SYM Joyride, HD 125 User Manual

HOW TO USE THIS MANUAL
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CONTENTS
MECHANISM ILLUSTRATIONS
HD125 / 200
SERVICE MANUAL
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Contents
This service manual contains the technical data of each component inspection and repair for the SANYANG HD 125 / 200 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, HD 125 / 200, 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 HD 125/200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information and special tools manual. The third to the 11th chapters cover engine and driving systems. The 12th chapter is cooling system. The 13th to the 16th chapter is contained the parts set of assembly frame body. The 17th chapter is electrical equipment. The 18th chapter is wiring diagram. Please see index of content for quick having the special parts and system information.
There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and “Mechanism Illustrations” 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 contents can reach to each chapter. There are two buttons, “Homepage and 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 contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this chapter contents” button at the second page of each content so that clicking the button can back to the contents of this chapter.
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Page Content Index
1-1 ~ 1-18 2-1 ~ 2-16 3-1 ~ 3-8 4-1 ~ 4-12 5-1 ~ 5-8 6-1 ~ 6-14
7-1 ~ 7-8
GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD/VALVE
CYLINDER/PISTON
CONTENTS
1 2 3 4 5 6
7
8-1 ~ 8-14
9-1 ~ 9-10 10-1 ~ 10-8 11-1 ~ 11-8 12-1 ~ 12-14 13-1 ~ 13-16 14-1 ~ 14-14
15-1 ~ 15-10 16-1 ~ 16-6
17-1 ~ 17-20
“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
FINAL DRIVING MECHANISM ALTERNATOR CRANKSHAFT/ CRANKCASE COOLING SYSTEM BODY COVER BRAKE SYSTEM
STEERING/FRONT WHEEL/SUSPENSION
REAR WHEEL/SUSPENSION ELECTRICAL EQUIPMENT
8
9 10 11 12 13 14
15 16
17
18-1 ~ 18-2
ELECTRICAL DIAGRAM
18
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Contents
MECHANISM ILLUSTRATIONS
LH12W / LH18W
Front brake lever
Winker relay
Horn
Radiator
Rear brake lever
Front winker light
Headlight
Battery/CDI
Oil lever / Oil filter Water pump AC. Generator
Fuel unit
Ignition coil
Luggage box
Spark plug
Fuel tank cap
Tail light/ Rear winker light
Radiator filler cap
Winker light / Horn / Dimmer & Passing switches
Reserve tank cap
Air cleaner
Gear oil drain bolt
Engine number Engine oil drain bolt
Headlight/Start switches
Main switch
Fuse box / Regulator rectifier Starter relay Headlight relay
Exhaust muffler
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Contents
Symbols and Marks............................... 1-1
General safety........................................1-2
Service Precautions..............................1-3
Specifications........................................1-9
1. GENERAL INFORMATION
Specifications.....................................1-10
Torque Values ....................................1-11
Troubles Diagnosis............................ 1-13
Parts to Be Greased........................... 1-17
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 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)
1
Grease King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Correct
Wrong
Indication Indication of components.
# 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.
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
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
Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery.
Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist.
If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor.
Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children.
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Service Precautions
y Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle.
y 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.
y 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.
1. GENERAL INFORMATION
y Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
y 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.
y 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.
y Store complex components such as
transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.
y 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.
y 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.
y Note the reassemble position of the important
components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).
y 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
y 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.
y 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.
y Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if the contact surface has any damage.
y The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.
Groove
Clamp
Connector
y Rubber and plastic boots should be properly
reinstalled to the original correct positions as designed.
y When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the manufacturer facing outside, check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.
Manufacturer's name
1-4
Boots
y 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.
To this chapter contents
y Lubricate the rotation face with specified
lubricant on the lubrication points before assembling.
y Check if positions and operation for installed
parts is in correct and properly.
y Make sure service safety each other when
conducting by two persons.
1. GENERAL INFORMATION
y After service completed, make sure all
connection points is secured. Battery positive (+) cable should be connected firstly.
y And the two posts of battery have to be greased
after connected the cables.
y Make sure that the battery post caps are
located in properly after the battery posts had been serviced.
y Note that do not let parts fall down.
y 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.
y 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
y When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service operation.
y Do not pull the wires as removing a connector
or wires. Hold the connector body.
y Make sure if the connector pins are bent,
extruded or loosen.
y Insert the terminal completely.
Check if the terminal is covered by the boot. Do not let boot open facing up.
y 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.
y 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.
y Check if the connector is covered by the twin
connector boot completely and secured properly.
y Wire band and wire harness have to be
clamped secured properly.
y Do not squeeze wires against the weld or its
clamp.
y Before terminal connection, check if the boot is
crack or the terminal is loose.
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y Do not let the wire harness contact with rotating,
moving or vibrating components as routing the harness.
y Keep wire harnesses far away from the hot
parts.
Never Touch
1. GENERAL INFORMATION
y 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.
y Secure the rubber boot firmly as applying it on
wire harness.
y Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of bolts and screws.
y Route harnesses so that they neither pull too
tight nor have excessive slack.
y Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around the damaged parts or replace them.
y Never clamp or squeeze the wire harness as
installing other components.
Never clamp or squeeze the wire harness
Never too tight
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1. GENERAL INFORMATION
y Do not let the wire harness been twisted as
installation.
y 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.
y With sand paper to clean rust on connector
pins/terminals if found. And then conduct connection operation later.
Clean rust
y Before operating a test instrument, operator
should read the operation manual of the instrument. And then, conduct test in accordance with the instruction.
Do you know how to set the instrument to its measurement position and the insert locations of its two probes?
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Specifications
MAKER SANYANG MODEL LH18W-6
Overall Length 2064 mm Front Telescopic Fork
Overall Width 760 mm
Overall Height 1165 mm Front 100 / 80 – 16 50P/TL
Dimension
Weight
Wheel Base 1385 mm
Curb Weight
Passengers/Weight Two /110 kg Max. Speed Above 108 km/hr
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement
1. GENERAL INFORMATION
Suspension
System
Tire Specifications
Front 53 kg Front Disk (ψ220mm)
Rear 82 kg
Total 135 kg
Front 75 kg
Rear 170 kg
Total 245 kg
Vertical, below center,
incline 80°
Brake System
Performance
Climb Ability Below 28°
Reduction
Transmission C.V.T.
Rear Unit Swing
Rear 120 / 80 - 16 60P/TL
Rear Drum (ψ130mm)
Primary
Reduction
Secondary
Reduction
Belt
Gear
Fuel Used Unleaded Speedometer 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore 61 mm Muffler
Stroke 58.6 mm
Cylinder
Engine
Number/Arrange
ment
Displacement 171.2 cc Solid Particulate
Compression Ratio 10.8 : 1 CO Below 5.5 g/ km
Max. HP 11.4kw / 8000rpm
Max. Torque 15.3Nm / 6500rpm E.E.C.
Ignition C.D.I. P.C.V.
Starting System Power & Foot
Single Cylinder Lubrication System
Exhaust Pipe Position and
Direction
on
Exhaust
Concentrati
Catalytic reaction control
system
HC Below 1.0g/ km
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
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1. GENERAL INFORMATION
Specifications
MAKER SANYANG MODEL LH12W-6
Overall Length 2064 mm Front Telescopic Fork
Overall Width 706 mm
Overall Height 1165 mm Front 100 / 80 -16 50P/TL
Dimension
Weight
Wheel Base 1385 mm
Front 53 kg Front Disk (ψ220mm)
Curb Weight
Passengers/ Weight
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement
Rear 82 kg
Total 135 kg
Front 75 kg
Rear 170 kg
Total 245 kg
Vertical, below center,
incline 80°
Two/110 kg Max. Speed Above 100 km/hr
Suspension System
Tire Specifications
Brake System
Performance
Reduction
Climb Ability Below 28°
Primary
Reduction
Secondary
Reduction
Transmission C.V.T.
Rear Unit Swing
Rear 120 / 80 -16 60P/TL
Rear Drum (ψ130mm)
Belt
Gear
Fuel Used Unleaded Speedometer 0 ~ 140 km/hr
Cycle/Cooling 4-Stroke/Water Cooled Horn 93~112 dB/A
Bore 57 mm Muffler
Stroke 48.8 mm
Cylinder
Engine
Compression Ratio 10.5 : 1 CO Below 5.5g/km
Number /
Arrangement
Displacement 124.5 cc Solid Particulate
Max. HP 9.2kw / 8500rpm
Max. Torque 10.9Nm / 6500rpm E.E.C.
Ignition C.D.I. P.C.V.
Starting System Power & Foot
Single Cylinder Lubrication System
Exhaust Pipe Position and
Direction
Exhaust
Catalytic Reaction Control
ation
Concentr
System
HC Below 1.2 g/km
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
Yes
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1. GENERAL INFORMATION
Torque Values
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
5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut
12 mm bolt、nut
Tighten Torque
0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
6 mm screwSH nut 6 mm bolt、nut 8 mm bolt、nut
10 mm bolt、nut
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder head nut 4 8 2.0~2.4 Cylinder head right bolt 2 8 2.0~2.4 Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.1 Cylinder head stud bolt (EX. pipe) 2 7 0.5~1.0 Tappet adjustment hole cap bolt 6 6 1.0~1.4 Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread Spark plug 1 10 1.0~1.2 Carburetor insulator bolt 2 6 0.7~1.1 Cylinder stud bolt 4 8 0.7~1.1 Engine left cover bolt 7 6 1.1~1.5 Engine oil draining bolt 1 12 1.1~1.5 Engine oil strainer cap 1 30 1.3~1.7 Mission draining bolt 1 8 0.8~1.2 Mission filling bolt 1 10 0.8~1.2 Clutch driving plate nut 1 28 5.0~6.0 Clutch outer nut 1 12 5.0~6.0 Drive face nut 1 12 5.0~6.0 Flywheel nut 1 12 5.0~6.0 Crankcase bolts 7 6 0.8~1.2 Mission case bolt 7 8 2.0~2.4
Type
Tighten Torque
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
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1. GENERAL INFORMATION
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Stopper nut for engine hanger rubber
Engine hanger nut 2 12 4.0~5.0 Engine hanger bolt 1 12 4.0~5.0 Engine connection bolt 1 10 3.5~4.5 Front wheel axle nut 1 12 5.0~7.0 Rear wheel shaft nut 1 14 10.0~12.0 Rear fork 2 8 4.0~5.0 Rear cushion upper bolt 2 10 3.5~4.5 Rear cushion under bolt 2 8 2.4~3.0 Nut for steering post 1 10 4.0~5.0 Front cushion 4 8 2.4~3.0 Brake lever nut 2 6 0.8~1.2 Nut for the rear brake arm 1 6 0.5~0.6 Front brake hose bolt 4 10 3.0~4.0 Front brake caliper bolt 4 6 3.0~3.5 Front brake disk mounting bolt 7 8 4.0~4.5 Air-bleed valve 1 5 0.5~0.6 Speedometer cable locking screw 1 5 0.15~0.3 Exhaust muffler bolt 3 8 3.2~3.8 Exhaust muffler connection nut 2 7 1.0~1.2
1 8 1.8~2.2
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1. GENERAL INFORMATION
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
Remove spark plug, install it
into spark plug cap, and perform
a spark test against engine
ground.
Check if sparks Weak sparks, no spark at
Perform cylinder compression
pressure test.
No fuel is supplied to
carburetor
all
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
7. Malfunction of main switch
Cylinder compression
pressure normal
Re-start by following the starting
procedures
No ignition There are some signs of
Remove the spark plug again
and check it.
Dry spark plug Wet spark plug
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Low compression
pressure or no pressure
ignition, nut engine can
not be started
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
Blowing in normal Blowing clogged
1. Malfunction of automatic by- starter
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1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
Try gradual acceleration and
check engine speed
Engine speed can 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
Check if carburetor jet is
clogged
Engine speed can not be
increased.
No compression pressure
1. Air cleaner clogged
Poor fuel supply
2.
Lines in fuel tank evaporation system
3.
clogged Exhaust pipe clogged
4.
Fuel nozzle clogged in carburetor.
5.
Fuel nozzle clogged in carburetor.
6.
Malfunction of CDI
1.
Malfunction of AC alternator
2.
1.
Cylinder & piston ring worn out
2. Cylinder gasket leaked
Sand hole in compression parts
3.
Valve deterioration
4.
Seized piston ring
5.
No clogged Clogged
Remove spark plug
No foul or discoloration Fouled and discoloration
Check if engine over heat
Normal Engine overheat
Continually drive in acceleration
or high speed
No knock Knock
Remove foreign
1.
Remove dirt
1.
Incorrect spark plug heat range
2.
1.
Piston and cylinder worn out
2. Lean mixture
3.
Poor fuel quality Too much carbon deposited in
4.
combustion chamber Ignition timing too advanced
5.
Poor circuit on the cooling system
6.
1. Too much carbon deposited in
combustion chamber Lean mixture
2.
Poor fuel quality
3.
Ignition timing too advanced
4.
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1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment Fault condition Probable causes
Check ignition timing (using
Air sucked through carburetor
spark plug into spark plug cap
and perform spark test against
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition
ignition lamp)
Normal
Adjust the air screw of
carburetor
Good Poo
gasket
No air sucked Air sucked
Remove spark plug, install
engine ground
Good spark Poo
Abnormal
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
Probable causes
Check ignition timing
Normal Abnormal
Check for fuel supplying system
in automatic fuel cup
Good Abnormal
Check if carburetor clogged
No clogged Clogged
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
1. Cleaning
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1. GENERAL INFORMATION
E. Clutch, driving and driving pulley
FAULT CONDITIONS
Engine can be started but
motorcycle can not be moved.
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)
PROBABLE CAUSES
1. Drive belt worn out or deformation
Ramp plate of movable drive face damaged
2.
Driving pulley spring broken
3.
Clutch weights broken
4.
Drive slide-shaft gear groove broken
5.
Transmission gear damaged
6.
1.
Clutch weights spring broken Clutch outer stuck with clutch weights
2.
Connection parts in clutch and shaft worn out or burned
3.
1. Drive belt worn out or deformation
Weight roller worn out
2.
Movable drive face shaft worn out
3.
Driven pulley spring deformation
4.
Driven pulley shaft worn out
5.
Greased in drive belt and driven face.
6.
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Parts to Be Greased
Steering shaft bearing
Acceleration cable/ Front & rear brake lever pivot
1. GENERAL INFORMATION
Seat catch
Speedometer gear/ front wheel bearing
Side stand pivot
Main stand pivot
Rear wheel bearing
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1. GENERAL INFORMATION
Note:
1-18
Home page
Contents
Precautions in Operation······················ 2-1 Periodical Maintenance Schedule········2-2 Fuel Lines / Cable·································· 2-3 Air Cleaner··············································2-4 Spark Plug·············································· 2-4 Valve Clearance ····································· 2-5 Carburetor Idle Speed Adjustment······· 2-6 Ignition System······································ 2-7 Cylinder Compression Pressure ·········· 2-7 Drive Belt················································ 2-8 Brake System (Front Disk Brake)·········2-8
Precautions in Operation
2. MAINTENANCE INFORMATION
Brake Light Switch/Starting Inhibitor Switch ················································· 2-10
Headlight Beam Distance·················· 2-10 Clutch Disc Wear································ 2-10 Side Stand··········································· 2-11 Cushion···············································2-11 Nuts, Bolts Tightness ························2-11 Wheel/Tire··········································· 2-12 Steering Handle Top Bearing············2-12 Special Tools List······························· 2-13
2
Specification
Fuel Tank Capacity 8000 c.c.
Engine Oil
Transmission Gear oil
Capacity of coolant
Clearance of throttle valve 2~6 mm
Spark plug
“F” Mark in idling speed BTDC 13º / 1000 rpm
Full timing advanced BTDC 27º / 6000 rpm
Cylinder compression pressure 12.0 ±2 kgf/cm²
Capacity 1000 c.c.
Change 800 c.c.
Capacity 110 c.c.
Change 100 c.c.
Engine + radiator 780 c.c.
Reservoir upper 420 c.c.
Type NGK CR8E
Gap 0.8 mm
Idling speed 1600±100 rpm
Valve clearance: IN/EX 0.12 ± 0.02 mm
Tire dimension
Tire pressure (cold)
Battery 12V8Ah (MF battery) type: YTX9-BS
Front 100/80-16 50P
Rear 120/80-16 60P
Single Front: 1.75 kg/cm² rear : 2.25 kg/cm²
Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²
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2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
Maintenance
Code
1 2 3 4 5 6 Tire pressure 7 Battery inspection 8 Brake & free ply check
9 Steering handle check 10 Cushion operation check 11 12 Gear oil check for leaking 13 14 15 Frame lubrication 16 Exhaust pipe 17 18 19 20 21 22
23 24 Main/side stands & springs
25 Fuel lines 26 Cushions 27 Cam chain 28 29 30 31 32 33 34 Coolant reservoir 35 Coolant
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
Air cleaner 2nd air jet leaner Fuel filter Oil filter Engine oil change
Every screw tightening
Spark plug check or change Gear oil change
Ignition timing emission check in Idling Throttle operation Engine bolt tightening CVT driving device(belt) CVT driving device(roller)
Lights/electrical equipment/multi-meters
Valve clearance Crankcase evaporative Crankcase blow-by
2nd air jet system Evaporative control system
Lines & connections in cooling
be performed 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 systemPerform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur. b. Carbon deposit removalRemove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious
lower. Than ever
Item
Every
300KM
I C R I C R
I I R C C R Replacement for every 1000 km
I I
I I
I I
I I
I I
I I
I I
I I R R Replacement for every 5000 km
L I I I I
A I
I I I I
I R
C I I I I
I I
I I I I A I C
Replacement for every 2000 km I I C
I I I I I I I R
1 Month
every
1,000KM
3 month
every
3,000KM
6 month
every
6000KM
1 year
every
12,000KM
15 month
every
14,500KM
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Fuel Lines / Cable
Remove luggage box. Remove rear carrier. Remove body covers. Check all lines, and replace it when they are deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Acceleration Operation
Have a wide open of throttle valve as handle in any position and release it to let back original (full closed) position. Check handle if its operation is smooth. Check acceleration cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth Measure the throttle grip free play in its flange part.
Adjustment can be done in either end. Secondary adjustment is conducted from top side. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment nut.
Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition.
Free play: 2~6 mm.
2. MAINTENANCE INFORMATION
Fuel tank
Fuel filter
Fuel hose
Vacuum hose
Throttle grip
Adjustment nut
Adjustment nut
Lock nut
2~6 mm
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2. MAINTENANCE INFORMATION
Air Cleaner
Air Cleaner Element
Remove 6 screws from the air cleaner cover and then remove the cover.
Remove 4 screws, and then remove the air cleaner element.
Caution
The air cleaner element is made of paper so do not soap it into water or wash it with water.
Spark Plug
Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug.
Measure the spark plug gap. Spark plug gap0.8 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 torque: 1.0~1.2kgf-m
Connect spark plug cap. Recommended spark plug: CR8E
6 screws
4 screws
0.8mm
Spark plug cap
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Valve Clearance
Caution
Checks and adjustment must be performed when the engine temperature is below 35℃.
Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.
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.
2. MAINTENANCE INFORMATION
Timing mark
Caution
Re-check the valve clearance after tightened the fixing nut.
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2. MAINTENANCE INFORMATION
Carburetor Idle Speed Adjustment
Caution
y Inspection & adjustment for idle speed have to
be performed after all 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. (It is enough that operates engine from stop to running for 10 minutes.)
Park the motorcycle with main stand and warm up engine. Connect tachometer (the wire clamp of tachometer is connected to the high tension cable). Open carburetor cover from the luggage box. Turn the throttle valve stopper screw to specified idle speed. Specified idle speed: 1600 ± 100 rpm
Ignition cable
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 1600±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 2.5~3.5%
HC: below 2000ppm
Stopper screw
Air adjustment screw
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Ignition System
Caution
y C.D.I ignition system is set by manufacturer so
it can not be adjusted.
y Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover. Connect tachometer and ignition lamp. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition lamp. Then, it is means that ignition timing is correct. Increase engine speed to 6000 rpm to check ignition advance degree. If indent is located within the ignition advance degrees, it is means that the ignition advance degree is in normal. If ignition timing is incorrect, check CDI set, pulse rotor and pulse generator. Replace it if malfunction of these parts is found.
2. MAINTENANCE INFORMATION
Cylinder Compression Pressure
Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.
Caution
Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
y Incorrect valve clearance. y Valve leaking. y 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.
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2. MAINTENANCE INFORMATION
Drive Belt
Remove mounting bolt located under air cleaner. Remove 7 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 above
7 bolts
Teeth
Width
Brake System (Front Disk Brake)
Brake System Hose
Make sure the brake hoses for corrosion or leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found
Brake hose
Caution
y In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
y Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
y Do not mix non-compatible brake fluid together.
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Filling Out Brake Fluid
Tighten the drain valve, and add brake fluid. Operate the brake lever so that brake fluid contents inside the brake system hoses.
Air Bleed Operation
Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release the brake lever.
Added Brake Fluid
Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.
2. MAINTENANCE INFORMATION
Screws
Master cylinder cap
Diaphragm plate
Diaphragm
Air bubble
Drain valve
Upper
Caution
Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.
Brake Lining Wear
The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc.
Caution
It is not necessary to remove brake hose when replacing the brake lining.
Remove the brake clipper bolt, and take out the clipper.
Caution
Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.
Pry out the brake lining with a flat driver if lining is clipped.
Caliper bolt
Transparent hose
Brake caliper
Lining
Brake disk
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2. MAINTENANCE INFORMATION
Make sure the brake lining condition. Replace the lining if the brake lining wear limitation groove close to the brake disc.
Brake Lining Replacement
Compress the caliper and let the brake lining out of the caliper mounting plate. Compress the brake lining locking spring. Remove the inner brake lining firstly and then remove the outer brake lining. Compress the brake caliper at first as installation. Install the inner brake lining firstly, and then install the outer brake lining.
Caution
In order to maintain brake power balance, the brake lining must be replaced with one set.
Brake Light Switch/Starting Inhibitor Switch
The brake lamp switch is to light up brake lamp as brake applied. Make sure that electrical starter can be operated only under brake applying.
Headlight Beam Distance
Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high.
Lining
Brake lining wear limitation groove
Master cylinder
Brake switch
Caution
y To adjust the headlight beam follows related
regulations.
y Improper headlight beam adjustment will
make in coming driver dazzled or insufficient lighting.
Clutch Disc Wear
Run the motorcycle and increase throttle valve opening gradually to check clutch operation. If the motorcycle is in forward moving and shaking, check clutch disc condition. Replace it
Adjust screw
Clutch weight
Drive plate
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Side Stand
Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly. Make sure that side stand is no bending or deformation.
Cushion
Warning
y Do not ride the motorcycle with poor cushion. y Looseness, wear or damage cushion will make
poor stability and drive-ability.
2. MAINTENANCE INFORMATION
Side stand
Front cushion
Press down the front cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found. Tighten all nuts and bolts.
Rear Cushion
Press down the front cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found. Park motorcycle with main stand. Turn the rear wheel forcefully and check if engine bracket bushing worn out Replace the bushing if looseness found. Tighten all nuts and bolts.
Nuts, Bolts Tightness
Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose clamps, and wire holders for security.
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2. MAINTENANCE INFORMATION
Wheel/Tire
Caution
Tire pressure check should be done as cold engine.
Check if tire surface is ticked with nails, stones or other materials.
Appointed tire pressure
Tire size Front tire Rear tire
Tire pressure as cold engine (Kg/cm²)
Check if front and rear tires’ pressure is in normal. Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:
Load for
under 90 Kg
Full loaded
Front tire: 1.5 mm Rear tire: 2.0 mm
1.75 2.25
1.75 2.5
Steering Handle Top Bearing
〝△〞mark
磨損極限指標
Caution
Check all wires and cables if they are interfered with the rotation of steering handle bar.
Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing.
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2. MAINTENANCE INFORMATION
Special Tools List
NAME
R/L. CRANK DISASS. TOOL
NAME
NO SYM-1120000-H9A NO SYM-1130000-H9A NO SYM-9100200-H9A
CRANK SHAFT PULLER
NAME
L. CRANK SHAFT BRG. DRIVER
(ψ30mm)
CRANK CASE BUSH PULLER
NAME
NAME
CRANK SHAFT BRG. FIXING SOCKET
NAME
NO SYM-9100210-H9A NO SYM-1120310 NO SYM-1120320
(ψ22mm)
CRANK CASE BUSH PULLER
NAME
VALVE COTTER REMOVE & ASSEMBLY TOOL
NAME
NO SYM-1471110/20 NO SYM-9001200 NO SYM-9001209
TAPPET ADJUSTING WRENCH
NAME
TAPPET ADJUSTER
NAME
UNIVERSAL HOLDER
NAME
CLUTCH NUT WRENCH
NAME
NO SYM-2210100 NO SYM-9020200 NO SYM-2301000
CLUTCH SPRING COMPRESSOR
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2. MAINTENANCE INFORMATION
NAME
INNER BEARING PULLER
NAME
NO SYM-6204002 NO SYM-6204001 NO SYM-3110A00
OUTER BEARING PULLER
NAME
AC.G. FLYWHEEL PULLER
NAME
(12*20*5)
WATER PUMP OIL SEAL DRIVER
(6901)
NAME
WATER PUMP BEARING DRIVER
NAME
WATER PUMP MECHANICL SEAL DRIVER
NO SYM-9120500-H9A NO SYM-9100100 NO SYM-1721700-H9A
NAME
(6301)
BEARING DRIVER
NAME
(6204)
BEARING DRIVER
(6203/6004UZ)
NAME
BEARING DRIVER Ø17mm
NO SYM-9610000 NO SYM-9110400 NO SYM-9620000
(27*42*7)
OIL SEAL DRIVER
NAME
(20*32*6)
OIL SEAL DRIVER
NAME
(25*40*8)
OIL SEAL DRIVER
NAME
NO SYM-9120200 NO SYM-9121600 NO SYM-9125500
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NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush (long)
NO SYM-1130000-L NO SYM-1130010 NO SYM-1130031
2. MAINTENANCE INFORMATION
NAME Extension bush (short) NAME NAME
NO SYM-1130032 NO NO
NAME NAME NAME
NO NO NO
NAME NAME NAME
NO NO NO
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2. MAINTENANCE INFORMATION
Note:
2-16
Home page
Contents
Precautions in Operation···················· 3-2 Troubleshooting ·································· 3-2 Engine Oil············································· 3-3
Press-In Lubrication
Oil Route
Con-Rod
3. LUBRICATION SYSTEM
Engine Oil Strainer Clean···················· 3-3 Oil Pump··············································· 3-4 Gear Oil················································· 3-7
Valve Rocker Arm
Cam Shaft
Spray Lubrication
3
Spray Lubrication
Press-In Lubrication
Oil Route
Oil through
Rotate Direction
Oil Strainer
Oil Pump
3-1
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3. LUBRICATION SYSTEM
Precautions in Operation
General Information:
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1000 c.c.
Change: 800 c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 110 c.c.
Change: 100 c.c.
Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils)
單位:mm
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Oil pump
Clearance between outer rotor and body 0.15~0.20 0.25 Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil strainer cap 1.5~3.0kgf-m Gear oil drain plug 1.0~1.5kgf-m Gear oil inspection bolt 1.0~1.5kgf-m Oil pump connection bolt 0.8~1.2kgf-m
Troubleshooting
Low engine oil level
y Oil leaking y Valve guide or seat worn out y Piston ring worn out
Low oil pressure
y Low engine oil level y Clogged in oil strainer, circuits or pipes y Oil pump damage
Dirty oil
y No oil change in periodical y Cylinder head gasket damage y Piston ring worn out
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Engine Oil
Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely.
Place a oil pan under the motorcycle, and remove oil drain bolt. After drained, make sure washer can be re-used. Install oil drain bolt.
Torque value1.9~2.5kgf-m
3. LUBRICATION SYSTEM
Drain bolt
Engine Oil Strainer Clean
Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap.
Torque value1.9~2.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30) Recommended using King serial oil.
Engine oil capacity: 0.8L when replacing
Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks.
Oil strainer cap
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3. LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to chapter 10)
Remove snap ring and take out oil pump driving chain and sprocket.
Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump.
Clip
Oil Pump Disassembly
Remove the screws on oil pump cover and disassemble the pump as illustration shown.
Oil Pump Inspection Check the clearance between oil pump body and outer rotor.
Limit: 0.25 mm
2 screws
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Check clearance between inner and outer rotors. Limit: 0.20 mm
Check clearance between rotor side face and pump body
Limit: 0.12 mm
Oil Pump Re-assembly
Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor. Install the driving shaft Install fixing pin
Install the oil pump cover and fixing pin properly
3. LUBRICATION SYSTEM
Pin
1 Screw
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3. LUBRICATION SYSTEM
Oil Pump Installation
Install the oil pump, and then tighten bolts.
Torque value0.8~1.2kgf-m
Make sure that oil pump shaft can be rotated freely.
Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft.
Install starting gear and generator. (Refer to chapter 10)
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Gear Oil
Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt.
Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil. Recommended using King series oils. Install oil inspection bolt.
Gear Oil Change
Remove oil level inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained.
Torque value: 1.0~1.4kgf-m
Make sure that the drain plug washer can be re-used. Add oil to specified quantity from the inspection hole.
Gear Oil Quantity: 100 c.c. when replacing
Make sure that the bolt washer can be re-used, and install the bolt. Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking.
3. LUBRICATION SYSTEM
Gear oil Inspection Bolt
Gear oil drain plug
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3. LUBRICATION SYSTEM
Notes:
3-8
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Contents
Precautions in Operation....................4-2
Trouble Diagnosis...............................4-3
Carburetor removal.............................4-4
Vacuum chamber................................4-4
Air Cut-Off Valve .................................4-6
4. FUEL SYSTEM
Auto By-Starter.................................. 4-7
Float Chamber.................................... 4-8
Fuel Tank............................................ 4-10
Air Cleaner..........................................4-11
4
To fuel vapor separator
4-1
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4. FUEL SYSTEM
Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline.
Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
y There is a drain screw in the float chamber for draining residual gasoline. y Do not disassemble auto by-starter and air cut valve arbitrarily.
Specification
ITEM LH12W-6 LH18W-6
Carburetor diameter 24 mm 25 mm I.D. number CVK039 CVK066 Fuel level 20.5 mm 20.5 mm Main injector #105 #108 Idle injector #35 #35 Idle speed 1600±100 rpm 1600±100 rpm Throttle handle clearance 2~6 mm 2~6 mm Pilot screw 2 1/4 turns 1 1/2 turns
Tool Special service tools
Vacuum/air pressure pump Fuel level gauge
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Trouble Diagnosis
Poor engine start
y No fuel in fuel tank y Clogged fuel tube y Too much fuel in cylinder y No spark from spark plug(malfunction of ignition
system )
y Clogged air cleaner y Malfunction of auto by-starter y Malfunction of throttle operation
Stall after started
y Malfunction of auto by-starter y Incorrect ignition timing y Malfunction of carburetor y Dirty engine oil y Air existing in intake system y Incorrect idle speed
4. FUEL SYSTEM
Mixture too lean
y Clogged fuel injector y Vacuum piston stick and closed y Malfunction of float valve y Fuel level too low in float chamber y Clogged fuel tank cap vent y Clogged fuel filter y Obstructed fuel pipe y Clogged air vent hose y Air existing in intake system
Mixture too rich
y Clogged air injector y Malfunction of float valve y Fuel level too high in float chamber y Malfunction of auto by-starter y Dirty air cleaner
Rough idle
y Malfunction of ignition system y Incorrect idle speed y Malfunction of carburetor y Dirty fuel
Intermittently misfire as acceleration
y Malfunction of ignition system
Late ignition timing
y Malfunction of ignition system y Malfunction of carburetor
Power insufficiency and fuel consuming
y Fuel system clogged y Malfunction of ignition system
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4. FUEL SYSTEM
Carburetor removal
Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Disconnect automatic by-starter connector. Release the clamp strip of air cleaner.
Remove fuel pipe, vacuum hose. Release the clamp strip of carburetor insulator.
Vacuum chamber
Auto by-starter
Air cleaner clamp
Vacuum hose
Throttle cable
Air cleaner clamp
Fuel pipe
2 Screws
Removal
Loosen drain screw, and drain out residual fuel in float chamber. Remove 2 screws of vacuum chamber cover and the cover.
Remove compress spring and vacuum piston.
Spring
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Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack.
Installation
Install needle, spring and needle seat to vacuum piston.
Install vacuum piston to carburetor body and align the indent on the diaphragm. Install compress spring.
Install vacuum chamber cover and tighten 2 screws.
4. FUEL SYSTEM
Needle seat
Piston
Needle
Spring
2 Screws
Caution
y Do not damage vacuum diaphragm. y When tightening the vacuum chamber screw,
hold down vacuum piston.
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4. FUEL SYSTEM
Air Cut-Off Valve
Inspection
Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve.
Vacuum value: 420~500 mm-Hg
Pump compressed air from air pump to air vent hose.
Caution
The vacuum can not be over 600 mm-Hg. Or the air cut-off will be damaged.
If the valve is in normal, it will restrict air-flow. If air-flow is no restrict, replace carburetor assembly.
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Auto By-Starter
Inspection
Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter.
Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes)
Replace the auto starter with a new one if resistance value exceeds standard. Remove carburetor, allow it to cool off for 30 minutes. Connect a pressure tester from air pump. Connect by-starter circuit. Pump compressed air to the circuit. Replace the auto by-starter if the circuit clogged. Connect battery posts (12V) to starter’s connectors. After 5 minutes, test the by-starter circuit with compressed air. If air flows through the circuit, then, replace the starter.
Removal
Remove fixing plate screw, and then remove the plate and auto by-starter from carburetor.
Valve inspection
Check if auto by-starter and valve needle for damage or wear out.
4. FUEL SYSTEM
Screw ×1
Auto by– starter
Plate
Screw ×1
Installation
Install auto by-starter to the bottom of carburetor body. Install fixing plate to the upper groove of auto by-starter, and install its flat surface to carburetor. Install screw and tighten it.
Needle
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4. FUEL SYSTEM
Float Chamber
Disassembly
Remove 3 mounting screws and remove float chamber cover. Remove the float pin and float.
Checking
Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
Caution
In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one.
Remove main jet, fuel needle jet holder, needle jet, slow jet, pilot screw.
Float
Float Pin
Needle jet
Pin
3 Screws
1 Screw
Float valve
Slow jet
Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
the way down and note the number of turns.
y Do not turn adjust screw forcefully to avoid
damaging valve seat face.
Clean jets with cleaning fluid. Then use compressed air to blow the dirt off. Blow carburetor body passages with compressed air.
Needle jet holder
Main jet
Needle jet
Slow jet
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Assembly
Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw.
Caution
Set the pilot screw in according to number of turns noted before it was removed.
Install the float valve, float, and float pin.
Checking fuel level
Caution
y Check again to ensure float valve, float for
proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber face is vertical to the main jet.
Fuel level: 20.5 mm
Installation of carburetor
Install carburetor in the reverse order of removal. Following adjustments must be made after installation.
˙Throttle cable adjustment. ˙Idle adjustment
4. FUEL SYSTEM
Pilot screw
Float gauge
Adjustment of pilot screw
Caution
y Pilot screw was set at factory, so no
adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation.
y The main stand must be used to support the
motorcycle to perform the adjustments.
Use a tachometer when adjusting engine RPM. Screw in adjustment screw gently, then back up to standard turns.
Standard turns:2±1/2(1 1/2~2 1/2) turns
Warm up engine, adjust the stopper screw of throttle valve to standard RPM.
Idle speed rpm: 1600 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust front end. Press test key on the analyzer. Adjust the pilot screw and read CO reading on the analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments, make sure rpm and CO value are in standard value after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above for adjusting to standard value.
Throttle cable adjust nut
Idle adjustment screw
Pilot screw
4-9
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4. FUEL SYSTEM
Fuel Tank
Fuel unit removal
Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts).) Remove body cover. Disconnect fuel unit connector. Remove fuel unit (4 screws).
Caution
˙Do not bend the float arm of fuel unit ˙Do not fill out too much fuel to fuel tank.
Fuel unit inspection. (Refer to electrical equipment
chapter 17)
Fuel unit installation
Install the gauge in the reverse order of removal.
Fuel unit connector
Caution
Do not forget to install the gasket of fuel unit or damage it.
Fuel tank removal
Remove the Fuel cut valve assembly and Fuel tube.
Remove fuel tank (4 screws).
Fuel cut valve
Fuel tube
4 bolts
Installation
Install the tank in the reverse order of removal.
4-10
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Air Cleaner
Removal
Open the seat. Remove the luggage box (6 bolts and 1 screw). Loosen the clamp strip of air cleaner. Remove the Vapor hose. Remove the Air cleaner (2 bolts).
Installation
Install the tank in the reverse order of removal.
4. FUEL SYSTEM
Clamp strip of air cleaner
Cleaning air cleaner element
Remove air cleaner cover (6 screws).
Remove the Air cleaner element. (Screw×4) With compressed air to cleaning dirty around the element. Replace it if it is too dirty to clean.
6 Screws
Screw×4
Caution
The air cleaner element is made of paper so do not soap it into water or wash it with water.
4-11
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4. FUEL SYSTEM
Notes:
4-12
Home page
Contents
Precautions in Operation....................5-1
Removal of Engine ..............................5-2
Engine Hanger removal.......................5-5
Removal of Engine Hanger Bush.........5-6
Engine Hanger Installation...................5-7
Engine Installation.................................5-7
5. ENGINE REMOVAL
Precautions in Operation
General Information
y The engine has to be supported with special service tools that can be lifted or adjustable. y The following parts can be serviced as engine mounted on frame. y Carburetor. y Driving pulley, driving belt, clutch, and driving disc assembly. y Final gear reduction mechanism.
Specification
Item Capacity
Replacement 800 c.c.
Engine oil capacity
Disassembly 1000 c.c.
5
Replacement 100 c.c.
Gear oil capacity
Disassembly 110 c.c.
Engine & radiator 780 c.c.
Coolant capacity
Reservoir 420 c.c. AS indicator shown
Total 1200 c.c.
Torque Value
Engine mounting bolt 4.0~5.0kgf-m Rear cushion upper connection bolt 3.5~4.5kgf-m Rear cushion under connection bolt 2.4~3.0kgf-m Engine hanger bolt 4.0~5.0kgf-m Rear wheel axle nut 11.0~13.0kgf-m
5-1
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5. ENGINE REMOVAL
Removal of Engine
Open seat and remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts). Remove battery cover (2 screws). Remove battery negative (-) post. Remove battery positive (+) post. Remove tail light connector. Remove right and left body cover (2 bolts). Disconnect the auto by-starter wire connector. Disconnect A.C.G wire connectors.
Remove starter motor wire from relay.
Remove spark plug cap.
Remove fuel pipe, vacuum tube and throttle valve wire from carburetor. Loosen the screw of air cleaner duct strip, and then remove the duct.
A.C.G wire coupler
Spark plug cap
Auto by-starter & AC. G. coupler
Starter relay
5-2
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Remove water hoses from water pump.
Remove the thermo-sensor wire.
Remove the muffler (3 bolts, 2 nuts).
Remove rear inner fender
Water hoses
Water pump
Thermo-sensor wire
3 bolts
Right side
5. ENGINE REMOVAL
2 nuts
Left side
2 Bolts
1 Bolt
5-3
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5. ENGINE REMOVAL
Remove the mounting bolt of right-rear cushion. Remove the rear fork mounting bolt. (2 bolts) Remove rear wheel mounting nut.
Remove rear fork and collars.
Remove rear wheel.
Remove the mounting bolt of left-rear cushion.
Rear wheel axle nut
2 Bolts
5-4
Left-rear cushion bolt
To this chapter contents
Remove the right and left side engine hanger mounting bolts and nuts, then remove engine.
Caution
˙Support engine and frame separately with
special supporters to prevent from engine or
frame falling down.
Engine Hanger removal
5. ENGINE REMOVAL
Left side
Engine hanger nut and bolt
Right side
Engine mounting nut and bolt
Remove the engine mounting bolt and nut, then remove engine hanger.
Engine mounting nut and bolt
5-5
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5. ENGINE REMOVAL
Removal of Engine Hanger Bush
Check if engine hanger bush and cushion rubber bush for damage.
Pressing out
If engine hanger and the rear cushion rubber bush damaged. Then, with the bush remover / presser, Ø 30mm & Ø 22mm, to press the bush out, and replace it with new one. Engine hanger bush: ψ 30mm Rear cushion bush: ψ 22mm
Place the detent section of the bush remover toward the bush, and drive both the pressing ring and bolt in to press the bush out.
Pressing In
Bush
Place the flat section of the remover toward the bush, and then drive the bush, pressing ring, and bolt in to install the bush.
5-6
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Engine Hanger Installation
Install engine hanger onto engine. Install engine mounting bolts & nuts and then tighten the nuts.
Torque value: 4.0~5.0kgf-m
Engine Installation
Check if the bush of engine hanger parts and cushion for damage. Install engine in the reverse procedures of removal.
Caution
y Pay attention of foot & hand safety as engine
installation to avoid hurting.
y Do not bend or twist wires. y Cables wires have to be routed in accordance
with normal layout.
y Small-end bearing collar has to forward to
inside (bearing) as assembling the rear fork.
5. ENGINE REMOVAL
Engine hanger Bolt: Torque value: 4.0~5.0kgf-m Rear cushion bolt: Torque value: upper3.5~4.5kgf-m
under2.4~3.0kgf-m
Rear wheel axle nut: Torque value: 11.0~13.0kgf-m
Bearing collar
5-7
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5. ENGINE REMOVAL
Note:
5-8
Home page
Contents
Mechanism Diagram··························· 6-1 Precautions in Operation··················· 6-2 Troubleshooting·································· 6-3 Cylinder Head Removal······················ 6-4 Cylinder Head Disassembly··············· 6-6 Cylinder Head Inspection··················· 6-7
Mechanism Diagram
0.8~1.2kgf-m
6. CYLINDER HEAD/VALVE
Valve Stem Replacement··················· 6-8 Valve Seat Inspection and Service··· 6-9 Cylinder Head Reassembly··············· 6-11 Cylinder Head Installation················· 6-12 Valve Clearance Adjustment············· 6-14
6
0.8~1.2kgf-m
2.0~2.4kgf-m
1.0~1.2kgf-m
2.0~2.4kgf-m
6-1
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6. CYLINDER HEAD/VALVE
Precautions in Operation
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm. y Cylinder head service can be carried out when engine is in frame.
Specification
Item Standard Limit
Compression pressure 12+/2 kg/cm2 ---
Intake 30.800~30.920 3.075 Camshaft Height of cam lobe
Exhaust 30.411~30.531 30.26 ID of valve rocker arm 12.000~12.018 12.10 Rocker arm OD of valve rocker arm shaft 11.966~11.984 11.910
Valve
Guide seat 5.000~5.012 5.030
Intake 4.975~4.990 4.900 OD of valve stem
Exhaust 4.955~4.970 4.900
Intake 0.010~0.037 0.080 Clearance between valve stem and guide
Free length of valve spring 35.000 31.500 Valve seat width 1.000 1.6
Tilt angle of cylinder head --- 0.05
Exhaust 0.030~0.057 0.100
Torque Value
Cylinder head bolt (LH) 2.0~2.4kgf-m Cylinder head Nut 2.0~2.4kgf-m Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m Bolt of cam chain auto-tensioner 1.2~1.6kgf-m Cam sprocket cover bolts 0.8~1.2kgf-m Cam sprocket bolt 0.8~1.2kgf-m Spark plug 1.0~1.2kgf-m
Tools Special service tools
Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor
6-2
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6. CYLINDER HEAD/VALVE
Troubleshooting
Engine performance will be effected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure
1. Valve
y Improper valve adjustment y Burnt or bent valve y Improper valve timing y Valve spring damage y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage y Tilt or crack cylinder
3. Piston
y Piston ring worn out.
High compression pressure
y Too much carbon deposit on combustion chamber or piston head
Noise
y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Chain wear out or looseness y Auto-tensioner wear out or damage y Camshaft sprocket y Rocker arm or rocker arm shaft wear out
6-3
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6. CYLINDER HEAD/VALVE
Cylinder Head Removal
Remove seat, luggage box and body cover. Remove engine. (Refer to chapter 5) Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator. Remove Air Injection system (AI) pipe mounting bolt.
Remove 1 bolt of thermostat and then remove the thermostat. Remove hole cap for the adjustment bolt of cam chain tensioner, and then loosen the tensioner by turning a flat-driver in C.W direction.
Remove the side cover mounting blots of cylinder head, and then take out the side cover.
Remove cam sprocket bolts and then remove the sprocket by prying chain out.
Vacuum tube
AI. Pipe bolt
Hole cap of adjustment bolt
Clamp strip
Thermostat bolt
2 bolts
2 bolts
6-4
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Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side.
Remove the cylinder head.
Remove 2 bolts of carburetor insulator and then take the insulator out.
Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.
6. CYLINDER HEAD/VALVE
2 Insulator bolts
Cylinder head mounting
Carburetor insulator
4 Nuts
Dowel pin
Caution
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide
Gasket
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6. CYLINDER HEAD/VALVE
Cylinder Head Disassembly
Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts. Then, remove the cap.
Remove the rocker arm pin stopper plate, and then screw a 5mm bolt into the rocker arm pin. Finally, remove the pin and the rocker arm.
Screw a 6 mm bolt into cam sprocket mounting bolt hole, and then pull the camshaft out.
Use a valve compressor to press the valve spring.
Stopper plate bolt
Caution
y In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length is based on the valve cotter in which can be removed.
Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120)
Remove valve stem guide seal. Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.
Caution
Do not damage the matching surface of cylinder head.
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Cylinder Head Inspection
Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
Service limit: 0.5 mm
Valve spring free length
Measure the free length of intake and exhaust valve springs.
Service limit: 28.90 mm
Valve stem
Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
Valve guide
Caution
Before measuring the valve guide, clean carbon deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
Service Limit: IN0.08 mm
EX0.10 mm
6. CYLINDER HEAD/VALVE
5.0 mm valve guide reamer
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6. CYLINDER HEAD/VALVE
Caution
If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide.
Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve guide.
Valve Stem Replacement
Heat up cylinder head to 100~150 with heated plate or toaster.
Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed as heating it.
y Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old valve guide from combustion chamber side.
Valve guide driver
5.0mm
Tool: Valve guide driver: 5.0 mm
Caution
y Check if new valve guide is deformation after
pressed it in.
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150
Adjust the valve guide driver and let valve guide height is in 13 mm. Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.
.
Caution
y Using cutting oil when correcting valve guide
with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues from cylinder head.
Tool: Valve guide reamer: 5.0 mm
Valve guide driver
5.0 mm
Valve guide reamer 5.0 mm
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Valve Seat Inspection and Service
Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.
Caution
y Do not let emery enter into between valve stem
and valve guide.
y Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is roughness, wear out, or incomplete contacted with valve seat.
Valve seat inspection
If the valve seat is too width, narrow or rough, correct it.
Valve seat width
Service limit: 1.6mm
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve seat chamfer cutter. Refer to operation manual of the valve seat chamfer cutter. Use 45° valve seat chamfer cutter to cut any rough or uneven surface from valve seat.
Caution
After valve guide had been replaced, it has to be ground with 45° valve seal chamfer cutter to correct its seat face.
Use 32° cutter to cut a quarter upper part out.
6. CYLINDER HEAD/VALVE
Valve seat width
Roughness
45°
Old valve seat width
32°
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6. CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat.
Use 45° cutter to grind the valve seat to specified width.
Caution
Make sure that all roughness and uneven faces had been ground.
Grind valve seat again if necessary.
Coat the valve seat surface with red paint. Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a seal track will be created on contact surface.
Contact surface too high
Old valve seat width
60°
1.0mm
Old valve seat width
45°
Caution
The contact surfaces of valve and valve seat are very important to the valve sealing capacity.
If the contact surface too high, grind the valve seat with 32° cutter. Then, grind the valve seat to specified width.
If the contact surface too low, grind the valve seat with 60° cutter. Then, grind the valve seat to specified width.
6-10
Contact surface too low
32°
Old valve seat width
60°
V
To this chapter contents
After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground.
Cylinder Head Reassembly
Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Install valve springs and retainers.
Caution
The closed coils of valve spring should face down to combustion chamber.
Use valve spring compressor to press valve spring.
6. CYLINDER HEAD/VALVE
Intake valve
Valve spring retainer
Exhaust valve
alve cotter
Valve stem seal
Valve spring
Caution
In order to avoid damaging the valve stem and the cylinder head, in the combustion chamber place a rag between the valve spring remover/installer as compressing the valve spring directly.
Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120)
Tap valve stem to make valve retainer and valve stem sealing properly.
Caution
Place and hold cylinder head on to working table so that can prevent from valve damaged.
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6. CYLINDER HEAD/VALVE
Cylinder Head Installation
Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts.
Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole. Then, insert the rocker arm pin. Install rocker arm pin mounting plate.
Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide. Install 2 set pins and cylinder head gasket.
Caution
Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.
Loosen the tensioner by turning a flat-driver in C.W direction. Install cylinder head.
Chain guide
Carburetor insulator
Stopper plate bolt
Dowel pin
Gasket
6-12
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Tighten 4 nuts and washers on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover.
Torque value: 2.0~2.4kgf-m
Install and tighten spark plug
Torque value: 2.0~2.4kgf-m
Caution
This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.
Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolt.
6. CYLINDER HEAD/VALVE
2 Insulator bolts
Cylinder head mounting bolts
4 Nuts
Caution
Make sure timing marks are matched.
Install a new O-ring onto thermostat and tighten its mounting bolts. Loosen sprocket chain tensioner and let it contact with chain plate tightly. Tighten the bolt cap of tensioner adjustment hole.
Install Air Injection system (AI) pipe. (2 bolts) Install carburetor insulator onto carburetor and tighten clamp strip bolt. Install the vacuum hose of carburetor insulator.
Hole cap of adjustment bolt
Vacuum tube
Timing mark
Thermostat bolt
Clamp strip
AI. Pipe bolts
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6. CYLINDER HEAD/VALVE
Valve Clearance Adjustment
Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
Standard Value: IN 0.12 ± 0.02 mm
EX 0.12 ± 0.02 mm
Install the valve clearance adjustment hole cap. (3 bolts)
Caution
The gasket is paper type. In case of broken, replace it and clean the Remnant gasket.
Start the engine after assembly. Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head. Stop the engine after confirmed, and then install the intake valve adjustment hole cap.
Install the seat, luggage box and the body cover.
Caution
y If lubricant does not flow to cylinder head,
engine components will be worn out seriously. Thus, it must be confirmed.
y When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate engine speed.
6-14
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Contents
7. CYLINDER/PISTON
Mechanism Diagram······························7-1 Precautions in Operation ······················7-2 Trouble Diagnosis··································7-2 Cylinder Removal···································7-3
Mechanism Diagram
Piston Removal ··································7-4 Piston Ring Installation ·····················7-6 Piston Installation ······························7-7 Cylinder Installation···························7-7
7
7-1
To this chapter contents
7. CYLINDER/PISTON
Precautions in Operation
General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification Unitmm LH12W & LH18W
Item Standard Limit
Cylinder
Piston/ Piston ring
OD of piston pin 14.960~15.000 14.930 Clearance between piston and piston pin 0.002~0.014 0.020 ID of connecting rod small-end 15.016~15.034 15.060
ID ( LA18W not included) 56.995~57.015 57.016 Bend - 0.050
Clearance between piston rings
Ring-end gap
OD of piston ( LA18W not included) 56.985~57.005 56.900 Clearance between piston and cylinder 0.010~0.040 0.100 ID of piston pin boss 15.002~15.008 15.040
Top ring 0.015~0.050 0.090
nd
ring 0.015~0.050 0.090
2 Top ring 0.150~0.300 0.500 2nd ring 0.300~0.450 0.650 Oil ring side rail 0.200~0.700 -
LH18W
Item Standard Limit Cylinder ID 60.995~61.015 61.016 Piston OD of piston 60.985~61.005 60.900
Trouble Diagnosis
Low or Unstable Compression Pressure
y Cylinder or piston ring worn out
Knock or Noise
y Cylinder or piston ring worn out y Carbon deposits on cylinder head top-side y Piston pin hole and piston pin wear out
Smoking in Exhaust Pipe
y Piston or piston ring worn out y Piston ring installation improperly y Cylinder or piston damage
Engine Overheat
y Carbon deposits on cylinder head top side y Cooling pipe clogged or not enough in coolant
flow
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7. CYLINDER/PISTON
Cylinder Removal
Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder.
Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
Coolant hose
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out or damaged. In the 3 positions, top, center and bottom, of cylinder, measure the X and Y values respective in the cylinder.
Service limit: LH12W: 57.016
LH18W: 61.10 mm
Check cylinder if warp.
Service limit: 0.05 mm
Top Center
Bottom
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7. CYLINDER/PISTON
Piston Removal
Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
Inspection
Measure clearance between piston ring and its grooves.
Service Limit: Top ring: 0.09 mm
nd
2
ring: 0.09 mm
Remove piston rings
Check if the piston rings are damaged or its grooves are worn.
Caution
Pay attention to remove piston rings because they are fragile.
Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston.
Service Limit: Top ring: 0.50 mm
nd
ring: 0.65 mm
2
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7. CYLINDER/PISTON
Measure the outer diameter of piston pin.
Service Limit: 15.040 mm
Measure the inner diameter of connecting rod small end.
Service Limit: 15.06 mm
Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.
Service Limit: 0.02 mm
Measure piston outer diameter.
Caution
The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin.
Service limit60.90 mm
Compare measured value with service limit to calculate the clearance between piston and cylinder.
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7. CYLINDER/PISTON
Piston Ring Installation
Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation. y All marks on the piston rings must be forwarded to up side. y Make sure that all piston rings can be rotated freely after installed.
Top ring
nd
2
ring
Oil ring
Top groove
nd
2
groove
Oil groove
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7. CYLINDER/PISTON
Piston Installation
Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring.
Caution
y Do not let the opening of piston pin snap ring
align with the opening piston ring.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from falling into crankcase as operation.
Cylinder Installation
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase.
Caution
Soap the residues into solvent so that the residues can be removed more easily.
Install dowel pins and new gasket.
Coat engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.
Caution
Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
Install coolant hose onto cylinder. Install cylinder head (refer to Chapter 6).
Coolant hose
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7. CYLINDER/PISTON
Notes:
7-8
Home page
Contents
Mechanism Diagram ··························· 8-1 Maintenance Description···················· 8-2 Trouble Diagnosis······························· 8-2 Left Crankcase Cover ························· 8-3
8. V-BELT DRIVING SYSTEM/KICK STARTER
Mechanism Diagram
Driving Belt···········································8-4 Drive Face·············································8-6 Clutch Outer/Driven Pulley··················8-9
3.5~4.5kgf-m
5.0~6.0kgf-m
5.0~6.0kgf-m
8
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Maintenance Description
Precautions in Operation General Information
y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. y Driving belt and driving pulley must be free of grease.
Specification Unitmm
Item Standard value (mm) Limit (mm) Driving belt width 19.000 17.500 ID of drive face boss 27.000~27.021 27.060 OD of drive face 26.970~26.990 26.940 OD of roller 19.950~20.100 19.500 ID of clutch outer 130.000~130.200 130.500 Thickness of clutch weight 4.000~4.100 2.000 Free length of driven pulley spring 88.300 83.200 OD of driven pulley 33.965~33.985 33.940 ID of drive face 34.000~34.025 34.060
Torque value
y Driven face nut: 5.0~6.0kgf-m y Clutch outer nut: 5.0~6.0kgf-m
Special Service Tools
Clutch spring compressor: SYM-2301000 Inner bearing puller: Clutch nut wrench 39 x 41 mm: Universal holder: Bearing driver:
SYM-6204002
SYM-9020200
SYM-2210100
SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can not be moved
1. Worn driving Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
Insufficient horsepower or poor high speed performance
1. Worn driving belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Left Crankcase Cover
Left crankcase cover removal
Remove body cover. Remove air cleaner. (2 bolts) Remove L crankcase cover. (7 bolts)
Left crankcase cover install
Install left crankcase cover in the reverse procedures of removal.
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Driving Belt
Removal
Remove left crankcase cover Hold drive face with universal holder, and remove nut and drive face.
Hold clutch outer with universal holder, and remove nut and clutch outer.
Caution
y Using special service tools for tightening or
loosening the nut.
y Fixed rear wheel or rear brake will damage
reduction gear system.
Universal holder
Drive belt
Nut
Push the driving belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley. Do not remove driving belt. Remove the driving belt from the groove of driven pulley.
Inspection
Check the driving belt for crack or wear. Replace it if necessary. Measure the width of driving belt as diagram shown.
Service Limit: 17.5 mm
Replace the belt if exceeds the service limit.
Caution
Universal holder
Belt tooth
Width
y Using the genuine parts for replacement. y The surfaces of driving belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.
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Installation
Caution
Pull out driven face to avoid it closing.
Install driving belt onto driven pulley.
Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.
Install the clutch outer with universal holder, and then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
8. V-BELT DRIVING SYSTEM/KICK STARTER
Driven face
Clutch outer
Nut
Universal holder
Install the drive face with universal holder, and then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Universal holder
8-5
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Drive Face
Removal
Remove left crankcase cover. Hold generator flywheel with universal holder, and
then remove drive face nut. Remove drive face.
Remove driving belt and movable drive face comp from crankshaft.
Remove ramp plate.
Universal holder
Crankshaft
Ramp plate
Movable drive face
Drive face boss
Remove weight rollers from movable drive face.
Movable drive face
Weight roller
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Inspection
The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be effected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter. Replace it if exceed the service limit.
Service limit: 19.50 mm Weight: 14.5g
Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face, and replace it if it exceed service limit.
Service limit: 26.94 mm
Weight roller
Movable drive face
Drive face boss
Measure the inner diameter of movable drive face, and replace it if it exceed service limit.
Service limit: 27.06 mm
Reassembly/installation Install weight rollers.
Caution
The weight roller two end surfaces are not certainly same. In order to lengthen the roller life and prevented exceptionally wears the occurrence, Please end surface of the closure surface counter clockwise assembles onto movable drive face.
Install ramp plate.
Weight roller
Guide collar
Closure surface
Ramp plate
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8. V-BELT DRIVING SYSTEM/KICK STARTER
With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss.
Caution
The movable drive face surface has to be free of grease. Clean it with cleaning solvent.
Install movable drive face comp. onto crankshaft.
Movable drive face
Crank shaft
Driven pulley installation
Press driving belt into pulley groove, and then pull the belt onto drive shaft.
Install drive face, washer and nut.
Press down
Drive belt
Drive face boss
Drive face boss
Nut
Caution
Make sure that two sides of pulley surfaces have to be free of grease. Clean it with cleaning solvent.
Hold drive face with universal holder. Tighten nut to specified torque.
Torque value: 5.0~6.0kgf-m
Install left crankcase cover.
8-8
Drive face
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch Outer/Driven Pulley
Disassembly
Remove drive belt and clutch outer/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily.
Caution
Do not press the compressor too much.
Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool. Release the clutch spring compressor and remove clutch weight and spring from driven pulley.
Remove seal collar from driven pulley.
Remove guide pin, guide pin roller, and movable driven face, and then remove O-ring & oil seal seat from movable driven face.
Clutch nut wrench
Movable driven face
Clutch spring compressor
Seal
Collar
Guide pin
Inspection Clutch outer
Measure the inner diameter of clutch outer. Replace the clutch outer if exceed service limit.
Service limit: 130.5 mm
O-ring
Inner diameter
Guide pin
Guide pin roller
Clutch outer
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch lining
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: 83.2 mm
Clutch lining
Clutch weight
Driven pulley
Check following items:
y If both surfaces are damaged or worn. y If guide pin groove is damaged or worn.
Replace damaged or worn components. Measure the outer diameter of driven face and the inner diameter of movable driven face. 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.
Outer ball bearing
Free length
Driven face
Movable driven face
Guide pin groove
Needle bearing
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8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch weight Replacement
Remove snap ring and washer, and then remove clutch weight and spring from driving plate.
Caution
Some of models are equipped with one mounting plate instead of 3 snap rings.
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 setting pins.
Spring
Clutch weight
Shock absorption rubber
Driving plate
Snap ring
Setting pin
Install new clutch weight onto setting pin and then push to the specified location. Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.
Caution
Grease or lubricant will damage the clutch weight and effect the block’s connection capacity.
Install the spring into groove with pliers.
Shock absorption rubber
Clutch weight
Spring
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