Sym Fiddle II 125 AW12W, Fiddle II 125, AW12W Service Manual
SERVICE MANUAL
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Fiddle II 125 – AW12W
SYM FORWARD
This service manual contains the technical data of each component
inspection and repair for the SYM series motorcycle. The manual is shown
with illustrations and focused on 「Service Procedures」, 「Operation Key
Points」, and 「Inspection Adjustment」 so that provides technician with service
guidelines.
If the style and construction of the motorcycle are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
This manual that contains all data, illustration, indication and specifications
is based on current production information. SYM reserves the right to make
changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SANYANG.
SERVICE DEPARTMENT
SAN YANG INDUSTRY CO., LTD.
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HOW TO USE THIS MANUAL SYM
This service manual describes basic information of different system parts and
system inspection & service for SYM series motorcycles. In addition, please
refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance.
The third to the eleventh chapters cover engine and driving systems.
The twelfth to fifteenth chapters are contained the parts set of assembly
body.
The sixteenth chapter is electrical equipment.
The seventh chapter is for wiring diagram.
Please see index of content for quick having the special parts and system
information.
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SYM CONTENTS
CONTENTS
GENERAL INFORMATION/TROUBLE DIAGNOSIS...................................1
MAINTENANCE INFORMATION .................................................................2
LUBRICATION SYSTEM..............................................................................3
FUEL SYSTEM.............................................................................................4
ENGINE REMOVAL......................................................................................5
CYLINDER HEAD/VALVE............................................................................6
CYLINDER/PISTON......................................................................................7
"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......................8
FINAL DRIVING MECHANISM.....................................................................9
A.C. GENERATOR/STARTING CLUTCH....................................................10
CRANKCASE/CRANKSHAFT .....................................................................11
BODY COVER..............................................................................................12
BRAKE SYSTEM..........................................................................................13
STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER........................14
REAR WHEEL/SUSPENSION......................................................................15
ELECTRICAL EQUIPMENT.........................................................................16
ELECTRICAL DIAGRAM .............................................................................17
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MECHANISM ILLUSTRATIONS SYM
Light/starter switch
Front disk brake
Exhaust muffler
Ignition switch
Gear oil draining
bolt
Battery/Fuse/CDI
Front brake lever
Rea
r
brake lever
Ai
r
cleane
r
Gearoil filling
bolt
Oil level
Tail light
Front turn
signal light
Fuel tank / Fuel unit
High&Low beam/Seat
open/turn signal/horn
Head light/
Position light
Rear turn
signal light
Engine number/engine
oil draining bolt
Ignition coil
Frame numbe
r
Meter
A.C. Generator
Start magnetic switch
Horn/REG.REC
RR. turning
signal light
Tail light
Front turn
signal light
Winker relay
Engine control
switch
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SPECIAL TOOL
1
ITEM: R/L CRANKCASE DISASSEMBLE TOOL
NO：SYM-1120100
PURPOSE: DISASSEMBLE CRANKCASE
ITEM: CRANK PULLER
NO：SYM-1130000
PURPOSE: INSTALL CRANKCASE
ITEM: OUTER BEARING PULLER
NO：SYM-6204010
PURPOSE: REMOVE THE BEARING
ITEM: ACG FLYWHEEL PULLER
NO：SYM-3110A00
PURPOSE:
REMOVE ACG FLYWHEEL
ITEM: LOCK NUT PULLER
NO：SYM-9020100
PURPOSE:
REMOVE THE LOCK NUT
ITEM: UNIVERSAL HOLDER
NO：SYM-2210100
PURPOSE:HOLD THE MDF/CLUTCH OUTER
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SPECIAL TOOL
2
ITEM: CLUTCHSPRING COMPRESSOR
NO：SYM-2301000
PURPOSE:DISASSEMBLE THE CLUTCH
ITEM: CLUTCH NUT WRENCH
NO：SYM-9020200
PURPOSE:LOOSE THE CLUTCH NUT
ITEM: GY6 STARTER GEAR PULLER
NO：SYM-2822100-GY6
PURPOSE:REMOVE THE
STARTER GEAR
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SYM 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
TROUBLES DIAGNOSIS..................... 1-12
LUBRICATION POINTS....................... 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 SH/CD class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
Grease
King Mate G-3 is recommended.
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).
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
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.
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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SYM 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 SYM
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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SYM 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 SYM
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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SYM 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 harness 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.
Do not touch it.
