SYM DD 50 User Manual

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MECHANISM ILLUSTRATIONS

DD 50

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG DD 50 series scooter. 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 scooter, DD 50 series, 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 DD 50 scooters. 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 tenth nine chapters covers engine and driving systems. The tenth to the fourteenth is contained the parts set of assembly body. The fifteenth chapter is electrical equipment. The sixteenth chapter is wiring diagram

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

All information, illustration, directions and specifications included in this manual are current as at the time of publication. Sanyang reserves the rights to make changes at any time without prior notice and without incurring any obligation whatever. Without written consent by SANYANG can not copy any part of this manual.

There are 4 buttons, “Forward,” “How to use this manual,” “Mechanism

Illustrations,” and “Contents” on the CD-R version, and can be access to

these items by click the mouse. If user wants to look for the content of each chapter, selecting the words of each chapter on the main contents can reach to each chapter. There are two buttons, Back to homepage and Main contents, onto 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 main 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 “This chapter contents” button at the top line of each page so that clicking the button can back to the contents of this chapter.

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CONTENTS

Page Content Index

1-1 ~ 1-16

2-1 ~ 2-14

3-1 ~ 3-6

4-1 ~ 4-6

5-1 ~ 5-8

6-1 ~ 6-4

GENERAL INFORMATION

SERVICE MAINTENANCE INFORMATION

LUBRICATION SYSTEM

ENGINE REMOVAL

CYLINDER HEAD/CYLINDER/PISTON

ALTERNATOR

7-1 ~ 7-14

8-1 ~ 8-6

9-1 ~ 9-6

10-1 ~ 10-10

11-1 ~ 11-12

12-1 ~ 12-14

13-1 ~ 13-10

14-1 ~ 14-4

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

FINAL DRIVING MECHANISM

CRANKCASE/CRANKSHAFT

FUEL SYSTEM

BRAKE SYSTEM

BODY COVER

STEERING/FRONT WHEEL/SUSPENSION

REAR WHEEL/SUSPENSION

15-1 ~ 15-18

ELECTRICAL EQUIPMENT

16-1 ~ 16-2

ELECTRICAL DIAGRAM

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MODEL ILLUSTRATION

FT05V

Front turn signal

Head light

Light / Starter switch

Helmet hook

High & Low beam / Turn signal / Horn switch

Fuel tank cap

Battery / Fuses / C.D.I. / Eng. Oil tank cap

Front brake lever

Rear brake lever

Tail light / Rear turn signal

Storage box

Air cleaner

Frame number

Ignition switch

Engine number

Muffler

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Contents

FT05T

MODEL ILLUSTRATION

FT05U

FT05W

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Contents

1. GENERAL INFORMATION

Symbols and Marks··························1-1 General Safety ··································1-2 Service Precautions ·························1-3 Specifications ··································· 1-5

Torque values···································1-6 Cables and Harness Routing ··········1-8 Troubleshooting·······························1-11 Lubrication Points····························1-15

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

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)

Grease

Gear oil Locking

sealant Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

Indication

Directions

King Mate G-3 is recommended.

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

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

Apply with lubricant.

Replace with a new part before installation.

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools.

Meaning correct installation.

Meaning wrong installation.

Indication of components.

Indicates position and operation directions.

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

through the component (invisibility).

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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.

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.

Battery

Caution

y Battery emits explosive gases; flame is

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

y 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.

y 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.

y 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.

Caution

Inhaling dust 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.

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This chapter Contents

1. GENERAL INFORMATION

Service Precautions

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 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 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

stiff control and premature worn out.

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.

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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.

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.

z Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

Boots

z The tool should be pressed against two (inner

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.

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.

1-4

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.

This chapter Contents

1. GENERAL INFORMATION

Specifications

Make SANYANG MODEL FT05 Series

Overall Length 1660 mm Front TELESCOPIC

Overall Width 630 mm

Overall Height 1020 mm Front 3.00 - 10 42J(T/L)

DIMENSION

Wheel Base 1155 mm

Front 32 kg

Curb

Passengers/

WEIGHT

Total Weight

Rear 48 kg

Wei

Total 80 kg

Weight

Front 54 kg Climb Ability 20° Below

Rear 136 kg Primary Reduction BELT

Total 190 kg

Suspension

System

Tire

Specifications

Brake

System

Two /110 kg Max. Speed 48 km/hr Below

Secondary

Reduction

Rear UNlT SWING

Rear 3.00 - 10 42J(T/L)

DlSK (ψ160mm)

Front

DRUM (ψ110mm)

Rear

DRUM (ψ95mm)

GEAR

Type Gasoline Clutch Centrifugal, dry type

Installation and

arrangement

Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr

Cycle/Cooling

Bore 39 mm Muffler Expansion & Pulse Type

Stroke 41.4 mm

Cylinder

Number/Arran

ENGINE

gement

Displacement 49.4 cc Solid Particulate

Compression

Ratio

Max. HP 2.7 kw / 6250 rpm

Max. Torque 4.41 Nm / 5000 rpm E.E.C. Below 2g / test

Ignition C.D.I. P.C.V. X

Vertical, below center,

incline

2-stroke/forced air

cooled

Single Cylinder Lubrication System Separated-lubrication

7.1 : 1 CO

PERFORMANCE

Transmission C.V.T.

Horn 80 ~ 112 dB/A

Exhaust Pipe Position

and Direction

Exhaust

Concentration

HC Below 4000 ppm

Right side, and Backward

15 % ↓

3.5 % ↓

Starting System Electrical & kick

Catalytic reaction control

system

○

1-5

This chapter Contents

1. GENERAL INFORMATION

Torque values

Standard Torque Values for Reference

Type Torque value Type Torque value

5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m 6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m 8 mm Bolt, nut 1.8 - 2.5 kg-m 6 mm Flange bolt, nut 1.0 - 1.4 kg-m 10 mm Bolt, nut 3.0 - 4.0 kg-m 8 mm Flange bolt, nut 2.4 - 3.0 kg-m 12 mm Bolt, nut 5.0 - 6.0 kg-m 10 mm Flange bolt, nut 3.5 - 4.5 kg-m

The torque values listed in below table are for more important tighten torque values. Please see above standard values for not listed in the table.

Engine

Item Q’ty

Cylinder head bolt

Spark plug Flywheel nut Sliding driving disc nut Sliding driving disc nut Clutch outer cover nut Drain bolts Crankcase bolts

Thread Dia.

(mm) 4 1 14 1.4

1 10 3.8 1 10 3.8 1 28 5.5 1 10 3.8 1 8 1.3 6 6 1.0

6 1.0

Torque Value

(Kgf-m)

When engine

Remarks

cooled

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This chapter Contents

1. GENERAL INFORMATION

Frame

Item Q’ty

Bolt for engine suspension

Bolt for engine suspension bracket

Upper bolt for rear shock absorber

Lower bolt for rear shock absorber

Mounting screws for exhaust pipe connection

Nut for exhaust

Brake hose bolts

Thread Dia.

(mm)

10 5.0

12 6.0

10 4.0

8 2.7

6 1.2

8 3.3

10 3.5

Torque Value

(Kgf-m)

Remarks

Brake caliper mounting bolts

Brake cushion guide bolts

Brake cushion guide bolts cap

Brake drain valve

Rear brake arm bolts

Tightening nut for steering rod

Front shaft nut

Mounting bolt for handle

Mounting nut for front hub

Mounting bolt for front brake disc

8 3.1

6 1.8

6 1.0

6 0.6

5 0.55

25.4 7.0

12 6.0

10 5.0

8 2.5

8 4.5

Rear shaft nut

Nut for rear hub

14 11.0

8 2.5

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This chapter Contents

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.

O：Correct X：Wrong

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This chapter Contents

1. GENERAL INFORMATION

Starter switch

Front brake lamp switch

Speedometer

Headlight switch

Throttle cable

Winker relay

Winker switch

High/low beam switch

Rear brake lamp switch

Horn switch

Headlight

Winker light

Main switch

Regulator

Resistor

Front brake cable

Throttle cable

Speedometer cable

Rear brake cable

Horn

Speedometer cable

Front brake cable

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This chapter Contents

1. GENERAL INFORMATION

Battery/fuse/starting relay/CDI set

Throttle cable

Fuel unit

Carburetor

Spark plug cap

Fuel filter

Fuel pump

Throttle cable

Rear brake cable

Engine oil operation cable

Engine oil filling pipe

Fuel pump

Fuel unit

1-10

Oil pump

Engine oil return pipe

This chapter Contents

1. GENERAL INFORMATION

Troubleshooting

A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

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

Fuel supplied tom carburetor sufficient

No fuel is supplied to carburetor

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

Check if sparks

Week sparks or no spark at all

Perform cylinder compression pressure test.

cylinder compression pressure normal Low compression

pressure or no pressure

Re-start by following the starting procedures

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

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

6. Crankcase leakage for pre-compression

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 supplement circuit. Then blow the hose with air

Blowing in normal

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

Blowing clogged

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

1. Malfunction of auto-starter

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This chapter Contents

1. GENERAL INFORMATION

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

Engine speed can be increased.

