca...

Page 90: ...etor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve...

Page 91: ...meter to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replac...

Page 92: ...that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor is i...

Page 93: ...e screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Installation Install the idle jet the needle jet...

Page 94: ...ith bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Connect the automatic by starter connector Install air cl...

Page 95: ...after installed Fuel Pump Inspection Remove the body cover Warm up the engine and adjust idle speed Remove fuel hose from carburetor and then wait for 5 minutes Measure the output of fuel pump Its ou...

Page 96: ...YSTEM 10 9 Air Cleaner Removal Installation Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Install in the reverse order of removal procedures Bolts This chapter Contents H...

Page 97: ...10 FUEL SYSTEM 10 10 Notes This chapter Contents...

Page 98: ...ormation 11 3 Troubleshooting 11 4 Hydraulic Disc Brake 11 5 Disc Brake Air Bleed 11 6 Disc Brake Caliper 11 6 Brake Disc 11 7 Disc Brake Master Cylinder 11 7 Drum Brake 11 10 Front Disc Brake System...

Page 99: ...11 BRAKE SYSTEM 11 2 Rear Drum Brake System 2 5 kgf m 11 0 kgf m 0 55 kgf m This chapter Contents...

Page 100: ...stic or rubber parts to avoid damage y Check the operation of the brake system before you go Specifications Item Standard mm Limit mm The thickness of front brake disc 3 5 2 0 Front brake disc run out...

Page 101: ...ng disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel Drum Brake Poor brake...

Page 102: ...g brake performance to be reduced or totally lost Connect drain hose to drain valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Cl...

Page 103: ...y 6 Cover the cap Disc Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hoses Caution Do not spill brake fluid on painted sur...

Page 104: ...into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Remove the front and rear handlebar guards Remove the leads of brake lamp s...

Page 105: ...e the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup ont...

Page 106: ...ten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper rou...

Page 107: ...if necessary Measure the inner diameter of brake drum and record the max value Allowable limit rear 110 5mm Caution y Clean the rust onto the brake drum with 120 sand paper y Measure the inner diamet...

Page 108: ...d point Tighten the bolts and nuts to specified torque Torque value 0 4 0 7 kgf m Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated Caution Brake...

Page 109: ...11 BRAKE SYSTEM 11 12 Notes This chapter Contents...

Page 110: ...9 Steering Handle Cover 12 10 Under Cover 12 11 Body Overview 12 Seat Floor mat Battery cover Luggage box Battery case Rear fender Rear mudguard Right body cover Left body cover Rear center cover Rig...

Page 111: ...on 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 a...

Page 112: ...buckles and slot never pull them with force or it would crack the buckles Luggage Box 1 Removal y Lift up seat cushion y Remove battery compartment screw and cover y Remove luggage box mounting screw...

Page 113: ...carrier and then remove rear carrier y Remove 1 screw and 2 nuts and 1bolt from luggage box and then remove luggage box z Remove 3 screws from the tail cover and then remove the tail cover Remove 2 s...

Page 114: ...12 BODY COVER 12 5 Remove 2 screw form of the body cover Remove the body cover 2 Installation y Install in reverse order of removal procedures Bolts This chapter Contents...

Page 115: ...e front side reflector y Remove 2 screws from the front inner box and front cover y Remove 1 screw from the front cover y Remove electric cord coupler from the head light y Remove the front cover 2 In...

Page 116: ...over 6 screws y Remove 4 screws from the front inner box y Remove 2 screws from the front upper part of the front spoiler and the front inner box y Remove the front spoiler 2 Installation y Install in...

Page 117: ...y Remove the front under spoiler y Remove hook and 1 screw y Remove key set cover y Remove 2 bolts from the floor panel y Remove the front inner box 2 Installation y Install in reverse order of remov...

Page 118: ...the body cover y Remove the floor panel 4 bolts 2 Installation y Install in reverse order of removal procedures Front Fender Removal y Ramoval 1 bolt and fr brake hose clamp y Ramoval 2 screws form fr...

