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Sym GTS 250, Service Manual

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15. Steering / Front Wheel / Front Cushion

 

15-3 

 

Steering Handle 

Remove 

Remove the right and left handle side cover, 
handle upper cover and front cover. (Refer to 
chapter 13) 
Loosen the lock bolts for the master cylinder of the 
front brake. 
 
 
 
 
 
 
 
Loosen the deceleration throttle cable fixing nut. 
Loosen 1 screw from the acceleration throttle 
fixing plate. 
 
 
 
 
 
 
 
 
 
 
 
Loosen 2 screws from the throttle holder. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Remove throttle holder, handle switch, cables and 
grip. 

 

 

 

 

 

 

 

 

 

2 screws

2 bolts

Fixing nut 

1 screw

Master cylinder

Holder

Throttle cables

To this chapter contents

Summary of Contents for GTS 250

Page 1: ...GTS 250 JOYMAX 250 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER...

Page 2: ...ce Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter LM25W series scooter are different from th...

Page 3: ...the special parts and system information There are 4 buttons Forward Contents How to use this manual and Mechanism Illustrations on the CD R version and can be access to these items by click the mouse...

Page 4: ...8 Cylinder Piston 7 8 1 8 14 V Type Belt Driving System Kick Starter 8 9 1 9 8 Final Driving Mechanism 9 10 1 10 10 Alternator 10 11 1 11 8 Crankshaft Crankcase 11 12 1 12 14 Cooling System 12 13 1 13...

Page 5: ...Serial Number Home page Contents...

Page 6: ...30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil Grease King Mate G 3 is recommended Gear oil King Mate gea...

Page 7: ...s been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is strictly prohibited Kee...

Page 8: ...cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent unsmooth control and premature worn out y Rubber parts may become deteriorated when old and prone to be...

Page 9: ...e install the oil seal with the name of the manufacturer facing outside and 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...

Page 10: ...gative 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 Batte...

Page 11: ...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 c...

Page 12: ...ht 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...

Page 13: ...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 pa...

Page 14: ...NE Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 160 km hr Cycle Co...

Page 15: ...nder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0 Air inject pipe bolt 4 6 1 0 1 4 A...

Page 16: ...4 10 3 5 4 5 Rear cushion upper connection bolt 1 10 3 5 4 5 Rear cushion under connection bolt 1 8 2 4 3 0 Rear fork mounting bolt 2 10 4 0 5 0 Brake hose bolt 2 10 3 0 4 0 Brake air bleeding valve 1...

Page 17: ...hose onto fuel rich circuit Then blow 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...

Page 18: ...1 Air cleaner clogged 1 Poor fuel supply 2 Lines in fuel tank evaporation system clogged 3 Exhaust pipe clogged 4 Fuel level too low in carburetor 5 Fuel nozzle clogged in carburetor 1 Malfunction of...

Page 19: ...Vacuum hose crack 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 Insu...

Page 20: ...amaged 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 jumpi...

Page 21: ...n 1 16 Lubrication Points Steering shaft bearing Seat locker Clutch bearing Main stand shaft Side stand shaft Speedometer gear front wheel bearing Acceleration cable Front rear brake lever pivot To th...

Page 22: ...pecial Tools List 2 15 Precautions in Operation Model LM25W Fuel Tank Capacity 12 000 c c capacity 1 400 c c Engine Oil change 1 200 c c capacity 180 c c Transmission Gear oil change 170 c c Engine ra...

Page 23: ...s connections in cooling system I I I I I 34 Coolant reservoir I I I I I 35 Coolant I Replacement for every 1 year Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necess...

Page 24: ...remove oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Eng...

Page 25: ...ggage box Remove rear carrier Remove body covers Check all lines and replace it when they are deterioration damage or leaking Warning y Gasoline is a low ignition material so any kind of fire is stric...

Page 26: ...ondition Air Cleaner Air Cleaner Element Remove 8 screws from the air cleaner cover and then remove the cover Remove the body cover Loosen bolt from the air cleaner air hose Remove 6 screws and then r...

Page 27: ...r side cover Remove ignition timing hole cap located in front upper side of engine right cover Turn camshaft bolt in C W direction and let the T mark on the camshaft sprocket aligns with cylinder head...

Page 28: ...d Specified idle speed 1500 100 rpm Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment Connect the tachometer onto engine Adjust the throttle v...

Page 29: ...ted within the ignition advance degrees it is means that the ignition advance degree is in normal If ignition timing is incorrect check CDI set pulse rotor and pulse generator Replace it if malfunctio...

Page 30: ...ve leaking y Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head Drive Belt Remove mounting bolt lo...

Page 31: ...the motorcycle with poor cushion y Looseness wear or damage cushion will make poor stability and drive ability Front cushion Press down the front cushion for several times to check it operation Check...

Page 32: ...patible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system hoses Added Brake Fluid Ad...

Page 33: ...lining Remove the brake clipper bolt and take out the clipper Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat...

Page 34: ...t beam adjustment will make in coming driver dazzled or insufficient lighting Wheel Tire Caution Tire pressure check should be done as cold engine Appointed tire pressure Tire size Front tire Rear tir...

Page 35: ...rse procedures of removal Caution y If there is rust on the posts very serious spray some hot water on the posts Then clean it with steel brush so that can remove rust for more easily y Apply some gre...

Page 36: ...adjusting wrench NAME Tappet adjusting NO SYM 1130000 HMA H9A NO SYM 9001200 NO SYM 9001200 08 09 10 NAME R crank case bearing 6201 assembles tool NAME Left crankshaft oil seal assembly socket NAME R...

Page 37: ...uller NO SYM 9020200 NO SYM 2210100 NO SYM 3110000 HMA NAME Steering head top thread wrench NAME Bearing driver HK1516 NAME Bearing puller 6205 NO SYM 5320010 NO SYM 9100200 HMA RB1 HK1516 NO SYM 9100...

Page 38: ...E Drive shaft oil seal 25 40 8 socket NAME Bearing puller 6303 NO SYM 9615000 6205 NO SYM 9120200 HMA NO SYM 6303000 HMA H9A 6303 NAME Bearing driver 6201 NAME Steering stem top thread wrench NAME NO...

Page 39: ...2 Maintenance Information 2 18 Note To this chapter contents...

Page 40: ...ng 3 2 Engine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication...

Page 41: ...e 0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 3 1 7kgf m Engine oil drain...

Page 42: ...er drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O...

Page 43: ...nd take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil p...

Page 44: ...nd outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving sha...

Page 45: ...d then tighten screws Torque value 0 1 0 3kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install star...

Page 46: ...her can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 170c c when replacing Make sure that the join bolt washer can be re used and install the bolt Torque value 1 0 1 4...

Page 47: ...3 Lubrication System 3 8 Notes To this chapter contents...

Page 48: ...stall 4 4 Vacuum Chamber 4 4 Air Cut off Valve 4 6 Automatic by starter 4 7 Float Chamber 4 8 Adjustment of Idle Speed 4 10 Fuel Tank 4 11 Fuel Pump 4 13 Air Cleaner 4 14 Mechanism Diagram 4 Home page...

Page 49: ...n disassembling fuel system parts pay attention to O ring position replace with new one as re assembly y There is a drain screw in the float chamber for draining residual gasoline y Do not disassemble...

Page 50: ...ion of carburetor y Dirty fuel Intermittently misfire as acceleration y Malfunction of ignition system Late ignition timing y Malfunction of ignition system y Malfunction of carburetor Power insuffici...

Page 51: ...and release the cable from carburetor Release the clamp strip of carburetor and then remove the carburetor Installation Install in reverse order of removal procedures Vacuum Chamber Removal Loosen dr...

