Sym Joyride 125, Joyride 200i EVO, X'PRO RV125, 200 EFi, Joyride 125 EVO Service Manual

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Foreword

How to Use This Manual

Contents

Mechanism Illustration

Joyride 125 / 200i EVO X’PRO RV125 / 200 EFi

SERVICE MANUAL

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Contents

Foreword

This service manual contains the technical data of each component inspection and repair for the Sanyang JOYRIDE 125/200i EVO, X’PRO RV 125/200 EFi 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, JOYRIDE 125/200i EVO, X’PRO RV 125/200 EFi, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

Service Department

Sanyang Industry Co., LTD.

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Contents

How to Use This Manual

This service manual describes basic information of different system parts and system inspection & service for Sanyang JOYRIDE 125/200i EVO, X’PRO RV 125/200 EFi 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 information. Th third to the thirteenth chapter covers the engine and driving systems. The fourteenth to the seventeenth is contained the parts set of assembly body. The eighteenth chapter is electrical equipment. The nineteenth chapter is special tool. The twentieth chapter is wiring diagram Please see index of content for quick having the special parts and system information.

There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and “Mechanism Illustration” in the PDF version, and can be access to these items by clicking on the buttons. If user wants to look for the content of each chapter, selecting the words of each chapter on the contents can reach to each chapter. There are two buttons, “Homepage and contents, on the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this Chapter Contents” button at the second page of each content so that clicking the button can back to the contents of this chapter.

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Contents

Page Content Index

1-1 ~ 1-20 General Information

2-1 ~ 2-12 Maintenance Information 3-1 ~ 3-8 Lubrication System

4-1 ~ 4-12 Fuel System-Carburetor 5-1 ~ 5-56 Fuel Injection System 6-1 ~ 6-14 Engine Removal 7-1 ~ 7-14 Cylinder Head / Valve 8-1 ~ 8-8 Cylinder / Piston 9-1 ~ 9-14 V-Belt Drive System 10-1 ~ 10-8 Final Drive Mechanism 11-1 ~ 11-8 AC Generator / Starting Clutch

12-1 ~ 12-8 Crankshaft / Crankcase 13-1 ~ 13-12 Cooling System 14-1 ~ 14-10 Body Cover 15-1 ~ 15-10 Brake System

16-1 ~ 16-12 Steering / Front Wheel / Front Cushion

17-1 ~ 17-6 Muffler / Rear Wheel / Rear Cushion 18-1 ~ 18-22 Electrical System 19-1 ~ 19-12 Special Tools 20-1 ~ 20-4 Wiring Diagram

Home page

Contents

Mechanism Illustration

Light switch / start switch / engine stop (hazard) switch

Front winker

Fuel tank /

Dimmer switch / winker switch / horn switch / seat open (passing) switch

fuel pump

ECU / throttle body

Coolant filler cap

Ignition / Seat open switch

Front brake lever

Rear brake lever

Side stand

Fuel tank cap

Taillight / rear winker

Luggage box

Air cleaner

Main stand

Main switch

Reserved tank cap

Battery

Muffler

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Contents

1. GENERAL INFORMATION

Symbols and Marks .............................. 1-1

General Safety....................................... 1-2

Service Precautions.............................. 1-3

Specifications ........................................ 1-5

Cables and Harness Routing..............1-11

Troubleshooting-Carburetor model ...1-12

Troubleshooting-EFi model ................1-16

Lubrication Points ...............................1-20

Torque Values ....................................... 1-9

Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service are needed, 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.

Warning

Caution

Engine oil

Grease King Mate G-3 is recommended.

Means that serious injury or even death may result if procedures are not followed.

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

Limits to use SAE 20 JASO FC class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: MAX-2 serial oils)

Gear oil

Locking sealant

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 tools Special tools.

correct Meaning correct installation.

wrong Meaning wrong installation.

Indication Indication of components.

directions Indicates position and operation directions.

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140)

Apply sealant, medium strength sealant should be used unless otherwise specified.

Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross

through the component (invisibility).

1-1

To this chapter contents

1. GENERAL INFORMATION

General Safety

Carbon monoxide

If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.

Caution

Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.

Gasoline

Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode under some conditions, keep it away from children.

Battery

Caution

‧ Battery emits explosive gases; flame is

strictly prohibited. Keep the place well ventilated when charging the battery.

‧ Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist.

‧ If you swallow it by mistake, drink a lot of

water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor.

‧ Keep electrolyte beyond reach of children.

Brake shoe

Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying.

Used engine oil

Caution

Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.

Hot components

Caution

Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.

Caution

Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system.

Brake fluid

Caution

Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children.

1-2

1. GENERAL INFORMATION

Service Precautions

To this chapter contents

z Always use with Sanyang genuine parts and

recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle.

z Special tools are designed for remove and

install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.

z When servicing this motorcycle, use only

metric tools. Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.

z Clean the outside of the parts or the cover

before removing it from the motorcycle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause a damage.

z Wash and clean parts with high ignition point

solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.

z Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

z Rubber parts may become deteriorated when

old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.

z When loosening a component which has

different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.

z Store complex components such as

transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.

z Note the reassemble position of the important

components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).

z Components not to be reused should be

replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

Caution

In addition to damaging paint finish, brake oil can also damage the structural integration of plastic or rubber parts.

1-3

To this chapter contents

1. GENERAL INFORMATION

z The length of bolts and screws for assemblies,

cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.

z Tighten assemblies with different dimension

fasteners as follows: Tighten all the fasteners with fingers, then tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.

z When oil seal is installed, fill the groove with

grease, install the oil seal with the name of the manufacturer facing outside, check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.

Manufacturer's name

z Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if the contact surface has any damage.

z The ends of rubber hoses (for fuel, vacuum,

or coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.

Groove

Clamp

Connection

z Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

z The tool should be pressed against two (inner

Boots

and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.

Both of these examples can result in bearing damage.

z Lubricate the rotation face as assembling.

Check if positions and operation for installed parts is in correct and properly.

1-4

1. GENERAL INFORMATION

Specifications

Maker SANYANG MODEL LF12W-6/F

To this chapter contents

Overall Length 2100 mm Front Telescopic Fork

Overall Width 760 mm

Overall Height 1390 mm Front 110 / 90-13 56P

Wheel Base 1440 mm

Front 63 kg Front

Curb

Passengers/

WEIGHT DIMENSION

Total Weight

Position and

arrangement

Rear 93 kg

Wei

Total 156 kg

Two /170 kg Max. Speed >100 km/hr

Weight

Front 97 kg Climb Ability 28°

Rear 229 kg Primary Reduction Belt

Total 326 kg

Type Gasoline Clutch

Horizontal, below

center, CYL incline 80°

Suspension

System

Tire

Specifications

Brake System

Secondary

Reduction

PERFORMANCE

Transmission C.V.T.

Rear Unit Swing

Rear 130 / 70-12 64L

Disk (ψ273mm)

Rear

Disk (ψ200mm)

Gear

3-piece centrifugal, dry

type

Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A

Bore Ø 57 mm Muffler Expansion & Pulse Type

Stroke 48.8 mm

Cylinder

ENGINE

Number/Arran

gement

Displacement 124.5 cc Co

Compression Ratio 10.5 : 1 HC

Max. HP 13 ps / 8500 rpm

Max. Torque 1.1 kg-m / 6500 pm E.E.C. -

Ignition C.D.I P.C.V. -

Starting System Kick & Electrical Starter Catalytic Converter Equipped

Single Cylinder Lubrication System

Exhaust Pipe Position

and Direction

Exhaust

Concentratio

NOx

Right Side & Backward

Forced Circulation &

Splashing

〈 2.0 g/km

〈 0.8 g/km 〈 0.15 g/km

1-5

To this chapter contents

1. GENERAL INFORMATION

Specifications

Maker SANYANG MODEL LF12W2-7

Overall Length 2100 mm Front TELESCOPIC FORK

Overall Width 760 mm

Overall Height 1390 mm Front 110 / 90-13 56P

Wheel Base 1440 mm

Front 63 kg Front

Curb

WEIGHT DIMENSION

Total Weight

arrangement

Rear 93 kg

Wei

Total 156 kg

Passengers/

Weight

Front 97 kg Climb Ability 28°

Rear 229 kg Primary Reduction BELT Total 326 kg

Type Gasoline Clutch

Position and

Two /170 kg Max. Speed >100 km/hr

Horizontal, below

center, CYL incline 80°

Suspension

System

Tire

Specifications

Brake System

Secondary

Reduction

PERFORMANCE

Transmission C.V.T.

Rear Unit SWING

Rear 130 / 70-12 64L

DlSK (ψ273mm)

Rear

DlSK (ψ200mm)

GEAR

3-piece centrifugal, dry

type

Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A

Bore Ø 57 mm Muffler Expansion & Pulse Type

Stroke 48.8 mm

Cylinder

ENGINE

Number/Arran

gement

Displacement 124.5 cc Co

Compression Ratio 10.5 : 1 HC

Max. HP 13 ps / 8500 rpm

Max. Torque 1.1 kg-m / 6500 pm E.E.C. -

Ignition Full Transistor Ignition P.C.V. Equipped

Starting System Electrical Starter Catalytic converter Equipped

Single Cylinder Lubrication System

Exhaust Pipe Position

and Direction

Exhaust

Concentratio

NOx

Right Side & Backward

Forced pressure and wet

sump

〈 2.0 g/km

〈 0.8 g/km 〈 0.15 g/km

1-6

1. GENERAL INFORMATION

Specifications

Maker SANYANG MODEL LF18W-A/W3-H/W5-C

To this chapter contents

Overall Length 2100 mm Front TELESCOPIC FORK

Overall Width 760 mm

Overall Height 1390 mm Front 110 / 90-13 56P

Wheel Base 1440 mm

Front 63 kg Front

Net

Passengers/

WEIGHT DIMENSION

Total Weight

Position and

arrangement

Rear 93 kg

Weight

Total 156 kg

Two /170 kg Max. Speed >109 km/hr

Weight

Front 97 kg Climb Ability 28°

Rear 229 kg Primary Reduction BELT

Total 326 kg

Type Gasoline Clutch

Horizontal, below center,

CYL incline 80°

Suspension

System

Tire

Specifications

Brake System

Secondary

Reduction

PERFORMANCE

Transmission C.V.T.