Engine speed can not be increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct Incorrect ignition timing

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct No compression pressure

Check if carburetor is clogged

Normal Clogged

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

1. Malfunction of CDI

2. Malfunction of AC generator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Crankcase leakage for pre-compression

1. Remove dirt

Remove spark plug

No foul or discoloration Fouled and discoloration

Check if engine over heat

Continually drive in acceleration or high speed

1-12

Normal Engine overheat

No knock Knock

1. Remove dirt

2. Incorrect spark plug heat range

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

1. Too much carbon deposited in combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Lean mixture

This chapter Contents

1. GENERAL INFORMATION

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

Air sucked through carburetor gasket

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

Engine runs sluggish (High speed)

Normal

Good Poor

No air sucked

Good spark

Abnormal

Air sucked

Poor

1. Incorrect ignition timing (malfunction of CDI or AC generator)

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

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 FAULT CONDITION PROBABLE CAUSES

Check ignition timing

Check for fuel supplying system in automatic fuel cup

Normal

Good

Check if carburetor clogged

Abnormal

Poor

1. Malfunction of CDI

2. Malfunction of AC generator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Normal

Clogged

1. Cleaning

1-13

This chapter Contents

1. GENERAL INFORMATION

. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITION PROBABLE CAUSES

Engine can be started but motorcycle can not be driving

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

Poor initial driving (Poor climbing performance)

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 damage

7. Transmission gear worn out or burned

1. Clutch ling spring broken

2. Clutch outer cover stuck with clutch balance weights

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

1. Driving belt worn out or deformation

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.

1-14

This chapter Contents

1. GENERAL INFORMATION

Lubrication Points

Steering shaft bearing

Throttle cable/ Front & rear brake lever pivot

Engine suspension bushing

Seat lock

Speedometer gear/ front wheel bearing

Side stand shaft

Main stand shaft

Rear wheel bearing

1-15

This chapter Contents

1. GENERAL INFORMATION

Note:

1-16

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Contents

2. SERVICE MAINTENANCE INFORMATION

General Information··························2-1 Periodical Maintenance Schedule···2-2 Air Cleaner ········································2-3 Fuel Lines··········································2-3 Fuel Filter ··········································2-4 Engine Oil Line ·································2-4 Oil Pump Control Cable ···················2-5 Tire·····················································2-6 Battery···············································2-6 Rear Brake Free Play: (Drum Brake Type)

····························································2-7

Brake System Hose: (Front Disc Brake Type)··················································2-8

Steering System································2-10

Suspension····································· 2-10 Transmission Oil···························· 2-11 Spark Plug ······································ 2-11 Control Cable Lubrication············· 2-12 Driver Belt······································· 2-12 Ignition Timing ······························· 2-12 Throttle Valve Operation················ 2-12 Carburetor Idle Speed Adjustment 2-13 Carbon Removing For Exhaust Pipe &

Muffle ·············································· 2-13 Cylinder Compression Pressure Test 2-13 Headlight Adjustment···················· 2-14

General Information

Specification

Tire dimension

Tire pressure at cold Only rider Front brake lever free play 10~20 mm

Rear brake lever free play 10~20 mm

Transmission oil Recommendation

Spark plug Recommendation

Driving belt width Ignition timing F mark

Front: 3.00-10 42J Rear: 3.00-10 42J

Front: 1.5kg/cm Rear: 2.25 kg/cm

Standard 18.0mm Allowable limit: replace it if below 16.5mm

17°, BTDC/1500 rpm

Type: HYPOID GEAR OIL Oil: SAE #140 Quantity: 0.1 L

Type: NGK BR8HSA Plug gap: 0.6-0.7mm

Acceleration operation 2~6 mm Idle speed Cylinder compression pressure

2000±100 rpm 7±1 kgf/cm²

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This chapter Contents

2. SERVICE MAINTENANCE INFORMATION

Periodical Maintenance Schedule

Check item

☆

1. Air cleaner

☆

2. Fuel filter

☆

3. Engine oil filter cleaning

4. Oil pump linkage operation

☆

☆ ☆

☆

☆ ☆ ☆

☆

Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement

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

Remarks:

check

5. Tire pressure

6. Battery inspection

7. Brake & free play check

8. Steering handle check

9. Cushion operation check

10. Every screw tightening check

11. Gear oil check for leaking

12. Spark plug check or change

13. Gear oil change

14. Frame lubrication

15. Exhaust pipe

16. Carburetor

17. Driving belt check

18. Ignition timing

19. Emission check in Idling

20. Idle speed check

21. Fuel lines

22. Throttle operation

23. Engine bolt tightening

24. Engine screw torque

25. Carbon cleaning for cylinder head, cylinder, piston head, and exhaust system.

C ~ Cleaning (replaced if necessary) L ~ Lubrication

1. Clean or replace the air cleaner element more often for pro-long engine life-span when the scooter is operated on dusty roads or in the Heavily- polluted environment.

2. Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage.

Maintenance kilometer

Maintenance interval

300KM

New 1 month 3 month 6 month 1 year

I C R

C C

I I I I

I I I I I I I I I I I I I R

R Replacement for every 5000km

L I I I I

I I I I I I I I I I I I I

Every

1000KM

Every

3000KM

Every

6000KM

Every

12000KM

Reference

2-2

This chapter Contents

2. SERVICE MAINTENANCE INFORMATION

Air Cleaner

• Remove the mounting screw from the air cleaner cover

• Remove the air cleaner cover

Remove the air cleaner element Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

Caution

Never use gasoline or acid organized solvent to clean the element.

Mounting screw X 7

Air cleaner element

Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.

• Limit to use SAE 20 JASO FC class engine oil, otherwise, SYM is no responsible for the warranty.

• Recommended engine oil: MAX-2 serial oils.

Fuel Lines

Remove the body cover Check fuel lines and replace damaged lines if found. Install the body cover.

Squeeze oil out

Fuel pump

Clean

Soap

Squeeze out remaining oil

Carburetor

Fuel line

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2. SERVICE MAINTENANCE INFORMATION

Fuel Filter

Remove the luggage box. Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking.

Engine Oil Line

Remove the body cover. Check the engine oil line and replace damaged parts. Remove the filling pipe from the oil pump, and drain oil into a cleaning container. Loosen the clamp under the engine oil tank, and then remove the oil pipe. Bleed the air inside the oil pump and oil pipe if air found. Install the body cover.

Fuel filter

Engine oil pipe

Oil pump

Oil filling pipe

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2. SERVICE MAINTENANCE INFORMATION

Oil Pump Control Cable

Caution

To adjust the oil pump control cable after adjusted the throttle grip play.

Remove the body cover. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body. Loosen the adjustment nut of the oil pump control cable. Turn the adjustment nut and align with the point, then tighten the nut.

Mounting nut

Adjustment nut

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2. SERVICE MAINTENANCE INFORMATION

Tire

Caution

Tire pressure should be checked when cold.

Check tire for cracks, damage, nail, or other object stuck in tread. Recommended tire and tire pressure

Tire size Tire pressure

(cold) kg/cm

Check if the tire tread and wall rubber for crack or damage, and replace if necessary. Check if foreign materials such as nail, metal pieces, and stones stuck on tire. The thread depth can be checked by visual inspection or by a depth gauge.

• If the tread bend too much, replace the tire.

• If tire wear exceeds limitation, replace the tire,

and check it for un-even wear.

Front:

3.00-10 42J

1.75 2.0

Rear:

3.00-10 42J

Caution

Wear indicator “△” is distributed on average along the wall rubber for check.

Battery

Open the seat. Loosen two screws of battery cap and then remove the cap. Check if the battery terminals are loosen. Remove the battery if its terminals are corroded obviously.

Battery Removal

1. Remove the Negative (-) battery cable at

first.

2. Then, remove the Positive (+) battery cable.

3. Remove the battery.

Clean the rust with steel brush. Install the battery in reverse order of removal, and apply with grease onto two terminals.

