sym fiddle ii 50 (en)

SERVICE MANUAL

SYM FORWARD

This service manual contains the technical data of each component

inspection and repair for the SYM series motorcycle. The manual is shown

with illustrations and focused on 「Service Procedures」, 「Operation Key

Points」, and「Inspection Adjustment」 so that provides technician with service

guidelines.

If the style and construction of the motorcycle are different from that of the

photos, pictures shown in this manual, the actual vehicle shall prevail.

Specifications are subject to change without notice.

This manual that contains all data, illustration, indication and specifications

is based on current production information. SYM reserves the right to make

changes at any time without notice and without incurring any obligation

whatever. No part of this manual can be duplicated by any means without

written permission of SANYANG.

SERVICE DEPARTMENTSAN YANG INDUSTRY CO., LTD.

HOW TO USE THIS MANUAL SYM

This service manual describes basic information of different system parts and

system inspection & service for SYM series motorcycles. In addition, please

refer to the manual contents in detailed for the model you serviced in

inspection and adjustment.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance.

The third to the eleventh chapters cover engine and driving systems.

The twelfth to fifteenth chapters are contained the parts set of assembly

body.

The sixteenth chapter is electrical equipment.

The seventh chapter is for wiring diagram.

Please see index of content for quick having the special parts and system

information.

SYM CONTENTS

CONTENTS

GENERAL INFORMATION/TROUBLE DIAGNOSIS ...................................1

MAINTENANCE INFORMATION .................................................................2

LUBRICATION SYSTEM..............................................................................3

FUEL SYSTEM .............................................................................................4

ENGINE REMOVAL......................................................................................5

CYLINDER HEAD/VALVE............................................................................6

CYLINDER/PISTON......................................................................................7

"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/ STARTER CLUTCH.......8

FINAL DRIVING MECHANISM.....................................................................9

A.C. GENERATOR/STARTING CLUTCH ....................................................10

CRANKCASE/CRANKSHAFT .....................................................................11

BODY COVER ..............................................................................................12

BRAKE SYSTEM..........................................................................................13

STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER........................14

REAR WHEEL/SUSPENSION......................................................................15

ELECTRICAL EQUIPMENT .........................................................................16

ELECTRICAL DIAGRAM .............................................................................17

MECHANISM ILLUSTRATIONS SYM

Light/starter switch

Front disk brake

Exhaust muffler

Ignition switch

Gear oil drainingbolt

Battery/Fuse/CDIFront brake lever

Rear brake lever

Air cleanerGear oil fillingbolt

Oil level

Tail light

Front turnsignal light

Fuel tank / Fuel unit

High & Low beam/Passing/turnsignal/horn

Head light/Position light

Rear turnsignal light

Engine number/engineoil draining bolt

Ignition coil

Frame number

Meter

A.C. Generator

Start magnetic switch

Horn/REG.REC

RR. turningsignal light

Tail light Front turnsignal light

Winker relay

Engine controlswitch

SPECIAL TOOL SYM

1

ITEM: OUTER BEARING PULLERNO：SYM-6204010PURPOSE: REMOVE THE BEARING

ITEM: ACG FLYWHEEL PULLERNO：SYM-3110A00PURPOSE: REMOVE ACG FLYWHEEL

ITEM: LOCK NUT PULLERNO：SYM-9020100PURPOSE: REMOVE THE LOCK NUT

ITEM: UNIVERSAL HOLDERNO：SYM-2210100PURPOSE:HOLD THE MDF/CLUTCH OUTER

ITEM: CLUTCHSPRING COMPRESSORNO：SYM-2301000PURPOSE:DISASSEMBLE THE CLUTCH

ITEM: CLUTCH NUT WRENCHNO：SYM-9020200PURPOSE:LOOSE THE CLUTCH NUT

SYM SPECIAL TOOL

2

ITEM: GY6 STARTER GEAR PULLERNO：SYM-2822100-GY6PURPOSE:REMOVE THE STARTER GEAR

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-1

SYMBOLS AND MARKS ....................1-1GENERAL SAFETY............................1-2SERVICE PRECAUTIONS .................1-3SPECIFICATIONS..............................1-9

TORQUE VALUES (ENGINE).............. 1-10TORQUE VALUES (FRAME) ............... 1-11TROUBLES DIAGNOSIS ..................... 1-12LUBRICATION POINTS ....................... 1-16

SYMBOLS AND MARKSSymbols and marks are used in this manual to indicate what and where the special service areneeded, in case supplemental information is procedures needed for these symbols and marks,explanations will be added to the text instead of using the symbols or marks.

WarningMeans that serious injury or even death may result if procedures are notfollowed.

Caution Means that equipment damages may result if procedures are not followed.

Engine oilLimits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover thedamage that caused by not apply with the limited engine oil.

Grease King Mate G-3 is recommended.

Locking sealantApply sealant, medium strength sealant should be used unless otherwisespecified.

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special toolsSpecial service tools.

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions.

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt crossthrough the component (invisibility).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-2

GENERAL SAFETYCarbon monoxideIf you must run your engine, ensure the place iswell ventilated. Never run your engine in aclosed area. Run your engine in an open area, ifyou have to run your engine in a closed area, besure to use an extractor.

Caution

GasolineGasoline is a low ignition point and explosivematerial. Work in a well-ventilated place, noflame or spark should be allowed in the workplace or where gasoline is being stored.

Caution

Used engine oil

Caution

Hot components

Caution

Battery

Caution

Brake shoeDo not use an compressed air or a dry brush toclean components of the brake system, use avacuum cleaner or the equivalent to avoidasbestos dust flying.

Caution

Brake fluid

Caution

Exhaust contains toxic gas which may causeone to lose consciousness and even result indeath.

Battery emits explosive gases; flame isstrictly prohibited. Keep the place wellventilated when charging the battery.Battery contains sulfuric acid (electrolyte)which can cause serious burns so be carefuldo not be spray on your eyes or skin. If youget battery acid on your skin, flush it offimmediately with water. If you get batteryacid in your eyes, flush it off immediatelywith water, then go to hospital to see anophthalmologist.If you swallow it by mistake, drink a lot ofwater or milk, and take some laxative suchas castor oil or vegetable oil, and then go tosee a doctor.Keep electrolyte beyond reach of children.

Gasoline is highly flammable, and may explodeunder some conditions, keep it away fromchildren.

Prolonged contact with used engine oil (ortransmission oil) may cause skin canceralthough it might not be verdict.

Inhaling asbestos dust may cause disordersand cancer of the breathing system.

Spilling brake fluid on painted, plastic, or rubberparts may cause damage to the parts. Place aclean towel on the above-mentioned parts forprotection when servicing the brake system.Keep brake fluid beyond reach of children.

Components of the engine and exhaust systemcan become extremely hot after engine running.They remain very hot even after the engine hasbeen stopped for some time. When performingservice work on these parts, wear insulatedgloves and wait until cooling off.


1-3

SERVICE PRECAUTIONSAlways use with SANYANG genuine partsand recommended oils. Using non-designedparts for SANYANG motorcycle may damagethe motorcycle.

Special tools are designed for remove andinstall of components without damaging theparts being worked on. Using wrong toolsmay result in parts damaged.

When servicing this motorcycle, use onlymetric tools. Metric bolts, nuts, and screwsare not interchangeable with the Englishsystem, using wrong tools and fasteners maydamage this vehicle.Clean the outside of the parts or the coverbefore removing it from the motorcycle.Otherwise, dirt and deposit accumulated onthe part's surface may fall into the engine,chassis, or brake system to cause a damage.Wash and clean parts with high ignition pointsolvent, and blow dry with compressed air.Pay special attention to O-rings or oil sealsbecause most cleaning agents have anadverse effect on them.

Never bend or twist a control cable to preventstiff control and premature worn out.

Rubber parts may become deteriorated whenold, and prone to be damaged by solvent andoil. Check these parts before installation tomake sure that they are in good condition,replace if necessary.When loosening a component which hasdifferent sized fasteners, operate with adiagonal pattern and work from inside out.Loosen the small fasteners first. If the biggerones are loosen first, small fasteners mayreceive too much stress.Store complex components such astransmission parts in the proper assembleorder and tie them together with a wire forease of installation later.

Note the reassemble position of the importantcomponents before disassembling them toensure they will be reassembled in correctdimensions (depth, distance or position).Components not to be reused should bereplaced when disassembled includinggaskets metal seal rings, O-rings, oil seals,snap rings, and split pins.


1-4

The length of bolts and screws forassemblies, cover plates or boxes is differentfrom one another, be sure they are correctlyinstalled. In case of confusion, Insert the boltinto the hole to compare its length with otherbolts, if its length out side the hole is thesame with other bolts, it is a correct bolt.Bolts for the same assembly should have thesame length.

Tighten assemblies with different dimensionfasteners as follows:Tighten all the fasteners with fingers, thentighten the big ones with special tool firstdiagonally from inside toward outside,important components should be tightened 2to 3 times with appropriate increments toavoid warp unless otherwise indicated. Boltsand fasteners should be kept clean and dry.Do not apply oil to the threads.

When oil seal is installed, fill the groove withgrease, install the oil seal with the name ofthe manufacturer facing outside, check theshaft on which the oil seal is to be installedfor smoothness and for burrs that maydamage the oil seal.

Remove residues of the old gasket or sealantbefore reinstallation, grind with a grindstone ifthe contact surface has any damage.

The ends of rubber hoses (for fuel, vacuum,or coolant) should be pushed as far as theycan go to their connections so that there isenough room below the enlarged ends fortightening the clamps.

Rubber and plastic boots should be properlyreinstalled to the original correct positions asdesigned.

The tool should be pressed against two (innerand outer) bearing races when removing aball bearing. Damage may result if the tool ispressed against only one race (either innerrace or outer race). In this case, the bearingshould be replaced. To avoid damaging thebearing, use equal force on both races.

Both of these examples can result in bearing damage.

Manufacturer'sname

Groove

Clamp

Connector

Boots


1-5

Lubricate the rotation face with specifiedlubricant on the lubrication points beforeassembling.

Check if positions and operation for installedparts is in correct and properly.

Make sure service safety each other whenconducting by two persons.

Note that do not let parts fall down

Before battery removal operation, it has toremove the battery negative (-) cable firstly.Notre tools like open-end wrench do notcontact with body to prevent from circuit shortand create spark.

After service completed, make sure allconnection points is secured. Batterypositive (+) cable should be connected firstly.And the two posts of battery have to begreased after connected the cables.

Make sure that the battery post caps arelocated in properly after the battery posts hadbeen serviced.

If fuse burned, it has to find out the causeand solved it. And then replace withspecified capacity fuse.

capacityverification


1-6

When separating a connector, it locker has tobe unlocked firstly. Then, conduct theservice operation.

Do not pull the wires as removing aconnector or wires. Hold the connectorbody.

Make sure if the connector pins are bent,extruded or loosen.

Insert the connector completely. If there aretwo lockers on two connector sides, makesure the lockers are locked in properly.Check if any wire loose.

Check if the connector is covered by the twinconnector boot completely and securedproperly.

Before terminal connection, check if the bootis crack or the terminal is loose.

Insert the terminal completely. Check if theterminal is covered by the boot. Do not letboot open facing up.

Secure wires and wire harnesses to theframe with respective wire bands at thedesignated locations. Tighten the bands sothat only the insulated surfaces contact thewires or wire harnesses.

Wire band and wire harness have to beclamped secured properly.

Do not squeeze wires against the weld or itsclamp.


1-7

Do not let the wire harness contact withrotating, moving or vibrating components asrouting the harness.

Keep wire harnesses far away from the hotparts.

Route wire harness to avoid sharp edges orcorners and also avoid the projected ends ofbolts and screws.

Route harnesses so that they neither pull tootight nor have excessive slack.

Protect wires or wire harnesses with electricaltape or tube if they contact a sharp edge orcorner. Thoroughly clean the surface wheretape is to be applied.

Secure the rubber boot firmly as applying iton wire harness.

Never use wires or harnesses whichinsulation has been broken. Wrap electricaltape around the damaged parts or replacethem.

Never clamp or squeeze the wire harness asinstalling other components.

Do not touch it.

Do not extendit too much.

Please do not clip orsqueeze the wire.


1-8

Do not let the wire harness been twisted asinstallation.

Wire harnesses routed along the handlebarshould not be pulled too tight or haveexcessive slack, be rubbed against orinterfere with adjacent or surrounding parts inall steering positions.

Before operating a test instrument, operatorshould read the operation manual of theinstrument. And then, conduct test inaccordance with the instruction.

With sand paper to clean rust on connectorpins/terminals if found. And then conductconnection operation later.

Do you know how to set theinstrument to its measurementposition and the insert locationsof its two probes?

Clean rust.


1-9

SPECIFICATIONS

MAKER SANYANG MODEL AKA(AW05W-6)

Overall Length 1870mm Front Telescopic fork

Overall Width 698 mm Sus

pen

sion

Sys

tem

Rear unit swing

Overall Height 1140 mm Front 110/70-12(47J)

DIM

EN

SIO

N

Wheel Base 1325mm Tire

Spe

cifi

catio

ns

Rear 120/70-12(51J)

Front 40kg

Rear 59kgFront DISK (ø 190 mm)

Cur

b W

eigh

t

Total 99kg

Bra

keS

yste

m

Rear DRUM (ø 110 mm)

Passengers/Weight Two men/110 kg Max. Speed <45km/h

Front 84kg Per

form

anc

eClimb Ability 26° Below

Rear 125kg Primary Reduction BELT

WE

IGH

T

Tota

l Wei

ght

Total 209kg Final Reduction GEAR

Type 4-STROKE ENGINE Clutch Auto centrifugal clutch

Installation andarrangement

Vertical, below center,incline 80°

Dec

eler

atio

neq

uipm

ent

Transmission C.V.T.