Rear UNlT SWING

Rear 130 / 70-12 64L

DlSK (ψ273mm)

Rear

DlSK (ψ200mm)

GEAR

3-piece centrifugal, dry

type

Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A

Bore Ø 61 mm Muffler Expansion & Pulse Type

Stroke 58.6 mm

Cylinder

ENGINE

Number/Arran

gement

Displacement 171.2 cc Co

Compression Ratio 10 : 1 HC

Max. HP 13 / 8000 ps/rpm

Max. Torque 1.2 / 6000 kg-m/rpm E.E.C. -

Ignition C.D.I. P.C.V. Equipped

Starting System Kick & Electrical Starter Catalytic converter Equipped

Single Cylinder Lubrication System

Exhaust Pipe Position

and Direction

Exhaust

Concentratio

NOx

Right Side & Backward

Forced pressure and wet

sump

〈 12.0 g/km

〈 1.0 g/km

1-7

To this chapter contents

1. GENERAL INFORMATION

Specifications

Maker SANYANG MODEL LF18W-6/W1-9/W2-7/W4-8

Overall Length 2100 mm Front TELESCOPIC FORK

Overall Width 760 mm

Overall Height 1390 mm Front 110 / 90-13 56P

Wheel Base 1440 mm

Front 63 kg Front

Curb

Passengers/

WEIGHT DIMENSION

Total Weight

arrangement

Rear 93 kg

Wei

Total 156 kg

Two /170 kg Max. Speed >109 km/hr

Weight

Front 97 kg Climb Ability 28°

Rear 229 kg

Total 326 kg

Type Gasoline Clutch 3-piece centrifugal, dry type

Position and

Horizontal, below

center, CYL incline 80°

Suspension

System

Tire

Specifications

Brake System

Primary

Reduction

Secondary

Reduction

PERFORMANCE

Transmission C.V.T.

Rear UNlT SWING

Rear 130 / 70-12 64L

DlSK (ψ273mm)

Rear

DlSK (ψ200mm)

BELT

GEAR

Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A

Bore Ø 61 mm Muffler Expansion & Pulse Type

Stroke 58.6 mm

Cylinder

Number/Arran

ENGINE

Compression Ratio 10 : 1 HC

Starting System Electrical Starter Catalytic converter Equipped

gement

Displacement 171.2 cc Co

Max. HP 15 / 8000 ps/rpm

Max. Torque 1.35 / 6500 kg-m/rpm E.E.C. -

Ignition Full Transistor Ignition P.C.V. - / Equipped

Single Cylinder Lubrication System

Exhaust Pipe Position

and Direction

Exhaust

Concentratio

NOx

Right Side & Backward

Forced pressure and wet

sump

〈 2.0 g/km

〈 0.3 g/km 〈 0.15 g/km

1-8

1. GENERAL INFORMATION

Torque Values

Item Q’ty

To this chapter contents

Thread Dia.

(mm)

Torque Value

Remarks

(Kgf-m)

Cylinder head bolt Valve clearance adjust nut Spark plug L. Crankcase cover bolts Crankcase bolts Oil drain bolt Oil strainer cap Gear oil drain bolt Gear oil inspection bolt Transmission cover bolt Flywheel bolt Clutch driving plate bolt Driving disc nut Clutch outer cover nut Transmission cover bolts Stopper nut for engine hanger

bracket Nut for engine hanger bracket Bolt for engine hanger bracket Engine mounting bolt Front wheel shaft nut Rear wheel shaft nut Bolt for rear shock absorber (upper) Bolt for rear shock absorber (under) Bolt for steering rod Front shock absorber Brake arm bolts Brake hose bolts Bolt for brake caliper Bolts for the lining guide pin Brake disk bolts Mounting screw for speedometer

cable Muffler bolts Mounting bolts for exhaust pipe

connection The torque values listed in above table are for more important tighten torque values. Please see

standard values for not listed in the table.

4 8 2.0-2.4 4 5 0.7-1.1 1 10 1.0-1.4 7 6 1.1-1.5 7 6 0.8-1.2 1 8 1.1-1.5 1 30 1.3-1.7 1 6 1.0-1.4 1 6 1.0-1.4 7 6 1.0-1.4 1 14 5.0-6.0 1 28 5.0-6.0 1 12 5.0-6.0 1 10 3.5-4.5 7 6 1.0-1.4

1 8 1.8-2.2 1 10 4.0-5.0

1 10 4.0-5.0 1 10 3.5-4.5 1 12 5.0-7.0 1 14 11.0-13.0 2 10 3.5-4.5 2 8 2.4-3.0 1 10 4.0-5.0 4 8 2.4-3.0 2 6 0.8-1.2 4 10 3.3-3.7 4 10 3.0-3.5 4 6 1.6-2.0 7 10 4.0-4.5

1 5 0.15-0.3 4 8 3.2-3.8 2 7 1.0-1.2

Apply oil to thread

1-9

To this chapter contents

1. GENERAL INFORMATION

Standard Torque Values for Reference

Type Torque value kgf-m

5 mm Bolt, Nut 0.45 - 0.6 6 mm Bolt, Nut 0.8 - 1.2 8 mm Bolt, Nut 1.8 - 2.5 10 mm Bolt, Nut 3.0 - 4.0 12 mm Bolt, Nut 5.0 - 6.0 5 mm Screw 0.35 - 0.5 6 mm Screw & 6mm bolt with 8mm head 0.7 - 1.1 6 mm Flange bolt, nut 1.0 - 1.4 8 mm Flange bolt, nut 2.4 - 3.0 10 mm Flange bolt, nut 3.5 - 4.5

1-10

1. GENERAL INFORMATION

Cables and Harness Routing

Note the following when routing cables and wire harnesses:

• A loose wire, cable or harness may cause

safety hazard. After clamping, check each wire to make sure it is secured.

• Do not squeeze wires against the weld or its

clamp.

• Secure wires and wire harnesses to the

frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

• Route harnesses so that they neither pull too

tight nor have excessive slack.

• Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or corner.

• Route wire harnesses to avoid sharp edges

or corners.

• Avoid the projected ends of bolts and screws.

• Keep wire harnesses far away from the

exhaust pipes and other hot parts.

• Be sure grommets are seated in their groves

properly.

• After clamping, check each harness to be

certain that it is not interfered with any moving or sliding parts.

• After routing, check that the wire harnesses

are not twisted or kink.

• Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

• Thoroughly clean the surface where tape is to

be applied.

• Wrap electrical tape around the damaged

parts or replace them.

To this chapter contents

○：correct ╳：wrong

1-11

To this chapter contents

1. GENERAL INFORMATION

Troubleshooting-Carburetor model

A. Engine hard to start or can not be started

Check and adjustment Failure condition Possible causes

Loosen carburetor drain bolt to check if there is gasoline inside the carbureto

Fuel supplied to carburetor sufficient.

Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.

Check if sparks Weak sparks, no

Perform cylinder compression pressure test.

No fuel is supplied to carburetor.

ark at all.

1. No fuel in fuel tank

2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.

3. Float valve clogged

4. Lines in fuel tank evaporation system clogged

5. Malfunction of fuel pump

6. Loosen or damaged fuel pump vacuum hose

7. Fuel filter clogged

1. Malfunction of spark plug

2. Spark plug foul

3. Malfunction of CDI set

4. Malfunction of AC generator

5. Ignition coil is in open or short circuit

6. Ignition coil leads open or short circuit

7. Malfunction of main switch

Cylinder compression pressure normal.

Re-start by following the starting procedures.

No ignition

Remove the spark plug again and check it.

Dry spark plug Wet spark plug

Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air.

Low compression pressure or no pressure.

There are some signs of ignition, but engine can not be started.

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Sand hole in compression parts

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Fuel level in carburetor too high

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

Blowing in normal Blowing clogged

1. Malfunction of automatic by- starter

1-12

To this chapter contents

1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Try gradual acceleration and check engine speed.

Check ignition timing (Using ignition lamp)

Engine speed can be increased.

Engine speed can not be increased.

1. Air cleaner clogged

1. Poor fuel supply

2. Lines in fuel tank evaporation system clogged

3. Exhaust pipe clogged

4. Fuel level too low in carburetor

5. Fuel nozzle clogged in carburetor.

Ignition timing correct Incorrect ignition timing

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if carburetor jet is clogged

No clogged Clogged

Remove spark plug

No foul or discoloration Fouled and discoloration

No compression pressure

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

1. Remove foreign

1. Remove dirt

2. Incorrect spark plug heat range

Check if engine over

Normal Engine overheat

Continually drive in acceleration or high speed.

No knock Knock

1. Piston and cylinder worn out

2. Lean mixture

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

6. Poor circuit on the cooling system

1. Too much carbon deposited in combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

1-13

To this chapter contents

1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Check ignition timing (Using ignition lamp)

Adjust the air screw of carburetor

Normal Abnormal

Good Poor

Air sucked through carburetor gasket

No air sucked Air sucked

Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground.

Good spark Poor

D. Engine runs sluggish (High speed)

1. Incorrect ignition timing (malfunction

of CDI or AC alternator)

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

5. Vacuum hose crack

1. Spark plug fouled

2. Malfunction of CDI

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug

leads

6. Malfunction of main switch

Check and adjustment

Check ignition timing

Check for fuel supplying system in automatic fuel cup

Normal Abnormal

Good Poor

Check if carburetor clogged

No clogged Clogged

1-14

Fault condition Probable causes

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

1. Cleaning

To this chapter contents

1. GENERAL INFORMATION

E. Clutch, Driving And Driving Pulley

FAULT CONDITIONS

PROBABLE CAUSES

Engine can be started but motorcycle can not be moved.

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damaged

Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)

1. Clutch ling spring broken

2. Clutch outer cover stickled with clutch balance weights

3. Connection parts in clutch and shaft worn out or burned

1. Driving belt worn out or deformation

Poor initial driving (Poor climbing performance)

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

1-15

To this chapter contents

1. GENERAL INFORMATION

Troubleshooting-EFi model

A. Engine cannot be started or difficult to be started

Check and adjustment Fault condition Probable causes

Press the fuel injector feed pipe and confirm whether there is fuel in the feed pipe

1. Check the fuel amount in the fuel tank

2. Check if the fuel pipe and the vacuum

The fuel supply to the fuel injector is sufficient

Check the spark plug ignition condition

The fuel injector is not supplied with sufficient fuel

tube are blocked or not

3. Malfunction of fuel pump relay or wiring

4. Malfunction of fuel pump

5. The fuel strainer is blocked or not

Sparks

Perform cylinder compression

ressure test

Normal cylinder compression pressure

Restart the engine

No ignition With signs of ignition but

Remove and check the spark plug

Week sparks or no spark

Low or no compression pressure

the engine cannot be started

1. Malfunction of spark plug

2. Spark plug contamination

3. Malfunction of ECU

4. Malfunction of the AC Generator

5. Ignition coil is in open or short circuit

6. Malfunction of main switch

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leakage

5. Sand hole in the com

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

ression parts

1. Contaminated or clogged fuel injector

Dry spark plug Wet spark plug

1-16

2. Malfunction of throttle valve operation

3. Malfunction of fuel pressure regulator

To this chapter contents

1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Accelerate gradually and

check engine RPM

Engine RPM can be increased

Engine RPM cannot be increased

1. Clogged air cleaner

2. Poor fuel supply

3. Clogged exhaust pipe

4. Clogged

uel injector

Check ignition timing (Using ignition lamp)

Correct ignition timing Incorrect ignition timing

Check cylinder compression pressure (using compression pressure gauge)

Normal compression pressure Abnormal compression

pressure

Check if the fuel injector is clogged or not

Not clogged Clogged

Remove and check the spark plug

No contamination or discoloration

Check if the engine is over

Contaminated or discolored

1. Malfunction of ECU

2. Malfunction of AC Generator

1. Worn out cylinder or piston ring

2. Cylinder gasket leakage

3. Sand hole in compression parts

4. Valve deterioration

5. Jammed piston ring

1. Replace the fuel injector

1. Remove the dirt

2. Incorrect spark plug heat range

1. Worn out piston or cylinder

Normal Engine overheated

Continually drive in acceleration or high speed

No knocking Knocking

2. Abnormal fuel injector

3. Poor fuel quality

4. Carbon deposit in the combustion chamber

5. Abnormal ignition timing

1. Carbon deposit in the combustion chamber

2. Malfunction of fuel injector

3. Poor fuel quality

bnormal ignition timing

1-17

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To this chapter contents

1. GENERAL INFORMATION

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

Check for any air sucked in through the throttle body insulator gasket

D. Engine runs sluggish (High speed)

Check and adjustment Fault condition Probable causes

Check ignition timing (using ignition lamp)

Normal

No air sucked in

Remove the spark plug and check the spark condition

Good spark Poor spark

Check and adjustment Fault condition Probable causes

Check ignition timing

Abnormal

Air sucked in

1. Incorrect ignition timing (malfunction of ECU or AC Generator)

1. Abnormal throttle body insulator gasket.

2. Abnormal throttle body installation

3. Abnormal inlet pipe gasket

4. Damaged ABV pipe

1. Contaminated spark plug

2. Malfunction of ECU

3. Malfunction of AC Generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

Normal Abnormal

Check the fuel pump

condition

Good Poor

Check if fuel injector clogged

Normal Clogged

1. Malfunction of ECU

2. Malfunction of AC Generator

1. Insufficient fuel in the fuel tank

2. Pressed or clo

1. Replace the fuel injector

ed fuel pipe

1-18

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1. GENERAL INFORMATION

E. CLUTCH AND DRIVING PULLEY

FAULT CONDITION PROBABLE CAUSES

Engine can be started but the vehicle cannot run

Engine shuts down or trembles when the vehicle is running (rear wheel rotates during engine idling).

1. Worn out or damaged drive belt

2. Damaged movable drive face

3. Damaged driven face spring

4. Broken clutch weight

5. Broken drive shaft groove

6. Worn out or damaged transmission gear

1. Broken clutch spring

2. Clutch outer stuck with clutch weights

3. Connection parts between clutch and shaft worn out or burned

Poor initial driving (poor climbing performance)

1. Worn or deformed drive belt

2. Worn weight roller

3. Worn driven face

4. Deformed driven face spring

5. Grease on drive belt or drive / driven face

1-19

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1. GENERAL INFORMATION

Lubrication Points

Steering stem bearin

Throttle cable / front &

rear brake lever pivot

Seat catch

1-20

Front wheel bearing

Side stand pivot

Main stand pivot

Rear wheel bearing

Homepage

Contents

2. Maintenance Information

Precautions in Operation..................2-1

Periodical Maintenance

Schedule ............................................2-2

Fuel Lines ..........................................2-3

Throttle Operation.............................2-3

Air Cleaner.........................................2-4

Spark Plug .........................................2-4

Valve Clearance.................................2-5

Ignition System..................................2-6

Cylinder Compression Pressure......2-7

Drive Belt ...........................................2-7

Brake System (front/rear

disk brake) .........................................2-8

Brake Hose ........................................2-8

Precautions in Operation

Brake Fluid ........................................ 2-8

Filling out brake fluid........................ 2-8

Air bleed operation........................... 2-9

Add brake fluid.................................. 2-9

Brake lining ....................................... 2-9

Brake light switch............................. 2-10

Headlight beam distance.................. 2-10

Clutch weight .................................... 2-10

Side Stand ......................................... 2-11

Front / Rear Cushion ........................ 2-11

Nut, bolts tightness. ......................... 2-11

Wheel / Tire........................................ 2-12

Model

Fuel Tank Capacity 7,600 c.c. Engine Oil

Transmission Gear oil

Capacity of

Clearance of throttle valve 2~6 mm Spark plug CR7E CR7E CR8E CR7E

〝F〞Mark in idling speed Full timing advanced BTDC 27º BTDC 24º BTDC 27º BTDC 24º

Idling speed 1,800±100 rpm

Cylinder compression pressure 12 ± 2 Kg/cm²

Valve clearance

coolant

capacity 1,000 c.c. change 800 c.c. capacity 110 c.c. change 100 c.c.

Engine + radiator 780 c.c.

Reservoir upper 420 c.c.

IN 0.12±0.02 mm EX 0.12±0.02 mm

LF12W-6/F

BTDC 13º /

1800r

LF12W2-7

BTDC 10º

1800rpm

LF18W-A/W3-H

/W5-C

BTDC 13º

1800rpm

LF18W-6/W1-9

/W2-7/W4-8

BTDC 10º

1800rpm

Tire dimension Front 110/90-13 56P Tire dimension Rear 130/70-12 64L

Tire pressure (cold)

Battery 12V8Ah (MF battery) YTX9-BS / GTX9-BS

single Front: 1.75 Kg/cm² Rear: 2.25 Kg/cm² Load 90 Kg

(full load)

Front: 1.75 Kg/cm² Rear: 2.5 Kg/cm²

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2. Maintenance Information

Periodical Maintenance Schedule

Mainte

nance

Code

item

Every

300KM

1 ☆Air cleaner I C C R C 2 ☆Fuel filter I I R 3 ☆Oil filter C C C 4 ☆Engine oil cha nge R Replacement for every 1000 km 5 Tire pressure I I I I I I 6 Battery inspection I I I I I I 7 Brake & free play check I I I I I I 8 Steering handle check I I I 9 Cushion op eration che ck I I I

10 Every screw tightening

I I I I I I

check 11 Gear oil check for leaking I I I I I I 12 ☆Spark plug check or change I I R R R 13 ☆Gear oil change R Replacement for every 5000 km 14 Frame lubrication L L 15 Exhaust pipe I I I I I I 16 ☆Ignition timing I I I I I I 17 ☆emission check in Idling A I I I I I 18 ☆Throttle operation I I I I I 19 ☆Engine bolt tightening I I I I I 20 ☆CVT driving device(belt) I R I 21 ☆CVT driving device(roller) C C C 22 Lights/electrical

I I I I I I

equipment/multi-meters 23 Main/side stands & springs I I I 24 Fuel lines I I I I I 25 Shock absorbers I I I I 26 Cam chain I I I I I 27 ☆Valve clearance I A A A A 28 Lines & connections in

I I I I I I

cooling system 29 Coolant reservoir I I I I I I 30 Coolant I Replacement for every 1 year

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

Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

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

must be performed normally perio dical ma inte nance foll owing the use r manua l instr ucti ons. They are

prohibited to be adjusted or re paired by una uthorize d pe ople . Otherwise, SYM is no responsible for the

charge.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment.

3. Maintenance should be performed more often if the motorcycle is frequentl y oper ated in high speed and after the motorcycle has accumulated a higher mileage.

4. Preventive maintenance

a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating

occur.

b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is

obvious lower. Than ever

c. Replace worn out pistons, cylinder head.

1 Month

every

1000KM

3 month

every

3000KM

6 month

every

6000KM

1 year

every

12000KM

15 month

every

14500KM

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Fuel Lines

Remove trunk Remove side cover. Remove central cover. Remove body frame cover. Remove pedal. Remove front glove box. Check all lines, and replace it when they are deterioration, damage or leaking.

Warning

Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

Throttle Operation

Have a wide open of throttle valve as handle bar in any position and release it to let back original (full closed) position. Check handle bar if its operation is smooth. Check acceleration cable and replace it if deteriorated, twisted or damaged.

Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part.

Free play: 2~6 mm.

Adjustment can be done in either end. Secondary adjustment is conducted from top side. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment nut.

Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition.

2. Maintenance Information

Fuel pump

Filler hole

Fuel tank

2~6 mm

2-3

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2. Maintenance Information

Air Cleaner

Remove trunk. Remove side cover. Remove 8 screws from the air cleaner cover and then remove the cover.

Caution

Air cleaner element contains a paper made filter so do not try to clean it.

Spark Plug

Recommended spark plug: CR7E / CR8E Remove trunk. Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Spark plug gap：0.8 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed. Connect spark plug cap.

Ground electrode

Central electrode

0.8 mm

2-4

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Valve Clearance

Caution

Checks and adjustment must be performed when the engine temperature is below 35℃.

Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover.

Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.

2. Maintenance Information

Caution

Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.

Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX): 0.12 ± 0.02 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

Re-check the valve clearance after tightened the fixing nut.

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2. Maintenance Information

Ignition System

Caution

Transistor ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether ECU function is in normal or not.

Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover. Connect tachometer and ignition lamp. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition lamp. Then, it means that ignition timing is correct. Increase engine speed to 6000 rpm to check ignition advance degree. If indent is located within the ignition advance degrees, it means that the ignition advance degree is in normal. If ignition timing is incorrect, check ECU, pulse rotor and pulse generator. Replace it if malfunction of these parts is found.

Ignition coil cable

2-6

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Cylinder Compression Pressure

Warm up the engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.

Caution

Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.

2. Maintenance Information

Compression pressure: 12 ± 2 Kg/cm²

Check following items if the pressure is too low:

․Incorrect valve clearance. ․Valve leaking. ․Cylinder head leaking, piston, piston ring and

cylinder worn out. If the pressure is too high, it means carbon deposits in combustion chamber or piston head.

Drive Belt

Remove left side cover. Remove mounting bolt located under air cleaner. Remove 9 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.

Teeth

Width

2-7

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2. Maintenance Information

Brake System (FRONT/REAR DISK BRAKE)

Free play of front/rear brake: 10~20 mm

Brake Hose

Make sure the brake hoses for corrosion or leaking oil.

Brake Fluid

10～20mm (3/8～3/4 in)

Brake hose

Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found.

Caution

In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop. Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. Do not mix non-compatible brake fluid together.

Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid. Operate the brake lever so that brake fluid contents inside the brake system hoses.

LOWER

Master cylinder cap

Plate diaphragm

Diaphragm UPPER

2-8

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Air Bleed Operation

Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.

Caution

Before closing the air bleed valve, do not release the brake lever.

Add Brake Fluid

Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.

2. Maintenance Information

Air bubble

LOWER

Drain valve

Transparent hose

Master cylinder cap

Plate diaphragm

Diaphragm

UPPER

Caution

Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

Brake Lining

The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc.

Caution

It is not necessary to remove brake hose when replacing the brake lining.

Remove the brake clipper bolt, and take out the clipper.

Caution

Lining

Brake caliper

Brake disk

Caliper bolt

Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining is clipped.

2-9

Adj

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2. Maintenance Information

Remove brake lining bolt. Take out the lining.

Caution

In order to maintain brake power balance, the brake lining must be replaced with one set.

Brake Light Switch

The brake lamp switch is to light up brake lamp as brake applied. Make sure that electrical starter can be operated only under brake applying.

Headlight Beam Distance

Lining

Lining bolt

Master

linder

Turn on main switch Turn the headlight adjust screw with driver to adjust headlight beam high.

Caution

To adjust the headlight beam follows related regulations.

Warning

Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.

Clutch Weight

Run the motorcycle and increase throttle valve opening gradually to check clutch operation. If the motorcycle is in forward moving and shaking, check clutch disc condition. Replace it if necessary.

Brake switch

ust screw

2-10

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Side Stand

Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly. Make sure that side stand is no bending or deformation.

Front / Rear Cushion

Warning

Do not ride the motorcycle with poor shock absorber. Looseness, wear or damage shock absorber will make poor stability and drive-ability.

2. Maintenance Information

Side stand

Front Cushion

Press down the front shock absorber for several times to check it operation. Check if it is damage Replace relative parts if damage found. Tighten all nuts and bolts.

Rear Cushion

Press down the front shock absorber for several times to check it operation. Check if it is damage Replace relative parts if damage found. Park the vehicle with main stand. Turn the rear wheel forcefully and check if engine bracket bushing worn out Replace the bushing if looseness found. Tighten all nuts and bolts.

Nuts / Bolts Tightness

Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose clamps, and wire holders for security.

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2. Maintenance Information

Wheel / Tire

Caution

Tire pressure check should be done as cold engine.

Check if tire surface is ticked with nails, stones or other materials.

Appointed tire pressure

Tire size Front tire Rear tire

Tire pressure as cold engine (Kg/cm²)

Check if front and rear tires’ pressure is in normal. Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:

Load for under 90 Kg Full loaded

Front tire: 1.5 mm Rear tire: 2.0 mm

1.75 2.25

1.75 2.5

2-12

Homepage

Contents

3. LUBRICATION SYSTEM

Precautions in Operation..................3-2

Troubleshooting................................3-2

Engine Oil ..........................................3-3

Engine Oil Strainer Clean.................3-3

Oil Pump Removal.............................3-4

Press-In Lubrication

Oil Route

CON-ROD

Spray Lubrication

Press-In Lubrication

OIL STRAINER

Oil Pump Disassembly ..................... 3-4

Oil Pump Inspection......................... 3-5

Oil Pump Reassembly...................... 3-5

Oil Pump Installation........................ 3-6

Gear Oil.............................................. 3-7

VALVE ROCKER ARM

CAM SHAFT

Spray Lubrication

Oil Route

Rotate Direction

OIL PUMP

3-1

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3. LUBRICATION SYSTEM

Precautions in Operation

General Information

‧ This chapter contains maintenance operation for the engine oil pump and gear oil replacement.

Specifications

Engine oil quantity Disassembly: 1000 c.c. Change: 800 c.c.

Gear oil Disassembly: 110 c.c. Change: 100 c.c.

Oil Oil viscosity SEA 10W-30

(Recommended King serial oils)

Gear oil Gear oil viscosity SEA 85W-140

(Recommended SYM Hypoid gear oils)

Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20

SAE

Oil pump

Torque value oil strainer Engine oil drain bolt

Gear oil drain plug 1.1~1.4 Kgf-m Gear oil inspection bolt 1.1~1.4 Kgf-m Oil pump connection bolt 0.8~1.2 Kgf-m

Clearance between outer rotor and body 0.15~0.20 0.25 Clearance between rotor side and body 0.04~0.09 0.12

1.3~1.7 Kgf-m

1.9~2.5kgf-m

Troubleshooting

Low engine oil level

．Oil leaking ．Valve guide or seat worn out ．Piston ring worn out

Low oil pressure

．Low engine oil level ．Clogged in oil strainer, circuits or pipes ．Oil pump damage

Dirty oil

．No oil change in periodical ．Cylinder head gasket damage ．Piston ring worn out

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3. LUBRICATION SYSTEM

Engine Oil

Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

Caution

Drain oil as engine warmed up so that makes sure oil can be drained smoothly and com

Place a oil pan under the motorcycle, and remove oil drain bolt. After drained, make sure washer can be re-used. Install oil drain bolt.

Torque value: 1.1~1.5 Kgf-m

Fill out engine oil (oil viscosity SEA 10W-30). Recommended using King serial oil.

Engine oil capacity: 0.8L when replacing

Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks.

letely.

Engine Oil Strainer Clean

Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap.

Torque value: 1.3~1.7 Kgf-m

Add oil to crankcase (oil viscosity SAE 10W-30) Recommended using King serial oil.

Drain bolt

3-3

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3. LUBRICATION SYSTEM

Oil Pump Removal

Remove generator and starting gear.

Remove snap ring and take out oil pump driving chain and sprocket.

Torque value: 0.8~1.2 Kg-m

Make sure that pump shaft can be rotated freely.

Remove 2 bolts on the oil pump, and then remove oil pump.

Oil Pump Disassembly

Remove the screws on oil pump cover and disassemble the pump as illustration shown.

BOLT×2

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3. LUBRICATION SYSTEM

Oil Pump Inspection

Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm

Check clearance between inner and outer rotors.

Limit: 0.20 mm

Check clearance between rotor side face and pump body

Limit: 0.12 mm

Oil Pump Reassembly

Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor. Install the driving shaft Install fixing pin

3-5

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3. LUBRICATION SYSTEM

Install the oil pump cover and fixing pin properly

Tighten screw Make sure that oil pump shaft can be rotated freely.

Oil Pump Installation

Install the oil pump, and then tighten bolts.

Torque value: 0.8~1.2 Kg-m

Make sure that oil pump shaft can be rotated freely. Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft.

Install starting gear and generator.

3-6

SCREW×1

plug

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3. LUBRICATION SYSTEM

Gear Oil

Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt.

Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil. Recommended using King serial oils. Install oil inspection bolt.

Torque value: 1.0~1.4 Kgf-m

Gear Oil Change

Remove oil level inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained.

Torque value: 1.0~1.4 Kgf-m

Make sure that the drain plug washer can be re-used. Add oil to specified quantity from the inspection hole.

Gear Oil Quantity: 100 c.c. when replacing

Make sure that the bolt washer can be re-used, and install the bolt. Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking.

