Sym EuroMX 125 Service Manual

SERVICE MANUAL

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CONTENTS

HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

Forward

This service manual contains the technical data of each component
inspection and repair for the SANYANG Euro MX 125 motorcycle.
The manual is shown with illustrations and focused on “Service Procedures”,
“Operation Key Points”, and “Inspection Adjustment” so that provides technician
with service guidelines.

If the style and construction of the motorcycle are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.

This manual that contains all data, illustration, indication and specifications
is based on current production information. SANYANG reserves the right to
make changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SANYANG.

Service Department

SANYANG Industry Co., LTD.

Home page Contents

How to Use This Manual

This service manual describes basic information of different system parts
and system inspection & service for SANYANG Euro MX 125 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 and special service tools

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

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

body.
The sixteenth chapter is electrical equipment.
The seventh chapter is for wiring diagram.

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

Home page Contents

Contents

Page

Content Index

1-1 ~ 1-16

General Information / Trouble Diagnosis

1

2-1 ~ 2-18

Service Maintenance Information

2

3-1 ~ 3-8

Lubrication System

3

4-1 ~ 4-14

Fuel System

4

5-1 ~ 5-10

Engine Removal

5

6-1 ~ 6-16

Cylinder Head / Valve

6

7-1 ~ 7-8

Cylinder / Piston

7

8-1 ~ 8-14

“V” Type Belt Driving System / Foot-Starter

8

9-1 ~ 9-6

Final Driving Mechanism

9

10-1 ~ 10-10

Alternator / Starting Clutch

10

11-1 ~ 11-6

Crankcase/Crankshaft

11

12-1 ~ 12-14

Body Cover

12

13-1 ~ 13-12

Brake System

13

14-1 ~ 14-8

Steering/Front Wheel/Suspension

14

15-1 ~ 15-4

Rear Wheel/Suspension

15

16-1 ~ 16-22

Electrical Equipment

16

17-1 ~ 17-2

Wiring Diagram

17

Home page

Model illustration

Horn

Spark plug

Engine number

Engine oil drain plug

Light /
Starter switch

High & Low beam /
Passing /
Turn signal /
Horn switch

Exhaust
muffler

Ignition switch

Gear oil drain
plug

Battery / Fuse

IG. Coil /
Start relay

Fuel tank

Oil level
Oil strainer

Front brake
lever

Rear brake
lever

Air cleaner

Gear oil
Inspection plug

Headlight

Front winker light

Tail light

Winker relay

AC. Generator

Carburetor

Seat lock

Rear winker light

Frame number

Home page Contents

1. General Information/Trouble Diagnosis

1-1

Symbols And Marks.................. 1-1

General safety........................... 1-2

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

Specifications............................ 1-9

Torque Values (Engine).......... 1-10

Torque Values (Frame) ........... 1-11

Standard Torque Values for

Reference................................. 1-11

Troubles Diagnosis................. 1-12

Parts To Be Greased............... 1-16

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

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

Caution

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

Engine oil

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover
the damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended. (KING MATE G-3)

Gear oil

King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended.
(SAE 85W-140)

Locking sealant

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

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 service tools.

correct

Meaning correct installation.

wrong

Meaning wrong installation.

Indication

Indication of components.

directions

Indicates position and operation directions.

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

cross through the component (invisibility).

1

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1. General Information/Trouble Diagnosis

1-2

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

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

Used engine oil

Caution

Hot components

Caution

Battery

Caution

Brake shoe

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

Caution

Brake fluid

Caution

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

• 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, 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.

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

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

Inhaling asbestos dust may cause disorders
and cancer of the breathing system.

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 brake fluid
beyond reach of children.

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.

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1. General Information/Trouble Diagnosis

1-3

Service Precautions

• Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts
for SANYANG motorcycle may damage the
motorcycle.

• 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.

• 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.

• 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.

• 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.

• Never bend or twist a control cable to prevent
stiff control and premature worn out.

• 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.

• 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.

• Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.

• Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).

• Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.

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1. General Information/Trouble Diagnosis

1-4

• 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.

• 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.

• 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.

• Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.

• 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.

• Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.

• 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.

Both of these examples can result in bearing

damage.

Manufacturer's name

Groove

Clamp

Connector

Boots

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1. General Information/Trouble Diagnosis

1-5

• Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.

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

• Make sure service safety each other when
conducting by two persons.

• Note that do not let parts fall down.

• Before battery removal operation, it has to

remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not
contact with body to prevent from circuit short
and create spark.

• After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
And the two posts of battery have to be
greased after connected the cables.

• Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.

• If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.

capacity

verification

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1. General Information/Trouble Diagnosis

1-6

• When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.

• Do not pull the wires as removing a connector
or wires. Hold the connector body.

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

• Insert the connector completely.

If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.

• Check if the connector is covered by the twin

connector boot completely and secured
properly.

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

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

• 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.

• Wire band and wire harness have to be
clamped secured properly.

• Do not squeeze wires against the weld or its
clamp.

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1. General Information/Trouble Diagnosis

1-7

• Do not let the wire harness contact with
rotating, moving or vibrating components as
routing the harness.

• Keep wire harnesses far away from the hot
parts.

• Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of
bolts and screws.

• 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. Thoroughly clean the surface where
tape is to be applied.

• Secure the rubber boot firmly as applying it on
wire harness.

• Never use wires or harnesses which insulation
has been broken. Wrap electrical tape
around the damaged parts or replace them.

• Never clamp or squeeze the wire harness as
installing other components.

NEVER TOUCH

NEVER TOO
TIGHT

Never clamp or

squeeze the wire

harness

1. General Information/Trouble Diagnosis

1-8

• Do not let the wire harness been twisted as
installation.

• 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.

• Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.

• With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.

Do you know how to set the
instrument to its measurement
position and the insert
locations of its two probes?

Clean rust

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1. General Information/Trouble Diagnosis

1-9

Specifications

Maker SANYANG MODEL HF12W-6

Overall Length 1945 mm Front TELESCOPE

Overall Width 700 mm

Suspension

System

Rear UNlT SWING

Overall Height 1160 mm Front 100 / 90-12 (61L)

DIMENSION

Wheel Base 1335 mm

Tire

Specifications

Rear 130 / 70 –12 (64L)

Front 48 kg

Rear 75 kg

Front DISK (ø 273 mm)

Curb

Weight

Total 123 kg

Brake System

Rear DRUM (ø 130 mm)

Passengers/

Weight

Two /110 kg Max. Speed 96 km/hr Above

Front 84 kg

PERFOR

MANCE

Climb Ability 28° Below

Rear 162 kg

Primary

Reduction

BELT

WEIGHT

Total

Weight

Total 246 kg

Secondary

Reduction

GEAR

Type 4-STROKE ENGINE Clutch Centrifugal, dry type

Installation and

arrangement

Vertical, below center,

incline 80°

Reduction

Transmission C.V.T.

Fuel Used Unleaded Speedometer 0 ~ 140 km/hr

Cycle/Cooling

4-stroke/forced air

cooled

Horn 70~90 dB/A

Bore 52.4 mm Muffler Expansion & Pulse Type

Stroke 57.8 mm

Exhaust Pipe Position

and Direction

Right side, and

Backward

Cylinder

Number/Arran

gement

Single Cylinder Lubrication System Separated-lubrication

Displacement 124.6 cc

Solid

Particulate

-

Compression

Ratio

10.3 : 1 CO Below 4 %

Max. HP 11.0 ps / 8250 rpm

Exhaust

Concentration

HC Below 2000 ppm

Max. Torque 1.0 kg-m / 7000 rpm E.E.C. NO

Ignition C.D.I. P.C.V. NO

ENGINE

Starting System Power & Foot

Catalytic reaction

control system

NO

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1. General Information/Trouble Diagnosis

1-10

Torque Values (Engine)

Item Q’ty

Thread Dia.

(mm)

Torque

Value(Kg-m)

Remarks

Cylinder head bolts 4 6 1.0~1.4
Cylinder head nuts 4 8 2.0~2.4

Cylinder/cylinder head two-ends
bolts

4 8 0.7~1.1 Tighten to crankcase

Cylinder head left bolts 4 6 1.0~1.4
Valve adjustment fixing nuts 4 5 0.7~1.1 Apply oil to thread
Cylinder head left cover bolts 2 6 1.0~1.4
Spark plug 1 10 1.0~1.2

Carburetor heat protector
connecting nuts

2 6 0.7~1.1

Engine oil draining plug 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.0~2.0
Gear oil draining plug 1 8 0.8~1.2
Gear oil filling bolt 1 10 1.0~1.4
Oil pump screws 3 3 0.1~0.3
Engine left side cover bolts 8 6 1.0~1.5 Rubber washer attached
Camshaft chain tensioner bolt 1 6 0.35~0.5 Hex socket bolt
Camshaft chain adjuster bolts 1 6 0.8~1.2
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer bracket nut 1 12 5.0~6.0
Driving disk nut 1 12 5.0~6.0
Flywheel nut 1 12 5.0~6.0
One-way clutch tighten bolts 3 6 1.0~1.4 Apply locking sealant
One-way clutch nut 1 22 9.0~10.0 Apply oil to thread

Crankcase bolts/right crank
cover bolt

12 8 1.5~2.0

Gear box cap bolts 7 8 2.0~2.4
Exhaust pipe bolts 2 8 3.0~3.6
Exhaust pipe connection nut 2 7 0.5~1.0

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1. General Information/Trouble Diagnosis

1-11

Torque Values (Frame)

Item Q’ty

Thread Dia.

(mm)

Torque

Value(Kg-m)

Remarks

Mounting bolt for steering
handlebar

1 10 4.0~5.0

Mounting nut for steering rod

1 25.4 1.0~2.0

Cone seat for steering rod

1 25.4 0.2~0.3

Front wheel shaft nut

1 12 5.0~7.0

Rear wheel shaft nut

1 16 11.0~13.0

Wheel hub/rim mounting nuts

1 5 0.15~0.3

Speedometer cable locking
screw

4 8 2.4~3.0

Front shock absorber mounting
bolts

1 10 3.5~4.5

Rear shock absorber upper
connection bolt

1 8 2.4~3.0

Rear shock absorber upper
connection bolt

4 6 1.0~1.4

Brake lever bolts

2 4 0.1~0.2

Front brake hose bolts

2 6 1.0~1.4

Front brake air-bleeding valve

2 10 3.0~4.0

Front brake disc mounting bolts

1 6 0.7~1.1

Front brake clipper mounting
bolts

4 8 4.0~4.5

Drum brake arm bolts
(front/rear)

2 8 2.9~3.5

Engine suspension bracket
bolts

2 10 4.5~5.5

On frame side

Engine connection bolt

1 12 5.0~7.0

On engine side

Main standard nut

1 10 3.5~4.5

Foot-starting lever bolt

1 6 1.6~1.8

Air cleaner bolts

2 6 1.0~1.4

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

Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque

5mm bolt、nut

0.45~0.60 kgf-m

3mm screw

0.05~0.08 kgf-m

6mm bolt、nut

0.80~1.20 kgf-m

4mm screw

0.10~0.15 kgf-m

8mm bolt、nut

1.80~2.50 kgf-m

5mm screw

0.35~0.50 kgf-m

10mm bolt、nut

3.00~4.00 kgf-m

6mm screw、SH nut

0.70~1.10 kgf-m

12mm bolt、nut

5.00~6.00 kgf-m

6mm bolt、nut

1.00~1.40 kgf-m

8mm bolt、nut

2.40~3.00 kgf-m

10mm bolt、nut

3.50~4.50 kgf-m

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1. General Information/Trouble Diagnosis

1-12

Troubles Diagnosis

A. Engine hard to start or can not be started

Cylinder compression

pressure normal

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.

Perform cylinder

compression pressure test.

Check if sparks

Weak sparks, no spark

at all

Low compression pressure

or no pressure

Re-start by following the

starting procedures

No ignition

There are some signs of

ignition, nut engine can

not be started

Remove the spark plug

again and check it.

Remove carburetor after 30

minutes and connect a hose

onto fuel rich circuit. Then

blow the hose with air

Dry spark plug

Wet spark plug

Blowing in normal

Blowing clogged

1. No fuel in fuel tank

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

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 automatic by- starter

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1. General Information/Trouble Diagnosis

1-13

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

This chapter Contents

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)

Check cylinder compression

pressure (using compression

pressure gauge)

Ignition timing correct Incorrect ignition timing

Compression pressure correct

No compression pressure

Check if carburetor jet is

clogged

No clogged

Clogged

Remove spark plug

Check if engine over heat

No foul or discoloration Fouled and discoloration

No knock Knock

0. Air cleaner clogged

1. Poor fuel supply

2. Lines in fuel tank evaporation
system clogged

3. Exhaust pipe clogged

4. Fuel level too low in carburetor

5. Fuel nozzle clogged in carburetor.

1. Malfunction of 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

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

Normal Engine overheat

Continually drive in

acceleration or high speed

1. Too much carbon deposited in
combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

1. General Information/Trouble Diagnosis

1-14

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

D. Engine runs sluggish (High speed)

This chapter Contents

Check ignition timing (using
ignition lamp)

Good spark

Poor

No air sucked Air sucked

Good Poor

Abnormal

Air sucked through carburetor
gasket

Adjust the air screw of
carburetor

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

Normal

Check and adjustment Fault condition Probable causes

Check for fuel supplying system
in automatic fuel cup

Check if carburetor clogged

1. Incorrect ignition timing (malfunction of

CDI or AC alternator)

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. 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

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Good

Poor

Check and adjustment Fault condition Probable causes

Check ignition timing

1. Malfunction of CDI

2. Malfunction of AC alternator

Normal Abnormal

No clogged Clogged

1. Cleaning

1. General Information/Trouble Diagnosis

1-15

E. Clutch, driving and driving pulley

1. Clutch weights spring broken

2. Clutch outer stuck with clutch weights

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

Engine can be started but
motorcycle can not be moved.

FAULT CONDITIONS PROBABLE CAUSES

1. Drive belt worn out or deformation

2. Ramp plate of movable drive face damaged

3. Driving pulley spring broken

4. Clutch weights broken

5. Drive 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)

Poor initial driving ( Poor climbing
performance)

1. Drive belt worn out or deformation

2. Weight roller worn out

3. Movable drive face shaft worn out

4. Driven pulley spring deformation

5. Driven pulley shaft worn out

6. Greased in drive belt and driven face.

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1. General Information/Trouble Diagnosis

1-16

Parts To Be Greased

Acceleration cable/ Front & rear
brake lever pivot

Steering shaft bearing

Seat lock catch

Rear wheel bearing

Main stand pivot

Side stand pivot

Speedometer gear/
front wheel bearing

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2. Maintenance Information

2-1

Precautions In Operation .......... 2-1

Periodical Maintenance

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

Lubrication System.................... 2-3

Gear Oil....................................... 2-4

Fuel System................................2-4

Air Cleaner..................................2-5

Throttle Valve Operation ........... 2-5

Crankcase Ventilation ............... 2-6

Valve Clearance Adjustment..... 2-6

Valve Clearance Inspection

And Adjustment ......................... 2-7

Carburetor Idle Speed

Adjustment................................. 2-7

Ignition System.......................... 2-8

Spark Plug ..................................2-8

Cylinder Compression

Pressure......................................2-9

Driving System...........................2-9

Steering System.......................2-10

Suspension System.................2-10

Disk Brake System (Front Disk

Brake)........................................2-11

Drum Brake System.................2-13

Wheel / Tire...............................2-14

Battery.......................................2-15

Headlamp Adjustment.............2-15

Nuts, Bolts Tighteness............2-15

Special Service Tools

Catalogue..................................2-16

Precautions In Operation

Specification

Fuel Tank Capacity 7500 c.c.

Capacity 1000 c.c.

Engine Oil

Change 800 c.c.

Capacity 110 c.c.

Transmission Gear oil

Change 100 c.c.

Clearance of throttle valve 2~6 mm
Spark plug NGK CR8E Gap: 0.8 mm
“F” Mark in idling speed BTDC 13º / 1700 rpm
Full timing advanced BTDC 27º / 8000 rpm
Idling speed 1600±100 rpm
Cylinder compression pressure 10.3 ± 0.2 kgf/cm²
Valve clearance: IN/EX 0.12 ± 0.02 mm

Front 110/80-12 61L

Tire dimension

Rear 130/70-12 64L

Single Front: 1.75 kg/cm² rear : 2.25 kg/cm²

Tire pressure (cold)

Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²

Battery 12V8Ah (MF battery) type: YTX9A-BS (8Hr)

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Contents

2

2. Maintenance Information

2-2

Periodical Maintenance Schedule

Maintenance

Code

item

Initial

300KM

1 Month

every1000KM

3 month

every3000KM

6 month

every6000KM

1 year

every12000KM

1

☆Air cleaner

I C C R

2

☆2nd air jet cleaner

I C C R

3

☆Fuel filter

I I R

4

☆Oil filter

C C C

5

☆Engine oil change

R

Replacement for every 1000km

6 Tire pressure

I I

7 Battery inspection

I I

8 Brake & free play check

I I

9 Steering handle check

I I

10 Cushion operation check

I I

11 Every screw tightening check

I I

12 Gear oil check for leaking

I I

13

☆Spark plug check or change

I I R

14

☆Gear oil change

R

Replacement for every 5000km

15 Frame lubrication

L

16 Exhaust pipe

I I

17

☆Ignition timing

I I

18

☆Emission check in Idling

A I

19

☆Throttle operation

I I

20

☆Engine bolt tightening

I I

21

☆CVT driving device(belt﹞

I R

22

☆CVT driving device(roller)

C

23 Lights/electrical equipment/mutli-meters

I I

24 Main/side stands & springs

I I

25 Fuel lines

I I

27 Cam chain

I I

28

☆Valve clearance

I A

Note: I - Inspection, A-Adjustment R- Replacement C- Cleaning L- Lubrication (The 33rd, 34th, and 35th items are

for the fuel injection system)

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

perform normally periodical maintenance following the user manual instructions.

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 frequently operated 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.

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2. Maintenance Information

2-3

Lubrication System

Engine Oil Capacity

Caution

Remove dipstick to check the oil level. If oil level
is below the lower limit mark, add oil to the
specified upper limit mark.

Engine Oil change

Shut off the engine and remove dipstick.
Remove the oil drain plug on the bottom-left of
crankcase to drain oil.
After draining out oil, clean oil plug and its gasket
and reinstall. Replace the gasket if it is damaged.

Torque value: 3.5~4.5 kgf-m

Caution

Add oil to the specified capacity.
Oil Viscosity: SAE 10W-30, or equivalent
recommended using King-Mate serial oil.

Engine oil capacity: Disassembly: 1050cc

Change: 800cc

When checking for oil leak, run the engine at idle
speed for a few minutes, then check oil capacity
with dipstick.

Cleaning the oil strainer

Drain oil from engine, remove the strainer cover,
spring and strainer.
If there is an accumulation on the screen, wash it
off with suitable solvent (recommended using
compressed air to cleaning the foreign).
Check O-ring for damage, replace if necessary.
Reinstall strainer, spring, O-ring and strainer
cover.

Torque value: 1.3~1.7 kgf-m

• The vehicle must be parked on a level

ground when checking oil capacity.

• Run the engine for 3-5 minutes then stop,

wait about 3-5 more minutes allowing
engine oil to settle before checking the oil
level.

Warm up the engine. This will make the oil
flow out easily.

Oil drain plug

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2. Maintenance Information

2-4

Gear Oil

Inspection

Check gear oil if leaking.
Park the motorcycle with main stand on flat level
place.
Turn off engine and remove the gear oil draining
plug.
Place a measurement cup under the draining
hole.
Check gear oil if enough.

Replacement

At first, remove the gear oil refilling bolt, and then
remove the draining plug.
Install the draining plug after drained oil out.

Torque value: 0.8~1.2 kgf-m

Caution

Fill out specified gear oil from the engine oil filling
opening.
Install the oil filling bolt.

Torque value: 1.0~1.4 kgf-m
Quantity: 100 c.c.
Recommended: King-Mate HYPOID GEAR OIL
(#140)

Fuel System

Fuel Lines

Remove luggage box.
Check all lines, and replace it when they are
deterioration, damage or leaking.

Warning

Fuel filter

Remove luggage box.
Check if the fuel filter is clogged, broken. If so,
replace the fuel filter with new one.

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

Inspect if washer is in good condition.
Replace it with new one if it was deformed or
damaged.

Gear oil draining plug

Fuel filter

Gear oil
refilling bolt

Fuel pipes

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2. Maintenance Information

2-5

Air Cleaner

Air element

Remove the air cleaner cover (6 screws).
Remove the lock plate from the element of air
cleaner.
Check the element if dirt or damaged.
If it dirt, clean it with solvent and then soap it into
cleaning engine oil after cleaned. Finally,
squeeze it.
Replace it with new one if dirt or damaged.

Caution

Throttle Valve 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 throttle valve cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth.
Measure handle bar free play in its flange part.

Free play：2~6 mm

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

2~6 mm

Fixing nut

Adjustment nut

Rubber boot

6 screws

• Make sure that the air cleaner cover had

been installed properly after installation
because improperly installation will cause
foreign sucking into cylinder.

• Do not wet the air cleaner as washing the

motorcycle. Or it may effect engine
performance.

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2. Maintenance Information

2-6

Primary adjustment is conducted from button
side of cable on the throttle body.
Loosen fixing nut, and adjust by turning the
adjustment nut for its free-play.
Tighten the fixing nut, and check acceleration
operation condition after adjusted.

Crankcase Ventilation

Pull out the plug from draining hose to clean
deposits.

Caution

Valve Clearance Adjustment

Caution

Remove luggage box.
Remove center cover.
Remove cylinder head left cap.
Remove the ignition timing check hole cap on the
cooling fan cover.
With T type wrench, turn crankshaft in clockwise
motion so that mark (T) on the generator flywheel
aligns with the mark on the crankshaft, and
camshaft is at TDC position also as same as
level of cylinder head top-end. A single hole on
camshaft sprocket is forward to up. (Piston is at
TDC position in the compression stroke.)

Caution

When always riding in rainy area or full
throttle position, maintenance travel must be
shorted. The deposits can be seen in the
transparent section of draining hose.

Checks and adjustment must be performed

when engine is cold (below 35℃).

The model that equipped with starting
compression pressure reduction system can
not be rotated in counter-clockwise to prevent
from operating compression pressure
reduction function so that valve clearance can
not be measured.

Crankcase blow-by plug

Ignition
timing
mark

TDC mark

Fixing nut

Adjustment nut

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2. Maintenance Information

2-7

Valve Clearance Inspection And
Adjustment

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

Carburetor Idle Speed Adjustment

Caution

Park the motorcycle with main stand and
warn up engine.
Connect tachometer (the wire clamp of
tachometer is connected to the high voltage
coil).
Open the carburetor cover from the trunk.
Turn the throttle valve stopper screw to
specified idle speed.

Specified idle speed: 1700±100 rpm
Emission adjustment in Idle speed

Warm up the engine for around 10 minutes

and then conduct this adjustment.

1. Connect the tachometer onto engine.

2. Adjust the idle speed adjustment screw and
let engine runs in 1700±100 rpm.

3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust
pipe. Adjust the air adjustment screw so
that emission value in idle speed is within
standard.

4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for
2~3 times.

5. Read engine RPM and value on the
exhaust analyzer. Repeat step 2 to step 4
procedures until measured value within
standard.

Emission standard: CO: below 4.0%

HC: below 2000 ppm

It has to make sure that valve rock-arm is be
adjusted to standard level when adjusting it,
and re-check the valve clearance after
tightened the fixing nut.

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y Inspection & adjustment for idle speed

have to be performed after all other parts
in engine that needed adjustment have
been adjusted.

y Idle speed check and adjustment have to

be done after engine is being warm up
(around 10 minutes).

Throttle valve stopper screw

High voltage coil cable

Air adjustment screw

2. Maintenance Information

2-8

Ignition System

Ignition Timing

Caution

Remove right side cover.
Remove ignition timing hole cap located on the
cooling fan cap.
Connect tachometer and ignition lamp.
Start engine and set engine idle speed in 1600
rpm, and if the mark aligns with the “F”, then it
means that ignition timing is correct.
Increase engine speed to 8000 rpm to check
ignition timing advance. If the detent aligns with
advance mark “װ”, then it means ignition timing
advance is in functional.
If not, check CDI set, pulse flywheel, and pulse
generator. Replace these components if
malfunction of these parts are found.

Spark Plug

Appointed spark plug：CR8E (NGK)

Remove luggage box.
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.

Torque value: 1.0~1.2 kgf-m

Connect spark plug cap.

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

Ignition
lamp

F mark

0.8mm

Side electrode

Central electrode

Spark plug cap

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2. Maintenance Information

2-9

Cylinder Compression Pressure

Warn up engine and then turn off the engine.
Remove the luggage box and the center cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of stepping the foot-starting lever.

Caution

Compression pressure: 10.3 ± 0.2 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.

Driving System

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.

Width limit: 18.5mm or more

Clutch Pad

Start the motorcycle and gradually increase
throttle valve openness to check clutch pad
operation.
If the motorcycle moves with shaking, then check
its clutch pad for wearing. Replace it if
necessary.

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

Gear teeth

Width

Cylinder
pressure
gauge

Clutch

Clutch pad

Spark plug

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