Page 119: ...ws y Disconnect each switch connectors y Remove speedometer cable y Remove handle rear cover 2 Installation y Install in reverse order of removal procedures Caution Push the front connection part of r...

Page 120: ...2 BODY COVER 12 11 Under Cover 1 Removal y Remove 2 bolts from the under cover y Remove under cover 2 Installation y Install in reverse order of removal procedures 2 bolts 2 nuts This chapter Contents...

Page 121: ...12 BODY COVER 12 12 Note This chapter Contents...

Page 122: ...SPENSION 13 1 Maintenance Information 13 2 Troubleshooting 13 2 Steering Handle 13 3 Front Wheel 13 4 Front Shock Absorber 13 8 Front Fork 13 9 13 4 5 kgf m 2 7 kgf m 1 5 kgf m 3 3 kgf m 6 0 kgf m 0 2...

Page 123: ...1 The steering shaft bolt is too tight 2 The steering shaft bearing are damaged 3 The ball and the top cone of the steering shaft are damaged 4 Insufficient tire pressure The Steering Handle Is Tilted...

Page 124: ...move the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 5 kgf m Apply with grease onto throttle cable and the sliding surface of ha...

Page 125: ...nd then tighten lower bolt Install all components in reverse order of removal procedures Conduct following adjustment y Oil pump control cable y Throttle operation Brake lever free play Front Wheel Re...

Page 126: ...ion seat and turn the wheel to check its bearing free play If the bearing is noisy or its free play is too much replace it Place the wheel on to a rotation seat to check its rim wobbling Turn the whee...

Page 127: ...ng by grease Drive the left bearing and install the dist collar Install the right bearing Caution y Carefully install the bearing in correct and evenly y Bearing outer face should be faced up as beari...

Page 128: ...rum and disc must be free of grease Apply with grease onto the dust seal Install the dust seal and side collar Place the front wheel between the front shock absorbers Caution Align the brake disc groo...

Page 129: ...the caliper Take out the hose from hose clamp Remove the front shock absorber upper bolt and the shock absorber Installation Align the cover flange with upper level of the shock absorber clamp and the...

Page 130: ...mounted position Caution Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 29 balls Lubricate...

Page 131: ...10 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 5 kgf m Install in reverse order of removal procedures Steering stem mounting nu...

Page 132: ...14 REAR WHEEL SUSPENSION 14 1 Maintenance Information 14 2 Troubleshooting 14 2 Rear Wheel 14 3 Rear Shock Absorber 14 4 14 2 7 kgf m 4 0 kgf m 11 0 kgf m 3 3 kgf m Home page Contents...

Page 133: ...ut 11 0 kgf m Rear wheel hub 2 5 kgf m Exhaust muffler nut 1 2kgf m Exhaust muffler bolt 3 3 kgf m Troubleshooting Rear wheel wobbling 1 bend wheel rim 2 poor tire 3 loosen wheel shaft Shock absorber...

Page 134: ...st muffler bolt 3 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service limit Ra...

Page 135: ...t 1 2 kgf m Install the body cover Rear Shock Absorber Removal Remove body cover Remove rear shock absorber upper lower bolts Remove rear shock absorber Installation Install the rear shock absorber Ti...

Page 136: ...l Unit 15 16 Switch Horn 15 17 Bulb Replacement 15 19 15 Spark Plug AC Generator Fuse Box Battery IG Coil Fuel Unit Main Switch Reg Rec Comp Start Headlight Switch Start Relay Horn Horn Winker Dimmer...

Page 137: ...ecked with the voltmeter while charging the battery y As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignit...

Page 138: ...tarter motor is out of work Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short circuit of the discharging...

Page 139: ...0 13 2V Undercharged 12 V Charging Remove the battery Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negativ...

Page 140: ...O 100 AC Generator Auto by starter Regulator rectifier Main Switch Fuse 15A Battery Green Red Black Yellow Yellow Yellow Yellow White Yellow Green Red Resistor 10 2 5W Resistor 5 9 30W Green Black Pin...

Page 141: ...med up replace original battery with a fully charged battery Connect a digital voltmeter to the battery terminals Connect an ammeter between both ends of the main fuse Caution When the probe is revers...

Page 142: ...used do not have enough electricity or is over charged The fuse of the ammeter is blown The ammeter is improperly connected 3 The charging current is normal but the voltage is not The fuse of the vol...

Page 143: ...regulator Voltage Regulator Multi meter Multi meter White A Yellow L Red B Green E White A 4 7 Yellow B 2 4 4 8 Red B 4 7 Green E 2 4 4 8 If the resistance values are abnormal among the pins replace t...

Page 144: ...0 8 If the readings measured are not normal check parts in the circuit If the parts are normal then trouble is in the wiring If there is nothing wrong with parts and wiring replace the SCR Inspection...

Page 145: ...TRICAL EQUIPMENT 15 10 Ignition System JET 50 100 series JET EURO 50 100 series Black Red Blue Yellow Black White Black Yellow Green Blue Yellow Green Black Yellow Black Blue Black Red This chapter Co...

Page 146: ...rimary coil resistance Resistance 0 19 0 23K A B Measure the secondary coil resistance Resistance 8 2 9 3K A C Remove the high voltage coil cap and measure its negative terminal for the secondary coil...

Page 147: ...ith JET 50 100 Black white green Continuity as main switch OFF Main Switch compatible with JET EURO 50 100 Black Blue green Continuity battery voltage as master switch ON Exciter Coil compatible with...

Page 148: ...ove left crankcase cover Remove starter motor pinion Install the starter motor pinion in reverse order of removal Starter Motor Pinion Inspection y Pinion reduction gear for wear out or damage replace...

Page 149: ...y be short circuit if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces It ca...

Page 150: ...onnect oil gauge connector and check voltage between wire and ground Removal Installation Remove oil tank Remove oil level switch from the oil tank Install the oil level switch in reverse order of rem...

Page 151: ...ring in CW direction until matching to the arrow Inspection 1 Connect the fuel unit connector Turn the main switch ON Move the float in up and down and make sure that the fuel indicator can be reache...

Page 152: ...itch Wire color Black Black White Green Red Mark BAT2 IG E BAT1 LOCK OFF ON Turn signal light switch Wire color Gray Light blue Orange Mark WR R L R N L Horn Switch Wire color Light green Black Mark H...

Page 153: ...low Red Green Mark ST E FREE PUSH Front Rear Brake Light Switch If the switch is in continuity as braking it is in normal The switch is non adjustable Horn If the horn give out sound as connecting to...

Page 154: ...ront cover Loosen the headlight bulb stop plate and replace the bulb Remove the position light bulb seat and replace the bulb Install the all removed parts Tail light Brake light Remove 3 screws and t...

Page 155: ...UIPMENT 15 20 Rear winker light Remove rear winker lens Replace winker light bulb Front winker light Remove 6 screws and then remove handle front cover Replace winker light bulb 6 Screws 1 Screw This...

Page 156: ...ove 6 screws and then remove handle front cover Remove 2 screws and then remove clock unit Meter Remove handlebar front cover Take out the bulb seat from the bottom of instrument panel Install the all...

Page 157: ...15 ELECTRICAL EQUIPMENT 15 22 Notes This chapter Contents...

Page 158: ...16 ELECTRICAL DIAGRAM 16 1 JET 50 ELECTRICAL DIAGRAM 16 Home page Contents...

Page 159: ...16 ELECTRICAL DIAGRAM 16 2 JET 50 EURO ELECTRICAL DIAGRAM Home page Contents...

Page 160: ...16 ELECTRICAL DIAGRAM 16 3 JET 100 ELECTRICAL DIAGRAM Home page Contents...

Page 161: ...16 ELECTRICAL DIAGRAM 16 4 Notes Home page Contents...

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