Gear oil Inspection Bolt

Gear oil drain

3-7

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3. LUBRICATION SYSTEM

NOTES:

3-8

Homepage

Contents

Precautions in operation.....................4-2

Trouble diagnosis................................4-3

Air cut-off valve....................................4-4

Auto by-starter .....................................4-5

Carburetor removal..............................4-6

Vacuum chamber.................................4-6

4. FUEL SYSTEM

Float chamber..................................4-8

Installation of carburetor ................4-9

Adjustment of pilot screw...............4-10

Fuel tank .........................................4-11

Air cleaner........................................4-12

Carburetor

Fuel tank cap

Fuel pump

Fuel unit

Fuel tank

4-1

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4. FUEL SYSTEM

PRECAUTIONS IN OPERATION

General Information

Warning

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

Cautions

․Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. ․When disassembling fuel system parts, pay attention to O-ring position, replace with new one as

re-assembly

․There is a drain screw in the float chamber for draining residual gasoline. ‧Do not disassemble auto by-starter and air cut valve arbitrarily.

Specification

Item

Carburetor diameter 24 mm 25 mm I.D. number CVK039 CVK066 Fuel level 20.5 mm 20.5 mm Main injector #105 #108 Idle injector #35 #35 Idle speed 1600±100 rpm 1600±100 rpm Throttle handle clearance 2~6 mm 2~6 mm Pilot screw 2 1/4 turns 1 1/2 turns

LF12W-6/F LF18W-A/W3-H/W5-C

Torque value

Fuel valve tightening nut: 1.5~2.0Kgf-m

Tool

Special service tools

Vacuum/air pressure pump

General service tool

Fuel level gauge

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TROUBLE DIAGNOSIS

Poor engine start

z No fuel in fuel tank z Clogged fuel tube z Too much fuel in cylinder z No spark from spark plug(malfunction of ignition system) z Clogged air cleaner z Malfunction of auto by-starter z Malfunction of throttle operation z Malfunction of purge control valve

Stall after started

z Malfunction of auto by-starter z Incorrect ignition timing z Malfunction of carburetor z Dirty engine oil z Air existing in intake system z Incorrect idle speed z Malfunction of purge control valve

Rough idle

z Malfunction of ignition system z Incorrect idle speed z Malfunction of carburetor z Dirty fuel

Intermittently misfire as acceleration

z Malfunction of ignition system

Late ignition timing

z Malfunction of ignition system z Malfunction of carburetor

Power insufficiency and fuel consuming

z Fuel system clogged z Malfunction of ignition system

4. FUEL SYSTEM

Mixture too lean

z Clogged fuel injector z Vacuum piston stick and closed z Malfunction of float valve z Fuel level too low in float chamber z Clogged fuel tank cap vent z Clogged fuel filter z Obstructed fuel pipe z Clogged air vent hose z Air existing in intake system

Mixture too rich

z Clogged air injector z Malfunction of float valve z Fuel level too high in float chamber z Malfunction of auto by-starter z Dirty air cleaner

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4. FUEL SYSTEM

AIR CUT-OFF VALVE

Inspection

Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve.

Vacuum value: 420~500 mm-Hg

Pump compressed air from air pump to air vent hose.

Caution

The vacuum can not be over 600 mm-Hg. Or

the air cut-off will be damaged.

If the valve is in normal, it will restrict air-flow. f air-flow is no restrict, replace carburetor assembly.

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AUTO BY-STARTER

Inspection

Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter.

Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes)

Replace the auto starter with a new one if resistance value exceeds standard. Remove carburetor, allow it to cool off for 30 minutes. Connect a pressure tester from air pump. Connect by-starter circuit. Pump compressed air to the circuit. Replace the auto by-starter if the circuit clogged. Connect battery posts (12V) to starter’s connectors. After 5 minutes, test the by-starter circuit with compressed air. If air flows through the circuit, then, replace the starter.

Removal

Remove fixing plate screw, and then remove the plate and auto by-starter from carburetor.

Valve inspection

Check if auto by-starter and valve needle for damage or wear out.

Installation

Install auto by-starter to the bottom of carburetor body.

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

Screw ×1

Plate

4. FUEL SYSTEM

Auto by– starter

Needle

Vacuum tube

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4. FUEL SYSTEM

Carburetor removal

Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove air cut-off valve hose. Remove fuel pipe, vacuum hose. Disconnect automatic by-starter connectors. Release the clamp strip of carburetor isolation. Release the clamp strip of air cleaner.

Vacuum chamber

Removal

Loosen drain screw, and drain out residual fuel in float chamber. Remove 2 screws of vacuum chamber cover and the cover.

Remove compress spring and vacuum piston.

Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack.

Auto by-starter

Throttle cable

Air cleaner clamp

Screw ×2 Spring

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Installation

Install needle, spring and needle seat to vacuum piston.

Install vacuum piston to carburetor body and align the indent on the diaphragm.

Install compress spring.

Install vacuum chamber cover and tighten 2 screws.

Piston

Needle

4. FUEL SYSTEM

Needle seat

Spring

Screw ×2

Caution

․Do not damage vacuum diaphragm. ․When tightening the vacuum chamber screw,

hold down vacuum piston.

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4. FUEL SYSTEM

FLOAT CHAMBER

Disassembly

Remove 4 mounting screws and remove float chamber cover. Remove the float pin and float.

Checking

Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.

Float

Screw ×3

Caution

In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one.

Remove main jet, fuel needle jet holder, needle jet, slow jet, pilot screw.

Caution

․Take care not to damage jets and adjust

screw.

․Before removing adjustment screw, turn it all

the way down and note the number of turns.

․Do not turn adjust screw forcefully to avoid

damaging valve seat face.

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

Float

Needle jet holder

Needle jet

Screw ×1

Float valve

Caution

Remove vacuum chamber and air cut-off valve as a set.

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Main jet

Slow jet

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Assembly

Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw.

Caution

Set the pilot screw in according to number of turns noted before it was removed.

Install the float valve, float, and float pin.

Checking fuel level

Caution

• Check again to ensure float valve, float for proper installation.

• To ensure correct measurement, position the float meter in such a way so that float chamber face is vertical to the main jet.

4. FUEL SYSTEM

Pilot screw

Fuel level: 20.5 mm

Installation of carburetor

Install carburetor in the reverse order of removal. Following adjustments must be made after installation.

․Throttle cable adjustment. ․Idle adjustment

Float gauge

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4. FUEL SYSTEM

Adjustment of pilot screw

Caution

․Pilot screw was set at factory, so no

adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation.

․The main stand must be used to support the

motorcycle to perform the adjustments.

Use a tachometer when adjusting engine RPM. Screw in adjustment screw gently, then back up to standard turns.

Standard turns: LA12W : 2 ± 1/4 turns LA15W : 2 ± 1/2 turns LA18W : 1 ± 1/2 turns

Throttle cable adjust nut 帽

Idle adjustment screw

Pilot screw

Caution

Do not screw in forceful to avoid damaging screw seat face.

Warm up engine, adjust the stopper screw of throttle valve to standard RPM.

Idle speed rpm: 1600 ± 100 rpm

Connect the hose of exhaust analyzer to exhaust front end. Press test key on the analyzer. Adjust the pilot screw and read CO reading on the analyzer

CO standard value: 1.0~1.5 %

Accelerate in gradual increments, make sure rpm and CO value are in standard value after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above for adjusting to standard value.

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FUEL TANK

Fuel unit removal

Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear bracket (2 bolts). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 bolts). Remove the central cover (6 screws). Remove the left & right body covers and the central upper cover (4 screws and 2 bolts). Remove pedal (4 bolts and 4 screws). Disconnect fuel unit connector. Remove fuel unit (4 screws).

Caution

․Do not bend the float arm of fuel unit .

․Do not fill out too much fuel to fuel tank.

4. FUEL SYSTEM

Fuel unit inspection (Refer to electrical equipment 17-15).

Fuel unit installation

Install the gauge in the reverse order of removal.

Caution

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

Fuel tank removal

Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 bolts). Remove the central cover (6 screws). Remove pedal (4 bolts and 4 screws). Disconnect fuel unit connector. Remove fuel unit (4 screws). Remove fuel pump (2 bolts). Remove fuel tank bracket (4 bolts). Remove vacuum tube and fuel filter. Remove fuel tank

Installation

Install the tank in the reverse order of removal.

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4. FUEL SYSTEM

AIR CLEANER

Open the seat. Loosen the clamp strip of air cleaner. Remove left cover (2 screws). Remove mounting bolts for crankcase and gear box (2 bolts). Remove air cleaner cap (8 screws). Remove air cleaner set (4 screws).

Caution

The air cleaner element is made of paper so do not soap it into water or wash it with water.

Screw ×8

Element

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Homepage

Contents

EFi System Diagram······························5-1 EFi System Introduction························5-2 EFi System Components·······················5-3 EFi System Location ····························· 5-4 EFi System Component Description···· 5-5 EFi System Circuit·································5-8 Precautions in Operation······················ 5-9 Troubleshooting ···································· 5-10 Throttle Body & By-pass Valve Clean

Procedure··············································· 5-14 Fuel Lines··············································· 5-15 Ignition System······································5-16

EFi System Diagram

. Fuel Injection System

Crankshaft Position Sensor··················5-17 Engine Temperature Sensor / T-Map Sensor

·································································5-18 Air By-pass Valve···································5-19 Fuel Injector············································5-19 Fuel Pump···············································5-19 Fuel Unit··················································5-20 Fuel Tank················································5-23 Air Cleaner··············································5-24 EFi Troubleshooting & Solution ···········5-25 EFi Components Malfunction Check &

Replacement Procedure························5-53

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5. Fuel Injection System

EFi System Introduction

Based on 4-stroke SOHC engine, displacement 180 c.c. electronically controlled fuel injection. The O2 sensor enhances the efficiency of the catalytic converter, by dynamically controlling the Fuel/Air ratio.

Electronic Fuel Injection Device

Fuel supply devices: fuel tank, fuel pump, fuel filter, and fuel pressure regulator. Fuel control devices: fuel injector, and ECU. The fuel is pumped from electrical fuel pump in the fuel tank, to the injector on the inlet pipe. The fuel pressure regulator keeps the pressure around 2.5 Bar. The signals from ECU enable the injector to spray fuel into the combustion chamber once each two crankshaft-revolutions. The excessive fuel flows back to the fuel tank through the fuel pressure regulator. Fuel pump is placed inside the fuel tank to reduce the working noise, and the complicity of fuel pipes. Electrically controlled ignition and injection system effectively reduce fuel consumption rate and pollution.

In traditional gasoline engine, carburetor supplies the fuel. The process is done by the engine vacuum, and the negative pressure in the carburetor mixes fuel with air. Under this condition, three major processes are done simultaneously in the carburetor: 1. air quantity measurement, the determination of fuel quantity, the mix of fuel and air.

Electronic fuel injection system separates the three major processes into three different devices:

1. T-MAP sensor measures the air quantity and temperature and sends the signal to ECU as a reference. 2. ECU determines the amount of fuel to be injected, according to the default A/F rate.

3. ECU enables the injector to spray appropriate fuel amount. The independence of these three functions will raise the accuracy of the whole process.

EFi engine uses computer-programmed fuel injection, the main features are:

1. The quantity of fuel injected is determined according to the condition of the engine. The engine RPM, and throttle position determines the fuel quantity and injection time-length.

2. The quantity of fuel injection, and the determination of injection time length, are all controlled by 16-bit microcomputer.

3. The fuel pressure regulator maintains a 2.5 Bar pressure difference between inlet pipe and fuel pipe, raising the accuracy of fuel injection.

4. By measuring the air pressure of inlet pipe, this system gives the vehicle better accommodation to the environment.

5. Air by-pass system supplies fuel and air to stabilize the idle running, and cold starting.

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EFi System Components

ECT Sensor

Battery

5V 12V

ECU Integrated with T-MAP Sensor, TPS, ABV, and Throttle Body

Main Switch

. Fuel Injection System

Fuel Pump

Ignition Coil

CPS

Fuel Injector

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5. Fuel Injection System

EFi System Location

Injector

Ignition Coil

ECU

Fuel Pump

ECT Sensor

CPS

5-4

Fuel Pump Relay

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EFi System Component Description

Integrated ECU Module

Engine Control Unit (ECU)

• Powered by DC 8~16V, and has 32 terminals connector on the unit.

• The hardware component consists of an 16-bit computer that is its

control center. It contains the functional circuit interface of engine condition sensing and the driving actuator for the air by-pass valve, fuel injector, and fuel pump, as well as transistor ignition coil.

• Its major software is a monitor strategy operation program that

includes with controlling strategy, microarray profile and self-diagnosis programs.

Air Bypass Valve (ABV)

• Its major component is the solenoid valve of high resistance driven

by electric current.

• By means of signals from all sensors, ECU outputs a signal to

control the opening angle of the valve so that can adjust air flowing to the inlet manifold through the air by-pass valve, and then correct the idle speed to have engine in normal operation.

T-MAP Sensor

• The major component of the T-MAP sensor is a variable transistor IC.

Its reference voltage is DC 5V, and output voltage range is DC 0~5V.

• It is a sensor of combination by both sensing pressure and

temperature, and can measure the absolute pressure and temperature in intake process. It also conducts the fuel injection quantity correction based on environmental temperature and position level.

Throttle Position Sensor (TPS)

• Its major component is a highly variable resistor. The input voltage

range: 5V DC.

• Located on the side of throttle body. By means of the throttle valve

rotation to cause voltage change in linear, it provides ECU with current throttle valve openness information. And also, the ECU determines the most properly fuel injection and ignition timing.

. Fuel Injection System

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5. Fuel Injection System

Fuel Injector

• Powered by DC 8~16V, and has 2 terminals connector on the

• Its major component is the solenoid valve of high resistance driven

• The two terminals are connected to power source and ground

Fuel Pump

• Powered by DC 8~16V, and has 2 terminals connector on the pump.

• The two terminals are connected to power source and ground

• Its major component is a driving fan pump that equipped with a low

• The fuel pump is located inside of the fuel tank, and installed a filter

injector.

by electronic current.

respective. It is controlled by ECU to determine the injection timing, and the injector pulse width. Working with 4-valve engine, the unique 2-hole designed injector can provide each intake valve with suitable fuel quantity to reduce HC emission.

respective. The ECU is to control and manage the operation of fuel pump through electrical power.

electrical consuming DC motor. Powered by 12V voltage and keep fuel pressure inside the fuel pump in 2.5 bars, which can offer 14 liters of fuel per hour.

in front of its inlet so that can prevent from foreign materials sucking into the fuel pump to damage it and the fuel injector.

Ignition Coil

• Powered by DC 8~16V, and has 2 terminals connector on the coil.

• The two terminals are connected to power source and ground

respective. Its major component is the high transferring rate transformer.

• Its ignition timing is controlled by computer program. From the

signals of crankshaft position sensor, throttle position sensor, and engine temperature sensor as well as intake air temperature sensor, and correspondence with engine speed, then the ECU determines the ignition timing properly by means of controlling primary current in ON & OFF operation to create the secondary voltage of 25000~30000V. And then, the voltage triggers the spark plug ignition. Such kind of ignition system not only can enhance engine performance to maximum, but also increases fuel consumption efficiency and improves emission quality.

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ECT Sensor

CPS

. Fuel Injection System

• Powered by 5V DC from ECU, and has 2 terminals connector on the

sensor. One terminal is for voltage output and the other one for ground.

• Its major component is the thermo-resistance of negative

temperature coefficient (temperature rises up while resistance falls down).

• Located on the cylinder head. Correspondence with engine coolant

temperature change, it transferred to voltage signal and sent to ECU to calculate current temperature. Then, the ECU will correct fuel injection time and ignition timing according to engine warm up condition.

• It does not need power supply, and has 2-signal terminals connector

on the sensor.

• Its major component is the magnetic pickup coil, and its output

voltage range is ±0.8~100V.

• The air gap between the sensor and flywheel must have .07~1.1mm.

• By cutting the magnetic field, the magnetic sensor sends an

inductive voltage that is created with the rotation gear (24-1 tooth) on the flywheel, and the pulse will be sent to the ECU. Then, the ECU calculates current engine speed and crank position based on the voltage so that controls fuel injection quantity and ignition timing properly.

O2 Sensor

• Powered by DC 8~16V, and has 4 terminals connector on the sensor.

The first terminal is for power input; the second is for heating coil. The third is for ground, and the last is for signal output.

• The O2 sensor feeds signal to ECU, and the ECU can control the

air/fuel rate around 14.6. It’s a close –loop control system.

• The catalytic converter reaches the best converting rate when this

14.6 A/F ratio is maintained.

• The heating coil resistance <200kohm (30—45kohm)

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5. Fuel Injection System

EFi System Circuit

5-8

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. Fuel Injection System

Precautions in Operation

General information

Warning

● Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated

place and strictly prohibit flame when working with gasoline.

● Release the fuel pressure before removing the fuel pipe to prevent splashing the fuel.

Caution

● Do not bend or twist throttle cable. Damaged cable will make unstable drive ability.

● When disassembling the fuel system parts, pay attention to O-ring position, replace with new

one as re-assembly.

Fuel pressure release procedure: Disconnect the fuel pump relay, switch on and press the start switch for a few seconds to crank the engine.

Specification

Item

Idle speed 1800±100 rpm

Throttle grip free play 2~6 mm

Fuel pressure 2.5 bar

Torque value

Engine temperature sensor：0.74~0.88 kgf-m O2 sensor：3.6~4.6 kgf-m

Special tools

Injection system diagnostic tool Fuel pressure gauge SYM-HT07010

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5. Fuel Injection System

Troubleshooting

EFi circuit inspection

Does the warning lamp goes on for 2 seconds and then off?

Is battery voltage over 12.5V?

The voltage difference between battery and ECU is less than 0.2V.

1. Turn off the main switch.

2. Disconnect the ECU connector.

3. Turn on the main switch.

4. With a multi-meter to measure the voltage between the F4 pin(+) and the H4 pin (-).

Make sure the voltage difference between battery and ECU is less than 0.2V.

The voltage difference between battery and active components is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the connectors of the fuel injector, by-pass valve, and ignition coil.

3. Measure the voltage between battery negative side and the each connector (1).

4. Make sure the voltage difference between

battery and those active components is less than 0.2V.

The voltage difference between 5V-sensors is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the connectors of throttle valve position sensor and intake manifold temperature/pressure sensors.

3. Turn on the ignition switch.

4. Measure the voltage between the pins(1)(4) of throttle valve position, and the pins of intake manifold temperature/pressure sensors (1) (3) is within 5V±0.2V.

The voltage difference between battery and fuel pump is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the fuel pump connector.

3. With the probes of multi-meter to touch the positive & negative sides of the fuel pump.

4. Turn on the ignition switch.

5. Record the voltage difference of the fuel pump within 3 seconds.

6. Make sure the voltage difference between battery and fuel pump is less than 0.2V.

Switch on

END

1. Burnt Bulb?

2. Blown fuse?

3. Battery voltage too low?

4. Poor wire contact on ECU circuit?

5. Poor contact on the master switch?

6. Malfunction of ECU?

1. Abnormal charging circuit?

2. Battery cannot be charged?

1. Abnormal wire connection?

2. Malfunction of ECU?

1. Abnormal wire connection?

2. Malfunction of relay?

3. Malfunction of ECU?

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Engine cannot be started or difficult to start.

Does the warning lamp goes on for 2 seconds and then off?

Is the warning lamp out of order?

Is the electrical circuit abnormal?

Is the fuel system abnormal?

Is the engine abnormal?

Cannot be started or difficult to start

END

. Fuel Injection System

1. Check electrical circuit according to

procedure.

1. Connect the diagnostic tool and check trouble content.

2. Trouble shooting according to the troubleshooting procedure.

1. No spark on the spark plug?

2. Wet spark plug?

3. Loosen spark plug cap?

4. Short in RPM sensor?

5. Loosen high voltage cable?

6. No connection for the by-pass valve?

7. Abnormal ECU?

8. Clean the throttle valve body and ECU does not be set-u

1. Low fuel in fuel tank.

2. The fuel pressure of the injector is lower than 2.5bar.

3. Fuel leaking in pipe?

4. Abnormal regulator?

5. Fuel pump pipe leaking?

6. Abnormal fuel pump?

7. Abnormal fuel injector?

1. No valve clearance?

2. Incorrect ignition timing?

3. Stuck valve?

4. Worn out cylinder and piston ring?

5. Improperly adjustment of the air

adjustment screw onto the throttle valve body?

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5. Fuel Injection System

Diagnosis of Idle Speed Misfire

Idle speed misfire

1. Connect the Data Scan and check trouble content

2. Troubleshooting according to the troubleshooting procedure.

Is fuel enough?

Are the battery wires loose?

Is the vacuum pipe leaking?

Does the throttle cable stuck so could not be set-up?

Connect the Data Scan and enter into CO adjustment at idle menu. Positive value is for enrichment, and negative value is for lean.

Is the CO value in idle speed out of set up range? (0.5%~3.0%)

Does the carbon deposited onto the throttle body?

Does the by-pass valve operate or out of order?

If the idle speed misfire problem still can not be solved after check above related EFI components item by item, then check if the other traditional components on the engine is in abnormal.

Replace with new one for confirmation

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. Fuel Injection System

Abnormal CO value

If the system has O2 sensor, the CO value doesn’t have to be adjusted. If the CO value still goes abnormal, please check O2 sensor first, to see if any malfunction occurred.

Idle speed misfire.

Connect the Data Scan and check trouble content if there is an abnormal CO correct value in idle speed.

Is fuel enough?

re the battery wires loose? Is the voltage enough?

Is the vacuum pipe leakin

Does the throttle valve cable stuck so could not be set-up?

Connect the Data Scan and enter into the data analysis menu.

Start the engine and warm it up to 115℃~125℃. Make sure whether the engine RPM, the openness (75 of the by-pass valve, and the fuel injection time are in normal.

Is the CO value in idle speed out of set up range? (0.5%~3.0%)

Keep the engine run for 3~5 minutes and then turn off the engine after confirmed engine operation in normal. Conduct Error code erasing o

eration.

If the abnormal co correct value problem still cannot be solved after check above related EFI components item by item, then check if the other traditional components on the engine are in abnormal.

º~90º)

Switch the Data Scan to CO adjustment at idle menu. Positive value is for enrichment, and negative value is for lean.

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5. Fuel Injection System

Throttle Body & By-pass Valve Clean Procedure

● It’s suggested that clean the air by-pass valve before cleaning the throttle body.

● Recommended cleaning frequency: every 6000 km.

Clean procedure:

1. Air by-pass valve：

1. Switch off; disconnect the air tube between the air by-pass valve and connecting pipe.

2. Turn on the engine and keep the idle speed.

3. Spray a little carburetor cleaner into the air by-pass vale for 3~5 minutes. Do not shut down the engine during cleaning.

4. Connect the air tube.

2. Throttle body:

1. Switch off; remove the throttle body.

2. Spray a little carburetor cleaner into the throttle body.

3. Wipe off the dirty oil with clean cloth or tissue.

4. Dry the throttle body with compressed air and install the throttle body. Connect the diagnostic tool and switch on.

Idle speed learning:

After performing air by-pass valve or throttle body cleaning, idle speed learning should be carried out to let ECU know the engine condition well. When performing the idle speed learning, run the engine at idle speed over 10 minutes after the engine temperature reaches the working temperature (around 70℃~95℃), and then ECU will get

the parameters from sensors.

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Fuel Lines

Injector

. Fuel Injection System

Regulator

Fuel filter

Fuel tank

Fuel

Vacuum pipe

ECU

Battery

System description:

1. After key-on, all sensors’ signals sent to the ECU first. The electrical fuel pump will be activated by ECU signal. If the engine did not start for 2~3 seconds, then the fuel pump will be turned off to save electricity. The pressure regulator maintains the fuel pressure around

2.5 Bar, and the fuel injector spray proper fuel quantity according to the conditions and environmental coefficient. When key-off or engine stopped, the fuel pumps stop operating.

2. The fuel filter is to filter alien materials so it has to be replaced regularly.

3. Do not let the starting motor keep running when the engine cannot start. It will cause battery voltage to decrease. If the voltage drops under 8V, the pump will not operate. The countermeasure will be starting the engine by connecting a new battery or with kick-starter.

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5. Fuel Injection System

Ignition System

TPS

T-MAP

AC Generator Flywheel (24-1 teeth)

ET Sensor

CPS

Regulator rectifier

Transistor ignition coil

ECU

Spark plug

Battery

Principle of operation

The engine is equipped with a computerized ignition control system that collects signals from CPS, TPS, ET Sensor, and T-MAP Sensor. Then, correspondence with engine RPM, this 8-bit microcomputer in the system controls ignition timing properly. The secondary coil creates 25000~30000V high voltage to ignite the spark plug by means of the transistor operation of the primary current entry from the ECU. This can maximize engine performance and also decrease fuel consumption.

Specification

1. Ignition timing: BTDC 10°/ 1800RPM

2. Spark plug: NGK CR8E

Gap: 0.8mm

3. CPS pulse generator coil: 80~160Ω / 20ºC (G/W-LY)

4. Ignition coil

Primary circuit：0.63±0.03Ω(23ºC)

5. Battery:

Type: YTX9-BS / GTX9-BS Capacity: 12V 8Ah

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Crankshaft Position Sensor

. Fuel Injection System

No tooth

ECU signal

Secondary voltage

Sensor si

Description:

The magnetic field type sensor generates a voltage signal to calculate engine speed with ACG gear ring (24-1 tooth).

There is one tooth every 15 degree on the gear ring. But, one of the teeth is blank for the TDC calculating base.

nal

TDC TDC

Closed

Ignition

Time

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5. Fuel Injection System

Engine Temperature Sensor / T-Map Sensor

ECU

Engine temperature sensor: According to the semiconductor’s characteristic, the sensor detects the temperature of engine oil and metal parts and then sends a voltage signal to the ECU. On this base, the ECU can correct fuel injection and ignition timing.

T-MAP Sensor： Sensor combined both pressure and NTC can detect the absolute pressure and temperature in

the intake manifold, and then provides the ECU with signal for adjustment fuel injection quantity based on environmental temperature and air pressure difference from elevation level change.

NTC- Negative Temperature

Coefficient Resistor

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-40ºC

140ºC

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Air By-pass Valve

. Fuel Injection System

Description:

ECU receives all sensors’ signals to control the throttle valve openness with PWM, and adjust airflow through the by-pass valve of the intake manifold. It can adjust idle speed for a stably running engine.

1. When engine cold starting---the by-pass valve open for a while to increase airflow and to stabilize engine idle speed within initial starting

2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts airflow according to engine temperature (engine oil temperature), and raises idle speed.

3. Speed decreasing--- ECU controls the by-pass valve in correspondence with throttle operation, to provide inlet pipe with proper airflow quantity. Such operation will smooth the engine rpm reduction process, preventing the engine from stalling, excessive negative pressure, and also reduce HC emission.

Fuel Injector

The double-hole injector provides each intake valve a fuel jet. This can reduce the pollution of HC. The shortened version of fuel pump plate makes its size more compact, and sturdier against shocks. ECU signal controls the regulator to maintain 2.5 bars between the fuel pressure and the air pressure of inlet pipe. Through controlling the time length of injection under steady fuel pressure, the system can optimize the fuel injection quantity according to different engine workloads.

Fuel Pump

Electrical fuel pump is mounted inside the fuel tank. The power source is DC current provided and controlled by ECU; the pump can provide 14L/hour under the pressure of 2.5 bars.

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5. Fuel Injection System

Fuel Pump / Fuel Unit

Removal

Remove the front cover and right/ left side

covers.

Remove the luggage box.

Remove the right/ left body covers.

Remove the central cover and footrest.

Remove the front inner cover.

Remove the fuel tank fixing bracket (2 lock

bolts).

Disconnect the fuel pump and fuel unit

Coupler

2 bolts

Fuel output pipe

couplers.

Remove the fuel pipes.

Remove the fuel pump lock bolts.

Fuel backflow pipe

5 bolts

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Remove the fuel pump and fuel unit.

Caution

● Check if the oil seal is deformed or

damaged. Replace it with new one if

necessary.

Check if the fuel filter is contaminated or clogged. Replace it with new one if necessary.

. Fuel Injection System

Oil seal

Fuel filter

Installation Install in the reverse order of

removal.

Caution

● Do not bend the fuel unit float arm

● Do not fill out too much fuel in the tank.

● Align the assembly mark when installing

the fuel pump.

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5. Fuel Injection System

Check the oil seal of fuel pressure regulator for any damage or deformation.

Caution

● Replace the oil seal if any damage or

deformation is found.

Installation

Install in the reverse order of removal.

Inspection：

Disconnect the fuel pipe from the fuel injector. Connect the fuel pressure gauge to check the fuel pressure.

Fuel pressure regulator

O-ring

Fuel pressure regulator

Fuel pressure gauge

Fuel inlet pipe

Caution

● Make sure the fuel pressure is normal

(2.5 bar).

● Always release the fuel pressure before

removing the fuel pipe to prevent the fuel from splashing.

Special tool： Fuel pressure gauge SYM-HT07010

Replace the fuel pressure regulator with new one if malfunction is confirmed.

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Fuel outlet pipe

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Fuel Tank

Removal

Caution

● Make sure the fuel in the tank is not too

much before removing the fuel tank.

Remove the fuel tank fixing brackets (4 bolts).

Disconnect the fuel pump/ unit coupler, fuel output/ backflow pipes and fuel tank ventilation pipe.

Remove the fill-in pipe and overflow pipe.

Remove the fuel tank (4 lock bolts).

Coupler

Fuel backflow pipe

Ventilation pipe

. Fuel Injection System

4 bolts

Fuel output pipe

Overflow pipe

Fill-in pipe

Caution

● Replace the fuel tank if there is any

damage or leakage.

Installation

Install in the reverse order of removal.

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5. Fuel Injection System

Air Cleaner

Remove the air cleaner cover (8 screws).

Remove the air cleaner element (4 screws).

Caution

8 screws

4 screws

Element

● The air cleaner is paper-base; please

blow it clean with compressed air. Don’t use water or other solvent

● Replace it with new one if the dirt cannot

be removed.

Installation

Install in the reverse order of removal.

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. Fuel Injection System

EFi Troubleshooting and Solution

Readings of Trouble Code through Check Lamp

When the engine might have problem and there is no diagnostic tool to determine, the problem can be judged by reading the flash times of Check Lamp on the speedometer. And then, you can know the service priority level, or the FLASH CODE. Then you can try to fix the problem. Here are the descriptions for the two ways:

To show “Service Priority”

Once the error in the EFi system is detected during driving (or anytime when the engine is running).The Check Lamp on the speedometer will start to light in two ways. Service Priority 1：Check Lamp keeps blinking: to warn the driver that the vehicle should be

checked immediately.

Service Priority 2：Check Lamp keeps lighting up: to warn the driver that the vehicle should be

checked as soon as possible, yet the vehicle has no immediate problem.

Service Priority Light up types

0.3 sec

OFF

0.3 sec

OFF

To show “FLASH CODE”

Turn the key on without starting the engine; Check Lamp will start to show Flash Code for four times and then stop. If you turn the key off before Check Lamp shows Flash Code for four times, it will show another four times after you turn the key on again. Check Lamp lights on for 1 second to show tens digit, and lights on for half a second to show units digit.

=light on

Key on

First Flash Code

2 3 1

Light on for 2 seconds: regular check

Check Lamp shuts for 3seconds

Check Lamp lights on for one second, shuts for half a second and lights on for half a second; this means Flash Code 11

0.5 0.5

Check Lamp shuts for 3 seconds, which means there is a second Flash Code

If the engine is started during Check Lamp is showing the Flash Code, Check Lamp will start to show the service priority by blinking or lighting up.

=light off

3 1

Second Flash Code

0.5 0.5 0.5 0.5

Check Lamp lights on for one second, shuts and lights on for half a second for two rounds; this means Flash Code 12

Check Lamp shuts for 6 seconds and the second Flash Code blinking section will start.

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5. Fuel Injection System

Error Code Message and Solution Operation

DTC

code

P0217 1 1

P0335 2 2

P0120 3 2

P0121 4 2

Flash

code

Service priority

Message Solution operation

Stop the vehicle immediately, and solve it with priority.

Engine temperature overheat

Abnormal crankshaft position sensor

Abnormal throttle position sensor learning value

Abnormal throttle position sensor output voltage

Check the lubricant system for malfunction. Check if the ignition or fuel supply system is in normal. Check if the engine is burnt. Make sure if the engine temperature sensor is in normal. Make sure if the connector is in normal.

Check if the connection of the crank position sensor is open-circuit. Check if the gap between the sensor and gear tooth is within specification. Check if the crank rotation is run-out. Check if the sensor is in normal according to the new component re

lacement procedure.

Connect the diagnostic and reset the throttle valve position. Make sure if the idle speed position is within standard range. Make sure if the wire circuit of the throttle valve position sensor is loosen or short. Check if the openness of idle speed by-pass valve is within specification. (40~100%) Adjust the idle speed CO value to specified range. (0.5%~2.0%) If this problem symptom still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

Make sure if the wire circuit of the throttle valve position sensor is loosen or short. If this problem symptom still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

P0124 5 2

P0560 6 1

P0110

7 2

Abnormal throttle position sensor turning speed

Abnormal battery voltage

Abnormal intake air temperature sensor

Make sure if the wire circuit of the throttle valve position sensor is loosen or short. If this problem still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

Make sure if the battery voltage is too low or high (below 10V or exceed 16V) Make sure if the ACG generator charging system circuit is short or abnormal. Check if the G4 terminal on the ECU to battery positive post is short. Make sure if the battery is in normal. Replace it with new if the battery is out or order.

Make sure if the sensor’s wire is in open-circuit. Make sure if the sensor is normal according to the new component replacement procedure.

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DTC

code

P0505 9 2

P0200 10 2

P0350 11 2

P0230 12 2

Flash

code

Service priority

. Fuel Injection System

Message Solution operation

Abnormal air bypass valve learning value

Abnormal fuel injector

Abnormal ignition circuit

Abnormal fuel pump relay

Check if the air bypass valve openness is in normal. Check if the intake manifold is leaking.

Make sure if the fuel injector resistance is within specification. (12 Ω, 20℃) Check if the connector or wire is in open-circuit. (The G1 terminal of ECU) Make sure if the fuel injector power supplied is normal. (12~15V)

Make sure if the ignition coil resistor is within specification. (0.63 Ω, 23℃)

Make sure if the connector or wire is in open-circuit. (The 12th terminal of ECU) Make sure if the ignition coil’s power supplied is in normal. (12~15V)

Make sure if the connector or wire is in open-circuit. Replace with new relay to make sure if this abnormal is disappeared.

P0219 13 2

P0700 15 2

P0115 16 2

P0650 18 2

P0136 19 2

P0141 20 2

Engine over-RPM

Too high RPM when starting engine

Abnormal engine temperature sensor

Abnormal check lamp

Abnormal O2 sensor wiring

Abnormal O2 sensor heater wiring

Engine speed exceed safety limit. Decrease the speed and then the DTC code disappeared. Check if the CVT belt is broken.

If the engine RPM exceeds 3000rpm as starting, in order to prevent run-away accident, the ECU will decrease engine speed or stop the engine. Rider should avoid to starting engine with WOT suddenly. Check if acceleration cable is stuck. Re-set the idle speed adjustment position. Make sure if the sensor’s resistor is within specification. (60℃,

703.8±40.9Ω) Make sure if the sensor’s wire is in open-circuit. (9th terminal of

ECU)

Check if the check lamp is burnt. Check if the check lamp circuit is open. (C2 terminal of ECU)

Check O2 sensor coupler. Check O2 sensor wiring (D2, D1 terminal of ECU).

Check O2 sensor coupler. Check O2 sensor wiring (H1 terminal of ECU). Check O2 sensor white cable voltage (12V).

P0105 21 2

Abnormal MAP sensor

Clean the sensor. Replace the ECU.

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5. Fuel Injection System

DTC

code

P0170 23 2

P1001 25 2

ECU coupler terminal layout：

Flash

code

Service priority

Message Solution operation

Fuel supply too thick or too thin

Abnormal reset coupler

C D

Check the fuel tank. Check and clean the air cleaner. Check the fuel injector, O2 sensor and fuel pump.

Check the coupler wiring.

G H

ECU coupler

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Injection System for Use diagnosis - V70

LCD monitor

Function set Button

Leave button

Cable connector

. Fuel Injection System

Information transmission indicator

Button to turn the pages, and numerical adjustment

Executive Function button

Link cable

Digital button

Soft cartridge slots

Software cartridge

Note:

● When problems arise, can be used for diagnosis tool of the fault is detected, and exclusion.

● In addition to testing, troubleshooting, another of the operation can be carried out data

analysis-type monitor.

Method of Use:

1. Maintain engine flameout state, do not open main switch.

2. Opened the luggage box lighting light cover (screw x2), connected to the diagnostic connector for diagnosis tool.

3. Then open the main switch and the diagnosis tool power switch after diagnosis display screen appeared the words connection.

4. Press the "ENTER" button into the main screen (there are 6 major functions: ECU ID, DATA STREAM, FREEZED DATA, TROUBLE CODE, ERASE TB CODE and CO ADAPTION)

5. Use ▲, ▼ select button under the function, press the "ENTER" button access into various functions.

Example: select "DATA STREAM," by the "ENTER" button, the screen showed that the

existing fault codes; indicates no fault "system is OK."

6. Press "EXIT" buttom to leave of the various functions.

7. Must to close the main switch or power switch of the diagnosis tool after, and then can removal of diagnosis tool coupler.

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5. Fuel Injection System

Diagnostic tool illustration

Connect the diagnostic tool wire connector and turn on the main switch. Press <Enter> button to proceed.

Press <Enter> button to enter function-options page.

Press <Enter> button to enter ECU ID version page.

System Information

Press <Enter> button to get back to the function-options page.

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DATA STREAM

Press <Enter> button to enter Data Stream page.

Press <UP> or <DOWN> button to choose Fault No. item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <UP> or <DOWN> button to choose Intake Air item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose Engine Temp item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <UP> or <DOWN> button to choose BARO item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose BATT. VOLT item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <UP> or <DOWN> button to choose Engine SPD item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose TPS position item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <UP> or <DOWN> button to choose IDLE LEARN item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose IDLE SET item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <RIGHT> button to get to next page to choose MAP item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose INJECT TIME item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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5. Fuel Injection System

Press <UP> or <DOWN> button to choose IGN. ANGLE item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

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Press <UP> or <DOWN> button to choose IGN. CHARGE item.

Press <F1> button to enter description page. Press any key to get back to Data Stream page.

Press <F4> button to enter waveform page. Press <EXIT> button to get back to Data Stream page.

. Fuel Injection System

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Sym Joyride 125, Joyride 200i EVO, X'PRO RV125, 200 EFi, Joyride 125 EVO Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual