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Sym Fiddle III 50, Service Manual

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Sym Fiddle III 50 Service Manual Download Page 133

SYM                                                                    5. REMOVAL OF ENGINE 

5-1

 

 

MECHANISM 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 

Summary of Contents for Fiddle III 50

Page 1: ...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 cove...

Page 2: ...e 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 immediatel...

Page 3: ...tion to O rings or oil seals because most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent stiff control and premature worn out Rubber parts may become det...

Page 4: ...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...

Page 5: ...negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secured Batte...

Page 6: ...ly Check if any wire loose Check if the connector is covered by the twin connector boot completely and secured properly Before terminal connection check if the boot is crack or the terminal is loose I...

Page 7: ...her pull too tight nor have excessive slack 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...

Page 8: ...adjacent or surrounding parts in all steering positions Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the inst...

Page 9: ...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 Muff...

Page 10: ...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 He...

Page 11: ...nt 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...

Page 12: ...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 clogg...

Page 13: ...oration 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 carbu...

Page 14: ...el 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 Carb...

Page 15: ...on 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 forw...

Page 16: ...ON 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...

Page 17: ...NSTALLATION 10 4 FLY WHEEL INSTALLATION 10 4 PRECAUTIONS IN OPERATION General information Refer to chapter 5 Engine removal and installation Refer to chapter 1 The troubleshooting and inspection of A...

Page 18: ...ts 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...

Page 19: ...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 cra...

Page 20: ...over 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 INSTALLAT...

Page 21: ...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 muf...

Page 22: ...ANKSHAFT 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 k...

Page 23: ...aced 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 o...

Page 24: ...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...

Page 25: ...ins 2 Scrape gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase Do not damage contact surface of the crankcase Soap the gasket residues into solvent and...

Page 26: ...cal 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...

Page 27: ...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 tensione...

Page 28: ...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...

Page 29: ...UGGAGE BOX 12 8 FLOOR PANEL 12 8 SIDE COVER 12 9 UNDER COVER 12 10 Double Seat Front handle cover Under cover Luggage box Left side cover Left body cover Rear handle cover Floor panel FR Inner box Rig...

Page 30: ...re assembly operation Align the buckles on the guards with slot on the covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the co...

Page 31: ...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 Inst...

Page 32: ...move the 2 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 a...

Page 33: ...er box Remove the front cover from the frame Installation Install according to the reverse procedure of removal FRONT INNER BOX Removal Remove the 6 mounting screws of front cover from the inner box A...

Page 34: ...ner 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 4 bolts in th...

Page 35: ...the rear fender Remove the 2 mounting screws 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...

Page 36: ...ll the front center cover according to the reverse procedure of removal LUGGAGE BOX Removal Open the seat Remove the 4 bolts in front of the luggage box Remove the 2 bolts in the rear of the luggage b...

Page 37: ...y cover Remove the 1 screw in the front center cover Remove the front center cover Remove the 4 bolts in the floor panel Remove the luggage box and the double seat Remove the 2 bolts between the floor...

Page 38: ...n 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 pr...

Page 39: ...3 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...

Page 40: ...13 BRAKE SYM 13 2 MECHANISM DIAGRAM Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m...

Page 41: ...dard Limit The thickness of front brake disc 3 50 2 00 Front brake disc eccentricity 0 15 0 30 Master cylinder inner diameter 25 40 ID of front rear brake drums 130 00 131 00 OD of front brake disc 22...

Page 42: ...d operation of brake lever Blocked brake system Poor brake caliper Blocked brake pipe Seized worn master cylinder piston Bent brake lever Uneven brake Dirty brake lining disc Poor wheel alignment Clog...

Page 43: ...nded 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...

Page 44: ...ir 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...

Page 45: ...outer 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...

Page 46: ...brake 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...

Page 47: ...ton 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 mast...

Page 48: ...ied 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 M...

Page 49: ...RAKE 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...

Page 50: ...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 s...

Page 51: ...e inner 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...

Page 52: ...GRAM 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...

Page 53: ...nut 2 4 3 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 c...

Page 54: ...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 br...

Page 55: ...rts 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...

Page 56: ...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...

Page 57: ...nnected 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 bearin...

Page 58: ...d the front wheel side collar Apply with some grease on both side of the speedometer gear oil seal and then install the seal Do not install used bearing and replace the bearing once it has been remove...

Page 59: ...t 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 v...

Page 60: ...k 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 abso...

Page 61: ...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...

Page 62: ...5 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...

Page 63: ...gf m Rear shock 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 bend wheel rim poo...

Page 64: ...3 6kgf m Exhaust muffler connection nut 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...

Page 65: ...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 absor...

Page 66: ...ON 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 Starter switc...

Page 67: ...trolyte and then charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devic...

Page 68: ...n Standard NGK CR7HSA Recommended usage Hot type NGK CR8HSA Cold type NGK CR6HSA Spark plug Spark plug gap 0 6 0 7 mm Primary 0 21 10 With plug cap 7 6 10 K Ignition coil resistance 20 Secondary Witho...

Page 69: ...D I alternator is out of work Engine does not crank smoothly Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch Secondary coil circuit Poor ignition coil...

Page 70: ...it 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 In the current...

Page 71: ...ort connect positive terminal at first and next negative terminal Electrolyte diluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind In case of bei...

Page 72: ...s with clean grease Strictly keep flames away from a charging battery The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires Turn the charger s swi...

Page 73: ...acement battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not The replacement battery is aged and does not have enough capacity Battery used do not...

Page 74: ...sured 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 circui...

Page 75: ...he measured value exceeds standard Alternator lighting coil Check Remove the 3P connector of the alternator Measure the resistance between the yellow wire on the alternator and frame ground by multi m...

Page 76: ...ion at each terminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200 Primary Black yellow green 0 21 10 Green high voltage cable w o cap 3 5K Ign...

Page 77: ...y 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 b...

Page 78: ...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...

Page 79: ...sitive 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...

Page 80: ...move 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 Rem...

Page 81: ...meter Caution Installation Install the meter in reverse order of removal Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components Odometer Trip...

Page 82: ...stalled 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...

Page 83: ...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 br...

Page 84: ...Black white LOCK OFF ON 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 Side stand switch Side...

Page 85: ...ite Green White Blue White gre en Passing Horn switch color Location White green Light green FREE turn signal switch High Low beam switch seat open horn switch white green White green white Horn switc...

Page 86: ...amaged 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 sh...

Page 87: ...full 4 10 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 C...

Page 88: ...ADJUSTMENT 2 15 NUTS BOLTS TIGHTEN 2 15 PRECAUTIONS IN OPERATION Specification Fuel Tank Capacity 6 5L capacity 800 c c Engine Oil change 650 c c capacity 110 c c Transmission Gear oil change 100 c c...

Page 89: ...t 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 optimu...

Page 90: ...sassembly 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...

Page 91: ...2 kgf m Transmission oil capacity 110 c c 100 c c for change Recommended genuine SYM HYPOID gear oil SAE 85W 140 Fuel System Fuel Pipe Remove luggage box rear center cover body cover and rear fender a...

Page 92: ...ts operation 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...

Page 93: ...o 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 forw...

Page 94: ...exhaust 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 th...

Page 95: ...e these components if malfunction of these parts are found SPARK PLUG Appointed spark plug TORCH A7RC Remove luggage box Remove center cover Remove spark plug cap Clean dirt around the spark plug hole...

Page 96: ...amber or piston 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...

Page 97: ...r 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 scratc...

Page 98: ...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...

Page 99: ...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 reducin...

Page 100: ...Free play 10 20 mm Adjust the free play by turning the front brake adjustment nut if necessary BRAKE CONFIRAMTION Caution After brake adjustment it has to check the brake operation to make sure the f...

Page 101: ...2 Check 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 insp...

Page 102: ...tment 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...

Page 103: ...IONS 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 lub...

Page 104: ...Standard 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 Engi...

Page 105: ...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...

Page 106: ...t crankcase cover Make sure that 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 ro...

Page 107: ...the pump body Align the 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 Installati...

Page 108: ...oil level too low Standard quantity 110 cc Replacement 100 cc Gear Oil Replacement Remove the gear oil filling bolt and its draining plug and then drain oil completely Install the draining plug and ti...

Page 109: ...OUBLE 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 CLEA...

Page 110: ...orque value 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...

Page 111: ...ect idle speed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor...

Page 112: ...ler connector Release 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 flo...

Page 113: ...iston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm Note direction as installing the piston...

Page 114: ...ove 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 t...

Page 115: ...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 plat...

Page 116: ...etor 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...

Page 117: ...t 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...

Page 118: ...rder 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 co...

Page 119: ...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 c...

Page 120: ...System 4 5 Throttle position sensor illustration 4 7 ET Sensor Illustration 4 9 O2 sensor illustration 4 10 ECU connector illustration 4 11 Diagnostic instrument using method introduce 4 12 MECHANISM...

Page 121: ...4 ELECTRONICALLY CONTROLLED CARBURETOR SYSTEM SYM 4 2 ECS Electronically controlled carburetor system Vehicle Configuration Right...

Page 122: ...g instructions ECU Input Internal operation Output Crankshaft rotate speed Throttle Position Sensor O2 Sensor Engine temperature sensor Battery voltage Manifold pressure optional MAP Duty factor solen...

Page 123: ...driving performance Electronically controlled carburetor system working principle 1 Electronically controlled carburetor Use one or two by the ECU to control the duty ratio of magnetic air compensati...

Page 124: ...imary coil magnetization time dynamically control under different working conditions of the magnetization time ignition and precise control ignition energy under various working conditions Not only ou...

Page 125: ...nce induction coil The distance between the Sensor and flywheel shall be 0 7 1 1 mm Testing Procedures Resistance measurement Remove the connector of crankshaft rotate speed blue yellow green white Us...

Page 126: ...vice on carburetor provide perceive to ECU and judge the APP PID of throttle according to the signal to control the valve capacity and the angle of ignition 4 Device nearby the carburetor Through the...

Page 127: ...e values of throttle 0 7 0 1V Fully opened the output voltage values of throttle 3 9 0 1V Throttle position sensor standard inspection use diagnostic software The output signal of throttle using the d...

Page 128: ...nge and converted into a voltage signal is sent to the ECU to calculate the time of the engine temperature ECU again in accordance with the state of engine warming up correction repair time and igniti...

Page 129: ...king The blinking frequency of the fault light is 4 times judgment as failure 2 Use after sales service software inspect the O2 Sensor working position Start the vehicle Throttle fully opened and keep...

Page 130: ...ional loop of engine temperature sensor and others driving components such as transistor ignition coil Solenoid valve fault light The software parts main composition is monitor strategic operational p...

Page 131: ...parts Led blinking code Fault Description TPS Throttle position sensor 1 blinking signal TPS Error signal lower than 0 5V Air valve in short circuit Air compensating valves 2 blinking signals Air val...

Page 132: ...too low show as the above picture Air compensating valve failure When solenoid valve problem happened the software shows that air valve open circuit show as the above picture O2 sensor fault When engi...

Page 133: ...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...

Page 134: ...riving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Specification Disassemble 800 c c Engine Oil Capacity Replacement 650 c c Disassemble 110 c c Gear Oil Capacity...

Page 135: ...connector of Cylinder temperature sensor Remove the connector of crankshaft position sensor Remove the connector of oxygen sensor Remove the starter motor wire on the starter magnetic switch Remove t...

Page 136: ...d 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...

Page 137: ...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...

Page 138: ...ess the bushing out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and driv...

Page 139: ...ove 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 engi...

Page 140: ...e 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 Notice both feet and hands safety f...

Page 141: ...DER 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 INSTALLATI...

Page 142: ...0 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 Clearanc...

Page 143: ...alve carbon Poor sealing on valve seat Improper spark plug installation 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder surface 3 Piston Piston ring worn out High compres...

Page 144: ...tem 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 adju...

Page 145: ...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 t...

Page 146: ...M 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 b...

Page 147: ...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 Replaceme...

Page 148: ...late 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 cylinde...

Page 149: ...orrect 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...

Page 150: ...Grind valve seat with a rubber hose or other manual grinding tool Caution Remove the valve and check its contact face Caution Check if new valve guide is deformation after pressed it in When pressing...

Page 151: ...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...

Page 152: ...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 HE...

Page 153: ...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 th...

Page 154: ...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 val...

Page 155: ...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 MECHAN...

Page 156: ...cylinder 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 connectin...

Page 157: ...o 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 surfa...

Page 158: ...tive 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 posi...

Page 159: ...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...

Page 160: ...e 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...

Page 161: ...Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston r...

Page 162: ...en 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 Chapt...

Page 163: ...TCH 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 DIA...

Page 164: ...20 96 5 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...

Page 165: ...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 peda...

Page 166: ...ram 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...

Page 167: ...at 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 sp...

Page 168: ...tall 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 pulle...

Page 169: ...iving 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...

Page 170: ...rs 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 Ser...

Page 171: ...t 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 c...

Page 172: ...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 th...

Page 173: ...s 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...

Page 174: ...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...

Page 175: ...he bearing Install a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary Its sealing end should be forwarded to outside as bearing installation Ins...

Page 176: ...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 m...

Page 177: ...IAGRAM 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 M...

Page 178: ...g 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...

Page 179: ...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...

Page 180: ...ear 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...

Page 181: ...r 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 n...

Page 182: ...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 cra...

Page 183: ...SERVICE MANUAL...

Page 184: ...f 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...

Page 185: ...adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance information The third to the eleventh chapters cover engine and driving sys...

Page 186: ...OVAL 5 CYLINDER HEAD VALVE 6 CYLINDER PISTON 7 V TYPE BELT DRIVING SYSTEM KICK STARTER ARM 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 BODY COVER 12 BRAKE SYST...

Page 187: ...itch Rear brake level Side stand Frame number Gear oil filling bolt Gear oil draining bolt Front turn signal light Position light Front light High Low beam Turn signal Horn switch Air Cleaner Kick sta...

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