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Sym SYM series Manual Download Page 38

12. BODY COVER SYM

12-6

Remove the main switch cover.

Remove the front cover and front under
cover.
Remove the 2 screws between the inner box
and the floor panel.

Remove the front inner box

Installation

Install the inner box A and the front inner box
B according to the reverse procedure of
removal.

BODY COVER/REAR CENTER
COVER/REAR FENDER

Removal

Open the seat.
Remove 4 bolts in the front of the luggage
box.

Remove 2 bolts in the rear of the luggage
box.
Remove the luggage box.
Remove the rear carrier. (3 bolts)

2 screws

3 bolts

2 bolts

Main switch cover

4 bolts

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Summary of Contents for SYM series

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: ...o remove the battery 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 po...

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: ...y Reduction GEAR Type 4 STROKE ENGINE Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Deceleration equipment Transmission V belt Fuel Used Unleaded 93 95 Spee...

Page 10: ...in adjuster bolts 2 6 0 8 1 2 A I fixing flange bolt 4 6 0 8 1 2 Oil pump separator bolt 2 6 0 8 1 2 One way clutch lock nut 1 22 9 0 10 0 Apply oil to thread Right crankcase cover bolts 10 6 0 7 1 1...

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: ...ERATION 10 2 A C GENERATOR REMOVAL 10 3 RIGHT CRANKCASE COVER REMOVAL 10 4 STARTING CLUTCH 10 5 RIGHT CRANKCASE COVER INSTALLATION 10 8 MOUNTED COIL SET INSTALLATION 10 8 FLY WHEEL INSTALLATION 10 8 M...

Page 18: ...recaution items of starter motor Specification Unit mm Item Standard value Service Limit ID of starting driven gear 32 0 32 060 OD of starting clutch cover 28 0 27 940 Torque value Flywheel nut 5 0 6...

Page 19: ...ffler 2 bolts 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 Flywh...

Page 20: ...ssembly Caution RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 6 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover...

Page 21: ...emove the starting driven gear Remove starting clutch starting reduction gear and shaft Starting Clutch Inspection Install the starting clutch onto the starting driven gear Hold the starting clutch an...

Page 22: ...the OD of the starting reduction gear shaft Service Limit OD 9 94 mm or above Disassembly Remove the hex blots 3 bolts inside the starting clutch Separate the clutch body and the clutch cover Remove t...

Page 23: ...clutch outer and starter driven gear Hold the starting driven gear with the universal fixture Tighten the 22mm anti loosen lock nut and gasket Caution Special service tools Anti loosen lock nut socket...

Page 24: ...hten the cable guide 2 screws Torque 1 5 2 0kgf m Tie the wire harness hose onto the indent of crankcase Caution Install A C generator connector and pulse generator connector FLYWHEEL INSTALLATION Mak...

Page 25: ...e cooling fan 4 bolts Torque value 0 8 1 2kgf m Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Install the body cover Add some engine oil according the specified qua...

Page 26: ...RAM 11 1 OPERATIONAL PRECAUTIONS 11 2 TROUBLE DIAGNOSIS 11 2 DISASSEMBLY OF CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 0 8 1 2 kgf m 0 8 1 2 kgf m 3 5 4 5 k...

Page 27: ...on Unit mm Item Standard Limit Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Run out Left side Bel...

Page 28: ...rankcase 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 1...

Page 29: ...2 Scrape gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase l Do not damage contact surface of the crankcase l Soap the gasket residues into solvent and...

Page 30: ...Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit Left side 0 035mm Right side 0 030mm Bearing Inspection Rotate the bearing...

Page 31: ...ankcase gasket Install the right crankcase and tighten the crankcase bolts 2 bolts Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain t...

Page 32: ...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 19 8x30x5 Special service tools the...

Page 33: ...LOOR PANEL 12 8 SIDE COVER 12 9 UNDER COVER 12 10 Double Seat Front handle cover Under cover Luggage box Rear carrier Left side cover Left body cover Rear handle cover Floor panel FR Inner box Right s...

Page 34: ...ration 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 covers during ass...

Page 35: ...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 36: ...move the 1 mounting bolt of front cover from the frame Remove the front under cover 4 mounting screws between the front under cover and the frame Remove the 2 mounting screws between the front cover a...

Page 37: ...er box Remove the front cover from the frame Installation Install according to the reverse procedure of removal FRONT INNER BOX Removal Remove the 8 mounting screws of front cover from the inner box A...

Page 38: ...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 39: ...cover and the frame Remove the left right side 2 mounting bolts under rear of the body cover between the body cover and the frame Remove the rear fender Remove the left right body cover Installation I...

Page 40: ...nstall 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 lugga...

Page 41: ...ry 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 floo...

Page 42: ...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 43: ...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 44: ...13 BRAKE SYM 13 2 MECHANISM DIAGRAM Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m...

Page 45: ...Standard 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 di...

Page 46: ...tion of brake lever l Blocked brake system l Poor brake caliper l Blocked brake pipe l Seized worn master cylinder piston l Bent brake lever Uneven brake l Dirty brake lining disc l Poor wheel alignme...

Page 47: ...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 pla...

Page 48: ...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 CA...

Page 49: ...er 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 th...

Page 50: ...ake 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 wi...

Page 51: ...cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master c...

Page 52: ...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 53: ...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 54: ...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 55: ...er gear of wear indicator and the mark on the brake arm with the indent gear of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2 kgf m REAR BRAKE PANEL Apply...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...k 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 l bend wheel rim l poor tire l l...

Page 68: ...olt 3 0 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...

Page 69: ...e upper nut of the rear shock absorber bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution Torque values Rear sho...

Page 70: ...SYSTEM 16 11 STARTING SYSTEM 16 14 METER 16 15 LIGHTS BULBS 16 17 SWITCH 16 19 FUEL UNIT 16 22 MECHANISM DIAGRAM Spark plug Fuel unit Ignition coil Main switch Starter magnetic switch Light starter sw...

Page 71: ...yte and then charged to prolong the battery s life span l Please check electrical device according to the procedure of diagnosis chart l Do not disconnect and connect the connector of electrical devic...

Page 72: ...5W5O 4 5 5 5O Resistor Resistance 20 30W7 5O 7 0 8 0O Ignition System Item Specification Standard NGK CR7HSA Recommended usage Hot type NGK CR8HSA Cold type NGK CR6HSA Spark plug Spark plug gap 0 6 0...

Page 73: ...D I l alternator is out of work Engine does not crank smoothly l Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch l Secondary coil circuit Poor ignitio...

Page 74: ...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 l In the current l...

Page 75: ...rt connect positive terminal at first and next negative terminal l Electrolyte diluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind In case of be...

Page 76: ...lean grease l Strictly keep flames away from a charging battery l The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires l Turn the charger s switc...

Page 77: ...battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not l The replacement battery is aged and does not have enough capacity l Battery used do not have...

Page 78: ...lue is abnormal check the abnormal wire circuit If components are good it could be a poor wire circuit If all items are in good condition then replace the voltage regulator If main wire circuit check...

Page 79: ...Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 1O 20 Replace the alternator lighting coil if the measured value exceeds standard Resis...

Page 80: ...n at each terminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200O Primary Black yellow green 0 21O 10 Green high voltage cable w o cap 3 5KO Ig...

Page 81: ...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 bla...

Page 82: ...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 83: ...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 84: ...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 85: ...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 kilom...

Page 86: ...as been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment bolt located under the...

Page 87: ...removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the taillight left right turn light lens Remove the tail light assembly Replace the bulbs of the tail...

Page 88: ...n switch leads connector Check connector terminals for continuity color Location Black Black white Red Green 2 Green LOCK OFF ON Replacement Remove the main switch connector and fixing bolts bolts x 2...

Page 89: ...on Yellow red green FREE High Low beam switch seat open color Location blue white brown white black purple seat open Horn switch color Location Black Light green FREE headlight switch starting switch...

Page 90: ...w wire on the brake light switch should be in continuity when operating the brake lever If the switch damaged replace it with new one Horn Remove the front cover Connect the light blue wire on the hor...

Page 91: ...5 107 5O F full 4 10O 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 corre...

Page 92: ......

Page 93: ...TMENT 2 15 NUTS BOLTS TIGHTEN 2 15 PRECAUTIONS IN OPERATION Specification Fuel Tank Capacity 5 2L capacity 950 c c Engine Oil change 700 c c capacity 180 c c Transmission Gear oil change 170 c c Clear...

Page 94: ...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 95: ...sassembly 950cc Change 700cc 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 96: ...ue 0 8 1 2 kgf m Transmission oil capacity 180 c c 170 c c for change Recommended genuine SYM HYPOID gear oil SAE 85W 140 Fuel System Fuel Pipe Remove luggage box side cover center cover body frame co...

Page 97: ...eration is smooth Check throttle valve cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play...

Page 98: ...clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaf...

Page 99: ...sampling muffler of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle...

Page 100: ...rator Replace these components if malfunction of these parts are found SPARK PLUG Appointed spark plug A7RTC Remove luggage box Remove body side cover Remove spark plug cap Clean dirt around the spark...

Page 101: ...n head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover Check if the belt i...

Page 102: ...s scratched or leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if...

Page 103: ...e 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 unti...

Page 104: ...Pry out the brake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing...

Page 105: ...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 106: ...heck 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 inspect...

Page 107: ...tighten the adjustment screw after the beam height in proper position Caution NUTS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolt...

Page 108: ...IONS 3 2 TROUBLE DIAGNOSIS 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 6 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lub...

Page 109: ...nce 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5kgf m Engine oil screen cover 1 0 2 0kgf m...

Page 110: ...w one Install the oil drain plug and 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...

Page 111: ...be rotated freely Remove the oil pump cover 2 bolts Remove the oil pump fixing flat screw Remove oil pump body bolts 2 bolts Oil Pump Disassembly Remove the screw on oil pump cover Disassemble the oil...

Page 112: ...nner and outer rotors Limit below 0 12 mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the inde...

Page 113: ...bolts Install the starting gear and the alternator Refer to chapter 10 GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand Turn off engine and remove both engine oil filli...

Page 114: ...lacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it wit...

Page 115: ...AGNOSIS 4 3 CARBURETOR REMOVAL 4 4 VACUUM CHAMBER 4 4 AIR CUT OFF VALVE 4 6 AUTO BY STARTER 4 7 FLOAT CHAMBER 4 8 INSTALLATION OF CARBURETOR 4 9 IDLE SPEED ADJUSTMENT 4 9 FUEL TANK 4 10 AIR CLEANER 4...

Page 116: ...2 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level gauge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place...

Page 117: ...le speed l Malfunction of carburetor l Dirty fuel Intermittently misfire as acceleration l Malfunction of ignition system Late ignition timing l Malfunction of ignition system l Malfunction of carbure...

Page 118: ...s 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 float chamber R...

Page 119: ...o vacuum piston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm l Note direction as installin...

Page 120: ...screw x 2 of the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the vacuum diaphragm for deterioration or crack Installation Install the valve as reverse order of rem...

Page 121: ...ged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing plate scr...

Page 122: ...ges with compressed air In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve m...

Page 123: ...and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO valu...

Page 124: ...VAL Remove the seat and the luggage box Remove the body side cover Remove the L R floor panel cover Remove the fuel tank cover Remove the floor panel Disconnect the fuel unit connector Remove the fuel...

Page 125: ...stall the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove left side cover 2 screws Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With co...

Page 126: ...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 127: ...ing belt clutch and transporting disk 3 Final reduction gear mechanism Specification Item Specification Replacement 950 c c Engine Oil Capacity Disassemble 700 c c Replacement 180 c c Gear Oil Capacit...

Page 128: ...4 bolts Remove the body cover 4 screws 3 bolts Remove the power connector of auto by start Remove the generator connector and pulse generator connector Remove the starter motor wire on the Starter mag...

Page 129: ...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 130: ...Remove the engine suspension nuts and bolts 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 n...

Page 131: ...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 132: ...t of engine suspension frame Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame E...

Page 133: ...on 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 l Notice both feet and hands safety for squee...

Page 134: ...OVAL 6 4 CYLINDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 6 CYLINDER HEAD INSPECTION 6 7 VALVE SEAT INSPECTION AND SERVICE 6 9 CYLINDER HEAD REASSEMBLY 6 11 CYLINDER HEAD INSTALLATION 6 12 VALVE...

Page 135: ...haft 9 972 9 987 9 910 Intake 4 970 4 980 4 900 OD of valve stem Exhaust 4 955 4 970 4 900 ID of Guide 5 00 5 012 5 030 Intake 0 020 0 042 0 080 Clearance between valve stem and guide Exhaust 0 030 0...

Page 136: ...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 137: ...lat screwdriver to tighten the screw of camshaft chain adjuster in a clockwise motion for release adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel...

Page 138: ...20 570mm EX Replacement when less than 19 410 mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Measure the valve rocker arm I D Service Limit...

Page 139: ...ing bolts from cylinder head left side cover Remove cylinder head gasket and 2 dowel pins Remove chain plate Clean up residues from the matching surfaces of cylinder and cylinder head Caution CYLINDER...

Page 140: ...INDER HEAD INSPECTION Check if spark plug and valve holes are crack Measure cylinder head flat with a straightedge and flat feeler gauge Service limit 0 05mm Valve spring free length Measure the free...

Page 141: ...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 142: ...act face 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...

Page 143: ...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 144: ...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 145: ...h 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 Place the TDC marks of the cam sprocket at same level of the t...

Page 146: ...am sprocket adjuster in counter clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the adjuster hole T...

Page 147: ...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 148: ...d up 7mm of piston skirt Clearance between piston and cylinder 0 005 0 015 0 100 Piston Piston ring ID of piston pin hole 15 002 15 008 15 040 OD of piston pin 14 994 15 00 14 96 Clearance between pis...

Page 149: ...r 6 Remove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of c...

Page 150: ...tive in the cylinder Service limit 52 50mm 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 posit...

Page 151: ...he 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 145mm 2nd ring replace if over 0 145mm...

Page 152: ...e inner diameter of piston pin hole Service Limit 15 04mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 52 310mm Compare...

Page 153: ...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 154: ...installing piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder head gasket and lock pins Install cylinder head refer to Chapter 6 Ins...

Page 155: ...MECHANISM DIAGRAM 8 1 MAINTENANCE DESCRIPTION 8 2 TROUBLE DIAGNOSIS 8 2 LEFT CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 MECHANISM DIAGRAM 5 5...

Page 156: ...168 900 163 700 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...

Page 157: ...s found Reassembly Apply with some specified grease on the gear spindle shaft Install the kick starter shaft thrust washer the kick spindle bush kick return spindle kick return spring into the L crank...

Page 158: ...clutch 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 li...

Page 159: ...versal fixture and then tighten nut to specified torque value Torque value 5 5 6 0 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving be...

Page 160: ...rsal fixture and then remove driving pulley nut Remove driving pulley Remove the driving belt from the pulley Remove sliding pulley set and driving pulley hub from crankshaft Remove tilt plate Remove...

Page 161: ...e each rollers outer diameter Replace it if exceed the service limit Service limit 15 40 mm Check the pulley hub if damaged or wear out Replace it if necessary Measure the pulley hub s outer diameter...

Page 162: ...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 cl...

Page 163: ...pring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remov...

Page 164: ...ure 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 Bearin...

Page 165: ...sary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to spec...

Page 166: ...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 167: ...spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting...

Page 168: ...IAGNOSIS 9 2 DISASSEMBLY OF FINAL DRIVING MECHANISM 9 3 INSPECTION OF FINAL DRIVING MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANISM 9 6 MECHANISM DIAGRAM Driving gear Coun...

Page 169: ...Outer type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover 0 8 1 2 kgf m Gear oil drain plug 1 0 1 4 kgf m Gear oil filling bolt 0 8 1 2 kgf m TROUBL...

Page 170: ...emove the 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 countersha...

Page 171: ...ar for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase...

Page 172: ...aring puller 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...

Page 173: ...e oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 0 8 1 2 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left c...

Page 174: ...SERVICE MANUAL...

Page 175: ...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 176: ...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 177: ...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 178: ...itch Rear brake level Side stand Frame number Gear oil filling bolt Gear oil draining bolt Front turn signal light Front light Position light High Low beam Turn signal Horn switch Air Cleaner Kick sta...

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