Caution

The electrolyte is contained sulfuric acid so be careful not to let it touch to eyes, skin, or clothes. If touched by accident, flush them with clean water immediately. However, if the electrolyte sprays to eyes, medical care should be done quickly.

Wear indicator

△ Mark

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2. SERVICE MAINTENANCE INFORMATION

Rear Brake Free Play: (Drum Brake Type)

Measure the free play of the rear brake lever at the end of the lever. Free play: 10-20 mm (3/8-3/4 in)

Adjust the free play by turning the front brake adjustment nut if necessary.

Brake Confirmation

Caution

After brake adjustment, it has to check the brake operation to make sure the front and rear wheel can be braked.

10∼20mm (3/8∼3/4 in)

Adjustment nut

Decreasing free play

Increasing free play

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2. SERVICE MAINTENANCE INFORMATION

Brake System Hose: (Front Disc Brake Type)

Make sure that the brake hose is corrosion or damage, and also check the system for leaking.

Brake Fluid:

Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit. Also check brake system for leaking if low brake level found.

Caution

z In order to maintain brake fluid in the

reservoir in horizontal position, do not remove the cap until handle bar stop.

z Do not operate the brake lever after the cap

had been removed. Otherwise, the brake fluid will spread out if operated the lever.

z Do not mix non-compatible brake fluid

together.

Lower limit

Brake fluid reservoir cap

Arrow

Brake Lining Wear: (Rear Drum Brake Type)

Replace the brake lining if the wear limit mark “△” on the brake arm aligning with the indicator

of brake drum.

Brake Lining Wear: (Front Disc Brake Type)

The arrow 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

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

Wear limit mark

Brake lining

Brake caliper

Brake disc

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2. SERVICE MAINTENANCE INFORMATION

z Remove the pin bolt cap. z Loosen the bolt. z Remove the front wheel shaft bolt. z Take out the front wheel.

Remove brake caliper mounting bolt and then remove the brake caliper.

Caution

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

Pin bolt cap

Mounting bolt

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

Remove brake lining bolt. Take out the lining.

Tighten Torque: Mounting bolt: 2.9-3.5 kgf-m Pin bolt: 1.5-2.0 kgf-m Pin bolt cap: 0.8-1.2 kgf-m

The brake light switch is to light up brake light as brake applied. Replace the switch if the light does not light up in properly.

Caution

The brake light switch is un-adjustable.

Pin bolt

Brake lining

Pin bolt

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2. SERVICE MAINTENANCE INFORMATION

Steering System

Caution

The control cables can not interfere with the rotation of steering handle.

Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut.

Suspension

Warning

Do not ride the scooter with poor suspension. Looseness, wear or damage suspension system will make poor stability and drive-ability.

Front Shock Absorber

Press down the front shock absorber for several times to check it operation. Check if the shock absorber assembly is damage. Replace it if damage found and can not be repaired. Tighten all nuts and bolts.

Rear Shock Absorber

Park the scooter with its main stand. Shake the rear wheel side to side to check engine suspension bushing for wear. Replace the bushing if looseness found. Check the shock absorber for damage. Tighten all nuts and bolts.

Nuts, Bolts Tightness

Check if all bolts and nuts on the frame are tightened to specified torque in accord with the interval of Periodical Maintenance Schedule. Check all split pins, snap rings, hose clamps, and wire holders for security.

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2. SERVICE MAINTENANCE INFORMATION

Transmission Oil

Leak

Check if the transmission is leak.

Check

Caution

Park the scooter on flat ground with its main stand.

Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt.

Replacement

Remove the oil level check bolt.

Remove the oil draining bolt, and then drain oil out. Install the oil draining bolt.

Tighten torque: 1.3 kgf-m

Caution

Check if oil seal and washer is in good condition.

Replacement Quantity: 0.09 L (90 cc) Recommended oil: King Bramax HYPOID GEAR OIL #140

Spark Plug

Oil level check bolt

Draining bolt

Oil level check bolt hole

Recommended plug: NGK BR8HSA

z Remove the luggage box. z Remove the spark plug cap. z Clean any dirt on the spark plug seat. z Remove the spark plug. z Visually inspect the spark plug electrodes for

wear.

z The center electrode should have square

edges and side electrode should have a constant thickness. Replace the spark plug if there is apparent wear or if the insulator is cracked and/or chipped. If the spark plug deposits can be removed by sandpaper, the spark plug can be reused.

z Measure the spark plug gap with feeler

gauge.

Spark plug gap: 0.6-0.7mm (0.024-0.028in)

z Adjust the gap by careful bending the side

electrode.

z Install the spark plug by screwing it with

hands after installed the spark plug washer so that can prevent the plug from out of thread. Then, tighten the spark plug with a spark plug wrench.

z Install the spark plug cap.

0.6~0.7mm

Center electrode

Side electrode

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2. SERVICE MAINTENANCE INFORMATION

Control Cable Lubrication

Remove the throttle control and the brake cables periodically, and lubricate the moving parts of the cables thoroughly.

Driver Belt

z Remove left crankcase cover. z Check if the belt is crack or worn out.

Replace the belt if necessary.

z Measure the driving belt width

Allowable limit: 16.5mm

Ignition Timing

Caution

z C.D.I ignition timing can not be adjusted. If

the ignition timing is incorrect, check the C.D.I. device and the alternator and replace damaged components.

z Check ignition timing with standard

instrument.

Remove the right-side cooling fan cover. Check ignition timing with the timing light. When engine speed setting to 1800 rpm, and if the mark aligns with “F” mark, then it means that the ignition timing is correct.

Tooth face

Belt width

Ignition lamp

“F” mark

Throttle Valve Operation

Check if each steering positions are operated in smooth, and handle bar if its operation is smooth as the throttle valve wide opening or fully closed. Check throttle cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth Measure throttle valve handle free play.

Free play：2~6 mm (1/8-1/4 in)

Loosen the mounting nut, and turn the free play adjustment nut of the throttle valve handle for adjustment. Replace the cable if it can not be adjusted.

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2. SERVICE MAINTENANCE INFORMATION

Carburetor Idle Speed Adjustment

Caution

z Inspection & adjustment for idle speed have

to be performed after all parts in engine had been adjusted in specification.

z Idle speed check and adjustment have to be

done after engine is being warn up. It around operates engine from stop to running for 10 minutes.

Remove the body cover. Park the scooter with main stand after warned up engine. According to the required idling and air screw to adjust to specified idle speed.

Idle speed: 2000±100 rpm

Carbon Removing For Exhaust Pipe & Muffle

Remove the body cover. Remove the exhaust pipe & muffler. Clean the carbon deposits on the muffler & cylinder exhaust edge.

Pilot screw

Idle speed adjustment screw

Adjust the idling after warn up engine for 10 minutes.

1. Connect tachometer.

2. Adjust the idle speed screw to let engine speed in 2000±100 rpm.

3. Insert the sampling pipe of the CO/HC meter to the test hole on the front end of exhaust pipe. Adjust the idling emission value to standard range. (CO: 1.8-2.6%)

4. Slightly accelerate the throttle valve and release it. Repeat this operation for 1-2 times.

5. Read the engine idle speed and the emission value after engine speed in stable. Repeat the operation on step No. 2 – No. 4. until these value within standard range.

Compression pressure gauge

Cylinder Compression Pressure Test

Remove the left body cover, and warn up engine. Stop the engine and remove the spark plug. Insert the compression gauge and wide open the throttle, and then rotate the engine by means of the starting motor.

Compression pressure: 7.0±1 kg/cm

Probable causes for low compression pressure.

z Damaged cylinder head gasket. z Worn piston ring z Worn cylinder

Probable causes for high compression pressure.

z Carbon on the combustion chamber or cylinder

head

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2. SERVICE MAINTENANCE INFORMATION

Headlight Adjustment

Loosen headlight mounting bolt. Move the headlight for adjustment its light beam. Tighten the headlight mounting bolt after adjusted.

Caution

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

Headlight mounting bolt

2-14

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Contents

3. LUBRICATION SYSTEM

Lubrication System Diagram············3-1 Precautions In Operation··················3-2 Lubricant············································3-2 Trouble Shooting·······························3-2

Lubrication System Diagram

Oil Pump Removal ····························3-3 Oil Pump Installation ························3-3 Oil Pump/Oil Tube Air Bleeding·······3-4 Oil Tank··············································3-5

Oil tank

Oil output tube

Oil lever switch

Oil tube

Oil pump

3-1

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3. LUBRICATION SYSTEM

Precautions In Operation

z Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump. z If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be

conducted air-bleeding operation.

z It should bleed the oil output tube (from oil pump to carburetor) as hose removed. z The adjustment of oil pump control cable.

Lubricant

z Appointed to apply SAE 20 JASO FC class oil. Otherwise, warranty shall not cover the damage. z Recommended Oil: MAX-2 oil. z Oil tank capacity: 1.2 lit.

Trouble Shooting

Too much smoke, carbon in spark plug.

1. Improperly oil pump adjustment (too much oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Over heat

1. Improperly oil pump adjustment (insufficient oil).

2. Poor quality oil.

3. Applying with poor quality oil.

Piston seized

1. No oil in oil tank or clogged hose.

2. Improperly oil pump adjustment (insufficient oil).

3. Air in oil hose.

4. Malfunction of oil pump.

Oil did not flow out the oil tank

1. Clogged breath hole on the oil tank cover.

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3. LUBRICATION SYSTEM

Oil Pump Removal

Caution

Before removing the oil pump, clean the oil pump and crankcase.

Remove the luggage box and seat. Loosen the mounting nut of the oil pump control cable, and remove the control cable. Remove the oil tube, and clip its end side to prevent oil from flowing out.

Remove the oil output tube form intake manifold. Remove the oil pump mounting bolt, and then take out the oil pump.

Inspection

Inspect the following items on the removed oil pump.

z Check if O-ring is damaged or softening. z Check if crankcase interface is damaged. z Check if pump body is damaged. z Check if pump gear is damaged. z Check for oil leaking.

Oil output tube

Control cable

Mounting nut

Oil tube

Adjustment nut

Mounting bolt

Caution

The oil pump can not be disassembled.

Oil Pump Installation

Install the oil pump onto the crankcase.

Caution

z Apply with some grease onto oil pump

O-ring.

z The connection between both oil pump and

crankcase has to be installed in position security.

Tighten the oil pump mounting bolt security. Install the oil tube. Installation in the reverse order of removal.

Caution

Inspection and adjustment following items as installed. The adjustment operation of control cable. Air bleeding operation of oil pump. Air bleeding operation of oil tube. Check each section for leaking.

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3. LUBRICATION SYSTEM

Oil Pump/Oil Tube Air Bleeding

Caution

The oil tube system has to be conducted air bleeding operation because air will clog or restraint oil flowing so that cause serious engine damage.

Caution

After disconnect the oil tube, air enters oil tube due to oil leak out without added oil. There is why the oil tube and oil pump have to conduct air bleeding operation.

Oil Tube/Oil Pump

z It has to add some oil into the oil tank. z Place a piece of dry cloth around the oil pump. z Disconnect the oil tube. z Fill out oil to oil pump connection section by

means of the oil pot so that the oil pump body is full with oil.

z Fill out oil to oil tube connection section so

that the oil tube is full with oil. Then, install the tube onto oil pump.

z Make sure whether air is in the oil tube or not

after installation. Caution

After bleeding the oil tube and oil pump, the oil tube has to be conducted air bleeding operation too.

Oil Tube Air Bleeding

Remove the oil output tube and plug its input connector. Bend the oil tube into “U “shape, and fill out new oil into the output tube. Connect the oil output tube to the oil pump connection part. Start engine, and run it in idling as the oil control lever in wide open position. Make sure oil flows out from the oil output tube.

Oil output tube

Oil tube

Control cable

Recommended oil

Caution

z Motorcycle’s exhaust gas includes with CO

which causes human to coma or death so perform this operation in well-ventilation place.

z Run the engine in extreme low speed to

avoid to damaging the engine caused from clogged oil tube.

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3. LUBRICATION SYSTEM

Oil Tank

Removal/Installation

Remove the battery and oil tank cap. Remove the luggage box and seat.

Remove the oil input tube from oil pump, and then drain oil to a clean container.

Remove the oil level switch wire of the oil indicator. Remove the mounting bolt on the oil tank upper side, and then remove the oil tank. Installation in the reverse order of removal. Air bleeding the oil tubes after installed.

Oil tank cap

Battery

Oil tube

Blot

Oil level switch

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3. LUBRICATION SYSTEM

Notes:

3-6

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4. ENGINE REMOVAL

Maintenance Information····················4-2 Engine removal····································4-3

Engine installation······························ 4-5

4.0kgf-m

3.3kgf-m

1.2kgf-m

6.0kgf-m

4-1

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4. ENGINE REMOVAL

Maintenance Information

There are parts that require removal of engine for maintenance.

y Crankcase y Crankshaft

Related bolts tightening torque for removal of engine: Engine hanger bolt 5.0kgf-m Engine bracket bolt 6.0kgf-m Rear shock absorber upper mounting bolts 4.0kgf-m Rear shock absorber lower mounting bolts 2.7kgf-m Exhaust pipe connection nut 1.2kgf-m Muffle mounting bolt 3.3kgf-m

4-2

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4. ENGINE REMOVAL

Engine removal

Remove body cover. Remove the spark plug cap from the spark plug section.

Remove the fuel output and the vacuum tubes from fuel pump. Remove the oil control cable from oil pump. Remove the oil tube from oil pump and then clip the tube.

Remove the wire connectors of auto by starter and AC.G .

Remove the upper parts and cable of the carburetor from its upper side. Remove the vapor emission vacuum tube from carburetor intake manifold.

Spark plug cap

Oil control cable Oil tube

Fuel output tube

Fuel pum

acuum tube

Wire connector

Upper parts

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4. ENGINE REMOVAL

Remove rear brake cable from engine rear-lower side.

Remove air cleaner mounting bolts. (2 bolts)

Support the engine and then remove shock absorber lower mounting bolt.

Remove two exhaust pipe connection nuts. Remove two bolts beside fan cover and exhaust pipe.

Brake cable

Mountingbolt

Shock absorber lower

Connection nut

4-4

Exhaust pipe

Bolt

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4. ENGINE REMOVAL

Remove engine mounting nut and bolt.

Engine installation

Install in the reverse order of removal procedures. Tighten the engine mounting and rear shock absorber upper/lower bolts.

Torque value:

Engine mounting bolt

Engine hanger bolt: Rear shock absorber upper

mounting bolts: Rear shock absorber lower

mounting bolts: Exhaust pipe connection nut: Muffle mounting bolt:

5.0kgf-m

4.0kgf-m

2.7kgf-m

1.2kgf-m

3.3kgf-m

Perform the following inspection and adjustment after installation.

y Check if control cable is correct. y Check if throttle valve cable is correct. y Check if oil pump control cable is correct. y Oil input and output of the oil pump. y Adjust rear brake.

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4. ENGINE REMOVAL

Note:

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5. CYLINDER HEAD/CYLINDER/PISTON

Maintenance Information···················5-2 Troubleshooting·································5-2

Cylinder Head·····································5-3 Cylinder/Piston···································5-5

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5. CYLINDER HEAD/CYLINDER/PISTON

Maintenance Information

Precautions in Operation

y The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine

mounted on the body.

y It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. y Remove all washes from the interfaces of cylinder head, cylinder and crankcase. y Be careful do not damage cylinder head, cylinder and piston when removing. y Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces before

installation.

Specification

Item

Cylinder head Deformation - 0.100

Piston OD 39.030~39.045 38.935 Clearance between cylinder and piston 0.040~0.050 0.100 Piston pin hole 12.002~12.008 12.030

Piston

Cylinder

ID: inner diameter OD: outer diameter

Piston pin OD 11.994~12.000 11.970 Clearance between piston and piston pin 0.002~0.014 0.030 Piston ring end gap 0.100~0.250 0.400 ID of connecting rod small end 17.05~17.015 17.025 ID 39.000~39.015 39.050 Deformation - 0.100

Standard value (mm) Limit (mm)

Tighten torque value

Cylinder head 1.0kgf-m Spark plug 1.4kgf-m

Exhaust pipe connection nut 1.2kgf-m Exhaust muffler mounting bolt 3.3kgf-m

FT05 series

Troubleshooting

Compression Pressure Too Low/Difficult To Start/Rough Idling

1. Cylinder head gasket leaking

2. Spark plug not tighten enough

3. Worn, seized or crack piston ring

4. Damaged, worn cylinder or piston

5. Poor reed

Compression Pressure Too High/Overheat/Knock

1. Too much carbon deposit built up in combustion chamber

5-2

Piston Noise

1. cylinder and piston worn out

2. piston pin or piston pin hole worn out

3. connecting rod small end bearing worn out

Piston Ring Noise

1. Worn, seized or crack piston ring

2. Cylinder worn out or damaged

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5. CYLINDER HEAD/CYLINDER/PISTON

Cylinder Head

Cylinder Removal

Removal body covers. Remove spark plug cap. Remove fan cover. Remove engine shield.

Remove two connection nuts of the exhaust pipe. Remove exhaust muffle mounting bolt, and then remove the exhaust pipe.

Cylinder Head Removal

Remove the 4 cylinder head bolts and then remove the cylinder head.

Muffle

Tightening bolts

Bolt x 2

Tightening bolt

Engine shield

Tightening bolt x 2

Caution

Loosen the cylinder head bolts with diagonal direction to avoid to damaging it.

Cleaning Carbon in Combustion Chamber

Clean carbon deposit in which built up in combustion chamber with shown chisel.

Caution

Do not scratch to the interfaces of combustion chamber and cylinder.

Chisel

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5. CYLINDER HEAD/CYLINDER/PISTON

Cylinder Head Inspection

Use a straight edge and a feeler gauge to measure the cylinder head for warp.

Service limit: 0.10 mm

Cylinder Head Installation

Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder. Tighten the 4 bolts with diagonal direction and by 2-3 sequences.

Tighten torque: 1.0kgf-m

Install spark plug

Tighten torque: 1.4kgf-m

Replace the exhaust pipe washer with new one and then install exhaust pipe. Tighten exhaust pipe connection nut.

Tighten torque: 1.2kgf-m

Tighten exhaust pipe mounting bolt.

Tighten torque: 3.3kgf-m

Install the removed parts in the reverse order of removal procedures. Inspect following item after installation. Compression pressure test. Check for engine noise.

Tightening bolts

Muffle

Bolt x 2

Tightening bolt x 2

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5. CYLINDER HEAD/CYLINDER/PISTON

Cylinder/Piston

Cylinder Removal

Be careful to pull the cylinder up and prevent piston from damage.

Caution

Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously.

Piston Removal

Place a clean rag onto crankshaft to cover the piston. Remove piston pin clip (one piece) and then push piston pin out the piston.

Piston

Caution

y Do not damage or scratch the piston. y Do not apply with lateral force to connecting

rod.

y Do not let piston pin snap ring falling into

crankcase.

Piston Ring Removal

Caution

Pry out the opening end of each piston ring and then remove the ring from piston.

Check if cylinder and piston are worn or damaged, and then clean carbon deposit on exhaust opening area as the diagram shown.

Piston pin clip

Piston pin

Caution

Do not scratch both the cylinder and the piston.

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5. CYLINDER HEAD/CYLINDER/PISTON

Use a straight edge and a feeler gauge to measure the cylinder head for warp.

Service limit: 0.10 mm

In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure. With the max. value to decide cylinder wear out condition.

Service limit : 39.05mm

Measure the OD of piston at the 7 mm from the bottom of the piston.

Service limit : 38.935 mm

Calculate the clearance between piston and cylinder.

Service limit: 0.100 mm

Measure the ID of piston pin hole.

Service limit : 12.030mm

Measure the OD of piston pin.

Service limit : 11.970 mm

7mm

The ID of piston pin hole

The OD of piston pin

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5. CYLINDER HEAD/CYLINDER/PISTON

Piston Ring Inspection

Measure the end gap of each piston ring.

Service limit: 0.40 mm

Caution

With the piston, push each piston ring into cylinder correctly.

Connecting Rod Inspection

Install bearing and piston pin onto connecting rod small end, and then check its clearance. Measure the ID of connecting rod small end.

Service limit: 17.025mm

Piston/Cylinder Installation

Install the expanding ring into the groove of 2nd ring. Align the ring end with the lock pin in the ring groove. Install the top ring and the 2 groove respective.

ring onto the ring

Clearance

Top ring

2nd ring

Piston ring mark

Caution

The top ring and the 2nd ring can not be changeable each other.

Push the rings into ring groove and then check rings’ mating condition. If ring could not be push in the ring groove, it means that ring groove is dirty or wrong ring groove installation.

Caution

y All rings should be installed with the marks

facing up.

y All rings should be replaced at same time,

and it can not be replaced one ring only.

y It should use same brand name piston ring in

an engine and can not mix with other one.

1T: top ring

2T: 2

ring

Expanding

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5. CYLINDER HEAD/CYLINDER/PISTON

Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase. Apply with two-stroke engine oil onto needle bearing and piston pin, and then install the piston pin onto connecting rod. Install piston, and place “EX” mark of the piston toward to exhaust side. Install new piston pin snap ring.

Clean all gaskets onto the interfaces of cylinder and crankcase. Place a new gasket onto the crankcase. Make sure that the piston ring aligns with the lock pin in piston ring groove.

Piston

〝EX〞mark

Piston pin

Piston pin snap ring

Caution

Make sure that all rings in the piston ring groove can not be rotated around the lock pin to avoid to damaging the rings, piston and cylinder.

Lubricate cylinder and piston with two-stroke engine oil. Hold the piston and then install it into cylinder.

Caution

To avoid to damaging the piston and the cylinder sliding surface.

Install the cylinder head.

Lock pin

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6. ALTERNATOR

Maintenance Information ··········6-2

Alternator Removal ···················6-3

3.8kgf-m

Alternator Installation ··············· 6-4

6-1

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6. ALTERNATOR

Maintenance Information

Precautions in Operation

y The maintenance service of A.C. alternator can be carried out directly on the scooter. y Please refer to Chapter 15 for the relative alternator inspection.

Torque value:

Flywheel 3.8kgf-m

Tool

General tool

Rotor puller Universal holder

Coil resistance value for the A.C. alternator

Y/L Y W R/B Earth

Earth 50~200Ω 0.2~0.8Ω 0.2~1.0Ω 400~800Ω

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6. ALTERNATOR

Alternator Removal

Remove the body cover. Remove two bolts and then take out cooling fan cover.

Remove four bolts, and then take out the cooling fan.

Hold flywheel with universal holder. Support the flywheel and the remove the 10 mm nut on the flywheel.

Remove the flywheel with rotor puller.

Cooling fan cover

10mm flanged nut

Bolt

Cooling fan

Universal holder

Rotor puller

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6. ALTERNATOR

Disconnect alternator wire connector and pulse generator connector.

Remove the pulse generator and alternator four (4) bolts, and then take out the alternator assembly.

Caution

Care to be taken for not damaging the alternator coil.

Wire harness connector

Universal holder

Alternator Installation

Install the alternator assembly. Connect the alternator connector.

Caution

Connect the alternator wire harness properly and then clip the harness with clipper.

Install the woodruff key onto the crankshaft groove.

Caution

y Clean dirt and metal pieces inside the

flywheel.

y Make sure that there is no foreign material

inside the flywheel.

Install the flywheel

Tighten the flywheel 10 mm nut.

Torque value: 3.8kgf-m

Install the removed parts in reverse order of removal procedures. Start engine and check its ignition timing.

10mm flanged nut

6-4

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Contents

7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Maintenance Information·················7-2 Trouble Shooting······························7-2 Left Crankcase Cover ······················7-3 Reassembly of Kick Starter·············7-4 Installation of the Left Crankcase Cover

···························································7-4

Drive Belt···········································7-5 Movable Driven Pulley······················7-6 Clutch/Driven Pulley·························7-10

3.8kgf-m

5.5kgf-m

3.8kgf-m

7-1

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Maintenance Information

Precautions in Operation

The surfaces of drive belt and driven pulley must be free of grease.

Specification

Item Standard value(mm) Limit(mm) Driving belt width ID of movable driving pulley OD of movable driving pulley boss OD of weight roller ID of clutch outer Thickness of clutch weight Free length of driven pulley spring OD of driven pulley ID of movable driven pulley

ID: Inner Diameter OD: Outer diameter

Torque Values:

Movable drive face: 3.8kgf-m Driven pulley: 5.5kgf-m Clutch outer: 3.8kgf-m

Trouble Shooting

18.0 16.5

20.035~20.085 20.120

20.010~20.025 19.98

15.92~16.08 15.40

107.0~107.2 107.5

4.0~4.1 2.0

98.1 92.7

33.965~33.985 33.94

34.000~34.025 34.06

Special Service Tools

Clutch spring compressor Bearing driver Clutch nut wrench 39x41 mm Bearing driver accessory 39x41 mm Universal holder Driver

Engine can be started but motorcycle can not be moved

1. Worn drive Belt

2. Worn ramp plate

3. Worn or damaged clutch weight

4. Broken driven pulley spring

Shudder or misfire when drive

1. Broken clutch weight

2. Worn clutch weight

7-2

Insufficient horsepower or poor high speed performance

1. Worn drive belt

2. Insufficient spring capacity of driven pulley

3. Worn weight roller

4. Driven pulley operation un-smoothly

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Left Crankcase Cover

Left crankcase cover removal

Remove left body side cover. Remove air cleaner. Remove kick start arm. Remove left crankcase cover.