Page 52: ...heck if the vacuum piston and needle for wear out crack or other damage Check if the diaphragm for damage or crack Caution Do not damage vacuum diaphragm Installation Install in reverse order of remov...

Page 53: ...of the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Caution z Do...

Page 54: ...omatic by starter if the circuit 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 by...

Page 55: ...g A worn out or dirty float valve must be replaced with a new a new one Remove main jet needle jet holder needle jet slow jet and air adjustment screw Caution Take care not to damage jets and adjust s...

Page 56: ...float valve float for proper installation y To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 18 5mm Installation o...

Page 57: ...s Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1500 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on the analyze...

Page 58: ...17 Fuel unit installation Install the fuel unit in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Remove the left and right side...

Page 59: ...System 4 12 Remove fuel tank upper bolts 2 bolts Remove fuel tank under bolt 1 bolt Remove fuel tank Installation Install the fuel tank in the reverse order of removal 2 bolts 1 bolt To this chapter c...

Page 60: ...p Its output time is 10 seconds Output quantity Min 20 c c If the output quantity is lower than 20 c c check fuel hose vacuum hose and fuel filter Removal Installation Remove floor plate Remove fuel i...

Page 61: ...Remove the air cleaner cover 8 screws Remove element mounting screws 6 screws Remove the air cleaner element With compressed air to cleaning dirty around the element Replace it if it is too dirty to...

Page 62: ...retor 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Item LM25W Replacement 1 200 c c Engine Oil Capacity Disassemble 1 400 c c Replacement 170...

Page 63: ...e Open the seat Remove the luggage box 6 bolts 2 screws Refer to chapter 13 Remove right and left side covers 4 screws on each side Remove rear carrier 4 bolts Remove body cover 4 screws 1 coupler Ref...

Page 64: ...Remove the fuel line vacuum hose and throttle valve cable from the carburetor Loosen the clamp strip of air cleaner and carburetor and then remove the air cleaner hose Remove the air cleaner inlet pi...

Page 65: ...2 bolts Remove the air cleaner Remove the exhaust muffler 3 bolts 2 nuts Drain out coolant and remove coolant inlet hose Remove the coolant inlet hose and thermo sensor wire To this chapter contents...

Page 66: ...emove the right rear cushion lower bolt 1 bolt Remove the rear fork bolts 2 bolts Remove the rear wheel axle nut 1 nut Remove the rear fork and rear axle collars Remove left rear cushion lower bolt 1...

Page 67: ...bolt and then remove engine Engine Hanger Removal Remove the engine side bolts of engine hanger 1 bolt on each side Remove the engine hanger Check if the engine hanger bush and cushion rubber for dama...

Page 68: ...ghtly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing removal Remove bearing mounting cir clip Drive the bearing out of the rear fork Bearing installation Instal...

Page 69: ...ing puller Special Service Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the rear fork bearing Install b...

Page 70: ...bush 28mm Rear cushion bush 20mm Pressing out Place the detent section of the bush remover toward the bush and drive both the pressing ring and bolt in to press the bush out Special Service Tools Cra...

Page 71: ...nd hands safety for squeezing as engine installation z Do not bent or squeeze each wires or hose z Route all cables and wires in accordance with the routine layout Engine hanger nut Torque Value 7 5 9...

Page 72: ...Head Inspection 6 8 Valve Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram 6...

Page 73: ...2 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Inner 38 700 35 200 Free length of valve spring outer 40 400 36 900 Valve seat width 1 600 Intake 0 10...

Page 74: ...valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure y...

Page 75: ...move the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove...

Page 76: ...the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side Remove the cylinder head Remove cylinder head gasket and 2 dowel pins...

Page 77: ...cotter remove assembly tool to press the valve spring and then remove valves Caution y In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the v...

Page 78: ...m seals Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution Do not damage the matching surface of cylinder head To this chapter c...

Page 79: ...spect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D and wear or damage oil hole clogged Service Limit...

Page 80: ...record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and...

Page 81: ...When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side T...

Page 82: ...seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the cont...

Page 83: ...ve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve...

Page 84: ...mbly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remove...

Page 85: ...oid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of c...

Page 86: ...pe 4 bolts Install inlet pipe onto cylinder head Install and tighten spark plug Torque value 1 0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can...

Page 87: ...uge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side cov...

Page 88: ...gram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 7 Home page...

Page 89: ...0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small en...

Page 90: ...inder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be remo...

Page 91: ...n rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of c...

Page 92: ...r of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance f...

Page 93: ...ully 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 al...

Page 94: ...tween piston and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Clean up all residues and foreign materials on the matching surface of crankcase...

Page 95: ...en when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coo...

Page 96: ...nism Diagram 8 1 Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram Home page Contents 5 0 6 0kg...

Page 97: ...40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive p...

Page 98: ...left side crank out cover remove it Remove left crankcase cover 8 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal To...

Page 99: ...rned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing replacement Remove bea...

Page 100: ...oove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection...

Page 101: ...e shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque va...

Page 102: ...n remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft D...

Page 103: ...ter diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Ser...

Page 104: ...pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution y Make sure that two sides of pulley surfaces have to be free...

Page 105: ...vice tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable...

Page 106: ...nd the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner beari...

Page 107: ...n Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch bloc...

Page 108: ...de of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution y Its sealing end should be for...

Page 109: ...nd clutch weight 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 n...

Page 110: ...2 Trouble Diagnosis 9 2 Disassembly of Final Driving Mechanism 9 3 Inspection of Final Driving Mechanism 9 4 Bearing Replacement 9 5 Re Assembly of Final Driving Mechanism 9 8 Mechanism Diagram 9 Fin...

Page 111: ...river SYM 9620000 Drive shaft oil seal 25 40 8 socket SYM 9120200 HMA Bearing HK1516 driver SYM 9100200 HMA HK1516 Bearing 6204 driver SYM 9110400 6204 Oil seal drive 34 52 5 SYM 9125500 HMA Inner bea...

Page 112: ...shaft and final shaft Remove the gasket dowel pin Remove final gear Remove counter shaft gear and 2 washers Remove final shaft Remove the drive shaft Special tool Shaft protector Caution y If non ess...

Page 113: ...he final shaft and gear are burn wear or damage and replace it if necessary Check bearings on gear box cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and...

Page 114: ...sing following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 Caution y Never install used bearings Once bearing removed it has to be replaced with new one Install new final shaft...

Page 115: ...side Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 Remove oil seal and then remove final s...

Page 116: ...Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the final shaft bearing Apply with grease onto final shaf...

Page 117: ...r 25 40 8 SYM 9120200 HMA Apply with grease onto the oil seal lip of final shaft Install counter shaft and final shaft into the gear box cover Install 2 dowel pins new gasket Install the gear box and...

Page 118: ...rankcase Cover Removal 10 3 AC G Set Removal 10 4 Right Cover Bearing 10 4 Flywheel Removal 10 5 Starting Clutch 10 6 AC G Flywheel Installation 10 8 AC G Set Installation 10 9 Right Crankcase Cover I...

Page 119: ...alue mm Limit mm ID of starting clutch gear 25 026 25 045 25 050 OD of starting clutch gear 42 192 42 208 42 100 Torque value Flywheel nut 5 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with a...

Page 120: ...2 nuts Drain out the engine oil and coolant refer chapter 5 Remove coolant hoses Disconnect the couplers of the Power source output line Remove water pump cover 4 bolts Remove 10 bolts from the right...

Page 121: ...g rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary Remove the bearing 6201with inner bearing puller Special tool Inner bearing puller SYM...

Page 122: ...s shaft protector onto the crank shaft Special tool Shaft protector Remove starter reduction gear and shaft Pull out flywheel with AC G flywheel puller Special tool AC G Flywheel puller SYM 3110000 HM...

Page 123: ...gear Service Limit ID 25 050 mm OD 42 100 mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage Install starting clutch driven gear onto one way clutc...

Page 124: ...Install the components in the reverse procedures of removal Torque value 1 0 1 4kgf m Caution Cannot lock the thread of socket bolt Caution The one way clutch must to with the generator flywheel and t...

Page 125: ...ne way clutch Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 5 0 6 0kgf...

Page 126: ...ight Crankcase Cover Installation Install dowel pins and new gasket Remove water pump cover Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump sh...

Page 127: ...10 Alternator Starting Clutch 10 10 Notes To this chapter contents...

Page 128: ...nism Diagram 11 1 General Information 11 2 Trouble Diagnosis 11 2 Disassembly of Crankcase 11 3 Crankshaft Inspection 11 4 Assembly of Crankcase 11 6 Mechanism Diagram 11 0 8 1 2kgf m 0 8 1 2kgf m 1 0...

Page 129: ...t mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Run out 0 100 Torque value Bolts for crank...

Page 130: ...t crankcase Caution Care should be taken not to damage the contact surfaces Install left crank shaft puller into crank case disassemble Hold left crank shaft puller nut by clutch nut wrench and turn t...

Page 131: ...ace Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Drive out left crankcase oil seal Crankshaft Inspection Use a thickness gauge to m...

Page 132: ...k crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If any roughness noise and loose linkage are...

Page 133: ...ft bearing into left crankcase Special tool Crank case disassemble SYM 1120000 HMA H9A L Crank shaft puller SYM 1130000 HMA H9A Clutch nut wrench SYM 9020200 Install crank shaft onto the left crankcas...

Page 134: ...r piece certainly must install Cannot install the wrong position or leak the attire Otherwise can cause the motorcycle to have the fierce vibration Install 2 dowel pins and new gasket Install the righ...

Page 135: ...al in the left crankcase with special tool Special tool Crank shaft install socket oil seal driver SYM 2341110 HMA RB1 Install the cam chain tensioner and tighten the bolts Torque value 1 2 1 6kgf m I...

Page 136: ...2 3 Change of coolant 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram 12 Home page Contents Radiator filler cap Radiator Thermo switch fan Reserve tank outlet pipe Thermo unit te...

Page 137: ...r Reservoir upper 850c c 420c c Thermostat Begins to activate at 82 92 C Stroke 0 05 3 0mm 80 C Boiling point Not pressure 107 7 C Pressurized 125 6 C Torque Value For water pump rotor 1 0 1 4kgf m To...

Page 138: ...it Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coolant...

Page 139: ...ntil the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then chec...

Page 140: ...y Check by pass hole whether has the air bubble to emit y If emits without the air bubble only has the coolant to flow out then backflow pipe joint on engine flameout y Remove radiator filler cap y St...

Page 141: ...ckflow floods Radiator Check Check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken...

Page 142: ...fun mounting bolts 3 bolts Remove thermo switch Installation Install the removed parts in the reverse order of removal Install radiator in the reverse order of removal Upon completion check for any le...

Page 143: ...A confirms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drai...

Page 144: ...out of the right crankcase Special tools Inner bearing puller Water pump bearing drive Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the rig...

Page 145: ...pecial tools Water pump bearing driver 6901 Caution y Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right...

Page 146: ...en Torque Value 1 0 1 4kgf m Caution y The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oi...

Page 147: ...17 for inspection of thermo unit Removal Remove the luggage box and body cover Drain out the coolant Remove the thermostat cover 2 bolts Remove the thermostat Inspection Visually inspect thermostat fo...

Page 148: ...splayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve...

Page 149: ...12 Cooling System 12 14 Notes To this chapter contents...

Page 150: ...rier cap Luggage box Rear mudguard Right side cover Right body cover Floor panel Back seat Seat Under cover Meter panel Luggage box mat Main cover Rear fender Front cover Meter visor Wind screen Wind...

Page 151: ...s 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 Rear fender Under cover R L Handle covers Floor pan...

Page 152: ...2 screws from handle upper cover rear end Remove the handle upper cover cap Loosen the 3 screws from the handle upper cover and then remove handle upper cover Installation Install in reverse order of...

Page 153: ...h and remove the wind screen garnish Loosen 8 screws from the wind screen and remove the wind screen Loosen 4 screws from the meter visor and remove the meter visor Loosen 8 screws from the inner box...

Page 154: ...e front cover upper side Disconnect the headlight foggy light and winker light couplers Remove the front cover Installation Install in reverse order of removal procedures Winker foggy light coupler 2...

Page 155: ...ve reserve tank cap Loosen 4screws from right left side of the meter panel Loosen 2 screws from in side of meter panel Loosen the meter cord coupler Remove the meter panel Installation Install in reve...

Page 156: ...1 screw from fuse box and remove it Loosen 1 screw from main switch cap and remove the cap Loosen DC power outlet mounting nut and remove DC power outlet Loosen 1 screw from battery cover and remove...

Page 157: ...Loosen 2 bolts from inner box under side Loosen 2 bolts from inside of the inner box Disconnect the hazard light and foggy light switch couplers Remove inner box Installation Install in reverse order...

Page 158: ...ver Remove Loosen 2 screws from the side cover side end Loosen 2 screws from the side cover upper end Remove the side cover Installation Install in reverse order of removal procedures 2 screws 2 screw...

Page 159: ...crew and 2 bolts from the front under spoiler upper end Remove the front spoiler Installation Install in reverse order of removal procedures Rear Carrier Remove Loosen 4 bolts from the rear carrier an...

Page 160: ...isconnect the luggage box light and switch coupler Remove the luggage box rear cover Loosen 2 bolts from luggage box front side Loosen 4bolts from luggage box rear side Remove the luggage box Installa...

Page 161: ...ar end of floor panel Loosen right and left side screws from rear side of the body cover Disconnect the tail light coupler Remove the body cover Installation Install in reverse order of removal proced...

Page 162: ...and body cover Loosen 4 bolts and 2 screws from floor panel Remove floor panel Installation Install in reverse order of removal procedures Front Fender Remove Loosen 4 screws from front cushion Remov...

Page 163: ...13 Body Cover 13 14 Rear Fender Loosen 4 bolts from rear fender Remove the rear fender Installation Install in reverse order of removal procedures 2 bolts Each side 1 bolt To this chapter contents...

Page 164: ...ction 14 4 Adding Brake Fluid 14 5 Brake fluid replacement Air bleed 14 6 Front Brake Caliper 14 7 Rear Brake Caliper 14 8 Brake Disk 14 9 Master Cylinder 14 9 Mechanism Diagram Front brake Master cyl...

Page 165: ...void damage y Check the operation of the brake system before riding Specifications unit mm Item Standard Limit The thickness of front brake disk 4 000 2 500 The thickness of rear brake disk 5 000 3 50...

Page 166: ...ver 1 Blocked brake system 2 Poor brake caliper 3 Blocked brake pipe 4 Seized worn master cylinder piston 5 Bent brake lever Uneven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged bra...

Page 167: ...replaced with new lining when the brake pad wear limit reaches the brake disk Park the motorcycle on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BR...

Page 168: ...c or rubber components may result in their damages Remove the master cylinder cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in t...

Page 169: ...ystem as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution y Do not release the brake lever before the drain valve is closed y A...

Page 170: ...se bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Remove brake caliper Remove b...

Page 171: ...Use M8 x 35 mm flange bolt only y Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the...

Page 172: ...the asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Master Cylinder Master Cylinder Removal Caution Do not le...

Page 173: ...brake 13 945 mm Master Cylinder Assembly Caution y It is necessary to replace the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before asse...

Page 174: ...h 2 new washers Tighten 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...

Page 175: ...14 Brake System 14 12 Note To this chapter contents...

Page 176: ...gram 15 1 Operational Precautions 15 2 Trouble Diagnosis 15 2 Steering Handle 15 3 Front Wheel 15 5 Front Cushion 15 8 Steering Stem 15 9 Mechanism Diagram Home page Contents 1 0 2 0kgf m 0 2 0 3kgf m...

Page 177: ...Inner bearing puller SYM 6204020 Steering nut wrench SYM 6204010 Driver 32 35mm Driver 42 47mm Trouble Diagnosis Hard to steer y The steering handle stem nut is too tight y The ball and the top crown...

Page 178: ...oosen the lock bolts for the master cylinder of the front brake Loosen the deceleration throttle cable fixing nut Loosen 1 screw from the acceleration throttle fixing plate Loosen 2 screws from the th...

Page 179: ...remove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 5 0kgf m Apply with grease onto throttle cable and the sliding surface...

Page 180: ...e brake lever to avoid the brake pad being squeezed out In case that the brake pad is accidentally squeezed out use a screwdriver to force it back to the place Loosen screw remove speedometer cable Tu...

Page 181: ...isy and loose when being moved remove and discard it Caution y The bearing shall be replaced in pair Wheel Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and...

Page 182: ...l the dist collar Install the right side bearing Caution y Carefully install the bearing in correct and evenly y Bearing outer face should be faced up as bearing installation Install the brake disk an...

Page 183: ...brake caliper Remove speedometer cable Loosen 4 bolts from steering stem Remove the front cushions Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Tor...

Page 184: ...remove the seats Remove bottom cone race body with a punch Caution y Do not damage the steering stem Installation Install a new bottom cone race onto the steering stem Push the cone race until to mou...

Page 185: ...orque value 0 25kgf m Caution y Check the steering stem that should be rotated freely and no clearance in vertical direction Install the steering stem mounting nut and tighten the nut by means of hold...

Page 186: ...Mechanism Diagram 16 1 Operational Precaution 16 2 Trouble Diagnosis 16 2 Muffler 16 3 Rear Wheel 16 3 Rear Fork 16 5 Rear Cushion 16 6 Mechanism Diagram Home page Contents 16 3 5 4 5kgf m 2 4 3 0kgf...

Page 187: ...t 3 2 3 8kgf m Brake clipper mounting bolts 2 9 3 5kgf m Brake disc mounting bolt 4 0 5 0kgf m Trouble Diagnosis Run out of rear wheel y Deformed or bent wheel hub y Improper tires y Loose wheel shaft...

Page 188: ...ler mounting bolt 3 2 3 8kgf m Muffler mounting nut 1 0 1 2kgf m Rear Wheel Removal Remove the exhaust muffler Remove the rear brake caliper 2 bolts and brake hose clamp 1 bolt Caution y Care shall be...

Page 189: ...l rim on a rotational support Rotate it by hand and measure the run out with a dial indicator Run out limit 2 0 mm Installation Install in reverse order of removal procedures Torque Value Rear wheel a...

Page 190: ...lock cir clip Uses the bearing driver drive out the bearing Special tool Bearing driver Install new rear fork bearing and bearing puller 6303 onto rear fork Install assembly directs puller bearing pul...

Page 191: ...hions Remove the upper bolts by left and right rear cushions and then remove the cushion Installation Install in reverse order of removal procedures Caution y The rear cushion must be replaced as a un...

Page 192: ...nsor 17 23 Water Temperature Meter 17 23 Mechanism Diagram Home page Contents 17 Winker Hazard control unit Spark plug A C Generator Fuse box Battery Ignition coil Main switch Reg Rec Start relay Fuel...

Page 193: ...e must be checked 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 w...

Page 194: ...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 195: ...ing Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 2A 1...

Page 196: ...ate Fuse 20A Ignition Fuse 15A Headlight Fuse 20A Headlight Hi Lo beam Winker hazard control unit Transistor ignition Meter Meter Horn Switch Luggage box light Power outlet Open seat motor Foggy light...

Page 197: ...passes the condition Item Check Points Standard Value Main switch connection R B Battery voltage ON Battery connection R G Battery voltage Charging coil Y Y 0 2 0 4 If the readings measured are not no...

Page 198: ...on and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal Disconnect each cable one by one and take measuremen...

Page 199: ...ect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A...

Page 200: ...5 30 10 100 10 100 10 100 R G 50 200 10 100 0 1 5 5 30 50 200 L Y 50 200 10 100 50 200 10 100 50 200 AC G Thermo switch Transistor ignition Auto by start Resistor G B Y L Y R G Ignition coil W Y R Y Y...

Page 201: ...ween the spark plug and the primary winding Standard resistance Without cap 9 20 K With cap 14 1 20 K Replacement on ignition coil Loosen 2 screws and replace the ignition coil if necessary Inspection...

Page 202: ...battery cover Disconnect the negative cable terminal of the battery Remove the luggage box Disconnect the cable positive terminal from the start relay Rear brake switch Engine stop relay Brake light F...

Page 203: ...egative terminal Check the continuity of the large terminal end If there is no continuity replace the relay Removal of Starter motor Turns off the main switch Remove the luggage box Disconnect the cou...

Page 204: ...TEMP LUGG Box Speed sensor Turn right indicator Meter O SB L W L BR R G R G Speedometer Main switch Fuel unit Fuse 20A R Red W White B Black L Blue G Green SB Sky blue Y Yellow O Orange P Pink GR Gray...

Page 205: ...front cover meter panel Refer chapter 13 Disconnect the coupler of the speedometer and take off the meter panel and meter Loosen 4 screws from meter panel Remove the speedometer Installation of meter...

Page 206: ...switch Foggy right indicator Hi beam indicator Hi beam light Lo beam light Foggy right R Main switch Fuse 20A B Battery Winker Hazard control unit B Ignition Fuse 15A Winker switch O SB R O SB R winke...

Page 207: ...ation Lo beam bulb 12V 55W H7 Hi beam bulb 12V 55W H7 Caution y Never touch the bulb with finger which will create a heat point y Clean the fingerprint left on the bulb with alcohol Installation Insta...

Page 208: ...n to remove the bulb seat and bulb Replace with new bulb if necessary Specification Foggy light bulb 12V 27W Winker light bulb 12V 21W Replacement the rear winker light bulb Remove the luggage box Tur...

Page 209: ...er turn the indicator bulb seat in C C W direction and take out the indicator bulb Uses the round nose pliers turn the illumination bulb seat in C C W direction and take out the illumination bulb Spec...

Page 210: ...l the new main switch and tighten the mounting bolts Install the main switch coupler and cap Right handle switch Remove the handle cover and front cover Disconnect the coupler of right handle switch C...

Page 211: ...ion R WR L FROM R PUSH OFF N FROM L Wire color Sky blue Gray Orange Brake Switch While grasp the brake lever firmly the terminals of white green and green yellow of the brake should have continuity Re...

Page 212: ...the E position the resistance measured shall be as follows Position Resistance E Empty 97 5 107 5 F Full 4 10 Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupl...

Page 213: ...n the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperature i...

Page 214: ...uld be used as a heating medium as the test temperature must be higher than 100 y Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Water Temperature Me...

Page 215: ...17 Electrical System 17 24 Note To this chapter contents...

Page 216: ...18 Electrical Diagram 18 1 18 Home page Contents LM25W Electrical Diagram...

Page 217: ...18 Electrical Diagram 18 2 Note Home page Contents...

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