Do not extend
it too much.
Please do not clip or
squeeze the wire.
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
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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SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-9
SPECIFICATIONS
MAKER SANYANG MODEL ALA125CC (AW12W-6)
Overall Length 1870mm Front TELESCOPIC FORK
Overall Width 698 mm
Suspen
sion
System
Rear UNIT SWING
Overall Height 1325 mm Front 110/70-12 47J
DIMENSION
Wheel Base 1325mm
Tire
Specifi
cations
Rear 120/70-12 51J
Front 41kg
Rear 68kg
Front DISK (ø 190 mm)
Curb Weight
Total 109kg
Brake
System
Rear DRUM (ø 130 mm)
Passengers/
Weight
Two men/110 kg Max. Speed ＞92km/h
Front 85kg
Performa
nce
Climb Ability ＞28°
Rear 134kg Primary Reduction BELT
WEIGHT
Total Weight
Total 219kg
Secondary
Reduction
GEAR
Type
4-STROKE ENGINE
(OHC)
Clutch Auto centrifugal clutch
Installation and
arrangement
Vertical, below center,
incline 80°
Deceleration
equipment
Transmission C.V.T.
Fuel Required Unleaded gasoline Speedometer 0 ~ 140 km/h
Cycle/Cooling
4-stroke/forced air
cooled
Horn 93~112dB
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
Forced-circulation&
splashing
Displacement 124.6 cc
CO <2.0 g/km
Compression
Ratio
9.6 : 1 HC
<0.8 g/km
Max. HP 6.25KW/8000 rpm
Exhaust
Emission
NOx <0.15 g/km
EURO3
Max. Torque 8.33N.m /6500 rpm
Air Filtration Paper filter
Ignition C.D.I.
Noise Emission < 77dB
ENGINE
Starting System Kick & electrical starter
Engine Weight(dry
weight)
30kg
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-10
TORQUE VALUES (ENGINE)
ITEM Q'TY
THREAD DIA
(mm)
TORQUE
VALUE(Kg-m)
REMARKS
A.C. generator fixing bolts 2 6 0.8~1.2
Pulse generator hex bolts 2 5 0.35~0.5
Gear oil filling bolt 1 8 1.0~1.4
Oil pump flat bolts 2 6 0.8~1.2
Crankcase flange bolts 2 6 0.8~1.2
Oil pump drive sprocket nut 1 6 0.8~1.2
Cylinder/cylinder head two-ends
bolts
4 8 0.7~1.1 Tighten to crankcase
Oil pump drive separator bolts 2 6 0.8~1.2
Cam holder nuts 4 8 1.8~2.2
Start clutch lock nut 1 22 9.0~10.0
Camshaft chain adjuster bolts 2 6 0.8~1.2
Cylinder head bolts 3 6 0.8~1.2
Cylinder head cover bolts 4 6 0.8~1.2
Right crankcase cover bolts 10 6 0.8~1.2
Flywheel nut 1 12 5.0~6.0
Shroud A/B tapping screws 3 5 0.8~1.2
Cooling fan bolts 4 6 0.8~1.2
Cooling fan cover 2 6 0.8~1.2
Transmission(Gear box) bolts 7 8 1.8~2.2
RR. brake arm bolt 1 6 0.8~1.2
Crankcase draining plug bolt 1 12 3.5~4.5
Drive pulley nut 1 12 5.0~6.0
Drive face nut 1 12 5.0~6.0
Start motor bolts 2 6 0.8~1.2
Left crankcase cover bolts 10 6 0.8~1.2
Carburetor nuts 2 6 0.8~1.2
A.I. fixing hex cap nuts 2 6 0.8~1.2
Valve adjustment fixing nuts 2 5 1.0~1.5 Apply oil to thread
Gear oil draining plug bolt 1 12 3.5~4.5
Camshaft chain tensioner pivot 1 6 0.8~1.2 Hex socket bolt
Spark plug 1 10 1.0~1.4
Engine oil strainer cap 1 30 1.0~2.0
Kick starter arm bolt 1 6 0.8~1.2
Exhaust pipe bolts 2 8 3.0~3.6
Exhaust pipe connecting nuts 2 6 1.0~1.4
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SYM 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 axle nut 1 12 5.0~7.0
Rear wheel axle nut 1 16 11.0~13.0
Wheel hub/rim mounting
nuts
8 8 2.8~3.2
Speedometer cable locking
screw
1 5 0.15~0.3
Front shock absorber
mounting bolts
4 8 2.4~3.0
Rear shock absorber upper
connection bolt
1 10 3.5~4.5
Rear shock absorber lower
connection bolt
1 8 2.4~3.0
Brake lever bolts 2 6 0.8~1.2
Front brake hose bolts 2 10 3.3~3.7
Front brake air-bleeding
valve
1 6 0.8~1.0
Front brake disc mounting
bolts
4 10 4.0~4.5
Front brake clipper mounting
bolts
2 10 3.1~3.5
Drum brake arm bolts
(front/rear)
2 6 0.8~1.2
Engine suspension bolts 2 10 4.5~5.5 On frame side
Engine connection bolt 1 10 4.5~5.5 On engine side
Main stand 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
0.45~0.60kgf-m
3mm screw
0.05~0.08kgf-m
6mm bolt、nut
0.80~1.20kgf-m 4mm screw 0.10~0.15kgf-m
8mm bolt、nut
1.80~2.50kgf-m 5mm screw 0.35~0.50kgf-m
10mm bolt、nut
3.00~4.00kgf-m
6mm screw、SH nut
0.70~1.10kgf-m
12mm bolt、nut
5.00~6.00kgf-m
6mm bolt、nut
1.00~1.40kgf-m
8mm bolt、nut
2.40~3.00kgf-m
10mm bolt、nut
3.50~4.50kgf-m
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-12
TROUBLES DIAGNOSIS
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.
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 bystarter
cylinder compression
pressure normal
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SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-13
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment
Fault condition
Probable causes
Try gradual acceleration
and check engine speed
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
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
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation
system clogged
4. Exhaust pipe clogged
5. Fuel level too low in carburetor
6. Fuel nozzle clogged in
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
s
y
stem
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
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-14
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
Check ignition timing
(using ignition lamp)
Good spark Poor
No air sucked Air sucked
Good Poor
Abnormal
Air sucked 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
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SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-15
E. CLUTCH, DRIVING AND DRIVING PULLEY
1. Clutch ling spring broken
2. Clutch outer stick with clutch balance 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. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damaged
Engine running and misfire as
motorcycle initial forward moving
or jumping suddenly (rear wheel
rotating as engine in running)
Poor initial driving ( Poor
climbin
g p
erformance
)
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.
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1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-16
LUBRICATION POINTS
A
cceleration cable/ Front & rear
brake lever pivot
Steering shaft bearing
Speedometer gear /
Front wheel bearing
Side stand shaft
Main stand shaft
Rear wheel bearing
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SYM 2. MAINTENANCE INFORMATION
2-1
PRECAUTIONS IN OPERATION.......2-1
PERIODICAL MAINTENANCE SCHEDULE........2-2
LUBRICATION SYSTEM....................2-3
FUEL SYSTEM...................................2-4
AIR CLEANER....................................2-5
THROTTLE VALVE OPERATION......2-5
VALVE CLEARANCE INSPECTION & ADJUSTMENT ......2-6
CARBURETOR IDLING SPEED ADJUSTMENT .2-7
IGNITION SYSTEM/SPARK PLUG ..2-8
CYLINDER COMPRESSION PRESSURE
.2-9
DRIVING SYSTEM.............................2-9
STEERING SYSTEM .........................2-10
SUSPENSION SYSTEM ....................2-10
FRONT DISK BRAKE SYSTEM.........2-11
DRUM BRAKE SYSTEM....................2-13
WHEEL/TIRE......................................2-14
BATTERY...........................................2-15
HEADLIGHT ADJUSTMENT..............2-15
NUTS、BOLTS TIGHTEN..................2-15
PRECAUTIONS IN OPERATION
Specification
Main 5000 c.c.
Fuel Tank Capacity
auxiliary 1500 c.c.
capacity 800 c.c.
Engine Oil
change 750 c.c.
capacity 120 c.c.
Transmission Gear oil
change 110 c.c.
Clearance of throttle valve 2~6 mm
Spark plug A7RC Gap: 0.6~0.7 mm
“F” Mark in idling speed
Before TDC 13º±3º /1800 rpm below
Full timing advanced Before TDC 26º / 8000 rpm
Idling speed 1700±100 rpm
Cylinder compression pressure 13 kg/cm²
Valve clearance: IN/EX
0.12±0.02/ 0.12±0.02 mm
Tire dimension front / rear 110/70-12 47J / 120/70-12 51J
single Front: 1.75 kg/cm² rear: 2.00 kg/cm²
Tire pressure (cold)
Two persons Front: 1.75 kg/cm² rear: 2.25 kg/cm²
Battery capacity 12V 7Ah (MF battery)
Play of drum brake lever 10~20 mm
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2. MAINTENANCE INFORMATION SYM
2-2
PERIODICAL MAINTENANCE SCHEDULE
Mainte
nance
Code
Item Initial 300KM
1 Month
Every1000KM
3 month
Every3000KM
6 month
Every6000KM
1 year
Every12000K
M
1
☆Air cleaner
I C C R
2
☆2nd air jet leaner
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 pipes
I I
27 Cam chain
I I
28
☆Valve clearance
I A
29
☆Crankcase vapor control System
I C
30
☆Crankcase blow-by over-flow pipe
I
Replacement for every 2000km
31
☆2nd air jet system
I I C
32
☆vapor control system
I
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes
first.
Remarks:
1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items
must be perform normally periodical maintenance following the use r manual instructions. They are
prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the
charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is 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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SYM 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.
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, recommended
using King-Mate serial oil.
Engine oil capacity:
Disassembly: 850cc
Change: 750cc
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).
Check O-ring for damage, replace if
necessary.
Reinstall strainer, spring, O-ring and strainer
cover.
Torque value: 1.0~2.0 kgf-m
The vehicle must be parked on a level
ground when checking oil capacity.
Run the engine for 2-3 minutes then stop,
wait about 2-3 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
Dipstick
strainer cove
r
oil straine
r
spring
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2. MAINTENANCE INFORMATION SYM
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.
Remove the oil drain plug and drain gear oil
into a measurement cup.
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: 3.5~4.5 kgf-m
Caution
Fill out gear oil to specified quantity from the
engine oil filling hole.
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 Pipe
Remove luggage box, rear center cover,
body cover, and rear fender, as well as front
inner box.
Check all pipes, and replace it when they are
deterioration, damage or leaking.
Warning
Fuel filter
Remove the fuel tank.
Remove fuel pipe from the fuel filter.
Replace the fuel filter with new one.
Install the fuel filter.
Caution
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.
The arrow on the fuel filter means the flow
direction of fuel and check it if leaking after
installation.
Gear oil refilling bolt
Gear oil draining plug
Fuel filte
r
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SYM 2. MAINTENANCE INFORMATION
2-5
AIR CLEANER
Element
Remove 6 screws from the air cleaner cover.
Remove element of air cleaner (2 screws).
Check the element if dirt or damaged.
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.
Air cleaner element contains a paper
made filter so do not try to clean it.
Make sure that the air cleaner cover had
been installed properly after installation.
2~6 mm
Fixing nut
Adjustment nut
Rubber boot
screws×2
Air cleaner element
screws×6
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2. MAINTENANCE INFORMATION SYM
2-6
Primary adjustment is conducted from button
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check
acceleration operation condition.
Caution
VALVE CLEARANCE ADJUSTMENT
Caution
Remove luggage box and front center cover.
Remove the left body cover & left side cover.
Remove cylinder head cap.
Remove the ignition timing check hole 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 period 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 crankshaft can not be rotated in
counter-clockwise to prevent from damage
so that valve clearance can not be
measured.
Ignition timing mark
TDC mark
Inspection hole
Adjustment nut
Fixing nut
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SYM 2. MAINTENANCE INFORMATION
2-7
VALVE CLEARANCE INSPECTION
AND ADJUSTMENT
Check & adjust valve clearance with feeler
gauge.
Valve clearance (IN/EX):
0.12±0.02/0.12±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.
Open the carburetor cover from the luggage
box.
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 muffler of
exhaust analyzer into the front section of
exhaust pipe. Adjust the air adjustment
screw so that emission value in idle speed
is within standard.
4. Slightly accelerate the throttle 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.
EXHAUST EMISSION(EURO3):
CO＜2.0g/km
HC＜0.8g/km
NOX＜0.15g/km
It has to make sure that valve-rocker arm is
be adjusted to standard level when
adjusting it, and re-check the valve
clearance after tightened the fixing nut.
Inspection & adjustment for idle speed
have to be performed after all other parts
in engine that needed adjustment have
been adjusted.
Idle speed check and adjustment have to
be done after engine is being warm up
(around 10 minutes).
Throttle valve stopper screw
Ignition coil cable
Air adjustment screw
Feeler gauge
Fixing nut
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