Fuel Used Unleaded gasoline Speedometer 0 ~ 80 km/hr

Cycle/Cooling 4-stroke/forced aircooled Horn 75~112dB(A)

Bore φ39.0 mm Muffler Expansion & Pulse Type

Stroke 41.35 mm Exhaust Pipe Positionand Direction

Right side, andBackward

Cyl

inde

r

Number/Arrangement

Single Cylinder/horizontal Lubrication System Forced-circulation&

splashing

Displacement 49.4 cc CO <12.0 g/km

CompressionRatio 11.8:1 HC <1.0 g/km

Max. HP 2.35KW/8500 rpm

Exh

aust

Em

issi

on

NOx <1.2 g/km

Max. Torque 2.91N.m /6500 rpm Air Filtration Paper filter

Ignition C.D.I. Noise Emission < 71dB

EN

GIN

E

Starting System Kick & electrical starter Engine Weight(dryweight) 23kg


1-10

TORQUE VALUES (ENGINE)

ITEM Q'TY THREAD DIA(mm)

TORQUEVALUE(Kg-m) REMARKS

Cylinder head bolts 4 6 0.8~1.2Cylinder head nuts 4 8 1.8~2.2 Apply oil to threadCylinder/cylinder head two-ends bolts 4 7 0.7~1.1 Tighten to crankcaseCam holder nut 4 7 1.0~1.4Right crank case cover bolts 10 6 0.8~1.2Pulse generator bolts 2 5 0.35~0.5Valve adjustment fixing nuts 2 5 0.7~1.1 Apply oil to threadSpark plug 1 10 1.0~1.4Engine oil strainer cap 1 30 1.0~2.0Gear oil draining plug 1 8 1.0~1.5Gear oil filling bolt 1 8 1.0~1.5Oil pump bolts 3 6 0.8~1.2Oil pump drive sprocket nuts 1 6 0.8~1.2Left crankcase cover bolts 10 6 0.8~1.2Cylinder head cover bolts 4 6 0.8~1.2Camshaft chain tensioner pivot 1 6 0.8~1.2 Hex socket boltCamshaft chain adjuster bolts 2 6 1.0~1.4Cooling fan bolts 4 6 0.8~1.2Shroud A/B 2 6 0.8~1.2RR. brake fixing nut 1 8 1.5~2.0Flywheel nut 1 10 3.5~4.5Transmission(Gear box) bolts 7 8 2.6~3.0RR. brake arm bolt 1 6 0.7~1.1Drive face nut 1 12 5.0~6.0Drive pulley nut 1 10 3.5~4.5A.C. generator flange bolt 2 6 0.8~1.2Air/C connect bracket bolts 2 6 0.8~1.2Start motor bolts 2 6 0.8~1.2Brake arm bolt 1 6 0.7~1.1Kick starter arm bolt 1 6 0.8~1.2Carburetor nut 2 6 0.8~1.2A.I. fixing hex cap nut 2 6 0.8~1.2Crankcase bolts 1 6 0.8~1.2Exhaust pipe bolts 2 8 3.0~3.6Exhaust pipe connecting nuts 2 6 1.0~1.4


1-11

TORQUE VALUES (FRAME)

ITEM Q'TY THREAD DIA(mm)

TORQUEVALUE(Kg-m) REMARKS

Mounting bolt for steeringhandlebar 1 10 4.0~5.0

Mounting nut for steering rod 1 25.4 1.0~2.0

Cone seat for steering rod 1 25.4 0.2~0.3

Front wheel shaft nut 1 12 5.0~7.0

Rear wheel shaft nut 1 16 11.0~13.0

Wheel hub/rim mounting nuts 8 8 2.8~3.2

Speedometer cable locking screw 1 5 0.15~0.3Front shock absorber mountingbolts 4 8 2.4~3.0

Rear shock absorber upperconnection bolt 1 10 3.5~4.5

Rear shock absorber upperconnection bolt 1 8 2.4~3.0

Brake lever bolts 2 6 0.8~1.2

Front brake hose bolts 2 10 3.3~3.7

Front brake air-bleeding valve 1 6 0.8~1.0

Front brake disc mounting bolts 4 10 4.0~4.5

Front brake clipper mounting bolts 2 10 3.1~3.5

Drum brake arm bolts (front/rear) 2 6 0.8~1.2

Engine suspension bracket bolts 2 10 4.5~5.5 On frame side

Engine connection bolt 1 10 4.5~5.5 On engine side

Main standard nut 1 10 3.5~4.5

Foot-starting lever bolt 1 6 1.6~1.8

Air cleaner bolts 2 6 1.0~1.4

The torque values listed in above table are for more important tighten torque values. Please seestandard values for not listed in the table.Standard Torque Values for Reference

TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE5mm bolt、nut 0.45~0.60kgf-m 3mm screw 0.05~0.08kgf-m6mm bolt、nut 0.80~1.20kgf-m 4mm screw 0.10~0.15kgf-m8mm bolt、nut 1.80~2.50kgf-m 5mm screw 0.35~0.50kgf-m

10mm bolt、nut 3.00~4.00kgf-m 6mm screw、SH nut 0.70~1.10kgf-m12mm bolt、nut 5.00~6.00kgf-m 6mm bolt、nut 1.00~1.40kgf-m

8mm bolt、nut 2.40~3.00kgf-m

10mm bolt、nut 3.50~4.50kgf-m


1-12

TROUBLES DIAGNOSISA. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

Loosen carburetor drainbolt to check if there isgasoline inside thecarburetor

Fuel supplied tomcarburetor sufficient

No fuel is supplied tocarburetor

Remove spark plug, installit into spark plug cap, andperform a spark testagainst engine ground.

perform cylindercompression pressure test.

Check if sparks Weak sparks, no sparkat all

Low compressionpressure or no pressure

Re-start by following thestarting procedures

No ignition There are some signs ofignition, nut engine cannot be started

Remove the spark plugagain and check it.

Remove carburetor after 30 minutesand connect a hose onto fuel richcircuit. Then blow the hose with air

Dry spark plug Wet spark plug

Blowing in normal Blowing clogged

1. No fuel in fuel tank2. Check if the pipes, fuel tank to

carburetor and intake vacuum,are clogged.

3. Float valve clogged4. Lines in fuel tank evaporation

system clogged5. Malfunction of fuel pump6. Loosen or damaged fuel pump

vacuum hose7. Fuel filter clogged

1. Malfunction of spark plug2. Spark plug foul3. Malfunction of CDI set4. Malfunction of AC generator5. Ignition coil is in open or short

circuit6. Ignition coil leads open or short

circuit7. Malfunction of main switch

1. Piston ring seized2. Malfunction of cylinder valves3. Worn cylinder and piston ring4. Cylinder gasket leak5. Sand hole in compression parts

1. Malfunction of throttle valveoperation

2. Air sucked into intake manifold3. Incorrect ignition timing

1. Fuel level in carburetor too high2. Malfunction of throttle valve

operation3. Throttle valve opening too wide

1. Malfunction of automatic by-starter

cylinder compressionpressure normal


1-13

B. Engine run sluggish (Speed does not pick up, lack of power)


Try gradual accelerationand check engine speed

Engine speed can beincreased.

Engine speed can not beincreased.

Check ignition timing(Using ignition lamp)

Check cylinder compressionpressure (using compressionpressure gauge)

Ignition timing correct Incorrect ignition timing

Compression pressure correct No compression

Check if carburetor jet isclogged

No clogged Clogged

Remove spark plug

Check if engine over heat

No foul or discoloration Fouled and discoloration

No knockKnock

1. Air cleaner clogged2. Poor fuel supply3. Lines in fuel tank evaporation

system clogged4. Exhaust pipe clogged5. Fuel level too low in carburetor6. Fuel nozzle clogged in

carburetor

1. Malfunction of CDI2. Malfunction of AC alternator

1. Cylinder & piston ring worn out2. Cylinder gasket leaked3. Sand hole in compression parts4. Valve deterioration5. Seized piston ring

1. Remove foreign

1. Remove dirt2. Incorrect spark plug heat range

1. Piston and cylinder worn out2. Lean mixture3. Poor fuel quality4. Too much carbon deposited in

combustion chamber5. Ignition timing too advanced6. Poor circuit on the cooling

system

Normal Engine overheat

Continually drive inacceleration or high speed

1. Too much carbon deposited incombustion chamber

2. Lean mixture3. Poor fuel quality4. Ignition timing too advanced


1-14

C. Engine runs sluggish (especially in low speed and idling)

D. Engine runs sluggish (High speed)

Check ignition timing(using ignition lamp)

Good spark Poor

No air sucked Air sucked

Good Poor

Abnormal

Air sucked throughcarburetor gasket

Adjust the air screw ofcarburetor

Remove spark plug, installspark plug into spark plugcap and perform spark testagainst engine ground

Normal


Check for fuel supplyingsystem in automatic fuel cup

Check if carburetor clogged

1. Incorrect ignition timing (malfunctionof CDI or AC alternator)

1. Rich mixture (loosen the screw)2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket2. Carburetor lock loose3. Poor intake gasket4. Poor carburetor O-ring5. Vacuum hose crack

1. Spark plug fouled2. Malfunction of CDI3. Malfunction of AC generator4. Malfunction of ignition coil5. Open or short circuit in spark plug

leads6. Malfunction of main switch

1. Insufficient fuel in fuel tank2. Fuel filter clogged3. Restricted fuel tank vent

Good Poor


Check ignition timing

1. Malfunction of CDI2. Malfunction of AC alternator

Normal Abnormal

No clogged Clogged 1. Cleaning


1-15

E. CLUTCH, DRIVING AND DRIVING PULLEY

1. Clutch ling spring broken2. Clutch outer stick with clutch balance weights3. Connection parts in clutch and shaft worn out

or burned

Engine can be started butmotorcycle can not be moved.

FAULT CONDITIONS PROBABLE CAUSES

1. Driving belt worn out or deformation2. Driving disk damaged3. Driving pulley spring broken4. Clutch ling broken5. Driving slide-shaft gear groove broken6. Transmission gear damaged

Engine running and misfire asmotorcycle initial forward movingor jumping suddenly (rear wheelrotating as engine in running)

Poor initial driving ( Poorclimbing performance)

1. Driving belt worn out or deformation2. Balance weight roller worn out3. Driving sliding gear shaft worn out4. Driving disk spring deformation5. Driving sliding gear shaft worn out6. Greased in driving belt and sliding gear.


1-16

LUBRICATION POINTS

Acceleration cable/ Front & rear brake lever pivot

Steering shaft bearing

Speedometer gear /Front wheel bearing

Side stand shaft Main stand shaft Rear wheel bearing

SYM 2. MAINTENANCE INFORMATION

2-1

、

PRECAUTIONS IN OPERATION

Specification

2. MAINTENANCE INFORMATION SYM

2-2

PERIODICAL MAINTENANCE SCHEDULE

☆ I C R☆ I C C R☆ I I R☆ C C☆ R I

I II II II II II II I

☆ I I R☆ R

LI I

☆ I I☆ A I☆ I I☆ I I☆ ﹞ I R☆ C

I II II II I

☆ I A☆ I C☆ I☆ I I C☆ I

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication

Remarks:1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items

must be perform normally periodical maintenance following the use r manual instructions. They areprohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for thecharge.


2-3

LUBRICATION SYSTEM

Engine Oil CapacityCaution

Oil change

Torque value:1.0~1.5 kgf-m

Caution

Engine oil capacity:Disassembly: 850cc`Change: 750cc

Cleaning the oil strainer

Torque value: 1.0~2.0 kgf-m


2-4

Gear OilInspection

Replacement

Torque value:1.0~1.5 kgf-mCaution

Torque value: 1.0~1.5 kgf-mQuantity: 90 c.c.

Fuel SystemFuel Pipe

Warning

Fuel filter

Caution


2-5

AIR CLEANERElement

Caution

THROTTLE VALVE OPERATION

Free play：2~6 mm

2~6 mm

×


2-6

Caution

VALVE CLEARANCE ADJUSTMENT Caution

Caution

℃


2-7

VALVE CLEARANCE INSPECTIONAND ADJUSTMENT

Valve clearance (IN/EX): 0.06±0.02 mm

Caution

CARBURETOR IDLE SPEEDADJUSTMENT

Caution

Specified idle speed: 2100±100 rpmEmission adjustment in Idle speed

Exhaust Emission:CO: ＜12.0g/km

HC: ＜1.0g/km


2-8

IGNITION SYSTEMIgnition timing

Caution

SPARK PLUGAppointed spark plug: TORCH A7RC

Spark plug gap: 0.6~0.7 mm

Torque value: 1.0~1.4 kgf-m

Ignition light

F mark

0.6~0.7mm0.6~0.7mm

Side electrodeCenter electrode

Spark plug cap


2-9

CYLINDER COPMRESSION PRESSURE

Caution

Compression pressure: .

DRIVING SYSTEMDRIVING BELT

Width limit: above 18.5 mm

Clutch pad

Spark plug cap


2-10

STEERING SYSTEM Caution

SUSPENSION SYSTEM Warning

Front shock absorber

Rear Shock absorber


2-11

FRONT DISC BRAKE SYSTEMBRAKE SYSTEM HOSE

BRAKE FLUID

Caution

FILLING OUT BRAKE FLUID

AIR BLEED OPERATION

Caution


2-12

ADDED BRAKE FLUID

Caution

BRAKE LINING WEAR

Caution

Caution

Caution


2-13

DRUM BRAKE SYSTEMFront Brake Free Play: (Drum brake)

Free play: 10-20 mm

REAR BRAKE FREE PLAY: (DRUMBRAKE TYPE)

Free play: 10-20 mm

BRAKE CONFIRAMTIONCaution

△”

10�20mm

“△”

“△”


2-14

BRAKE LIGHT SWITCH

WHEEL/TIRE

Caution

Appointed tire pressure

Appointed TireFront/Rear wheel:110/70-12(47J)/120/70-12(51J)

△

Caution

〝△〞

△


2-15

BATTERYBattery Removal

Caution

HEADLIGHT ADJUSTMENT

Caution

NUTS, BOLTS TIGHTENESS

SYM 3. LUBRICATION SYSTEM

3-1

MECHANISM DIAGRAM ....................3-1OPERATIONAL PRECAUTIONS .......3-2TROUBLE DIAGNOSIS......................3-2ENGINE OIL .......................................3-3

CLEANING ENGINE OIL STRAINER...3-3OIL PUMP ............................................3-4GEAR OIL ............................................3-7

MECHANISM DIAGRAM

Valve rockerarm

Camshaft

Scoop lubrication

Forcedly lubrication

Forcedlylubrication

Inner passageConnecting rod

Oil pumpOil strainer

Crankshaft

3. LUBRICATION SYSTEM SYM

3-2

OPERATIONAL PRECAUTIONSGeneral Information

This chapter contains maintenance operations for the engine oil pump, engine oil andgear oil.

SpecificationsEngine oil quantity Disassembly 800 c.c.

Replacement 750 c.c.Oil viscosity SAE 10W-30 or equivalent

Use SAE 5W-40 whenoutside temperature isbelow 0℃.

Gear Oil Disassembly 110 c.c.Replacement 100 c.c.

Oil viscosity of gear oil: SAE 85W-140

unit : mmItems Standard LimitInner rotor clearance - 0.12

Clearance between outerrotor and body - 0.12Oil pump

Clearance between rotorside and body 0.05~0.10 0.20

Torque valueEngine oil drain plug 1.0~1.5kgf-mEngine oil filter screen cap 1.0~2.0kgf-mGear oil drain bolt 1.0~1.5kgf-mGear oil filling bolt 1.0~1.5kgf-mOil pump fixing screws 0.8~1.2kgf-m

TROUBLE DIAGNOSISLow engine oil level

Oil leakingValve guide or seat worn outPiston ring worn out

Low Oil PressureLow engine oil levelClogged in oil strainer, circuits or pipesOil pump damage

Dirty oilNo oil change in periodicalCylinder head gasket damagePiston ring worn out

Oil viscosity


3-3

ENGINE OILTurn off engine, and park the motorcycle inflat ground with main stand.Check oil level with oil dipstick after 3-5minutes.Do not rotate the dipstick into engine aschecking.If oil level is nearly low level, fill outrecommended oil to upper level.

Oil ReplacementCaution

Place an oil pan under the motorcycle, andremove oil strainer cap.Make sure if the aluminum washer of thedraining bolt is damaged. If so, replace itwith new one.Install the drain bolt and tighten it.Torque value: 1.0~1.5 kgf-m

CLEANING ENGINE OIL STRAINERRemove the oil strainer cap.Remove oil strainer and spring.Clean oil strainer (recommended usingcompressed air to clean dirty foreign).Check if the strainer and O-ring of the oilstrainer are broken. Replace with new one iffound.Install the oil strainer and spring.Install the oil strainer cap and tighten it.Torque value: 1.0~2.0 kgf-mFill out oil to the oil filler (Oil viscosity SAE10W-30)Use SAE 5W-40 when outside temperatureis below 0℃.Engine oil quantity: Replacement 750 c.c.

Drain oil as engine warmed up so thatmake sure oil can be drained smoothly andcompletely.

Oil strainer cap

Dipstick

Oil drain plug

oil strainer

spring


3-4

OIL PUMPOil Pump RemovalRemove the alternator (refer to chapter10).Remove the engine right crankcase cover.Make sure that the pump axle can be rotatedfreely.Remove the oil pump driving gear nut.

Remove oil pump body bolts (3 bolts).

Remove the oil pump pin.Remove the oil pump.

Remove the 2 O-rings.

pump drivinggear nut

3 bolts

pin

2 O-rings


3-5

Oil Pump InspectionCheck the clearance between oil pump bodyand outer rotor.Limit: below 0.12 mm

Check clearance between inner and outerrotors.Limit: below 0.12 mm

Check clearance between rotor side faceand pump body.Limit: below 2.0 mm

Oil Pump Re-assemblyInstall inner and outer rotors into the pumpbody.Align the indent on driving shaft with that ofinner rotor. Install the driving shaft.Install the oil pump cover and fixing pinproperly and then tighten screw. (1 screw)

outer rotorinner rotor

Oil pump body

Oil pumpcover

Drive shaft

Fixing pin


3-6

Oil Pump InstallationInstall the 2 O-rings.

Install the oil pump pin.

Install the oil pump.Install the oil pump body bolts (3 bolts).

Install the oil pump driving gear nut.Install the alternator (refer to chapter10).Install the engine right crankcase cover.

pump drivinggear nut

3 bolts

pin

2 O-rings


3-7

GEAR OILOil Level InspectionPark the motorcycle on flat ground with mainstand.Turn off engine and remove both engine oilfilling bolt and oil draining bolt.

Remove gear oil filling hole bolt and place ameasurement cup under the draining plug.Remove the oil draining plug and the pourgear oil into the measurement cup.Measure the gear oil quantity if withinstandard value.Add specified gear oil if the oil level too low.Standard quantity: 110cc.Replacement: 100 cc.

Gear Oil ReplacementRemove the gear oil filling bolt and itsdraining plug and then drain oil completely.Install the draining plug and tighten it. (Makesure if the plug washer is damaged. If so,replace it with new one.)Torque Value：1.0~1.5 kgf-mAdd new gear oil (100 c.c.) from the gear oilfilling hole and then install the gear oil fillinghole bolt after added oil. And then, tightenthe bolt.Torque Value: 1.0~1.5 kgf-m

※Recommended to apply with SAE85W-140.Start engine and run it for 2~3 minutes.Turn off engine and check if oil leaking.

Filling bolt

Draining bolt

SYM 4. FUEL SYSTEM

4-1

MECHANISM ILLUSTRATION .............4-1PRECAUTIONS IN OPERATION .........4-2TROUBLE DIAGNOSIS........................4-3CARBURETOR REMOVAL ..................4-4VACUUM CHAMBER ...........................4-4AIR CUT-OFF VALVE ..........................4-6

AUTO BY-STARTER .......................... 4-7FLOAT CHAMBER ............................. 4-8

INSTALLATION OF CARBURETOR .. 4-9 IDLE SPEED ADJUSTMENT.............. 4-9 FUEL TANK........................................ 4-10 AIR CLEANER.................................... 4-11

MECHANISM ILLUSTRATION

Carburetor

Fuel strainer

Fuel tank capFuel unit

4. FUEL SYSTEM SYM

4-2

PRECAUTIONS IN OPERATIONGeneral Information

Warning

Cautions

SpecificationItem Specification

Main jet 85#

Slow jet 35#

Idle speed 2100±100 rpm

Fuel quantityadjustment screw 1 1/2±3/4 turns

Level in float chamber 3.5±1 mm

Jet needle DA8CD add 2 units 0.5mm washer

Throttle handle free play 2~6 mm

Torque valueFuel valve tightening nut: 1.5~2.0 Kgf-m

ToolSpecial service toolsVacuum/air pressure pumpGeneral service toolsFuel level gauge

Gasoline is a low ignition point and explosive materials, so always work in a well-ventilatedplace and strictly prohibit flame when working with gasoline.

Do not bend or twist throttle valve cable. Damaged cable will make unstable driveability.When disassembling fuel system parts, pay attention to O-ring position, replace with newone as re-assemblyThere is a drain screw in the float chamber for draining residual gasoline.Do not disassemble automatic by-starter and air cut-off valve arbitrarily.

SYM 4. FUEL SYSTEM

4-3

TROUBLE DIAGNOSISPoor engine start

No fuel in fuel tankClogged fuel tubeToo much fuel in cylinderNo spark from spark plug (malfunction ofignition system)Clogged air cleanerMalfunction of automatic by-starterMalfunction of throttle valve operation

Stall after startedMalfunction of automatic by-starterIncorrect ignition timingMalfunction of carburetorDirty engine oilAir existing in intake systemIncorrect idle speed

Rough idleMalfunction of ignition systemIncorrect idle speedMalfunction of carburetorDirty fuel

Intermittently misfire as accelerationMalfunction of ignition system

Late ignition timingMalfunction of ignition systemMalfunction of carburetor

Power insufficiency and fuel consumingFuel system cloggedMalfunction of ignition system

Mixture too leanClogged fuel injectorVacuum piston stick and closedMalfunction of float valveFuel level too low in float chamberClogged fuel tank cap ventClogged fuel filterObstructed fuel pipeClogged air vent hoseAir existing in intake system

Mixture too richClogged air injectorMalfunction of float valveFuel level too high in float chamberMalfunction of automatic by-starterDirty air cleaner

4. FUEL SYSTEM SYM

4-4

CARBURETOR REMOVALRemove the luggage box.Loosen the adjustment nut and fixing nut ofthrottle valve cable, and release the cablefrom carburetor.Remove fuel pipe, vacuum hose.Disconnect auto by-starter connectors.Release the clamp strip of air cleaner.Release the clamp strip of carburetor isolator.Take the carburetor out..

VACUUM CHAMBERRemovalLoosen drain screw, and drain out residualfuel in float chamber.Remove screws (2 screws) of vacuumchamber cover and the cover.

Remove compress spring and vacuumpiston.

throttle valve cable clamp strip of isolator

vacuum hose

Vacuum piston

compressspring

vacuum hose auto by-starter

Screws×2

Vacuum Chamber cover

SYM 4. FUEL SYSTEM

4-5

Remove fuel needle seat, spring, andinjector needle.Check if the vacuum piston for wear out,crack or other damage.Check if the diaphragm for damage or crack.

Cautions

InstallationInstall injector needle, spring and fuel needleseat to vacuum piston.

Cautions

Install vacuum piston to carburetor body.Install compress spring.

Install vacuum chamber cover and tighten 2screws.

Do not damage vacuum diaphragm.

Note direction as installing the pistonset because wrong direction of thepiston cab not be installed.Align the indent of vacuumdiaphragm with the carburetor body.

fuel needleseat

injectorneedle

Piston springpiston

fuel needlespring

piston diaphragm lock position

Screws×2

Vacuum Chamber cover

4. FUEL SYSTEM SYM

4-6

ACCELERATE PUMPRemovalLoosen the fixing screws from carburetor.

Remove the accelerate pump drive arm fromthe carburetor.

Remove 3 mounting screws and remove thefloat chamber cover.Remove 3 mounting screws and remove thefloat chamber cover.

InstallationInstall the valve as reverse order of removal.

CautionsDo not damage the vacuum diaphragm orin opposite installation direction.

Screws ×2

Accelerate pumpdrive arm

SYM 4. FUEL SYSTEM

4-7

AUTO BY-STARTERInspectionTurn off engine and waiting for over 10minutes for cooling.Check resistance across the two terminals ofthe auto by-starterResistance value: Max. 10Ω (Measuredafter engine stopped for more than 10minutes)Replace the auto by-starter with a new one ifresistance value exceeds standard.Remove the carburetor, allow it to cool off for30 minutes.Connect a hose to fuel richment circuit.Pump compressed air to the circuit.Replace the auto by-starter if the circuitclogged.

Connect battery posts (12V) to starter’sconnectors. After 5 minutes, test the richcircuit with compressed air. If air flow throughthe circuit, then replace the starter.

RemovalRemove fixing plate screw, and then removethe plate and auto by-starter from carburetor.

Valve inspectionCheck if auto by-starter and valve needle fordamage or wear out.

InstallationInstall auto by-starter to the carburetor body.Install fixing plate to the upper groove of autoby-starter, and install its flat surface tocarburetor. Install screw and tighten it.

Cautions

Align the round point of the starter withthe screw hole of air intake side.

valve needlefixing plate

Screw

fixing plate

auto by-starter

Screw

round point

4. FUEL SYSTEM SYM

4-8

FLOAT CHAMBERDisassemblyRemove 3 mounting screws and remove thefloat chamber cover.Remove the float pin and float valve.

CheckingCheck float needle valve and valve seat fordrop difference damage, wear out, dirty orclogged.

Cautions

Remove main jet,slow jet, fuel amountadjustment screw.

Cautions

Clean jets with cleaning fluid.Then use compressed air to blow dirt off.Blow carburetor body passages withcompressed air.

In case of worn out or dirt, the float needlevalve and valve seat will not tightly closecausing fuel level to increase and as aresult, fuel flooding. A worn out or dirty floatneedle valve must be replaced with a newone.

Take care not to damage jets and adjustscrew.Before removing adjustment screw, turn itall the way down and note the number ofturns.Do not turn adjustment screw forcefully toavoid damaging valve seat face.

main jet

slow jet

float

float pin

float needlevalve

float pin

main jetslow jet

fuel amountadjustment screw

screws× 3float

float pin

SYM 4. FUEL SYSTEM

4-9

InstallationInstall main jet, slow jet and fuel amountadjustment screw.

Cautions

Install the float needle valve, float and float pin.

Checking Fuel Level Cautions

Fuel level: 3.5±1 mmINSTALLATION OF CARBURETORInstall carburetor in the reverse order of removal.Following adjustments must be made afterinstallation.

Throttle valve cable clearance adjustmentIdle speed adjustment

IDLE SPEED ADJUSTMENT Caution

Use a tachometer when adjusting engine RPM.Screw in adjustment screw gently, then back up tostandard turns.Standard turns: 1 1/2±3/4 turnsWarm up engine, adjust throttle valve stopperscrew to standard RPM.Idle speed rpm: 2100±100 rpmConnect the sampling hose of exhaust analyzer toexhaust front end. Press test key on the analyzer.Adjust the air volume adjustment screw and readCO reading on the analyzer.CO standard value: 1.0~1.5 %Accelerate in gradual increments, make sure bothrpm and CO value are in standard values afterengine running in stable. If rpm and CO valuefluctuated, repeat the procedures described abovefor adjusting to standard value.

Set the adjustment screw in according to numberof turns noted before it was removed.

Check again to ensure float valve, float forproper installation.To ensure correct measurement, positionthe float meter in such a way so that floatchamber face is vertical to the main jet.

Fuel amount adjust screw was set at factory,so no adjustment is needed. Note thenumber of turns it takes to screw it all theway in for ease of installation.Never screw in forcedly to avoid damagingthe screw seat.The main stand must be used to support themotorcycle to perform the adjustments.

float meter

fuel amountadjustment screw

Throttle valve cableadjustment nut

throttle valvestopper screw

air volumeadjustment screw

4. FUEL SYSTEM SYM

4-10

FUEL TANKFuel unit removalOpen the seat.Remove the luggage box. (6 bolts)Remove the engine starter control switchwire connector .Disconnect fuel unit connector.Remove fuel unit.

Cautions

Fuel unit inspection. (Refer to chapter 16 -electrical equipment).Fuel unit installationInstall the gauge in the reverse order ofremoval.

Cautions

FUEL TANK REMOVALOpen the seat.Remove the luggage box assembly (6 bolts).Disconnect the engine start control switchconnector.Disconnect the fuel unit connector.Remove the fuel pipe, fuel filter.Remove the fuel tank (2 bolts).

Fuel Tank InstallationInstall the tank in the reverse order ofremoval.

Do not bend the float arm of fuel unit.Do not fill out too much gasoline tofuel tank.

Do not forget to install the gasket of fuel unitor damage it.

fuel unit

gasket

Fuel unit connectorFuel unit connector

SYM 4. FUEL SYSTEM

4-11

AIR CLEANERRemovalRemove the seat .Remove the luggage box assembly (4 bolts).Loosen the clamp strip of air cleaner.Remove evaporative return hose.Remove the air cleaner body bolts (2 bolts).Remove the air cleaner.

InstallationInstall the air cleaner in the reverse order ofremoval.

Air Cleaner Element CleaningRemove the air cleaner cover (7 screws).

Remove the air cleaner element (2 screws).With compressed air to clean dirty aroundthe element. Replace it if it is too dirty toclean.

CautionsThe air cleaner element is made of paperso do not soap it into water or wash itwith water.

air filter strap

bolts×2

screws×7

Air cleaner element

SYM 5. REMOVAL OF ENGINE

5-1

MECHANISM DIAGRAM ......................5-1OPERATIONAL PRECAUTIONS .........5-2ENGINE REMOVAL .............................5-3

REMOVAL OF ENGINE SUSPENSION BUSHING . 5-6ENGINE SUSPENSION FRAME.......... 5-7INSTALLATION 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

5. REMOVAL OF ENGINE SYM

5-2


Engine must be supported by a bracket or adjustable tool in height.The following parts can be serviced with the engine installed on the frame.1. Carburetor2. Driving disk, driving belt, clutch, and transporting disk3. Final reduction gear mechanism

Specification

SpecificationDisassemble 800 c.c.

Engine Oil CapacityReplacement 750 c.c.Disassemble 110 c.c.

Gear Oil CapacityReplacement 100 c.c.

Torque ValuesEngine suspension bolt (frame side) 4.5~5.5kgf-mEngine suspension nut (engine side) 4.5~5.5kgf-mBolt of rear shock absorber upper connection 3.5~4.5kgf-mBolt of rear shock absorber lower connection 2.4~3.0kgf-m


5-3

ENGINE REMOVALOpen the seat.Remove the luggage box assembly (6bolts ).Disconnect the engine start control switchconnector.Remove the power connector of auto by-start.Remove the generator wire and pulsegenerator connector.

Remove the starter motor wire on the Startermagnetic switch.

Remove the spark plug.

Spark plug

Starter magnetic switch

Auto by-startconnector

Generatorconnector

pulse generatorconnector


5-4

Remove the fuel pipe, vacuum hose, andthrottle valve cable from the carburetor.Loose the strap screw of the air cleanerguide, and then the air cleaner guide.

Remove the exhaust muffler (Bolts ×2, Nuts × 2).

Remove the rear wheel (Nut ×1).

Remove the air cleaner connection bolts (2bolts).

2 bolts

Bolts×2

Nut ×1


5-5

Remove the rear brake cable nut.Remove the rear brake cable.Remove the rear shock absorber lower bolt.

Loose the strap screw of engine left guide,and then remove the engine left guide.

Remove the engine suspension nut and bolt(engine side), and then remove the engine.

Caution

Check if the engine suspension, rear shockabsorber bushing, and cushion rubber fordamage. Replace them with new ones if so.

With a bracket to support the engineto prevent from it damage by fallingdown as removing the engine.

Engine suspension bolt/nut

Brake cable nut

Rear shockabsorber bolt

Bushing

Strap screw of guide


5-6

REMOVAL OF ENGINESUSPENSION BUSHINGIf engine suspension frame and the cushionrubber of rear shock absorber bushingdamaged. Then, with the bushing remover /presser, Φ28mm &Φ20mm, to press thebushing out, and replace it with new one.

Engine suspension bushing: Φ28mmRear shock absorber bushing: Φ20mm

Pressing outPlace the detent section of the bushingremover toward the bushing, and drive boththe pressing ring and bolt in to press thebushing out.

Pressing InPlace the flat section of the remover towardthe bushing, and then drive the bushing,pressing ring, and bolt in to install thebushing.


5-7

ENGINE SUSPENSION FRAMERemovalRemove the right side bolt of enginesuspension frame.

Remove the left side bolt of enginesuspension frame.

Check if the engine suspension framebushing and cushion rubber for damage. Ifso, replace with new ones.

InstallationTighten the bolts and nuts of enginesuspension frame.

Engine suspension frame nut:Torque Value: 4.5~5.5 kgf-m

Bolt of engine suspensionframe (left side)


5-8

INSTALLATION OF ENGINECheck if the bushings of engine suspensionframe and shock absorber for damaged. If so,replace with new ones.Install the engine according to the reversingorder of removal.

Caution

Engine suspension nut:Torque Value: 4.5~5.5kgf-m

Rear shock absorber bolt:Torque Value: Top: 3.5~4.5kgf-m

lower: 2.4~3.0kgf-m

Rear wheel axle nut:Torque Value: 11.0~13.0kgf-m

Notice both feet and hands safety forsqueezing as engine installation.Do not bent or squeeze each wires orhose.Route all cables and wires inaccordance with the routine layout.

Engine suspension nut×1

Brake cable nut

Rear shockabsorber bolt

Rear wheel axle nut×1

SYM 6. CYLINDER HEAD/VALVE

6-1

MECHANISM DIAGRAM ....................6-1PRECAUTIONS IN OPERATION .......6-2TROUBLE SHOOTING.......................6-3CAMSHAFT REMOVAL .....................6-4CYLINDER HEAD REMOVAL ............6-6CYLINDER HEAD DISASSEMBLY ....6-7

CYLINDER HEAD INSPECTION..........6-8VALVE SEAT INSPECTION AND SERVICE 6-10CYLINDER HEAD REASSEMBLY ....... 6-12CYLINDER HEAD INSTALLATION ...... 6-13CAMSHAFT INSTALLATION ...............6-13VALVE CLEARANCE ADJUSTMENT ..6-14

MECHANISM DIAGRAM

0.8~1.2 kgf-m

0.7~1.1 kgf-m

1.0~1.4 kgf-m

0.8~1.2 kgf-m1.0~1.4 kgf-m

6. CYLINDER HEAD/VALVE SYM

6-2


This chapter is contained maintenance and service for cylinder head, valve, and camshaftas well as valve rocker arm.Cylinder head service cannot be carried out when engine is in frame.

Specification unit: mm

Item Standard Limit

Compression pressure 12 kg/cm² -Intake 25.686~25.786 25.29

Camshaft Height of cam lobeExhaust 25.50~25.60 25.12

ID of valve rocker arm 10.000~10.015 10.10Rockerarm OD of valve rocker arm shaft 9.972~9.987 9.910

Intake 4.975~4.99 4.90OD of valve stem

Exhaust 4.955~4.97 4.90

ID of Guide 5.000~5.015 5.030

Intake 0.010~0.037 0.080Clearance betweenvalve stem and guide Exhaust 0.030~0.057 0.100

Outer 35.25 -

Valve

Free length of valvespring Inner 32.26~32.56 -

Torque ValueCylinder head cover bolt 0.8~1.2kgf-mCylinder head bolt (LH) 0.8~1.2kgf-mBolt of timing chain auto-adjuster 0.8~1.2kgf-mSpark plug 1.0~1.4kgf-mCam holder nut 1.0~1.4kgf-mValve adjustment fixing nuts 1.0~1.4kgf-m

TOOLSSpecial service toolsValve reamer: 5.0mmValve guide driver: 5.0mmValve spring compressor


6-3

TROUBLE SHOOTINGEngine performance will be effected by troubles on engine top end. The troubles usually canbe determinate or by performing cylinder compression test and judging the abnormal noisegenerated.

Rough IdleLow compression pressure.

Low compression pressure1. Valve

Improper valve adjustment.Burnt or bended valve.Improper valve timing.Valve spring damaged.Valve carbon.Poor sealing on valve seat.Improper spark plug installation.

2. Cylinder headCylinder head gasket leaking or damage.Tilt or crack cylinder surface.

3. PistonPiston ring worn out.

High compression pressureToo much carbon deposit on combustion chamber or piston head.

NoiseImproper valve clearance adjustmentBurnt valve or damaged valve springCamshaft wear out or damageCam chain wear out or loosenessAuto-adjuster wear out or damage of cam chainCamshaft sprocket wear outRocker arm or rocker arm shaft wear out

White smokeValve guide or valve stem wear outValve stem seal wear out


6-4

CAMSHAFT REMOVALRemove the shroud of the engine.Remove the crankcase blow-by system hosefrom the cylinder head.Remove the cylinder head bolts and thenremove the cylinder head (4 bolts).

Loosen the bolt of camshaft chain adjuster ina counter-clockwise motion for releaseadjuster.

Turn the flywheel in counter clockwisemotion with T type wrench until the “T” markon flywheel aligned with the mark on thecrankcase so that the hole on the camshaftsprocket is forward up and piston is at TDCposition.

Remove camshaft holder nut and washer. Caution

Loosen the nuts diagonally by 2-3sequences.

TDC mark

Hole

4 nuts

Blow-by hose

4 boltsA.I.

bolt

camshaft chain adjuster


6-5

Remove the camshaft holder and rocker armset.Remove the camshaft chain from thecamshaft sprocket.Remove the camshaft.

Camshaft InspectionInspect cam lobe height for damaged.Service LimitIN: Replacement when less than 25.29 mmEX: Replacement when less than 25.12 mmInspect the camshaft bearing for loosenessor wear out. If any, replace whole set ofcamshaft and bearing.

Disassembly Of Camshaft HolderWith a 5 mm bolt to screw in the cam rockerarm shaft so that take it out.Remove cam rocker arm.

Inspection Of Camshaft HolderCheck if the camshaft holder, cam rockerarm and rock arm shaft for wearing out ordamage.

Caution

Measure the I.D. of the camshaft holder.Service Limit: Replace when it is above10.10 mm

Further check is necessary if any wearis found on the moveable surface ofcam rocker arm.Check if the camshaft bearing mountingsurface for wear or damage.

5mm bolt

rocker armshaft

rocker arm

Camshaftbearing

rocker arm shaft

I.D.


6-6

Measure the valve rocker arm I.D.Service Limit: Replace when it is above10.100 mm

Measure the active O.D. of the valve rockerarm shaft.Service Limit: Replace when it is above9.910 mmCalculate the clearance between the rockerarm shaft and the rocker arm.Service Limit: Replace when it is above0.10 mm

CYLINDER HEAD REMOVALRemove double seat, luggage box and frontcenter cover.Remove the engine (refer to Chapter 5).Remove the cooling fan cover.Remove the engine shroud (L:2 bolts R:3bolts).

Remove the camshaft.


6-7

Remove the 2 cylinder head mounting boltsfrom cylinder head left side cover.Remove cylinder head gasket and 2 dowelpins.Remove chain plate.Clean up residues from the matchingsurfaces of cylinder and cylinder head.

Caution

CYLINDER HEAD DISASSEMBLYUse a valve compressor to press the valvespring.

After removed valve cotters, release thecompressor and then take out spring retainer,valve spring and valves.

Caution

Special Service Tool: Valve spring compressor.

Remove valve stem guide seal.Clean carbon deposits in combustionchamber.Clean residues and foreign materials oncylinder head matching surface.

Caution

Do not damage the matching surfaces ofcylinder and cylinder head.Avoid residues of gasket or foreignmaterials falling into crankcase ascleaning.

I In order to avoid to loosing springtension, do not compress the spring toomuch. Its length is based on theinstallation of latch.

Do not damage the matching surface ofcylinder head.

Cylinder head gasketChain plate

valve cotters

dowel pins


6-8

CYLINDER HEAD INSPECTIONCheck if spark plug and valve holes are crack.Measure cylinder head flat with astraightedge and flat feeler gauge.Service limit: below 0.05mm

Valve spring free lengthMeasure the free length of intake andexhaust valve springs.Standard:35.250 mm

Valve stemCheck if valve stems are bend, crack or burn.Check the operation condition of valve stemin valve guide, and measure & record thevalve stem outer diameter.Service Limit: IN→ 4.900mm EX→ 4.900mm

Valve guide

Caution

Special Service Tool: 5.0mm valve guidereamerMeasure and record each valve guide innerdiameters.Service limit: 5.030mmThe difference that the inner diameter ofvalve guide deducts the outer diameter ofvalve stem is the clearance between thevalve stem and valve guide.Service Limit: IN→ 0.08mm EX→ 0.10mm

Before measuring the valve guide, cleancarbon deposits with reamer.

5.0mm valve guide reamer

The narrow pitch of the spring shall face to thecombustion chamber.


6-9

Caution

Correct it with reamer after replacement.If clearance still exceeds service limit afterreplaced valve guide, replace valve stem too.

Caution

Valve guide replacementHeat up cylinder head to 100~150 ℃ withheated plate or toaster.

Caution

Hold the cylinder head, and then press out oldvalve guide from combustion chamber side.Tool: Valve guide driver 5 mm

Caution

Adjust the valve guide driver and let valveguide height is in 13mm.Press in new valve guide from rocker arm side.Tool: Valve guide driver 5 mmWait for the cylinder head cooling down toroom temperature, and then correct the newvalve guide with reamer.

Caution

Correct valve seat, and clean up all metalresidues from cylinder head.Special tool: Valve guide reamer 5 mm

If clearance between valve stem andvalve guide exceeded service limit, checkwhether the new clearance that onlyreplaces new valve guide is within servicelimit or not. If so, replace valve guide.

It must correct valve seat when replacingvalve guide.

Do not let torch heat cylinder headdirectly. Otherwise, the cylinder headmay be deformed as heating it.Wear on a pair of glove to protect yourhands when operating.

Check if new valve guide is deformationafter pressed it in.When pressing in the new valve guide,cylinder head still must be kept in100~150 ℃.

Using cutting oil when correcting valveguide with a reamer.Turn the reamer in same direction whenit be inserted or rotated.

Valve guide driver5.0mm

Valve guide driver5.0mm13 mm

(0.15in)

Valve guide reamer 5.0mm


6-10

VALVE SEAT INSPECTION ANDSERVICEClean up all carbon deposits onto intake andexhaust valves.Apply with emery slightly onto valve contactface. Grind valve seat with a rubber hose orother manual grinding tool.

Caution

Remove the valve and check its contactface.

Caution

Valve seat inspectionIf the valve seat is too width, narrow or rough,correct it.Valve seat widthService limit: 1.6mmCheck the contact condition of valve seat.Valve seat grindingThe worn valve seat has to be grinded withvalve seat chamfer cutter.Use 45° valve seat chamfer cutter to cut anyrough or uneven surface from valve seat.

Caution

Use 32° cutter to cut a quarter upper partout.

Do not let emery enter into betweenvalve stem and valve guide.Clean up the emery after corrected,and apply with red paint onto contactfaces of valve and valve seat.

Replace the valve with new one if valveseat is roughness, wear out, orincomplete contacted with valve seat.If the valve and the valve seat still cannot be matched sealing after grinded,replace it with new one.

After valve guide had been replaced, ithas to be grinded with 45° valve sealchamfer cutter to correct its seat face.

valve seatwidth

45°

Roughness

32°

Old valve seat width

Valve seatwidth


6-11

Use 60° cutter to cut a quarter lower part out.Remove the cutter and check new valveseat.

Use 45° cutter to grind the valve seat tospecified width.

Caution

Grind valve seat again if necessary.

Coat the valve seat surface with red paint.Install the valve through valve guide until thevalve contacting with valve seat, slightlypress down the valve but do not rotate it sothat a seal track will be created on contactsurface.

Caution

If the contact surface too high, grind thevalve seat with 32° cutter.Then, grind the valve seat with 45° cutter tospecified width.

If the contact surface too low, grind the valveseat with 60° cutter.Then, grind the valve seat with 45° cutter tospecified width.

Make sure that all roughness anduneven faces had been grinded.

The contact surfaces of valve and valveseat are very important to the valvesealing capacity.

Old valve seat width

60°

45°

1.0mm

Contact surface too high

32°

Old valve seatwidth

Contact surfacetoo low

60°

Old valve seatwidth


6-12

After the valve seat grinded, coat valve seatsurface with emery and then slightly pressthe grinded surface.Clean up all emery coated onto cylinder andvalve after grinded.

CYLINDER HEAD REASSEMBLYLubricate valve stem with engine oil, andthen insert the valve into valve guide.Install new valve stem oil seal.Install valve springs and retainers.

Caution

Use valve spring compressor to press valvespring.Install valve split locks and release the valvecompressor.

Caution

Special tool: valve spring compressor

Tap valve stem to make valve retainer andvalve stem sealing properly.

Caution

The closed coils of valve spring shouldface down to combustion chamber.

In order to avoid to loosing springtension, do not compress the spring toomuch. Its length is based on theinstallation of latch.

Place and hold cylinder head on to workingtable so that can prevent from valvedamaged.

Valve

Valve stemoil seal

Valve spring

Valve springretainer

Valve cotters


6-13

CYLINDER HEAD INSTALLATIONInstall the lock pins and new cylinder headgasket onto the cylinder head.Install the camshaft chain plate.

Install the cylinder head.

CAMSHAFT INSTALLATIONAssemble the camshaft holder.Install the exhaust valve rocker arm set ontothe camshaft holder showing “EX” mark.Install intake valve rocker arm and rockerarm shaft.

Caution

With T type wrench to turn crankshaft in aclockwise motion so that the “T” mark on theflywheel aligns with the mark on crankcase.(piston is at TDC position)Place the TDC marks of the cam sprocket atsame level of the top-end of cylinder head.The other single hole of the cam sprocket isin upward. Then, install the cam chain ontothe cam sprocket.

The tangent of rocker shaft of intakevalve should match with the bolt hole ofcamshaft mounting seat.

Lock pins Cylinder head gasket

Chain plate

5mm blot

Rockerarm shaft Rocker arm

Camshaft

Cam chain


6-14

Install the lock pins.Install the camshaft holder, gasket and nutonto the cylinder head.Tighten the cylinder head nuts. (4 nuts)At first, tighten the 4 nuts on the cylinder topand then tighten the 2 bolts on the left side ofcylinder head.Torque value: 1.8~2.2 kgf-mInstall the spark plug and tighten it.Torque value: 1.0~1.4 kgf-m

Caution

VALVE CLEARANCE ADJUSTMENTLoosen valve clearance adjustment nuts andbolts located on valve rocker arm.Measure and adjust valve clearance withfeeler gauge.After valve clearance had been adjusted tostandard value, hold adjustment bolt andthen tighten the adjustment nut.Standard Value: IN/EX 0.06±0.02mmTurn the cam chain adjuster in clockwisemotion so that the adjuster is pushed out tocontact the cam chain plate tightly. Tightenthe bolt cap of the adjuster adjustment hole.

Caution

Replace the O-ring of the cylinder head withnew one. Install the cylinder head.

Tighten the cylinder head lock bolts.Connect the blow-by hose onto the cylinderhead.Tighten the 2nd air injection (AI) nut.Install the engine onto the engine frame.(Refer to Chapter 5)

Apply with oil onto the thread of cylinderhead bolts and tighten the bolts indiagonally for 2-3 sequences.Do not over tightening the bolts to avoidthe cylinder head deformation, noisecreated or leaking so that effectsmotorcycle’s performance.

The O-ring must be installed into glove.

pin

Especial tool

Blow-by hose

4 boltsA.I

holder

SYM 7. CYLINDER/PISTON

7-1

MECHANISM DIAGRAM ....................7-1PRECAUTIONS IN OPERATION .......7-2TROUBLE DIAGNOSIS......................7-2CYLINDER REMOVAL .......................7-3

PISTON REMOVAL............................7-5PISTON RING INSTALLATION..........7-7PISTON INSTALLATION....................7-8CYLINDER INSTALLATION.............. 7-8

MECHANISM DIAGRAM

0.8~1.2kgf-m

7. CYLINDER/PISTON SYM

7-2

PRECAUTIONS IN OPERATION

General InformationBoth cylinder and piston service cannot be carried out when engine mounted on frame.

Specification unit: mmItem Standard Limit

ID 39.00 -

Bend/wrap age － 0.050

Roundness 0.005 0.050Cylinder

Cylindrical 0.005 0.050

Top ring 0.025~0.060 0.090Clearance betweenpiston and rings 2nd ring 0.015~0.050 0.090

Top ring 0.200~0.400 0.500

2nd ring 0.250~0.400 0.650Ring-end gap

Oil ring 0.200~0.700 -

OD of piston 38.970~38.990 -Clearance between piston andcylinder 0.025~0.040 0.100

Piston/Piston ring

ID of piston pin hole 13.002~13.008 13.040

OD of piston pin 12.994~13.000 12.980

Clearance between piston and piston pin 0.002~0.014 0.018

ID of connecting rod small-end 13.005~13.020 13.040

TROUBLE DIAGNOSISLow Or Unstable Compression Pressure

Cylinder or piston ring worn out.Compress pressure to high.Too much carbon deposited incombustion chamber and piston.

Knock or NoiseCylinder or piston ring worn out.Carbon deposits on cylinder headtop-side.Piston pin hole and piston pin wear out.

Smoking in Exhaust PipePiston or piston ring worn out.Piston ring installation improperly.Cylinder or piston damage.

Engine OverheatCarbon deposits on cylinder head topside.


7-3

CYLINDER REMOVALRemove cylinder head. (refer to chapter 6)Remove 2 bolts and then take out the camchain auto-adjuster.

Remove cam chain plate.Remove cylinder.

Remove cylinder gasket and lock pins

Clean the residues attached onto thematching surfaces of cylinder andcrankcase.

2 bolts


Cylinder 2 bolts


Cylinder


7-4

Cover the holes of crankcase and cam chainwith a piece of cleaning cloth.Clean up all residues or foreign materialsfrom the two matching surfaces of cylinderand crankcase.

Caution

INSPECTIONCheck if the inner diameter of cylinder isworn out or damaged.In the 3 positions (top, center and bottom)of cylinder, measure the X and Y directionvalues respective in the cylinder.Service limit:39.047mmCalculate both the real roundness (thedifference between X and Y motion values)and the cylindrical roundness (thedifference in the top, center or bottompositions of X or Y motion values.). Then,determinate by the max. value.Service limitReal roundness: correct or replace as

over 0.05 mmCylindrical roundness: correct or replace

as over 0.05 mm

Check Cylinder flat.Service limit: correct or replace as over

0.05 mm

To soap the residues into solvent so thatthe residues can be removed more easily.

TopCenterBottom

Exhaust side Intake side


7-5

PISTON REMOVALPlug crankcase opening with a cleaning clothto prevent from piston pin snap ring or otherparts falling into crankcase whendisassembling.Hold another snap ring with pliers.Push out the piston pin from the side that notremoved the snap ring.

Remove piston rings.Caution

Disassemble the piston rings.Check if the piston rings are damaged or itsgrooves are worn.Cleaning the carbon in piston ring grooves.

Install the piston rings and then measureclearance between piston ring and itsgrooves.Service Limit: Top ring: replace if over

0.09mm 2nd ring: replace if over

0.09mm

Take out the piston rings and place themrespective into cylinder below 20mm ofcylinder top. Measure each piston ringgaps.

Caution

Service Limit: Top ring: replace if over0.50mm

2nd ring: replace if over0.650mm

Pay attention to remove piston ringsbecause they are fragile.

Push the piston rings into cylinder withpiston top-end in parallel motion.

Piston ring

Push in

Feeler gauge

Piston

piston ring

Feeler gauge


7-6

Measure the outer diameter of piston pin.Service Limit: 12.980mm

Measure the inner diameter of connectingrod small end.Service Limit: 13.020mm

Measure the inner diameter of piston pinhole.Service Limit: 13.040mm

Calculate clearance between piston pin andits hole.Service Limit: 0.02mm

Measure piston outer diameter. Caution

Service limit: 38.970mmCompare measured value with service limitto calculate the clearance between pistonand cylinder.

The measurement position is 10 mmdistance from piston bottom side, and 90°to piston pin.


7-7

PISTON RING INSTALLATIONClean up piston top, ring groove, and piston skirt.Install the piston ring onto piston carefully.Place the openings of piston ring as diagram shown.

CautionDo 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 rings can be rotated freely after installed.

Top groove

2nd groove

Oil groove

Top ring

2nd ring

Oil ringSpacer

Side ring

Side ring

Over 20 mm

120°


7-8

PISTON INSTALLATIONInstall piston and piston pin, and place the INmark on the piston top side forward to intakevalve.Install new piston pin snap ring.

Caution

CYLINDER INSTALLATIONClean up all residues and foreign materialson the matching surface of crankcase.Pay attention to not let these residues andforeign materials fall into crankcase.

Caution

Install 2 lock pins and new gasket.

Coat engine oil to inside of cylinder, pistonand piston rings.Care to be taken when installing piston intocylinder. Press piston rings in one by one asinstallation.

Caution

Install the cam chain plate, the cylindergasket and lock pins.Install cylinder head. (refer to Chapter 6)Install the cam chain auto-adjuster. (2 bolts)

Do not let the opening of piston pin snapring align with the opening piston ring.Place a piece of cleaning cloth betweenpiston skirt section and crankcase inorder to prevent snap ring from fallinginto crankcase as operation.

Do not push piston into cylinder forcefullybecause this will cause the piston and thepiston rings to be damaged.

To soap the residues into solvent so thatthe residues can be removed moreeasily.

Piston pin

IN mark

Piston

2 bolts


SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

8-1

MECHANISM DIAGRAM ....................8-1MAINTENANCE DESCRIPTION ........8-2TROUBLE DIAGNOSIS......................8-2LEFT CRANKCASE COVER..............8-3

KICK STARTER ARM ........................8-3DRIVING BELT...................................8-4SLIDING PULLEY ..............................8-6CLUTCH/DRIVEN PULLEY............... 8-9

MECHANISM DIAGRAM

3.5~4.5kgf-m

5.0~6.0kgf-m

5.0~6.0kgf-m

0.8~1.2kgf-m

8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

8-2

MAINTENANCE DESCRIPTIONPRECAUTIONS IN OPERATIONGENERAL INFORMATION‧ Driving pulley, clutch, and driven pulley can be serviced on the motorcycle.‧ Driving belt and driving pulley surface must be free of grease.

Specification Unit: mmItem Standard value Limit

Driving belt width 17.50 16.8ID of sliding pulley bush 20.035~20.085 20.150OD of roller 15.920~16.080 15.570ID of clutch outer 107.00~107.20 107.50Thickness of clutch pad 4.000 2.0Free length of drive pulley

i97.20 96.5

OD of driven pulley 33.965~33.985 33.940

ID of sliding pulley 34.000~34.025 34.060ID: Inner DiameterOD: Outer diameter

Torque valueSliding pulley nut: 5.0~6.0kgf-mClutch outer nut: 5.0~6.0kgf-mdriving pulley nut: 3.5~4.5kgf-m

Special Service ToolsClutch spring compressorBearing puller (inner type)Clutch mounting nut wrenchUniversal fixture

TROUBLE DIAGNOSISEngine can be started but motorcyclecan not be moved1. Worn driving Belt2. Worn tilt plate3. Worn or damaged clutch lining4. Broken driven pulley

Shudder or misfire when driving1. Broken clutch lining2. Worn clutch lining

Insufficient horsepower or poor highspeed performance1. Worn driving belt2. Insufficient spring capacity of driven

pulley3. Worn roller4. Driven pulley operation un-smoothly


8-3

LEFT CRANKCASE COVERLeft crankcase cover removalRemove air cleaner. (2 bolts)Remove kick starter arm. (1 bolt)Loosen vent strap on the front-left side ofcover, and then remove the vent.Remove engine left-side cover (8 bolts).

KICK STARTER ARMDisassemblyRemove the return spring, starter shaft.Remove driving gear, friction spring andwasher.InspectionCheck if starter shaft, driving gear, for wearor damage. Replace it with new one ifnecessary.Check the return spring for spring force ordamaged. Replace it with one if poor partsfound.ReassemblyApply with some specified grease on thegear, shaft.Install the friction spring of driving gear ontoconvex part of the case cover.Install, return spring and starter shaft asdiagram shown.Install kick starter arm temporary.Rotate the lever and then align driving gearwith width-tooth on the starter shaft.Install thrust washer and socket onto startershaft.

Installation of the left crankcasecoverInstall the left crankcase cover. (8 bolts)Install front vent tube of left cover and tightenthe strap.Install kick starter arm. (1 bolt)Tighten the air cleaner. (2 bolts)

Return springStarter shaftStarter shaftFriction spring

Driving gear

driving gear

starter shaft gear

Kick starter arm shaft

Strap Bolts

air cleaner lock nutkick starter arm


8-4

DRIVING BELTRemovalRemove left crankcase cover.Hold the sliding pulley with a universal fixture,and then remove the nut and sliding pulley.

Hold driving pulley with universal fixture, andremove nut and clutch outer.

Caution

Push the driving belt into belt groove asdiagram shown so that the belt can beloosened, and then remove.Driving belt and clutch at same time.

InspectionCheck the driving belt for crack or wear.Replace it if necessary.Measure the width of driving belt as diagramshown. Replace the driving belt if it exceedmaintenance limited specification.Service Limit: 16.80mm

Caution

Using special service tools for tightening orloosening the nut. Fixed rear wheel or rearbrake only will damage reduction gearsystem.

Using the genuine parts for replacement.The surfaces of driving belt or pulley mustbe free of grease.Clean up all grease or dirt beforeinstallation.

Width

Tooth

Driving belt

Universal fixer

sliding pulley

Nut

Universal fixer

driving pulley


8-5

InstallationPull out the driving pulley and then insert thedriving pulley.

Caution

Install the starter gear.Install the clutch set with driving belt onto thedriving shaft.Install the sliding pulley on the other end ofbelt.Install clutch outer.

Install the clutch with universal fixture, andthen tighten nut to specified torque value.Torque value: 3.5~4.5 kgf-m

Caution

Pull out driving pulley and then insert thedriving belt into the driving pulley so that thedriving belt set can be installed onto slidingpulley more easily.

When install the driving belt, if there is aarrow mark, then the arrow mark mustpoint to rotation motion. If not, the letterson the belt must be forwarded toassembly direction.

Slidingdrivenpulley

Clutch outer

Nut

Universal fixer

clutch outer

starter gear

sliding pulley


8-6

SLIDING PULLEYREMOVALRemove left crankcase cover.Hold driving pulley with universal fixture, andthen remove driving pulley nut.Remove driving pulley.

Remove the sliding pulley fixing nut andremove the driving belt from the slidingpulley.Remove the driving belt from the slidingpulley.Remove the limited speed bush.Remove the bush and remove the slidingpulley from the crankshaft.

Remove tilt plate.

Remove weight rollers from sliding pulley.

Tilt plate

Sliding pulley

Roller

driving pulley

nut

Starter gear

Bush

Sliding pulley

Limited speedbush

Crankshaft


8-7

InspectionThe operation of sliding pulley is means ofthe weight roller to pressing on it withcentrifuge force. And then the speed ischanged by the title plate rotation. Thus, ifweight rollers are wear out or damage, thecentrifuge force will be effected.Check if rollers 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 slidingpulley.Service limit: 34.06 mm

Measure the inner diameter of the pulleybush.Replace it if exceed the service limit.Service limit: 20.15 mm

Assembly/InstallationInstall the weight rollers.

Install the title plate guide boot onto the titleplate.Install the title plate.

Weight roller

Sliding pulley

Pulley hub

Guide boot

Tilt plate

Weight roller


8-8

Apply with grease 4~5 g to inside of drivingshaft hole, and install driving pulley hub.

Caution

Install siding pulley assembly onto crankshaft.

Driving pulley installPress driving belt into pulley groove, andthen press down the up & down sides of thedriving belt to separate it away from thedriving pulley hub.

Caution

Install driving pulley, washer and nut. Caution

Hold driving pulley with universal fixture.Tighten nut to specified torque.Torque value: 5.0~6.0 kgf-mInstall left crankcase cover.

The pulley surface has to be free ofgrease. Clean it with cleaning solvent.

Make sure that two sides of pulleysurfaces have to be free of grease.Clean it with cleaning solvent.

To press down the up & down sides of thedriving belt can avoid to pressing anddamaging the belt when installing thedriving pulley, and also can make sure thatthe driving pulley can be tighten.

Driving belt

Press down

Pulley bush

Sliding pulley

Limited speedbush

Crankshaft

Pulley surface

Pulley bush


8-9

CLUTCH/DRIVEN PULLEYDISASSEMBLYRemove driving belt and clutch/driven pulley.Install clutch spring compressor onto thepulley assembly, and operate thecompressor to let nut be installed moreeasily.

Caution

Hold the clutch spring compressor ontobench vise, and then remove mounting nutwith special nut wrench.Release the clutch spring compressor andremove clutch and spring from driven pulley.Remove socket from driven pulley.

Remove oil seal from driven pulley.Remove guide pin, guide pin roller, andsliding pulley, and then remove O-ring & oilseal seat from sliding pulley.

INSPECTIONClutch outerMeasure the inner diameter of clutch outerfriction face. Replace the clutch outer ifexceed service limit.Service limit: 107.5 mm

Do not press the compressor too much.

Clutch outerInner

diameter

O-ring Guide pin Guide pinroller

Guide pinOil sealSliding pulley

Socket

Clutch spring compressor

Special nut wrench


8-10

Clutch liningMeasure each clutch lining thickness.Replace it if exceeds service limit.Service limit: 2.0mm

Driven pulley springMeasure the length of driven pulley spring.Replace it if exceeds service limit.Service limit: 93.2mm

Driven pulleyCheck following items;‧ If both surfaces are damage or wear.‧ If guide pin groove is damage or wear.Replace damaged or worn components.Measure the outer diameter of driven surfaceand the inner diameter of driven pulley.Replace it if exceeds service limit.Service limit: Outer diameter 33.94mm Inner diameter 34.06mm

Driven Pulley Bearing InspectionCheck if the inner bearing oil seal is damage.Replace it if necessary.Check if needle bearing is damage or too bigclearance. Replace it if necessary.Rotate the inside of inner bearing with fingersto check if the bearing rotation is in smoothand silent.

Free length

Guide pingrooveSliding disc

Driven pulley

Clutch

Clutch lining

Needle bearing

Outer ball bearing


8-11

Clutch Block ReplacementRemove snap and washer, and the removeclutch block and spring from driving plate.Check if spring is damage or insufficientelasticity.

Check if shock absorption rubber is damageor deformation. Replace it if 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 andthen push to specified location.

Caution

Install the spring snap into groove with pliers.

Grease or lubricant will damage theclutch block and effect the block’sconnection capacity.

Shock absorption rubber

Clutch block

Spring

SpringDriving plate

Snap ring

Clutch block

Shock absorption rubber

Setting pin


8-12

Install snap ring and mounting plate ontosetting pin.

REPLACEMENT OF DRIVEN PULLEYBEARINGRemove inner bearing.

Caution

Remove snap ring and then push bearingforward to other side of inner bearing.Place new bearing onto proper position andits sealing end should be forwarded tooutside.Apply with specified grease.Recommended to use the KING MATE G-3.Install the snap ring and hold the bearing.

Install a new inner bearing. Caution

Align oil seal lip with bearing, and then installthe new oil seal (if necessary).

Its sealing end should be forwarded tooutside as bearing installation.Install needle bearing with hydraulicpresser. Install ball bearing by meansof hydraulic presser.

If the inner bearing equipped with oilseal on one side in the driven pulley,then remove the oil seal firstly.If the pulley equipped with ball bearing,it has to remove snap ring and then thebearing.

Snap ring

Inner bearing

Sealing end

Oil seal

Inner needlebearing

Outer bearing

Snap ring

Snap ring

Outer bearing

Sealing end

Specified grease


8-13

INSTALLATION OF CLUTCH/DRIVENPULLEY ASSEMBLYInstall new oil seal and O-ring onto slidingpulley. Apply with specified grease tolubricate the inside of sliding pulley.

Install sliding pulley onto driven pulley.Install guide pin and guide pin roller.

Install oil socket.

Install driving belt, spring and clutch intoclutch spring compressor, and press downthe assembly by turning manual lever untilmounting nut that can be installed.Hold the compressor by bench vise andtighten the mounting nut to specified torquewith special nut wrench.Remove the clutch spring compressor.Torque value: 5.0~6.0 kg-mInstall clutch/driven pulley and driving beltonto driving shaft.

Oil seal

O-ringSpecifiedgrease

Oil socket

O-ring Guide pinGuide pinroller

Guide pinOil seal

Sliding pulley

Clutch spring compressor

Special nut wrench

SYM 9. FINAL DRIVING MECHANISM

9-1

MECHANISM DIAGRAM ....................9-1OPERATIONAL PRECAUTIONS .......9-2TROUBLE DIAGNOSIS......................9-2DISASSEMBLY OF FINAL DRIVINGMECHANISM......................................9-3

INSPECTION OF FINAL DRIVINGMECHANISM......................................9-3BEARING REPLACEMENT................9-4RE-ASSEMBLY OF FINAL DRIVINGMECHANISM......................................9-6

MECHANISM DIAGRAM

2.6~3.0 kgf-m

2.6~3.0 kgf-m

9. FINAL DRIVING MECHANISM SYM

9-2

OPERATIONAL PRECAUTIONSSpecificationApplication gear oil: 4-stroke lubricantRecommended gear oil: 85W-140Oil quantity: 110 c.c. (100 c.c. whenreplacing)

ToolsSpecial service toolsInner type bearing pullerOuter type bearing pullerGear box oil seal installerGear box bearing installer

Torque valueGear box cover 2.6~3.0 kgf-mGear oil drain plug 1.0~1.5 kgf-mGear oil filling bolt 1.0~1.5 kgf-m

TROUBLE DIAGNOSISEngine can be started but motorcyclecan not be moved‧ Damaged driving gear‧ Burnt out driving gear‧ Broken driving belt

Noise‧Worn or burnt gear‧Worn gear

Gear oil leaks‧ Excessive gear oil‧Worn or damage oil seal


9-3

DISASSEMBLY OF FINAL DRIVINGMECHANISMRemove the rear wheel. (refer to chapter 15)Remove the clutch.Drain gear oil out from gear box.Remove gear box cover bolts (7bolts) andthen remove the gear box cover and the finaldriving shaft.Remove gasket and setting pin.

Remove countershaft and gear.Remove final driving gear and shaft.

INSPECTION OF FINAL DRIVINGMECHANISMCheck if the countershaft and the gear arewear or damage.

Check if the final driving shaft and gear areburn, wear or damage.

final driving shaft

final driving gear

countershaft

countershaft gear

driving shaft

7 bolts

final driving shaft

final driving gear


9-4

Check bearings on the gear box cover.Rotate each bearing’s inner ring with fingers.Check if bearings can be turned in smoothand silent, and also check if bearing outerring is mounted on gear box & cover tightly.If bearing rotation is uneven, noising, orloose bearing mounted, then replace it.Check oil seal for wear or damage, andreplace it if necessary.

Check driving shaft and gear for wear ordamage.

BEARING REPLACEMENTCaution

Remove driving shaft bearing from leftcrankcase using following tools;Inner type bearing puller

Install new driving shaft bearing into leftcrankcase.Tool:Press the bearing into cover with C typehydraulic presser or bearing installer.

Never install used bearings. Once bearingremoved, it has to be replaced with newone.

final driving shaft

final driving gear

countershaft

countershaft gear

driving shaft

bearing

driving shaft bearing


9-5

Press out the driving shaft from thecrankcase.Remove oil seal from the crankcase.Remove the driving shaft bearing from thegear box cover with the inner type bearingpuller.

Caution

Specified tool:Inner type bearing puller.

If the driving shaft is pulled out with itsbearing, then remove the bearing with bearingpuller and bearing protector.Tool:Multi-functional bearing pullerBearing protector

Install a new driving shaft bearing ontocrankcase.Then, install the driving shaft.Specified tool:Press the bearing in with C type hydraulicpresser or bearing installer.

Install a new final driving shaft bearing ontocrankcase.Specified tool:Press the bearing in with C type hydraulicpresser or the bearing installer.Apply with some grease onto the lip sectionof oil seal and then install the seal.

Using the bearing protector as pressing outthe driving shaft from the left crankcase.

Bearing protector

Multi-functional bearing puller

Driving shaft

driving shaft

final driving shaftbearing


9-6

RE-ASSEMBLY OF FINAL DRIVINGMECHANISMInstall final driving shaft and final driving gear,countershaft, and countershaft gear.

Install the setting pins(2 pins) and new gasket.

Apply with grease onto the oil seal lip of finaldriving shaft.Install the gear box cover and 7 bolts.(tighten the bolts)Torque: 2.6~3.0 kgf-mInstall the clutch/sliding driving pulley.Install the driving pulley, belt and leftcrankshaft cover.Install the rear wheel.

Add gear oil.Recommended usage gear oil :SAE85W-140(110 cc: standard capacity)(100 cc: when replacement)

final driving shaftcountershaft

final shaft gear

dowel pins

7 bolts

Filling bolt

Draining bolt

SYM 10. A.C. GENERATOR

10-1

PRECAUTIONS IN OPERATION .......10-1A.C.GENERATOR REMOVAL............10-2RIGHT CRANKCASE COVERREMOVAL ..........................................10-3

RIGHT CRANKCASE COVERINSTALLATION..................................10-4MOUNTED COIL SETINSTALLATION..................................10-4FLY WHEEL INSTALLATION.............10-4

PRECAUTIONS IN OPERATIONGeneral information

Refer to chapter 5: Engine removal and installationRefer to chapter 1: The troubleshooting and inspection of A.C. generator

Torque value:Flywheel nut 3.5~4.5kgf-mExhaust muffler bolt 8 mm 3.0~3.6kgf-mOil screen cover 1.0~2.0kgf-m

Special service toolsFlywheel pullerUniversal fixture

10. A.C. GENERATOR/STARTING CLUTCH SYM

10-2

A.C. GENERATOR REMOVAL

Drain out the engine oil.Remove the exhaust muffler. (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

Flywheel

Cooling fan

Cooling fanshroud

Coil

Pulse generator

Cable guide

Universal fixture

Cooling fan

Exhaust muffler

Cooling fan shroud


10-3

Remove the flywheel with the flywheel puller.Special service tools:Flywheel pullerShaft protector

Caution

Remove the connectors of the A.C.generator and pulse generator.

Remove the 6 bolts for the pulse generator,the A.C. generator coil and cable guide.Then, remove the A.C. generator assembly.

Caution

RIGHT CRANKCASE COVERREMOVALRemove the right crankcase cover. (8 bolts)Remove setting pin and gasket.Remove the gasket or foreign materials onthe connection surfaces of both the coverand crankcase.

Caution

Do not damage the alternator coil.

Do not damage the connection surfaces.

Install a shaft protector on the right end ofcrankshaft to avoid damaging thecrankshaft before installing the flywheelpuller.

Flywheel puller

Pulse generator

Coil

Cable guide

8 bolts

generator connector

Pulse generator connector

10. A.C. GENERATOR/STARTING CLUTCH SYM

10-4

RIGHT CRANKCASE COVERINSTALLATIONInstall setting pin and new gasket on thecrankcase.Replace the right crankshaft oil seal of thecrankcase and apply some oil onto the oilseal lip.Install right crankcase cover onto the rightcrankcase. (8 bolts)Torque value: 1.5~2.0kgf-m

MOUNTED COIL SETINSTALLATIONInstall the coil set onto right crankcasecover. (2 bolts)Install pulse generator. (2 bolts)Torque: 0.8~1.2kgf-mTie the wire harness hose onto the indent ofcrankcase.

Install A.C. generator connector and pulsegenerator connector.

FLYWHEEL INSTALLATIONMake sure that there is no magnetic powder.If so, clean up it.Align insert on crankshaft with the flywheelgroove, and then install the flywheel.Hold the flywheel with flywheel holder, andtighten its nut.Torque value: 3.5~4.5kgf-mSpecial service tool:Universal fixture

Universal fixture

Auto by-startconnector

generator connector

Pulse generatorconnector

Pulse generator

Coil

8 bolts


10-5

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 thespecified quantity.

Exhaust muffler

Cooling fan shroud

Cooling fan

4 bolts

SYM 11. CRANKCASE/CRANKSHAFT

11-1

MECHANISM DIAGRAM .............. 11-1OPERATIONAL PRECAUTIONS...11-2TROUBLE DIAGNOSIS................11-2

DISASSEMBLY OF CRANKCASE 11-3CRANKSHAFT INSPECTION ....... 11-5ASSEMBLY OF CRANKCASE ..... 11-6

MECHANISM DIAGRAM

1.5~2.0 kgf-m

0.7~1.1 kgf-m

11. CRANKCASE/CRANKSHAFT SYM

11-2


This Section contains descriptions concerning disassembly of the crankcase so that thecrankshaft can be serviced.Complete following operations before disassembling crankcase.

Engine Chapter 5Cylinder head Chapter 6Cylinder and piston Chapter 7V-belt Drive pulley Chapter 8AC generator/ Starting Clutch Chapter 10

If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have toreplaced.

Specification Unit: mmItem Standard Limit

Left, right clearance of the big end of the connecting rod 0.100~0.350 0.550

Radial clearance of the big end of the connecting rod 0.000~0.008 0.050

Run-out ─ Below 0.030

Torque valueBolts for crankcase 0.8~1.2 kgf-mBolts for cylinder/cylinder head 0.8~1.2 kgf-mEngine oil draining plug 3.5~4.5 kgf-mBolts for cam chain tensioner 0.8~1.2 kgf-m

Special Service ToolsCrankcase remover/setCrankshaft installation pullerInner type bearing pullerOuter type bearing pullerBearing pressing toolsOil seal pressing tools

TROUBLE DIAGNOSISEngine noise Loose crankshaft bearing Loose crankshaft pin bearing Wear piston pin or piston pin hole


11-3

DISASSEMBLY OF CRANKCASERemove the 1 bolt from the right crankcase.

Remove the cam chain tensioner (hex socketbolt) from the left side of crankcase.

Place the left side of crankcase upward,and then install the crankcase remover/setonto the crankcase.Drive the screw of the crankcaseremover/set into the crankcase, and thenseparate the left and the right crankcases.Remove the cam chain.

Caution

Special Service Tools:Crankcase remover/set

Never pry out the connection surfacesof crankcases as separating.Otherwise, the connection surfacescould be damaged and cause oilleaking.It have to separate the cam chain andthe drive gear before pressing out theboth left and right crankcases.

1 bolt

1 hex socket bolt


11-4

Remove the crankshaft from the rightcrankcase.

Caution

Remove gasket and dowel pins (2).Scrape gasket residues off the crankcasecontact surface.

Caution

Remove oil seal from the left crankcase.

Do not damage contact surface of thecrankcase.Soap the gasket residues into solventand the residues will be removedeasily.

The left and right bearings of crankshaftis to press-fit onto the crankshaft.


11-5

CRANKSHAFT INSPECTIONMeasure left and right clearance of connectingrod big end.Service limit: Replace when it is morethan 0.55 mm

Measure the radical clearance of the bigend at the vertical directions.Service limit : 0.05 mm

Place the crankshaft onto a V-block andmeasure run-out of the crankshaft with dialgauge.Service limit: 0.10 mm

Bearing InspectionRotate the bearing with fingers and makesure the bearing can be rotated smoothlyand quietly.Check if the inner ring is connected onto thecrankshaft tightly.Replace crankshaft as a set when noise orlooseness is detected.

60 mm 90 mm

clearance

clearance


11-6

ASSEMBLY OF CRANKCASEInstall cam chain into the chain hole of theleft crankcase, and then split out the camchain.

Caution

Install crankshaft into the left crankcase andthen install two dowel pins and newcrankcase gasket.

Install the right crankcase and tighten thecrankcase bolts (1 bolts).Torque value: 0.8~1.2 kgf-m

Install the cam chain tensioner.Install a new O-ring onto the mounting boltof the chain tensioner.Apply some oil on the O-ring and tighten thebolt.Torque value: 0.8~1.2 kgf-m

Caution

Do not damage the cam chain asinstalling the crankshaft.

The O-ring must be installed into thebolt’s groove.

hex socket bolt

dowel pins

1 bolt


11-7

Apply with some grease onto the oil seal lipand then install it onto the left crankcase.

Press-fit the oil seal to specified positionwith the oil seal installer (25x37x6).Special service tools: the oil sealinstaller (25x37x6)

SYM 12. BODY COVER

12-1

MAINTENANCE INFORMATION........12-2HANDLE COVER ...............................12-3FRONT COVER..................................12-4UNDER COVER .................................12-5FRONT INNER BOX...........................12-6

BODY COVER/REAR FENDER.........12-7FRONT CENTER COVER..................12-9LUGGAGE BOX .................................12-9FLOOR PANEL ..................................12-9

Front centercover

Frame numbercover

Left body cover

Inner box

Double Seat Rear carrier

Luggage box

Floor panel

Front cover

Under cover

Rear fender

Rear handlecover

Front fender

Right body cover

Battery cover

RR. mudguard

Rear innerfender

Fuel tankFront handlecover

Front spoiler Left side cover

Right side cover

12. BODY COVER SYM

12-2

MAINTENANCE INFORMATIONBody covers disassemble sequence:

Be careful not to damage various covers in disassembly or re-assembly operation.Never injure hooks molded on the body covers in disassembly or 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 covers during assembly.

Battery cover

Luggage box & Seat

Front center cover

Front handle cover

Floor panel

Rear carrier

Rear fender

Rear handle cover

Front fender

Front cover

Inner box

Left/right body cover

Rear inner fender

Front cushion

Front spoiler

Left/right side cover

Under cover

SYM 12. BODY COVER

12-3

HANDLE COVERRemoval:Remove the left/right back mirror.Remove 2 lower mounting screws betweenthe front handle cover and the rear handlecover.

Remove the mounting screws (4 screws)between the front handle cover and the rearhandle cover.

Remove the headlight connector.Remove the front handle cover.

Remove the front handle cover.

InstallationInstall according to the reverse procedure ofremoval.

Screws 2×2

mounting screw×2

Headlight connector

12. BODY COVER SYM

12-4

Remove the mounting screws (2 screws)between the rear handle cover and theframe.

Remove the speedometer cable.Remove the mounting screws (4 screws)between the rear handle cover and meter.Remove the left/right handle switchconnectors.Remove the rear handle cover.

Installation:Install according to the reverse procedureof removal.

FRONT COVERRemovalRemove the 1 mounting bolt of front coverfrom the frame.

Remove the mounting screws (3×2 screws)between the front cover and inner box.

screws×2

leftright

screws×4

speedometercable

bolt×1

6 screws

SYM 12. BODY COVER

12-5

Remove the front turn left/right signal lightwire connectors.

Remove the front cover.Installation:Install according to the reverse procedure ofremoval.

UNDER COVERRemovalRemove the 1×2 mounting screws betweenthe left/right side cover and the floor panel.

Remove the 1×2 mounting screws betweenthe left/right side cover and the frame.

Remove the 2×2 mounting bolts betweenthe under cover and the frame.

Remove the under cover.Installation:Install according to the reverse procedure ofremoval.

wire connectors

1×2 screws

1×2 screws

2×2 bolts

12. BODY COVER SYM

12-6

FRONT INNER BOXRemovalRemove the front cover.Remove the 6 mounting screws of frontcover from the inner box.

Remove the 1×2 mounting screws of frontspoiler from the inner box.

Remove the 1×2 mounting screws of frontspoiler from the inner box.

Remove the screw on the front inner box. 1 screw

6 screws

2 screws

2 screws

front spoiler

SYM 12. BODY COVER

12-7

Remove the screw on the main switch.Remove the main switch cover.

Remove the front inner box A.

InstallationInstall the inner box A and the front inner boxB according to the reverse procedure ofremoval.

BODY COVER/REAR FENDERRemovalOpen the seat.Remove the luggage box. (6 bolts)

Remove the rear carrier. (3 bolts)

Remove the 1×2 mounting screws betweenthe body cover and frame.

3 bolts

1 screw

2 screws

6 bolts

12. BODY COVER SYM

12-8

Remove the 2×2 mounting screws betweenthe body cover and the rear fender.

Remove the 1×2 mounting screws betweenthe body cover and the floor panel.

Remove the 1 mounting screw between thebody cover and front center cover.

Remove the 2 mounting bolts of the rearfender.

Remove the left/right body cover.Remove the rear fender.

InstallationInstall the body cover and rear fenderaccording to the reverse procedure ofremoval.

2 bolts

2×2 screws

1 screw

1×2 screws

SYM 12. BODY COVER

12-9

FRONT CENTER COVERRemovalRemove the 1 mounting screw between thebody cover and the front center cover.

Remove the 4 screws from the battery cover.Remove the the battery cover.Remove the front center cover.

InstallationInstall the cover according to the reverseprocedure of removal.

LUGGAGE BOXRemovalOpen the seat.Remove the 6 bolts from the luggage box.Remove the luggage box and the doubleseat.Remove the engine start control switch wireconnectors.InstallationInstall the luggage box according to thereverse procedure of removal.

FLOOR PANELRemovalRemove the 4 bolts from the floor panel.

4 bolts

4 screws

6 bolts

1 screw

12. BODY COVER SYM

12-10

Remove the 4 screws from the batterycover.Remove the battery cover.

Remove the front center cover mountingscrew.

Remove the 1×2 screws between the bodycover and the floor panel.

Remove the 1×2 screws between theleft/right side cover and the floor panel.

Remove the floor panel.

InstallationInstall the floor panel according to thereverse procedure of removal.

4 screws

1×2 screws

1×2 screws

1 screw

SYM 13. BRAKE

13-1

MECHANISM DIAGRAM................................13-1MAINTENANCE INFORMATION....... 13-3TROUBLE DIAGNOSIS .....................13-4HYDRAULIC BRAKE SYSTEMINSPECTION .....................................13-5BRAKE FLUID REPLACEMENT/AIR-BLEED ........................................13-6

BRAKE CALIPER.............................. 13-7BRAKE DISK ..................................... 13-8BRAKE MASTER CYLINDER ........... 13-8DRUM BRAKE-DRUM ....................... 13-11BRAKE LING ..................................... 13-11BRAKE PANEL.................................. 13-12

MECHANISM DIAGRAMFront Disk Brake System

11.0~13.0 kgf-m

4.0~4.5 kgf-m

0.8~1.0 kgf-m3.3~3.7 kgf-m

2.8~3.2 kgf-m

13. BRAKESYM

13-2

Rear Drum Brake System

0.8~1.2 kgf-m

0.8~1.2 kgf-m

SYM 13. BRAKE

13-3

MAINTENANCE INFORMATIONPrecautions in Operation

Caution

The brake caliper can be removed without removing the hydraulic system.After the hydraulic system is removed, or the brake system is felt to be too soft, bleed thehydraulic system.While refilling brake fluid, care should be taken not to let the foreign material entering intothe brake system.Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.Check the operation of the brake system before you go.

Specifications Unit: mmItem Standard Limit

The thickness of front brakedisk

3.50 2.00

Front brake disk 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 disk 130.00 ─

Thickness of front disk brakepad

─ As brake ling mark

Thickness of front drum brakepad

─ 2mm or As brake ling mark

Thickness of rear brake pad ─ 2mm or As brake ling mark

Torque valuesBolt for front brake arm 0.8~1.2kgf-mBolt for rear brake arm 0.8~1.2kgf-mBrake hose bolt 3.3~3.7kgf-mBolt for brake caliper 3.1~3.5kgf-mAir-bleed valve 0.8~1.0kgf-m

Installing pad dusts may cause disorders of respiration system or cancer, therefore, neveruse air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized toolinstead.

13. BRAKESYM

13-4

TROUBLE DIAGNOSISDISK BRAKESoft brake lever

Air inside the hydraulic systemHydraulic system leakingWorn master pistonWorn brake padPoor brake caliperWorn brake pad/diskLow brake fluidBlocked brake pipeWarp/bent brake diskBent brake lever

Hard operation of brake leverBlocked brake systemPoor brake caliperBlocked brake pipeSeized/worn master cylinder pistonBent brake lever

Uneven brakeDirty brake pad/diskPoor wheel alignmentClogged brake hoseDeformed or warped brake diskRestricted brake hose and fittings

Tight brakeDirty brake pad/diskPoor wheel alignmentDeformed or warped brake disk

Brake noiseDirty padDeformed brake diskPoor brake caliper installationImbalance brake disk or wheel

DRUM BRAKEPoor brake performance

Improper brake adjustmentWorn brake padWorn brake drumWorn brake camImproper brake pad installationSeized brake cableDirty brake padDirty brake drumBrake pad worn in brake cam area.Poor contact between brake arm andcamshaft indent

Tight operation or low return speed ofbrake lever

Worn/broken/crack return springWorn drumDirty brake padBrake seized caused from dirty brakedrumSeized brake cableWorn brake camImproper brake pad installation

Brake noiseWorn brake padWorn drumDirty brake padDirty brake drum

SYM 13. BRAKE

13-5

HYDRAULIC BRAKE SYSTEMINSPECTIONInspectionVisual inspect for brake fluid leaking ordamage. Check if brake hose connectionloosen with wrench and turn the handlebarfrom right to left motion or press down theshock absorber to check if there is somethingis interfered with the brake system or brakecomponents.

Operate the brake system and check thebrake pad. Check the front brake from frontside, and replace the brake pad with new onewhen the brake pad wear limitation groovereaches to the brake disk.

Park the motorcycle on a flat ground andcheck its brake fluid level.Recommended brake fluid: WELLRUN DOT 3brake fluid

CAUTION

Brake Fluid AddTurn the handlebar to let the master cylinderin horizontal position before removed themaster cylinder cap.Place a rag onto painting, plastic or rubbercomponents when conduct brake systemmaintenance.

CAUTIONDo not over the upper level when addingbrake fluid and avoid to spilling brake fluidon painted surfaces, plastic or rubbercomponents to result in their damages.

master cylinder cap

Lower level

Hose connection

brake caliper

Brake disc

brake padwear limitationgroove

lowerlevel

The fluid level will not be correct ifparking the motorcycle in title or justparking. It has to waiting for around 3~5minutes.Never use faked brake fluid to preventfrom chemical reaction.It has to apply with same brand brakefluid to sure the brake performance.

13. BRAKESYM

13-6

Remove the master cylinder cap anddiaphragm.Add good quality brake fluid and it has to addsame brand brake fluid into the master cylinder.Clean dirty brake disk.

CAUTION

BRAKE FLUID REPLACEMENT/AIR-BLEEDConnect drain hose to drain valve.Open the drain valve on the caliper and holdand release the brake lever alternatively untilthe old brake fluid is entirely drained out.Close the drain valve and add specified brakefluid into the brake master cylinder.

CAUTION

Connect one end of transparent hose to thedrain valve, and put the other end into acontainer.Open the drain valve around 1/4 turns, and atthe same time hold the brake lever until thethere is no air bubble in the drain hose andalso feeling resistance on the brake lever.Close the drain valve when finishing thebrake system refilling fluid procedure, andoperate the brake lever to check whether airbubble is in brake system or not. If brake isstill soft, please bleed the system asdescribed below.1. Tightly hold the brake lever and open the

drain valve around 1/4 turns, and then closethe valve.

CAUTION

2. Slowly release the brake lever, and wait fora few seconds until it reaches its topposition.

3. Repeat the steps 1 and 2 until there is no airbubble at the end of the hose. Tightly closethe drain valve.

4. Make sure the brake fluid is in the UPPERlevel of the master cylinder, and refill thefluid if necessary.

5. Cover the cap.

To reuse the spent brake fluid will effectbrake performance.

The dirty brake pad or disc will reduce thebrake performance. The mixednon-compatible brake fluid will reduce brakeperformance. Foreign materials will blockthe system causing brake performance tobe reduced or totally lost.

Do not release the brake lever before thedrain valve is closed.Always check the brake fluid level whencarrying out the air bleeding procedure toavoid air entering into the system.

transparent draining hose

bubble drain valve

drain valve

mastercylinder

diaphragm

SYM 13. BRAKE

13-7

BRAKE CALIPERRemovalPlace a container under the brake caliper,and loosen the brake hose bolt and finallyremove the brake hoses.

CAUTION

Remove two caliper bolts and the caliper.

Make sure the brake pad condition. Replace thepad if the brake pad wear limitation grooveclose to the brake disk.Brake Pad ReplacementCompress the caliper and let the brake pad outof the caliper mounting plate. Compress thebrake pad locking spring. Remove the innerbrake pad firstly and then remove the outerbrake pad.Compress the brake caliper at first asinstallation. Install the inner brake pad firstly,and then install the outer brake pad.

INSTALLATIONInstall the brake caliper and tighten theattaching bolts securely.Torque: 3.3 kgf-m

CAUTION

Tighten the pad guide bolt.Torque: 1.8 kgf-m

Use two seal washers and hose bolts to lockthe hose and brake caliper in place.Torque: 3.5 kgf-m

Refill up the brake fluid to the reservoir andmake necessary air bleeding.

Do not spill brake fluid on paintedsurfaces.

Use M8 x 35 mm flange bolt only.Long bolt will impair the operation ofbrake disc.

bolts x 2

hose bolt

brake pad

brake pad wearlimitation groove

brake pad

brakecaliper

brake mountingplate

locking spring

piston

13. BRAKESYM

13-8

BRAKE DISKInspectionVisually check the brake disk for wear orbreak.Measure the thickness of the disk at severalplaces. Replace the disk if it hasexceeded the service limit.Allowable limit: 2.0 mm

Remove the brake disk from wheel.Check the disk for deformation and bend.Allowable limit: 0.30 mm

CAUTION

BRAKE MASTER CYLINDERRemoval

CAUTION

CAUTION

Remove the front and rear handlebarguards.Remove the leads of brake lamp switch.Drain out the brake fluid.Remove the brake lever from the brakemaster cylinder.Remove the brake hose.Remove the master cylinder seat and themaster cylinder.Remove the rubber pad.Remove the circlip.Remove the piston and the spring.Clean the master cylinder withrecommended brake fluid.

Do not let foreign materials enter into thecylinder.

The whole set of master cylinder, piston,spring, diaphragm and circlip should bereplaced after removal.

Do not let grease touch to the brake discthat will cause brake performance.Do not clean the brake pad with air gun.Operator should wear mask & glove anduse vacuum cleaner to clean the brakepad.

micrometer

brake disk

bolts x2

brake hose

rubber boot circlip

pistonspring

mastercylinder

rubberwasher

brake lampswitch

SYM 13. BRAKE

13-9

InspectionCheck the master cylinder for damage orscratch. Replace it if necessary.Measure the cylinder inner diameter at severalpoints along both X and Y directions.Replace the cylinder if the measured valuesexceed allowable limit.Allowable limit: 11.055 mm

Measure the outer diameter of the piston.Replace the piston if its measured valueexceeds allowable limit.Allowable limit: 10.945 mm

AssemblyCAUTION

Apply clean brake fluid to the piston cup, andthen install the cup onto the piston.Install the larger end of the spring onto themaster cylinder.The master cup’s cavity should be face insideof master cylinder when installing the mastercup.Install the circlip.

CAUTION

Install the rubber pad into groove properly.

It is necessary to replace the whole setcomprising piston, spring, piston cup,and circlip.Make sure there is no dust on allcomponents before assembling.

Never install cup lip in the oppositedirection.Make sure the circlip is seatedsecurely in the groove.

master cylinder

Dial gauge

Micrometer

Piston

rubber bootcirclip

piston

spring

mastercylinder

rubberwasher

brake lampswitch

13. BRAKESYM

13-10

INSTALLATIONPlace the master cylinder onto handlebar,and install the split ring and bolts. The“UP” mark on the split ring should faceupward.Align the split ring on the master cylinderseat with the alignment point on thehandlebar.Tighten the upper bolt of the seat tospecified torque value, and then tightenlower bolt to the same specified torquevalue.

Install the brake lever, and connect leads tobrake lamp switch.Connect brake hoses with 2 new washes.Tighten the brake hose bolt to the specifiedtorque value.Torque value: 3.5 kgf-mMake sure the hose is installed correctly.

CAUTION

CAUTION

Add specified brake fluid and bleed thesystem and conduct the air-bleeding job forthe system.

Improper routing may damage leads, hosesor pipes.

Kink of brake leads, hose or pipe mayreduce brake performance.

sealing washer

hose bolt

brake hose

bolts x 2

brakehose

master cylinder

split ring“UP” mark

mountingseat

SYM 13. BRAKE

13-11

DRUM BRAKE-DRUMBrake DrumRemovalUse a vacuum cleaner and other suitabletools to clean the brake parts to minimizethe hazard caused by the dust.

Caution

Remove wheel. Remove brake drum fromwheel hub.InspectionCheck the brake drum for wear and damage,replace wheel hub if necessaryMeasure the ID of hub at several points andrecord the largest value.Service limit : 131.0 mm

Caution

BRAKE PADInspectionMeasure the thickness of the brake pad atthree points (both ends and center).If the thickness is less than specified, or if it iscontaminated by oil or grease, replace as aset.Service limit : Front 2.0 mm Rear 2.0mm

‧Inhaling dust may cause respirationsystem disorder even cancer. Neveruse an air hose or a dry brush as toclean the brake parts.

‧Grease on brake pad will reducebraking efficiency.

‧Remove the rust by using #120 sandpaper.

‧An inside micrometer must be usedwhen measuring ID of brake drumbecause the brake drum has a frictionback plate.

Rear brake drum

Front brake drum

Brakepad

Front

Brake pad

13. BRAKESYM

13-12

Removal

Caution

Remove brake shoes from the brake panel bypulling out the brake pads with two hands.

InstallationApply a thin coat of grease to the brake camand the anchor pin.Hook the brake spring onto the brake cam.Pull out the brake pads and install them ontothe brake panel. Wipe off the excessivegrease from the brake cam and the anchor pinafter installation.Slightly grind the brake pad surfaces withsand-paper to clean the surfaces.

Caution

BRAKE PANELRemovalRemove the brake arm bolt and thenremove the brake arm, wear indicator,brake return spring and brake cam as wellas the oil seal from the brake panel.

Brake pads must be replaced as a set.

Bolt

Brake armFront

ReturnspringWear indicator

Brake cam

後 brake shoes

brake spring

front brake cam

anchor pin

brake spring brake shoes

brake cam

anchorpin

rear

Braking efficiency will be reduced ifbrake pad is contaminated by oil orgrease.

Rear

Return spring

Wear indicator

SYM 13. BRAKE

13-13

InstallationFRONT BRAKE PANELApply a thin cost of grease onto the brakecam shaft.Install the brake cam.Apply a thin cost of grease onto the oil seallip and then install the oil seal onto thebrake cam shaft. Finally, install it on thebrake panel.Align the end-part of the brake return springwith the hole of brake panel.Align both the inner gear of wear indicatorand the mark on the brake arm with theindent gear of brake cam, and then install it.Tighten the bolts and nuts to specifiedtorque.Torque: 0.8~1.2 kgf-m

REAR BRAKE PANELApply a thin cost of grease between the oilseals on the brake cam shaft.Install the brake cam.Align the mark on the brake arm with theinner gear of the brake cam.Tighten the bolts and nuts to specifiedtorque.Hook on the return spring.Torque: 0.8~1.2 kgf-m

Front

Brake cam

Brake arm

Wearindicator

Return spring

Oil seal

Rear

Return spring

Wear indicator

Brake arm

SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

14-1

MECHANISM DIAGRAM ....................14-1PRECAUTIONS IN OPERATION .......14-2TROUBLE DIAGNOSIS......................14-2STEERING HANDLE..........................14-3

FRONT WHEEL .................................14-4FRONT SHOCK ABSORBER.............14-8FRONT FORK/STEERING COLUMN 14-8

MECHANISM DIAGRAM

3.1~3.5kgf-m

1.0~2.0kgf-m

0.2~0.3kgf-m

4.0~5.0kgf-m

11.0~13.0kgf-m

2.4~3.0kgf-m

14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

14-2


Before remove front wheel, use a jack to lift the body until front wheel free of ground, andtake care not to rotate body in reverse.Be careful not to allow oil or grease get on brake drum or linings.

Torque valuesFront wheel axle 5.0~7.0kgf-mSteering handlebar nut 4.0~5.0kgf-mSteering column top cone sliding ring 0.2~0.3kgf-mSteering column lock nut 1.0~2.0kgf-mSpeedometer cable nut 0.15~0.3kgf-mFront shock absorber: Upper nut 2.4~3.0kgf-m

ToolsSpecial service toolsSteering column wrenchBearing removerInner type bearing removerAttachment, 32×35 mmAttachment, 42×47 mmSteering column nut wrenchSteering column top cone ring nut wrench

TROUBLE DIAGNOSISHard steering stem

Over tightening of steering stem lock nutBroken steering stem steel ball and conebearing seatInsufficient tire pressure

Steering stem off centerUneven left/right cushionBend forkBent front wheel/tire offset

Front wheel wobblingDeformed rimFront wheel bearing looseFaulty tireWheel axle nut tightened improperly

Soft front suspensionWeak fork springsOil leakage of the shock absorber seal

Front suspension noiseCushion cover friction noiseCushion bolts loose


14-3

STEERING HANDLEREMOVALRemove handle front & rear covers and thefront cover (refer to chapter 12).

Remove the 2 bolts of the brake mastercylinder, and then take out the mastercylinder and the split ring.

Caution

Remove acceleration handlebar screw andthen remove the handlebar, accelerationcable, and handlebar cover & seat.

Remove the rear brake lever nut and screw,then take out the rear brake cable.Remove the brake lever seat bolt, and thenremove the seat.

Do not operate the front brake lever to avoidto pressing out the brake lining whenremoving the master cylinder.

Accelerationhandlebar seatscrew

Brake leverscrew

Brake lever nut

Screw

Bolts x 2

Master cylinder

Splitring

Seat

Brake cable

Brake lever seat bolt

Brake lever screwBrake lever nut


14-4

With a wrench to hold the handlebar bolt andthen remove the nut.Take out the handlebar after removed thebolt.

InstallationInstall the handlebar according to thereverse procedure of removal.Apply with some grease onto the handlebarmoving parts when installing the accelerationhandlebar seat, acceleration handlebar, andacceleration cable.

FRONT WHEELRemovalSupport body bottom and lift front wheel freeof ground.Remove the bolts, and disconnectspeedometer cable from the gear box.

Remove the wheel axle nut and pull out theaxle. Then, remove the front wheel.

CautionDo not operate the front brake lever to avoidto pressing out the brake lining whenremoving the master cylinder.

Wheel axle nut

Speedometer cable

Bolt

Nut


14-5

InspectionWheel axleSet the axle in V-blocks and measure therun-out.Service limit: 0.2 mm.

Wheel RimPlace the wheel onto a rotated bracket.Turn the wheel with hand and measure itswobble value with a dial gauge.

Service limit:Radial : 2.0 mmAxial : 2.0 mm

DisassemblyRemove 3 hex socket bolts and brake disc.

Remove the left axle ring and dust seal.Remove the dust seal on the right side ofspeedometer gear.Remove the bearing with the inner typebearing remover.Take out the bearing spacer and thenremove the other bearing.Tool:Inner type bearing remover

Wheel axle

Dust seal

Wheel side collar

Speedometer gear dust seal

Bearing

Bearing

Bearing spacer


14-6

Bearing InspectionTurn the inner race of bearing with fingers.The bearing should be turn smoothly. Alsocheck if the outer collar is tightly connectedto the wheel hub.If the bearing do not turn smoothly, or if theyare too loose in the races, or damaged, then,remove and replace the bearings with newones.

Caution

InstallationInstall the bearing according to the reverseprocedure of removal.Apply some grease into the bearing seat ofthe wheel hub.Install the left bearing onto the seat.Install the bearing spacer and then installthe right bearing onto the seat.

Caution

Tool:C-type compressor or bearing compressor.

Apply with some grease inside of the dustbearing.Install the dust seal and the front wheel sidecollar.Apply with some grease on both side of thespeedometer gear oil seal, and then installthe seal.

Do not install used bearing andreplace the bearing once it has beenremoved.Do not the bearing in tile motion wheninstalling.

The bearing must be replaced in pair.

Clearance

Clearance

Dust seal

Wheel side collar

Speedometer gear dust seal

Bearing

Bearing

Bearing spacer

This two example will to louse the bearing.


14-7

InstallationAlign the flange part on the speedometergear with the slot of wheel hub, and theninstall the brake disc or speedometer gearbox.

Caution

Place the front wheel between the frontshock absorbers.

Align the flange part on the speedometergear with the slot of shock absorber stopper.

Install the front wheel axle from right shockabsorber side.Install the wheel axle nut, and tighten it tospecified torque value.Torque value: 11.0~13.0kgf-mConnect the speedometer cable to thespeedometer gear box.

Contaminated brake lining will reducebrake performance so the brake lining,brake disc must be free of grease.

Stopper

Gear box flange part

Speedometer cableWheel axle nut


14-8

FRONT SHOCK ABSORBERRemovalRemove the front fender, front lower spoiler,front guard, and front wheel as well as frontbrake components.Remove the brake fluid hose clipper or cableguide on the left shock absorber. (bolt x 1)As for disc brake, remove the cable guide onthe right shock absorber. (bolt x 1)

Remove the top connection bolt of the rightshock absorber. (bolt x 4)Remove the shock absorber from the frontfork.

InstallationInstall the shock absorbers according to thereverse procedure of removal.Align the shock absorber top-edge with thetop-end level of the front fork when installingthe front shock absorber onto the front fork.Then, tighten the nut.Torque value: 2.4~3.0kgf-m

FRONT FORK/STEERING COLUMNRemovalFirstly, remove the handlebar, front wheel,front brake set, and front shock absorbers.Remove the steering column nut.Remove the top cone ring, and then removethe steering column.

Caution

Place the steering column bearing ballsinto a parts container to avoid tomissing or shortage.

Steering column nut

Top cone race

Bolts

Shock absorbers

Brake fluidhose clipper


14-9

With a plastic hammer to tap the steeringcolumn slightly, and then remove the top ballbearing seat.Remove the lower-end cone bearing seat onthe frame with a punch.

Caution

InstallationInstall a new top-cone bearing seat onto thetop of steering column.And then, push the lower-cone bearing seatfrom bottom until to locking position.

Caution

Apply with some grease onto the top &bottom bearing balls, and then install theballs into bearing seat.Press in a new lower cone-race onto thesteering column, and lubricate it with grease.Install the steering column.Lubricate the top-cone race with grease.Drive the cone-race into the steering columnuntil contact with the top bearing seat noclearance. Note, return 1/2 turn and thentighten the top cone race to specified torque.(tighten the race around 1/4~3/8 turn more.)Torque value: 0.2~0.3kgf-m

Caution

Install the steering column nut and lock thetop cone race. Then, tighten the nut.Torque value: 1.0~2.0kgf-mInstall the bearing seat according to thereverse procedure of removal.

Caution

Do not damage the frame and thesteering column.

Do not let the ball bearing in title motionas installation.

Do not tighten the top cone race tootight to prevent from damage the ballbearing seat when tightening the topcone race.

Check the steering column if it can beturned freely and no clearance invertical motion.

Steering column nut

Top cone-race

Top ball bearing seat.

Lower all bearing seat

Lower cone-race

Balls

Balls

Steering column nut

Top cone-race

Steering column nut

Top cone-race

Locking to1/4~3/8 turn

Return 1/2 turn

SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

15-1

MECHANISM DIAGRAM.................... 15-1PRECAUTIONS IN OPERATION....... 15-2TROUBLE DIAGNOSIS ..................... 15-2

EXHAUST MUFFLER.........................15-3REAR WHEEL....................................15-3REAR SHOCK ABSORBER............... 15-4

MECHANISM DIAGRAM

0.8~1.2kgf-m

3.0~3.6kgf-m 11.0~13.0kgf-m

1.0~1.4kgf-m

2.4~3.0kgf-m

3.5~4.5kgf-m

15. REAR WHEEL/REAR SHOCK ABSORBER SYM

15-2

PRECAUTIONS IN OPERATIONGeneral InformationAs for the wheel removal, service, and installation procedures, please refer to the servicemanual of high speed tire.

Specification Unit: mmItems Standard Limit

Radial - 2.0Wheel wobbling

Axial - 2.0Thickness of rear brake lining 4.0 2.0

Torque values:Rear axle nut 11.0~13.0kgf-mRear shock absorber upper mount bolt 3.5~4.5kgf-mRear shock absorber lower mount bolt 2.4~3.0kgf-mExhaust muffler connection nut 1.0~1.4kgf-mExhaust muffler connection bolt 3.0~3.6kgf-m

TROUBLE DIAGNOSISRear wheel wobbling

bend wheel rimpoor tireloosen wheel shaft

Shock absorber too softinsufficient shockabsorber spring force

Braking Noiseworn brake liningbrake drum deformationimproperly brake panelinstallationunparalleled brake drumor wheel unparallel.

Poor brake performancePoor brake adjustmentcontaminated brakeliningworn brake lininggreased brake drumcontaminated andseized brake cableimproperly installation ofbrake cable

SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

15-3

EXHAUST MUFFLERRemovalRemove the front-end nut of the exhaustmuffler. (nuts x 2)Remove the bolts. (bolts x 2)Remove the exhaust muffler.

InstallationInstall the exhaust muffler according to thereverse procedure of removal.

Caution

Torque value:Exhaust muffler connection bolt:3.0~3.6kgf-mExhaust muffler connection nut:1.0~1.4kgf-m

REAR WHEELInspectionMeasure wheel rim wobbling.Service limit:Radial: 2.0mmAxial: 2.0mmIf the wheel rim wobbling out of thespecification, except resulted from thewheel rim deformation, it might be loosen orworn final driving shaft bearing or bend,deformed driving shaft.

RemovalRemove the right cover.(screws x 4)Remove the battery. (bolts x 2)Remove the battery cover assembly. (boltsx2, nuts x 2)Remove the rear wheel. (wheel axle nut x1)

Replace the exhaust muffler gasket if it isbroken or deformed. Bolts x 2

Nuts x 2

Exhaust muffler

15. REAR WHEEL/REAR SHOCK ABSORBER SYM

15-4

REAR SHOCK ABSORBERRemovalRemove the left & right covers. (screws x 8)Remove the luggage box. (bolts x 4, nuts x 2,screw x 1)Remove the rear carrier. (bolts x 3)Remove the body cover (bolts x2)Remove the air cleaner bolts (bolts x2)Remove the lower nut of the rear shockabsorber (bolt x 1)Remove the upper nut of the rear shockabsorber (bolt x 1)Remove the rear shock absorber.

InstallationInstall the rear shock absorber according tothe reverse procedure of removal.

Caution

Torque valuesRear shock absorber lower mount bolt:2.4~3.0 kgf-mRear shock absorber upper mount bolt:3.5~4.5 kgf-m

The rear shock absorber has to be replacedwith one set and can not be replaced byunauthorized persons. Otherwise, it mightdamage the rubber bushing andconstruction.

lower mount bolt

upper mount bolt

℃

℃ ± Ω

℃ ± Ω

℃ Ω

℃ Ω

±℃ ±

℃

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---

----

---

℃

℃

∞ ∞ ∞

∞

∞

∞

± Ω ℃

± Ω ℃

Ω

Ω

Ω

Ω± Ω ℃

Ω ℃

Ω ℃

± Ω ℃

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● ●

● ●

● ● ●

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● ● ● ●

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sym fiddle ii 50 (en)

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