Disassembly of Kick Starter

Remove snap clip and thrust washer from left crankcase cover. Install kick start arm, rotate the lever slightly and then remove driven gear and washer. Remove the kick starter arm, kick starter spindle, and return spring as well as socket.

Left crankcase cover

Kick start arm

Return spring

Starter spindle

Driven gear

Inspection of kick Starter

Check if starter spindle, driven gear for wear or damage.

Return spring

Bush

Bolt

Kick start arm

Snap ring

Thrust washer

Starter spindle

Driven gear

Friction spring

7-3

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Reassembly of Kick Starter

Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle. Install the friction spring of drive gear onto convex part of the cover.

Installation of the Left Crankcase Cover

Return spring

Dowel pin

Width-tooth

Convex part

Kick starter spindle

Driven gear

Friction spring

Install the dowel pin and gasket. Install the left crankcase cover.

Install kick start arm.

7-4

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Drive Belt

Removal

Remove left crankcase cover. Hold clutch outer with universal holder, and remove nut and clutch outer.

Caution

y Using special tools for tightening or

loosening the nut.

y Fixed rear wheel or rear brake will damage

reduction gear system.

Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley/clutch. Do not remove drive belt. Remove the drive belt from the groove of driven pulley.

Inspection

Check the drive belt for crack or wear. Replace it if necessary. Measure the width of drive belt as diagram shown.

Service Limit: 16.5 mm

Replace the belt if exceeds the service limit.

Nut

Universal holder

Clutch/drive belt

Belt tooth

Caution

y Using the genuine parts for replacement y The surfaces of drive belt or pulley must be

free of grease.

y Clean up all grease or dirt before installation.

Installation

Caution

y Pull out driven pulley to avoid it closing.

Install drive belt onto driven pulley.

Movable driven pulley

7-5

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Install the driven pulley that has installed the belt onto drive shaft.

Install the clutch with universal holder, and then tighten nut to specified torque value.

Torque value: 3.8kgf-m

Movable Drive Face

Drive face

Clutch/driven pulley

Nut

Drive belt

Universal holder

Drive shaft

Clutch outer

Removal

Remove left crankcase cover. Hold generator flywheel with universal holder, and then remove drive face nut.

Remove drive face.

Flywheel

Nut

7-6

Drive face

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Removal

Remove movable drive face set and drive belt from crankshaft.

Remove ramp plate.

Remove weight rollers from movable face.

Inspection

The weight roller is to press movable driven face by means of centrifuge force. Thus, if weight rollers are worn out or damage, the centrifuge force will be affected. Check if rollers are wear out or damage. Replace it if necessary. Measure each roller’s outer diameter. Replace it if exceed the service limit.

Service limit: 15.40 mm

Drive face boss

Crankshaft

Movable drive face

Weight roller

Movable drive face

Ramp plate

Weight roller

7-7

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Check if movable drive face boss is worn or damage and replace it if necessary. Measure the outer diameter of drive face boss, and replace it if it exceed service limit.

Service limit: 19.98 mm

Measure the inner diameter of drive face, and replace it if it exceed service limit.

Service limit: 20.120 mm

Reassembly / Installation

Install weight rollers.

Install ramp plate.

Apply with grease 4~5g to inside of movable drive face, and install drive face boss.

Movable drive face

Drive face boss

Weight roller

Ramp plate

Drive face

Caution

y The drive face has to be free of grease.

Clean it with cleaning solvent.

7-8

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Install movable drive face assembly onto crankshaft.

Drive Face Installation

Press drive belt into pulley groove, and then pull the belt on to crank shaft.

Install drive face, washer and nut.

Caution

Drive face boss

Crankshaft

Press down

Movable drive face

Drive belt

Universal holder

y Make sure that two sides of drive face have

to be free of grease. Clean it with cleaning solvent.

Hold flywheel with universal holder.

Tighten nut to specified torque.

Torque value: 3.8kgf-m

Install left crankcase cover.

Flywheel

Drive face

Nut

7-9

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Clutch/Driven Pulley

Disassembly

Remove drive belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily.

Caution

y Do not press the compressor too much.

Hold the clutch spring compressor onto bench vise, and then remove mounting nut with clutch nut wrench. Release the clutch spring compressor and remove clutch and spring from driven pulley. Remove socket from sliding pulley.

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

Sliding pulley

O-ring

Oil seal

Clutch nut wrench

Clutch spring compressor

Socket

Guide pin

Guide pin roller

Inspection Clutch outer

Measure the inner diameter of clutch outer friction face. Replace clutch outer if exceed service limit.

Service limit: 107.5 mm

7-10

Inner diameter

Clutch outer

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Clutch weight

Measure each clutch weight thickness. Replace it if exceeds service limit.

Service limit: 2.0 mm

Driven pulley spring

Measure the length of driven pulley spring. Replace it if exceeds service limit.

Service limit: 92.7 mm

Clutch weight

Free length

Driven pulley

Check following items:

y If both surfaces are damage or wear. y If guide pin groove is damage or wear.

Replace damaged or worn components. Measure the outer diameter of driven pulley and the inner diameter of sliding pulley. Replace it if exceeds service limit.

Service limit: Outer diameter 33.94 mm

Inner diameter 34.06 mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage. Replace it if necessary. Check if needle bearing is damage or too big clearance. Replace it if necessary. Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary.

Driven pulley

Sliding pulley

Guide pin groove

Needle bearing

Caution

y Some of models are equipped with two ball

bearings.

Outer ball bearing

7-11

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Clutch Block Replacement

Remove clip and washer, and then remove clutch weight and spring from drive plate.

Caution

y Some of models are equipped with one

mounting plate instead of 3 snap clips.

Check if spring is damage or insufficient elasticity.

Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto lock pins.

Install new clutch weight onto lock pin and then push to specific location. Apply with grease onto lock pins. But, the clutch weight should not be greased. If so, replace it.

Clutch weight

Shock absorption rubber

Spring

Drive plate

Snap clip

Caution

y Grease or lubricant will damage the clutch

weight and affect the weight’s connection capacity.

Install the spring into groove with pliers.

7-12

Clutch block

Spring

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Install snap clip and mounting plate onto lock pin.

Replacement of Driven Pulley Bearing

Remove inner bearing.

Caution

y If the inner bearing equipped with oil seal on

side in the driven pulley, then remove the oil seal firstly.

y If the pulley equipped with ball bearing, it

has to remove snap clip and then the bearing.

Remove snap clip and then push bearing forward to other side of inner bearing.

Place new bearing onto proper position and its sealing end should be forwarded to outside. Apply with specified grease.

Install new inner bearing.

Caution

Outer bearing

Snap clip

Inner needle bearing

Sealing end

Inner bearing

Snap clip

Clip

Inner ball bearing

Specified grease

Snap ring

Outer bearing

Sealing end

y Its sealing end should be forwarded to

outside as bearing installation.

y Install needle bearing with hydraulic presser.

Install ball bearing by means of hydraulic presser or driver.

Install snap clip into the groove of drive face. Align oil seal lip with bearing, and then install the new oil seal (if necessary).

7-13

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7. “V” TYPE BELT DRIVE SYSTEM/KICK-STARTER

Installation of Clutch/Driven Pulley Assembly

Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley.

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

Install socket.

Install driven pulley, spring and clutch into clutch spring compressor, and press down the assembly by turning manual lever until mounting nut that can be installed. Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench. Remove the clutch spring compressor.

Torque value: 5.0~6.0kgf-m

Install clutch/driven pulley and drive belt onto drive shaft.

Oil seal

O-ring

Sliding pulley

O-ring

Mounting nut

Oil seal

Guide pin

Specified grease

Guide pin

Guide pin roller

Socket

Clutch nut wrench

Clutch spring compressor

7-14

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Contents

8. FINAL DRIVING MECHANISM

Maintenance Information ·················8-2 Troubleshooting ·······························8-2 Disassembly of Final Driving Mechanism

····························································8-3

Inspection of Final Driving Mechanism

····························································8-4 Bearing Replacement·······················8-4 Re-Assembly of Final Driving

Mechanism········································8-4

8-1

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8. FINAL DRIVING MECHANISM

Maintenance Information

Limited usage of gear oil：gear oil #140 Recommended oil：Bramax serial oil. Oil quantity：100 c.c. (90 c.c. as replacement)

Special tools:

Inner type bearing puller (SYM-6204020) Outer type bearing puller (SYM-6204010) Final shaft oil seal installer (SYM-9125500) Drive shaft oil seal installer (SYM-9120200) Bearing driver 6204 (SYM-9110400) Bearing driver 6201 (SYM-9610001) Bearing driver 6203/6004UZ (SYM-9620000) L. crank puller (SYM-1130000-L) L. crank shaft install bush (SYM-1130010)

Troubleshooting

Trouble Diagnosis Engine can be started but scooter can not be moved.

1. Damaged drive gear

2. Burnt out or seized drive gear

Noise

1. Seized, worn or damage gear

2. Worn or loose bearing

Gear oil leaks

1. Excessive gear oil.

2. Worn or damage oil seal

8-2

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8. FINAL DRIVING MECHANISM

Disassembly of Final Driving Mechanism

Remove driven pulley Drain gear oil out from gearbox. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side.

Remove final gear, final shaft and counter gear, counter shaft.

Remove the drive shaft from left crankcase.

Final gear & shaft

Oil filling hole

Oil draining hole

Counter gear & shaft

Drive shaft

Caution

y The bearing must be replaced when

removing the drive shaft.

Remove drive shaft oil seal and bearing from left crankcase.

Oil seal

Bearing

8-3

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8. FINAL DRIVING MECHANISM

Inspection of Final Driving Mechanism

Check if the drive shaft, counter shaft and final gear shaft are worn or damage. Check if the gear box cover bearing, oil seal and the inner diameter of counter shaft are worn or damage. Check if the left crankcase cover bearing, oil seal and the inner diameter of countershaft are worn or damage.

Bearing Replacement

Caution

y Never install used bearings. Once bearing

removed, it has to be replaced with new one.

Remove gear box bearing from left crankcase and gear box cover using following tools:

Final driven gear & shaft

Countershaft

Drive shaft

Special tool:

Inner type bearing puller

Re-Assembly of Final Driving Mechanism

Re-assemble the gearbox cover and left crankcase with special tools:

Special tool: Gear Box Cover

Final shaft bearing: Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) Final shaft oil seal installer (SYM-9125500)

Left Crankcase

Drive shaft bearing: Bearing driver 6203/6004UZ (SYM-9620000) Bearing driver 6201 (SYM-9610001) L. crank puller (SYM-1130000-L) L. crank shaft install bush (SYM-1130010) Drive shaft oil seal installer (SYM-9120200) With the special service tools to install drive shaft by through the bearing. Install a new drive shaft oil seal. Install a new final shaft oil seal.

Driver

Punch guide

Adapter

Drive shaft

8-4

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8. FINAL DRIVING MECHANISM

Install countershaft, final driven gear and thrust washer.

Install new gasket and lock pin.

Final driven gear & shaft

Counter gear & shaft

Install gearbox cover. Install clutch/driven pulley assembly. Install driven pulley, drive belt, and left crankcase side cover. Install body cover. Install rear wheel. Fill out specified oil quantity into gearbox.

8-5

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8. FINAL DRIVING MECHANISM Notes:

8-6

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9. CRANKCASE/CRANKSHAFT

Maintenance Information··················· 9-2 Troubleshooting·································9-2 Crankcase Disassembly ····················9-3

1.0kgf-m

Crankshaft Removal·····························9-3 Crankshaft Inspection··························9-4 Crankcase Installation ·························9-5

Apply liquid gasket

9-1

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9. CRANKCASE/CRANKSHAFT

Maintenance Information

y This chapter concerns disassembly of the crankcase for repair purpose. y Before disassembling crankcase, except removing engine firstly, following components must be

removed too.

• Carburetor (chapter 10)

• Oil pump (chapter 3)

• Reed valve (chapter 10)

• Driving belt (chapter 7)

• Alternator (chapter 6)

• Cylinder head/cylinder/piston (chapter 5)

y Except above components are needed be removed, when disassembling L crankcase, following

components must be removed too.

• Final driving mechanism (chapter 8)

y When assembling both crankcase and crankshaft, it has press the inner ring edge of the crankshaft

bearing to push the crankshaft into the crankcase hole by using the specified service tools. The old bearing onto the crankshaft has to be removed. Then install a new bearing onto the crankshaft on the crankcase side. Oil seal has to be replaced with new one after assembled the crankcase.

Item Standard Limit (mm) Lateral clearance of the big end of the connecting rod Radial clearance of the big end of the connecting rod Crankshaft run-out point A Crankshaft run-out point B

─ ─ ─ ─

0.60

0.04

0.10

Special Tools

Crankcase disassemble tool (SYM-1120100-G5) Outer bearing puller (SYM-6204010) R. Crank shaft puller (SYM-1130000-R) R. Crank shaft install bush (SYM-1130020) L. Crank shaft puller (SYM-1130000-L) L. Crank shaft install bush (SYM-1130010) 20*32*6 Oil seal driver (SYM-9120200) Bearing driver 6204 (SYM-9110400)

Troubleshooting

Engine noise

1. Worn bearing of connecting rod bog end

2. Bend connecting rod

3. Worn crankshaft bearing

9-2

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9. CRANKCASE/CRANKSHAFT

Crankcase Disassembly

Remove the crankcase bolts.

Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the diagram shown. Disassemble the right crankcase.

Crankshaft Removal

As the diagram show with 3 special bolts to install the crankcase puller onto the left crankcase. Remove the crankcase.

Right crankcase

Bolts

Crankcase puller

Caution

Do not use iron hammer to knock out the crankshaft.

Remove crankshaft bearing with outer bearing puller. Remove the right and left side oil seals.

Caution

Replace the oil seal with new one as removing the crankshaft.

Special bolts

Shaft protection collar

Outer bearing puller

9-3

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9. CRANKCASE/CRANKSHAFT

Crankshaft Inspection

Measure the clearance of connecting rod big end.

Service limit: 0.60 mm

Measure the radial clearance of connecting rod big end at X-Y directions as diagram show.

Service limit: 0.04 mm

Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge.

Service limit: A: 0.10 mm

B: 0.10 mm

Check the crankshaft bearing by means of turning it with hand. If any noise and bigger clearance are detected, replace the bearing with new one.

37mm

70mm

Clearance

9-4

Lateral

Radial

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9. CRANKCASE/CRANKSHAFT

Crankcase Installation

Clean the crankshaft with solvent and blow it with compressed air. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase.

Caution

y All rotation and sliding surfaces have to be

applied with clean engine oil.

y Remove all gaskets onto the crankcase

interfaces and flat it with special tool.

Install new bearing into left crankcase.

Install crankshaft onto the left crankcase. Install left crankshaft puller and install bush onto crankshaft. Screw the left crankshaft puller onto crankshaft. Turn the puller in C.W. direction and then completely screw the puller to bottom. Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Apply liquid gasket and dowel pin onto the interface of left crankcase.

Bearing driver 6204

L. Crank shaft puller

Collar

L. Crank shaft install bush

Apply liquid gasket

Dowel pin

9-5

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9. CRANKCASE/CRANKSHAFT

Assemble the right crankcase with assembly tools. Install right crankcase onto the crankshaft. Install right crankshaft puller and install bush onto crankshaft. Screw the right crankshaft puller onto crankshaft. Turn the puller in C.W. direction and then completely screw the puller to bottom. Lubricate crankshaft bearing and bearing seat with 2-stroke engine oil.

Install the bolts and tighten them.

Torque value: 1.0kgf-m

With right crank shaft install bush, install new oil seal into the right crankcase. Its installation depth is 4mm as the diagram shown.

With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown.

R. Crank shaft puller

R. Crank shaft install bush

Bolts

R. Crank shaft install bush

Oil seal

Caution

Make sure that the crankshaft can be rotated freely after tightening the bolts.

Install the following components: ~ Final driving mechanism (chapter 8) ~ Alternator (chapter 6) ~ Piston/cylinder/cylinder head (chapter 7) ~ Oil pump (chapter 3) ~ Reed valve and carburetor (chapter 10) ~ Engine (chapter 4)

9-6

Oil seal driver

Home page Contents

10. FUEL SYSTEM

Maintenance Information··················10-2 Troubleshooting································10-2 Throttle Valve ····································10-3 Carburetor Remove···························10-4 Auto By-Starter··································10-4 Float/Float Valve/Jet ·························10-6

Vacuum hose

Flaot Level Inspection······················10-7 Carburetor Installation ·····················10-7 Reed Valve·········································10-7 Fuel Pump ·········································10-8 Air Cleaner·········································10-9

Throttle valve cable

Air hose

Oil tube

Fuel unit

Fuel pump

Carburetor

Vacuum tube

Fuel filter

Fuel tank

10-1

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10. FUEL SYSTEM

Maintenance Information

Precautions in Operations

Warning

Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline.

y Care must be taken when dealing with gasoline, and always work in a well-ventilated place and

strictly prohibit flame.

y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as

re-assembly

y It has to conduct air bleeding operation as removed the oil tube. y Idle speed adjustment.

Specification

Item DD 50 Venturi diameter 14 mm Fuel level

Air screw opener 1 3/8 Idle speed

Throttle handle free play 2~6 mm I.D. number PB2BE Main jet #82 Fuel pump output 20 c.c. minimum.

8.6±1.0mm

2000±100 rpm

Troubleshooting

Engine can not be started

1. No fuel in fuel tank

2. Fuel can not reach to carburetor

3. Too much fuel in cylinder

4. Clogged air cleaner

Stall after started

1. Incorrect idle speed adjustment

2. No spark on the spark plug

3. Low compression pressure

4. Rich mixture

5. Lean mixture

6. Clogged air cleaner

7. Inlet pipe leaking

8. Polluted fuel

Lean Mixture

1. Clogged carburetor jet

2. Clogged hose from carburetor to canister

3. Bend, squeezed or clogged fuel lines

4. Clogged fuel filter

5. Malfunction of float valve

6. Low fuel level in float chamber

7. Clogged vent pipe

8. Malfunction of fuel pump

Rich Mixture

1. Malfunction of float valve

2. Low fuel level in float chamber

3. Clogged carburetor air injector

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10. FUEL SYSTEM

Throttle Valve

Removal

Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle.

Inspection

Carburetor upper part

Oil hose

Throttle valve spring

Sealed cap

Needle clamp

Throttle valve cable

Carburetor upper part

Washer

Throttle valve

Fuel needle clip

Fuel needle

Installation

Place the fuel needle onto the throttle valve and clip it with needle clamp. Install the sealed cap, carburetor upper part, and throttle valve spring. Connect the throttle valve cable to the throttle valve. Install the throttle valve into the carburetor body.

Caution

Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.

Tighten the carburetor upper part. Install carburetor protector. Adjust the free play of throttle valve cable.

10-3

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10. FUEL SYSTEM

Carburetor Remove

Remove the body cover.

Disconnect the auto by-starter connector.

Loosen draining screw and then drain out fuel inside the carburetor. Loosen carburetor upper part and remove carburetor upper part. Remove fuel and oil hoses from carburetor. Remove carburetor mounting bolt and carburetor.

Auto by-starter

Fuel hose

Bolt

Carburetor upper part

Auto By-Starter

Inspection

Connect resistor meter to the terminals of auto by-starter, and then measure its resistance. If the resistance value exceeds specification too much, it means that the PTC in the auto by-starter is malfunction. Then, replace the auto by-starter.

Resistance value: Max. 10Ω(at cold engine)

Caution

If the resistance value exceeds the standard a little bit, the auto by-starter may still in normal. However, it is necessary to check other relative components for damage.

10-4

Draining screw

Auto by-starter

Connection hose clamp

Carburetor

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10. FUEL SYSTEM

Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged.

Connect battery to starter’s connectors and wait for several minutes. Pump compressed air into the fuel rich circuit. Air should not flow into the circuit. If air flow through the circuit, then, replace the starter.

Check resistor to make sure that the auto by-starter is in normal. Engine is running. If the resistor is in open-circuit, then current will not flow into the PTC. Thus, the auto by-starter is not operated. However, if the resistor is in short-circuit, current higher than specification will flow into the PTC. Then, it will cause the fuel rich circuit close rapidly, and difficult to start the scooter.

Resistance value: 10.2Ω

Automatic By-Starter Removal/Installation

Remove the cover of the auto by-starter. Remove screw and mounting plate. Remove the auto by-starter from carburetor. Install in the reverse order of removal procedures.

Battery

Alternator

Resistor

Auto by-starter

Screw

Mounting plate

10-5

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10. FUEL SYSTEM

Float/Float Valve/Jet

Removal

Remove the float from carburetor body. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as installation.

Caution

Do not tighten the screw forcedly to avoid to damaging the valve seat.

Remove main jet, needle jet seat and idle jet and clean them and each component with compressed air.

Float cap

Air inlet for fuel rich circuit

Installation

Install the idle jet, the needle jet seat and main jet. Then install the throttle valve stopper and air screws to their original position according to the marks as removal. Adjust the screws if replace with new ones.

Air screw

Needle jet

Idle jet

Needle jet seat

Throttle valve stopper screw

Float

Air inlet for idle speed

Float valve

Float pin

O-ring

Float cap

10-6

Main jet

Screw

Draining screw

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10. FUEL SYSTEM

Float Level Inspection

Measure float fuel level to have the upper end of float just contact with the float.

Float fuel level: 8.8 mm

Carefully bend the float arm for adjustment. Check the float operation and the install it.

Carburetor Installation

Caution

Do not let foreign materials into the carburetor.

Install the carburetor and insulator onto intake pipe with bolts. Install fuel and vent pipes onto carburetor. Install the carburetor upper part. Tighten the connection hose. Tighten the draining screw. Connect the automatic by-starter connector. Install air cleaner cap. Conduct following operations

y Adjustment of throttle valve cable. y Adjustment of oil pump. y Adjustment of idle speed.

Fuel hose

Bolt

Draining screw

Connection hose clamp

Inlet pipe

Carburetor upper part

Reed Valve

Removal

Remove the body cover. Remove the carburetor. Remove carburetor insulator. Remove inlet pipe. Remove the reed valve.

Reed valve

10-7

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10. FUEL SYSTEM

Inspection

Check the reed valve for damage and its reed strength. Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary.

Caution

Do not bend the reed valve stopper. Otherwise, it will cause its strength insufficient and rough engine running. If the reed valve or its seat is damaged, replace with a set.

Installation

Install in the reverse order of removal procedures. Check for leaking after installed.

Fuel Pump

Inspection

Remove the body cover. Warm up the engine and adjust idle speed. Remove fuel hose from carburetor and then wait for 5 minutes. Measure the output of fuel pump. Its output time is 10 seconds.

Output quantity: Min. 20 c.c.

If the output quantity is lower than 20 c.c., check fuel hose, vacuum hose and fuel filter.

Reed valve

Reed valve seat

Fuel hose

Reed stopper

Inlet pipe

Carburetor

Fuel hose connector

Bolt

Removal/Installation

Remove floor plate. Remove fuel inlet, outlet and vacuum hoses. Remove 2 bolts and fuel pump. Install the fuel pump in the reverse order of removal procedures.

10-8

Fuel inlet hose

Fuel outlet hose

Vacuum hose

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10. FUEL SYSTEM

Air Cleaner

Removal/Installation

Remove the EEC hose from the air cleaner outer case. Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner outer case. Install in the reverse order of removal procedures.

Install the air cleaner outer case.

Mounting screw X 7

Air cleaner element

10-9

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10. FUEL SYSTEM Notes:

10-10

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Contents

11. BRAKE SYSTEM

Front Disc Brake System ················ 11-1 Front Drum Brake System··············· 11-2 Rear Drum Brake System················ 11-3 Maintenance Information ················11-4 Troubleshooting ······························11-5 Hydraulic Disc Brake······················· 11-6

Front Disc Brake System

Disc Brake -Air Bleed·························11-7 Disc Brake - Caliper····························11-7 Brake Disc···········································11-8 Disc Brake - Master Cylinder·············11-8 Drum Brake·········································11-11

2.5kgf-m

0.55kgf-m

3.5kgf-m

1.8kgf-m

1.0kgf-m

4.5kgf-m

6.0kgf-m

11-1

This chapter Contents

11. BRAKE SYSTEM

Front Drum Brake System

0.55kgf-m

2.5kgf-m

6.0kgf-m

11-2

This chapter Contents

11. BRAKE SYSTEM

Rear Drum Brake System

11.0kgf-m

2.5kgf-m

0.55kgf-m

11-3

SYM DD 50 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual