Sym MB10A7-A series, Symba 100 Service Manual

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Symba 100

Service Manual

FOREWORD CONTENTS

HOW TO USE THIS MANUAL

MECHANICAL LAYOUT

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Foreword

This service manual contains the technical data of each component inspection and repair for the SANYANG MB10A7-A series motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment”, providing technician with service guidelines. Copyright reserved.

If the style and construction of the motorcycle, MB10A7-A series motorcycle, are different from that of the photos, pictures shown in this manual, the actual vehicle layout should be followed. Specifications may be changed without notice.

Service Department

SANYANG INDUSTRY CO., LTD.

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How to Use This Manual

This service manual describes basic information of individual parts and system inspection & service for SANYANG MB10A7-A series motorcycle. In addition, please refer to the manual contents for detailed information for the model year.

The first chapter covers general information and troubleshooting. The second chapter covers maintenance information and special tools catalog. The third to the 9th chapters cover engine, fuel and driving systems. The 10th and 11th chapters contain the parts of vehicle frame. The 12th chapter is electrical appliances. The 13th chapter is wiring diagram.

Please see index of content for brief information and quick guide.

There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and “Mechanical

Layout” on the PDF version homepage, and can access these items by clicking of the

mouse. If technician wants to see the content of one specific chapter, click on the title of each

chapter on the Index page. There are two buttons on the upper part of each page, “Homepage” and “contents”. The user can click on the “Homepage” button or the “Contents” button to go back to the homepage or contents index. Therefore, to check one paragraph inside the chapter, click on the paragraph index to go to the desired paragraph. In addition, there is a “To This Chapter Contents” button at the upper side of each page, by clicking the button; you can go back to the paragraph selection index of this specific chapter.

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Contents

Page Content Index

1-1 ~ 1-24

General Information / Troubleshooting

2-1 ~ 2-20

Maintenance Information

3-1 ~ 3-16

Fuel System

4-1 ~ 4-20

Clutch / Transmission / Lubrication System

5-1 ~ 5-10

AC Generator / Starting Clutch

6-1 ~ 6-6

Engine Removal

7-1 ~ 7-18

Cylinder Head / Valve

8-1 ~ 8-10

Cylinder / Piston

9-1 ~ 9-16

Crankshaft / Crankcase / Shifting Gear / Kick Starter

10-1 ~ 10-20

Steering / Front Wheel / Front Suspension / Front Brake

11-1 ~ 11-16

Rear Wheel / Rear Suspension / Rear Brake

12-1 ~ 12-26

Electrical System

13-1 ~ 13-10

Emission Control System

14-1 ~ 14-2

Electrical Diagram

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Mechanical Layout

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Contents

Air Filter

FR. Brake Lever

Meter

Headlight

Muffler

Engine Oil Dipstick

Shifting Pedal

Headlight / Starting Switch

Headlight Dimmer / Winker / Horn Switch

Main Switch

Taillight

Fuel Tank Cap

Rear Brake Pedal

Battery / Fuse / CDI / Regulator Rectifier

Kick Starter

RR. Winker

Ignition Coil

Winker Relay

Horn / Start Motor

FR. Winker

Electrical Resisto

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1. General Information

1-1

Symbols and Marks ··················1-1 General Safety···························1-2 Service Precautions··················1-3 Specifications····························1-9 Torque Reference Values·········1-10

Engine Torque Values···············1-10 Frame Torque Values················1-11 Troubleshooting························1-12 Cable & Wire Routing················1-19 Lubrication Points·····················1-24

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

Serious injury or even death may occur if procedures are not followed.

Caution

Equipment damages may occur if procedures are not followed.

Engine oil

Recommended oil: Bramax motor oil or equivalent motor oil, SAE 10W-30 API SH class oil. Warranty will not cover the damage which is caused by not applying with the recommended engine oil.

Grease

King Mate G-3 is recommended.

Locking sealant

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

Oil seal

Apply with lubricant.

Renew

Replace with a new part before installation.

Brake fluid

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools

Use special tools.

Correct

Correct installation.

Wrong

Wrong installation.

Indication Indication of parts.

Directions

Position and operation directions

Parts assembly directions. Bolt installation direction, --- means that bolt go through the component

(invisible).

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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 a ventilator.

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 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 you to 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 the vehicle is cooling down.

Battery

Caution

‧ Battery emits explosive gases; flame is strictly

prohibited. Keeps the place well ventilated when charging the battery.

‧ Battery contains sulfuric acid (electrolyte),

which can cause serious burns, so be careful not to get the sulfuric acid 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 plenty of water and then go to hospital to consult an ophthalmologist.

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

water or milk, and take some laxative such as 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 piece of clean cloth 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-genuine parts for SANYANG vehicle may damage it.

y Special tools are designed for remove and install

of components without damaging the part. Using wrong tools may result in damage.

y When servicing this bike, use only metric tools.

Metric bolts, nuts, using wrong tools and fasteners may damage this vehicle.

y Clean the outside of the parts or the cover before

removing it from the bike. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system, and cause 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 Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

y Rubber parts may become deteriorated when old,

and easy 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 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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y The length of bolts and screws for assembly,

cover plates or boxes is different from one another; make 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 When oil seal is installed, fill the groove with

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

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.

y Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

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.

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Both of these examples can result in bearing damage.

Manufacturer's name

Groove

Clamp

Connector

Boots

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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.

y Note that do not let parts fall down.

y Before battery removal operation, you have to

remove the battery negative (-) cable first. Avoid using tools like open-end wrench, which may contact with body or create spark.

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 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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y When separating a connector, it locker has to

be unlocked first. 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 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 Before terminal connection, check if the boot is

crack or the terminal is loose.

y Insert the terminal completely.

Check if the boot covers the terminal. 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 Wire band and wire harness have to be clamped

secured properly.

y Do not squeeze wires against the weld or its

clamp.

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y Do not let the wire harness contact with rotating,

moving or vibrating components when routing the harness.

y Keep wire harnesses far away from the hot parts.

y Avoid wire harnesses from sharp edges or

corners, and also avoid the jutted-out ends of bolts and screws.

y Route harnesses so that they neither pull too

tight nor have excessive slack.

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 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 when

installing other components.

Never Touch

Never too

Never clamp or squeeze the wire harness

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y Do not let the wire harness been twisted when

installation.

y Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, use rubber covering against adjacent or surrounding parts in all steering perimeters.

y Before operating a test instrument, operator

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

y Use sand paper to clean connector

pins/terminals if rust is found. And then continue the connection operation.

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

Clean rust

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Specifications

Manufacturer SANYANG Model MB10A7-A

Overall Length 1910 mm Front TELESCOPIC

Overall Width 690 mm

Suspension

System

Rear SWING ARM

Overall Height 1055 mm Front 2.50-17 38L

Dimension

Wheel Base 1225 mm

Tire

Specifications

Rear 2.50-17 38L

Front 38 kg

Rear 57 kg

Front Drum (ø 110 mm)

Curb

Weight

Total 95 kg

Brake System

Rear Drum (ø 110 mm)

Passengers/Weight 1 passenger /75 kg Max. Speed Over 80 km/hr

Front 53 kg

Performance

Climb Ability

Below 20°

Rear 117 kg

Primary

Reduction

4.059 (69/17T)

Weight

Total Weight

Total 170 kg

Secondary Reduction

2.571 (36/14T)

Type

Air cooled 4-stroke gasoline

engine

Clutch

Wet multi-plate, auto

centrifugal clutch

Installation and

arrangement

Vertical, below center,

incline 15°

Reduction

Transmission 4 speed, circulated

Fuel Used Unleaded gasoline Speedometer 0 ~ 120 km/hr

Fuel system Carburetor Horn 80~110 dB

Bore Ø 52.4 mm Muffler Expansion & Pulse Type

Stroke 47 mm

Exhaust Pipe Position and

Direction

Right side, and

Backward

Cylinder

Arrangement Single Cylinder Lubrication System Forced and wet sump

Displacement 101.4 cc Solid Particulate -

Compression Ratio 9.2 : 1 CO Below 1.8 %

Max HP 6.8 ps / 8500 rpm

Exhaust

Concentration

HC Below 2000 ppm

Max Torque

0.69 kg-m / 6000 rpm

E.E.C.

√

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

√

Engine

Starting System Kick/ Electrical Starter Catalytic Converter

√

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Torque Reference Values

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

Standard Torque Values for Reference

Tighten Torque Tighten Torque

Type

kgf-m N-m

Type

kgf-m N-m

5mm bolt、nut

0.45~0.6 4.4~6 4mm screw 0.1~0.15 1.0~1.5

6mm bolt、nut

0.8~1.2 8~12 5mm screw 0.35~0.5 3.4~5

8mm bolt、nut

1.8~2.5 18~25

6mm screw、SH nut

0.7~1.1 7~11

10mm bolt、nut

3.0~4.0 29~39

6mm bolt、nut

1.0~1.4 10~14

12mm bolt、nut

5.0~6.0 49~59

8mm bolt、nut

2.4~3.0 24~29

3mm screw 0.05~0.08 0.5~0.8

10mm bolt、nut

3.5~4.5 34~44

Engine Torque Values

Torque Value

Item

Q’ty

Thread

Dia. (mm)

kgf-m N-m

Remarks

Cylinder head nut

4 8 1.0~1.2 10~12

Cylinder head left bolt

1 6 0.8~1.2 7.8~12

Cylinder stud bolt

4 8 0.7~1.0 7~10

Cylinder head side cover bolt

3 6 0.8~1.2 7.8~12

Tappet adjustment hole cap

2 6 0.8~1.2 7.8~12

Tappet adjustment screw nut

4 5 0.7~1.1 7~11

Apply oil to thread

Cam gear bolt

2 6 1.0~1.2 10~12

Spark plug

1 10 1.0~1.2 10~12

Carburetor insulator bolt

2 6 0.7~1.1 7~11

Engine oil draining bolt

1 12 1.5~2.0 15~20

Clutch nut

1 14 3.8~4.5 38~45

Engine oil strainer cap

2 6 0.8~1.2 7.8~12

Engine oil pump cover screw

2 6 0.3~0.4 3~4

Engine oil pump screw

3 6 0.4~0.6 4~6

Right crankcase cover bolt

10 6 0.8~1.2 7.8~12

Left crankcase cover bolt

8 6 0.8~1.2 7.8~12

Left crankcase rear cover bolt

2 6 0.8~1.2 7.8~12

Driving

2 6 0.8~1.2 7.8~12

ACG. Flywheel nut

1 12 3.5~4.3 35~43

Starting clutch bolt

3 6 1.0~1.4 10~14

Apply glue to thread

Crankcase bolt

7 6 0.8~1.2 7.8~12

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Frame Torque Values

Torque Value

Item

Q’ty

Thread Dia.

(mm)

(kgf-m) (N-m)

Remarks

Handlebar luck bolt

4 8 3.0~3.5 29~35

Handlebar post locknut

1 10 4.0~4.5 39~49

Steering stem locknut

1 25.4 6.0~8.0 59~78

Steering top cone race

1 25.4 0.15~0.25 1.5~2.5

Front wheel axle nut 1 10 4.0~5.0 39~49 Rear wheel axle nut 1 12 5.0~6.0 49~59

Final driven sprocket nut

1 16 6.0~7.0 59~69

Drive sprocket nut

4 8 2.7~3.3 26~32

Front cushion mounting bolt

2 8 3.0~3.5 29~35

Rear cushion upper connection bolt

2 10 3.0~4.0 29~39

Rear cushion lower connection bolt

2 10 3.0~4.0 29~39

Brake lever nut

2 6 0.8~1.2 7.8~12

ear brake drum mounting bolt

1 8 1.5~2.5 15~25

Engine hanger link nut

2 8 3.0~3.5 44~54

Foot stand bolt

4 8 2.4~3.0 24~29

Kick starter bolt

1 6 1.6~1.8 15.7~17.6

Gear change pedal bolt

1 6 1.4~1.5 13.7~14.7

ear fork mounting bolt

1 10 3.0~4.0 29~39

Muffler mounting nut

2 6 1.0~1.4 10~13.7

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Troubleshooting

A. Engine hard to start or can not be started

Check and adjustment Fault condition Possible causes

Loosen carburetor drain bolt to check if there is gasoline

inside the

carburetor

Fuel supplied to carburetor sufficient

No fuel is supplied to carbureto

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

Perform cylinder compression pressure

test.

Good sparks Weak sparks, no spark

at a

Cylinder compression pressure normal

Low compression pressure or no pressure

Re-start by following the starting procedures

No ignition There are some signs of

ignition; but engine cannot be started.

Remove the spark plug again and check it.

Dry spark plug Wet spark plug

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 damaged

3. Malfunction of CDI set

4. Malfunction of AC generator

5. Ignition coil is in open or short circuit

6. Ignition coil wire open or short circuit

7. Main switch malfunction

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 leaking through 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

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

Check and adjustment Fault condition Possible causes

Try gradual acceleration and check engine speed

Engine speed increases. Engine speed cannot

increase.

Check ignition timing

(

Using ignition lamp)

Check cylinder compression pressure (using compression pressure gauge)

Correct ignition timing Incorrect ignition timing

Compression pressure correct

No compression

Check if carburetor jet is clo

Not clogged Clogged

Remove spark plug

Check if engine over heat

No foul or discoloration Fouled and discoloration

No knock Knock

1. Air cleaner clogged

1. Poor fuel supply

2. Lines in fuel tank evaporation system clogged

3. Exhaust pipe clogged

4. Fuel level too low in carburetor

5. Fuel nozzle clogged in carburetor.

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

1. Remove foreign object

1. Remove dirt

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

2. Lean mixture

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

6. Poor circuit on the cooling system

Normal Engine overheat

Continually drive in

1. Too much carbon deposited in

combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

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

Check and adjustment Fault condition Probable causes

Check ignition timing (Using ignition lamp)

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

Good spark Poor

No air sucked in Air sucked in

Good Poor

Normal Abnormal

Air sucked in through carburetor gasket

Adjust the air screw of

carburetor

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

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D. Engine runs sluggish (High speed)

Check for fuel supplying

syste

m in

automatic fuel cup

Check if carburetor clogged

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

Good Poor

Check and adjustment

Fault condition Probable causes

Check ignition timing

1. Malfunction of CDI

2. Malfunction of AC alternator

Normal Abnormal

Not clogged Clogged

1. Cleaning

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E. Starter Motor Malfunction

1. Starter Motor doesn’t rotate

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Check the battery circuit by activating turning signal

Push the staring button and check if the starting relay is activated

Flashing normally Not flashing or dimmed

Braking light is activated

Braking light not activated

Starting relay activated Starting relay not activated

Connect the starting motor to the battery

1. Bad contact in the starter switch

2. Abnormal Starter relay

3. Loose coupler or terminals

Pull the brake handle or step on the braking pedal

1. Burnt Fuse

2. Insufficient Battery Voltage

3. Braking Switch abnormal

4. Main switch abnormal

1. Insufficient Battery capacity

(60~120 flashes per minute)

Starter Motor rotates Starter Motor doesn’t rotate

1. Worn carbon brushes

2. Broken or shorted rotor windings

3. Broken Starter motor sub wire

4. Loose coupler

1. Loose coupler

Check and adjustment

Fault condition Possible causes

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2. Starting Motor rotates slowly or spins without engagement with crankshaft

3. Starter motor won’t stop rotating

Check the battery circuit by activating turning signal

Flashing normally

Not flashing or dimmed

1. Insufficient Battery capacity

Connect the starting motor to the battery

Starting Motor Still rotating slowl

Rotates Normally

Works smoothly Jammed

1. Loose coupler or terminals

2. Starting Relay bad contact

1. Engine Seized.

Kick the kick starter

Turn the main switch off

Motor keeps running Motor stops

1. Starting switch shorted/ stuck

1. Starting relay shorted

1. Starting Motor shorted or damaged

Check and adjustment

Fault condition Possible causes

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F. Abnormal Engine Noise

Fault condition Possible causes

Rocker arm noise

1. Excessive valve clearance

2. Worn rocker arm

3. Worn camshaft

Piston slapping

1. Worn piston and cylinder

2. Carbon deposit in the combustion chamber

3. Worn piston pin or connecting rod lower end

Cam chain noise

1. Worn camshaft bearings.

2. Worn cam sprocket.

3. Loose or worn cam chain.

Clutch knocking

1. Excessive clutch plate clearance

Transmission gear noise

1. Worn or deteriorated rear wheel damping rubber.

2. Gear surface worn

3. Worn transmission gear set

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Cable & Wire Routing

Left handlebar switch wire

Left winker wire

Handlebar right side wire band

Right handlebar switch wire

Right winker wire

Front brake switch wire

Left handlebar switch wire

Left winker wire

Right handlebar switch wire

Right winker wire

Front brake switch wire

Speedometer cable

Throttle cable

Front brake cable

Meter wire harness

Headlight wire

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1. General Information

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All cable & wire harness

Apply grease 5~7g to the inside part of handlebar post

Handlebar

50mm

Wire harness clamp

Speedometer cable

Front brake cable

Wire harness couplers

After clamp 1 is ready, clamp all cable and wire harness.)

(Front left winker wire, left handlebar switch wire, headlight wire, front right winker wire, front brake light switch wire, right handlebar switch wire and meter wire)

Clamp 2

Clamp 1

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Speedometer cable

Front brake cable

Make sure all cables and wires go throu

h wire grommet

Push the wire clamp when the wires are at right place.

Throttle cable and main wire harness should be placed between the left air cleaner intake duct and the frame.

Main switch coupler location

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Secondary air pipe and winker relay wire should be clamped.

Located on the rela

sta

Auto by-starter wire and main wire harness should be clamped properly.

AC Generator wire gear switch couplers should be packed well and clamped.

PCV drain pipe and carburetor drain pipe should go through the hole of body cover stay.

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Taillight wire, rear winker wire should be clamped.

Fuel level gauge wire should be clamped

Rear winker wire should be clam

Rear winker wire should go through winker stay hole.

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Lubrication Points

Throttle cable / Front brake lever

pivot

Steering stem bearing

Rear axle Main stand pivot

Side stand pivot

Speedometer pinion / Front axle

Drive chain

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Precautions in Operation ············ 2-1 Periodical Maintenance Chart·····2-2 Lubrication System······················2-3 Fuel System·································· 2-4 Air Cleaner···································· 2-5 Throttle Cable Operation·············2-6 PCV System·································· 2-6 Valve Clearance···························· 2-7 Idle Speed Adjustment ················ 2-8 Ignition System ····························2-9 Spark Plug ····································2-9 Compression Pressure················2-10

Clutch Adjustment ······················· 2-11 Drive Chain Adjustment···············2-12 Steering System···························2-13 Suspension System·····················2-13 Brake System ·······························2-14 Tire·················································2-15 Battery···········································2-16 Headlight Adjustment··················2-17 Brake Light Switch·······················2-17 Nuts, Bolts Tightness ··················2-17 Special Tool Catalog····················2-18

Precautions in Operation

Specification

Fuel Tank Capacity 4100 c.c.

Capacity 1000 c.c.

Engine Oil

Changed 800 c.c.

Throttle Cable Free Play 2~6 mm Spark Plug NGK C6HSA Spark Plug gap 0.6~0.7 mm Ignition Timing BTDC 15º±1º / 1600 rpm Ignition Advance BTDC 32º±1º / 3300 rpm Idle Speed 1600±100 rpm Compression Pressure 11±1 kgf/cm² (600 rpm) Valve Clearance In./Ex. 0.12±0.02 mm

Tire Size

Front/Rear 2.50-17 38L

Single Ride

Front：1.75 kg/cm² / Rear：2.25 kg/cm²

Tire Pressure(Cold)

Tandem Ride

Front：1.75 kg/cm² / Rear：2.75 kg/cm²

Battery Type 12N5A (12V 5Ah) Brake Lever Clearance 10~20 mm

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2. Maintenance Information

2-2

Periodical Maintenance Schedule

Items

Initial

300KM

1 month or

every

1000KM

3 months or

every

3000KM

6 months or

every

6000KM

1 year or

every

12000KM

☆Air filter element

I C C R

☆AICV filter

I C C R

☆Gasoline filter

I I R

☆Engine oil filter

C C C

☆Engine oil replacement

R Exchange every 1000 km

Tire pressure

I I

Battery Inspection

I I

Brake lever free play check

I I

Steering handle integrity check

I I

Shock absorber performance check

I I

Bolts tightening check

I I

Check the engine for oil leakage

I I

☆Spark plug inspection or re placement

I I R

☆Change gear oil

R Exchange every 5000 km

Lubrication of the whole bike

Exhaust pipe

I I

☆Ignition timing

I I

☆Idle emission check

A I A

☆Throttle operation

I I

☆Engine bolts torque

I I

☆Transmission / Chain

I I/L R

☆Clutch free play inspection

I I

Light/ electrical system/ instrument readings.

I I

Main stand/ side stand springs.

I I

Fuel lines

I I

Cam chain

I I

☆Valve clearance

I A

☆PCV system integrity

I C

☆Crankcase blow-by over-flow pipe

I Drain every 2000km

☆Second air injection system (filter)

I I C

☆E.E.C. Device check

Note：I-Inspection A-Adjustment R-Replacement C-Clean L-Lubrication

Please have your periodical maintenance data recorded by your SYM Authorized Dealer to maintain the motorcycle in excellent condition. The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference. Whichevertime or mileage- comes first will be regarded as an index for maintenance.

Remark：These marks “☆” in the schedule are emiss ion control items. A ccording to EPA regulations, these item checks

must be performed period ically fol lo wing the use r ma nua l instr uct ions . It’s prohibited to adjust or repair these emission control items by unauthorized people. Otherwise, SYM is no responsible.

1. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the

Heavily- polluted environment.

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

3. Preventive maintenance：

a. Ignition system－Perform maintenance or check when continuous abnormal ignition, misfire, after-burn, overheating occur. b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is decreasing. c. Replace worn out pistons, cylinder head.

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Lubrication System

Engine Oil Capacity

Caution

z Turn off engine, and park the motorcycle

on flat surface with main stand.

z Check oil level with oil dipstick. (Do not

screw the dipstick into engine when checking.)

If oil level is near lower limit, fill in the recommended engine oil to upper limit.

Engine Oil Replacement

Engine off and replace the oil dipstick. Remove the oil drain bolt under the crankcase to drain the engine oil.

After completely drain the engine oil, clean the drain bolt and the washer. If the washer is deformed or cracked, replace with a new one. Torque value：3.5~4.5kgf-m

Caution

z Warm up the engine before drain oil, that

will make engine oil easily drained thoroughly

Fill in the engine oil to the standard capacity. Oil viscosity SAE 10W-30 Recommended using Bramax series engine oil.

Engine Oil Capacity Full disassembly：1000 c.c.

Regular replacement：800 c.c.

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

Engine Oil Strainer Cleaning

Drain engine oil completely. Remove oil strainer. Using high pressure air to clean oil strainer is suggested. Check if oil strainer is deformed or damaged. Replace it if necessary. Reinstall oil strainer and oil strainer cap. Torque value：0.8~1.2kgf-m

Engine oil drain bolt

Upper limit

Lower limit

2 bolts

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Fuel System

Fuel lines

Check all fuel lines, and replace when they are deteriorated, damaged or leaking.

Caution

z Gasoline is a highly flammable

substance, so any source of fire or spark is strictly prohibited during operation.

Fuel filter replacement

Warning

z Any source of fire or spark is strictly

prohibited during operation.

z Fuel filter is sealed so cannot be cleaned.

Replace it if it’s clogged.

If fuel filter is clogged, please drain all the gasoline into a clean container, and wash the fuel tank. After replacing the fuel filter and washing the fuel tank, refill the tank with clean gasoline. Check the fuel line for leakage.

Vacuum type auto fuel cock

Fuel filter

Negative pressure pipe

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Air Filter

Air filter element

Remove the side cover. Remove the air filter duct (1 screw). Remove the air filter cover screw (4 screws).

Open the hold clip and remove the air filter cover.

Remove the air filter element. Check the filter element for dirty or damage.

Wash the air filter element with high flash point solvent (for example, kerosene or diesel) Squeeze out the cleaning solvent thoroughly, soak the element into engine oil, and squeeze out the excessive. Re-install the filter and the cover. If the air filter element is too dirty or damaged, replace it with new parts.

Caution

y Never use gasoline or other low-flash

point solvent for cleaning the element.

wash squeeze

soak squeeze

2 screws on both sides

Screw

Hold clip

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Throttle Operation

Operate the throttle grip to see if the throttle cable is going smoothly. If the throttle cable is deteriorated, twisted or damaged, replace it with new part. If the throttle cable doesn’t operate smoothly, apply some lubrication oil onto it. Measure the free play of the throttle grip, through the inner side flange of it.

Free play：2~6 mm

Please loosen the lock nut and adjust the throttle cable nut to reach the normal free play.

PCV System

Unplug the drain pipe, and leak the deposit off. Drain the pipe every 2,000 km.

Caution

z Under rainy or full- throttle situation, the

maintenance period should be shortened. You can check the deposit amount through the transparent pipe.

Drain pipe

2~6 mm

Locknut

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Valve Clearance Adjustment

Caution

z The valve clearance should be adjusted

when the engine is cold. (Under 35 degrees Celsius)

Remove the valve clearance-adjusting cap (2 bolts).Remove the cylinder head side cover (2 bolts). Remove the timing inspection cap and the AC.G cap on the crankcase L cover. Use a T socket wrench to rotate the crankshaft counterclockwise. Align the “T” mark on the AC.G flywheel with the crankcase sign, and simultaneously, the cam- chain sprocket TDC mark aligning with the cylinder head mark (That means the piston is in the upper end of compression stroke)

Valve clearance inspection and adjustment

Check the intake and exhaust valve clearance by inserting the feeler gauge between the adjusting screw and the lock nut.

Valve clearance：IN / EX 0.12±0.02 mm

Adjust by loosening the lock nut first, and turning the adjusting screw until you feel slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut.

Caution

z Check the valve clearance after the

adjustment.

Install the valve clearance-adjusting cap, cylinder head side cover, and the timing inspection cap and the AC.G cap on the crankcase L cover.

Caution

z Before installing the O-ring, check if the

O-ring is damaged, and apply some oil on it to prevent damage during assembly.

2 bolts

〝T〞mark

Timing inspection cap

TDC mark

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Idle Speed Adjustment

Caution

z All the other configurations should be

completed before idle speed adjustment.

z The engine must be fully warmed before

the idle speed adjustment.

Use the main stand of the bike, and warm up the engine. Clip on the RPM sensor (Clip the RPM sensor clamp on the spark plug cap wire) Turn the idle speed adjusting screw to reach the recommended idle speed.

Recommended idle speed：1600±100rpm

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. Turn the idle speed adjusting screw and let the engine run at the recommended idle speed.

3. Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe. Turn the air fuel ratio adjusting screw to make the emission value in idle speed within standard.

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

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

Emission standard： CO：3. 0 % ↓

HC：2000 P.P.M. ↓

Idle speed adjusting screw

Air fuel ratio adjusting screw

Spark plug cap wire

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Ignition System

Ignition timing

Caution

z C.D.I ignition system is set by

manufacturer so it cannot be adjusted.

z Ignition timing check procedure is for

checking whether CDI function is normal or not.

Remove the ignition timing inspection hole cap on the crankcase left cover.

Connect tachometer and ignition lamp and start the engine. Keep the engine run in the idle speed, if the “F” mark meets with the ignition lamp.

Increase engine RPM to check ignition advance degree. If the illustrated indent is within the ignition advance degrees, it means that the ignition advance degree is in normal. If ignition timing is incorrect, check CDI set, pulse rotor and pulse generator. Replace defective parts if malfunction is found.

Idle Speed：1600±100rpm Ignition Advance：3300±100rpm

Spark Plug

Recommended spark plug：C6HSA Remove the spark plug cap.

Clean dirt around the spark-plug hole. Remove the spark plug.

Measure the spark plug ignition gap.

Spark plug gap：0.6~0.7 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug and install the spark plug by screwing it with hand, after tightening the plug by hands, use plug socket to tighten it to the standard torque value

Torque value：1.0~1.2kgf-m

Reinstall the spark plug cap.

0.6~0.7mm

Ground electrode

Central electrode

Spark plug cap

Ignition advance indent”װ”

“F” mark

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Cylinder Compression Pressure

Warm up the engine and turn it off. Remove the side cover. Remove the spark plug cap and the spark plug.

Install compression gauge into the spark plug hole, full open the throttle, and kick the kick starter for several times.

Caution

Rotate the engine until the reading in the gauge gains no more.

z Usually the highest-pressure reading will

appear in 4~7 seconds.

Compression pressure：11 ±1 Kg/cm²

Check the following items if the pressure reading is too low:

z Incorrect valve clearance z Valve leaking z Cylinder head leaking, piston, piston ring,

cylinder worn out.

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

Compression gauge

Spark plug hole

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Clutch Adjustment

Gear change pedal free play inspection

Slightly step on the gear change pedal to check the free play before clutch disengagement.

Free play：10~20 mm

Gear change pedal free play adjustment

Before adjusting the gear change pedal, loosen the locknut first. Then turn the adjusting screw to achieve the recommended gear change pedal free play. Turn the adjusting screw counterclockwise to decrease the free play of the gear change pedal. Turn the adjusting screw clockwise to increase the free play. After adjustment, fix the adjusting screw and tighten the locknut.

Caution

z Turn the adjusting screw

counterclockwise to the tightest position, and then turn the adjusting screw clockwise 1/8 circle to 1/4 circle.

z Increase or decrease the free play

according to circumstances.

10~20 mm

Adjusting screw

Locknut

1/8~1/4

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Drive Chain Adjustment

Drive chain inspection

Place the bike on its main-stand with its neutral gear. Check the drive chain slack by moving the chain up and down by fingers, and measure the amount of chain slack.

Standard chain slack：10~20 mm

Caution

z Because the front and rear sprocket has

different wearing situation, so please rotate the rear wheel to find the minimum chain slack for the measurement.

Drive chain adjustment

If you need to adjust the chain slack, please loosen the rear axle nut and sleeve nut first. Turn the left side and the right side adjusting nut evenly to make the chain slack within the standard range.

Caution

y Turn the adjusting nuts of both sides

evenly to make the drive chain and sprockets rotate smoothly.

Turn the nuts clockwise to tighten the chain, or counterclockwise to loosen the chain Tighten the sleeve nuts, then the rear axle nut.

Torque value：4.0~5.0kgf-m

After tightening the rear axle nut, please check the sleeve nuts to prevent them from loosening. Check the chain slack again, and make sure the rear wheel rotates smoothly.

If the chain is too dirty, use high-flash point solvents (Kerosene or Diesel) to clean the chain.

Caution

y Do not use gasoline when cleaning a the

chain. The gasoline will damage the O-ring in the chain.

After cleaning, lubricate the chain with chain lubricant.

Sleeve nut

Rear axle nut

Adjusting nut

10~20 mm

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Steering Mechanism

Caution

z Check all wires and cables if they are

interfered with the rotation of the steering handle bar.

Lift the front wheel off the ground. Turn the handle bar from right to left end and check if turning is smooth. If handle bar is uneven or bending, or the handle bar can be lifted through vertical direction, adjust the steering top cone race.

Suspension System

Caution

z Do not ride the motorcycle with poor

suspension system.

z Loose, worn or damaged suspension

system will result in poor stability and maneuverability.

Front cushion

Press down the front cushion for several times to check its integrity. Check if any oil leaks or damage found. Replace relative parts if damage found. Tighten all nuts and bolts.

Rear cushion

Press down the rear cushion for several times to check its integrity. Check if any oil leaks or damage found. Replace rear cushion if any damage found. Park the motorcycle with main stand. Move the rear wheel sideways forcefully to see if the swing arm bushing and pivot nut are loosened. Tighten all nuts and bolts.

Locknut

Steering top cone race

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Brake System

Front drum brake lever free play inspection

Pull the front brake lever slightly, and measure the free play before brake engagement.

Free play：10~20 mm

Turn the brake adjusting nut to adjust the free play. Turn the brake adjusting nut clockwise to decrease the free play. Turn the nut counterclockwise to increase the free play.

Rear disk brake pedal free play inspection

Press down the brake pedal slightly, and measure the free play before brake engagement.

Free play：20~30 mm

Turn the brake adjusting nut to adjust the free play. Turn the brake adjusting nut clockwise to decrease the free play. Turn the nut counterclockwise to increase the free play.

Brake lining inspection

When pressing the brake pedal down, if the arrow mark on the braking arm reaches the triangle mark on the brake panel, it means that the brake lining needs to be changed. Please refer to Chapter 11 and 12 for brake lining exchange process.

Brake system integrity confirmation

Caution

z After changing the brake lining or the

brake cable, you must check the brake system to see if it works well or not.

10~20mm

20~30mm

Arrow mark

Triangle mark

Adjusting nut

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Tire

Check the tire pressure to see if it’s in the specified pressure range.

Caution

z Check the tire pressure when the tire is

cold.

Specified tire pressure range

Tire pressure Front Rear

Single ride 1.75 2.25

Tire pressure

when cold

(Kg/cm²)

With

passenger

1.75 2.75

Specified tire： Front/Rear：2.50-17 38L

Check the tire surface for embedded nails, stones or other objects.

Check if front and rear tires pressure is normal.

If the wearing of the tire thread reaches triangle △ mark index, the tire also have to be replaced. Measure the tire thread depth at the center of the tire, and if the depth is not enough, please replace the tire. Minimum tire tread depth：

Front：1.5 mm Rear：2.0 mm

Caution

z Wear mark index〝△〞is located along the

tire wall.

“△” mark

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Battery

Battery removal

Remove the right side cover. Unplug the ventilation tube. Remove the battery holder (2 bolts). Remove the〝─〞negative pole first, then

remove the〝＋〞positive pole. Remove the battery.

If the battery liquid level is too low, please remove the top plug, and fill in distilled water to the upper limit.

Caution

z Don’t fill in too much distilled water, or the

electrolyte may overflow and corrode the frame.

z Only distilled water is allowed. If any

impure water is filled in, it will shorten the battery life.

Warning

z The electrolyte contained sulfuric acid.

Please avoid touching the eyes, skin, or clothes. If any contact by accident, please flush with plenty of water.

If there is some rust on battery posts, clean it with steel brush. Install the battery in the reverse procedures of removal.

Caution

z If the rust on the posts is very serious,

spray some hot water on them. Then, more easily you can remove the rust by steel brush.

z Apply some grease on the posts after

cleaning rust to prevent from happening again.

Ventilation tube

2 bolts

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Headlight Adjustment

Start the engine, turn on the headlight. Loosen the headlight lock bolt, move the headlight upward or downward to adjust the headlight beam height. When the proper headlight beam height is reached, tighten the lock bolt.

Caution

z The factory setting of the beam height is

consistent with government orders.

z Improper headlight beam setting will

make driver in the opposite lane dazzled and cause danger.

Brake Switch

Brake switch inspection

When the brake lever is pulled, the brake switch will light up the brake lamp.

Make sure that electrical starter can be activated only under braking condition.

Rear brake switch adjustment

Turn on the main switch. When the brake pedal is stepped down for 20mm，the brake lamp should be activated.

If the brake lamp is not activated or activated too early, adjust through the rear brake switch adjusting nut. Turning clockwise will decrease the free play, and counterclockwise to increase the free play.

Nuts, Bolts Tightness

Apply periodical maintenance in according with the Periodical Maintenance Schedule. Check if all the bolts and nuts on the frame are tightened well. Check all fixing pins, snap rings, hose (pipe) clamps, and wire holders for security.

Rear brake switch adjusting nut

Headlight lock bolt

Brake switch

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Special Tool Catalog

Name

Rocker arm shaft disassemble tool

Name Valve spring compressor Name

Valve remove/ assemble tool

SY No. SYM-1445100 SY No. SYM-1471100 SY No. SYM-1471110/20

Name Tappet adjusting wrench Name TAPPET ADJUSTING TOOLS Name ACG puller

SY No. SYM-9001200 SY No. SYM-9001210 SY No. SYM-3110A00

(20*32*6)

(6203/6004UZ)

Name Special nut socket Name Oil seal driver Name Bearing driver

SY No. SYM-9023100-SY125 SY No. SYM-9120200 SY No. SYM-9620000

(6204)

(6301)

Name Bearing driver Name Bearing driver Name Bush puller

SY No. SYM-9110400 SY No. SYM-9610000 SY No. SYM-1120310

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Name

Steering stem locknut remove/ assemble tool

Name Steering top cone race wrench Name Universal bearing driver

SY No. SYM-5320000 SY No. SYM-5320020 SY No. SYM-6204024

Name Inner bearing puller set Name Outer bearing puller Name Electrical gauge

SY No. SYM-6204020 SY No. SYM-6204001 SY No. SYM-HE07007-01

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Note:

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3. Fuel System

3-1

Mechanism Diagram ···················3-1 Precautions in Operation ···········3-2 Troubleshooting··························3-3 Carburetor Removal····················3-4 Throttle Valve ······························3-6

Float Chamber / Jet Set ············· 3-7 Carburetor Installation··············· 3-10 Idle Speed Adjustment ·············· 3-11 Fuel Tank ···································· 3-12 Air Cleaner·································· 3-14

0BMechanism Diagram

Fuel gauge

Fuel tank

To vacuum tube

Vacuum type fuel cock

Carburetor

Fuel outlet tube

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3-2

1BPrecautions 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.

Caution

z 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.

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

one as re-assembly.

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

Specification

Item Specification

Carburetor diameter Ø 16 mm I.D. number PTE004D Fuel level 10.2 mm Main injector # 58 Idle injector # 40 Idle speed 1600±100 rpm Throttle free play 2~6 mm Pilot screw 1 3/4 turns

Torque value

Carburetor locknut 0.7~1.1kgf-m

Special service tool

Vacuum/air pressure pump

General tool

Float Chamber fuel level gauge

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2BTroubleshooting

Engine cannot be started

z No fuel in fuel tank z Clogged fuel tube z Excessive fuel in cylinder z No spark from spark plug (malfunction of

ignition system)

z Clogged air cleaner z Malfunction of auto by-starter z Throttle cable damaged

Engine stalled after being started

z Malfunction of auto by-starter z Incorrect ignition timing z Malfunction of carburetor z Improper engine oil z Air leakage into inlet manifold z Incorrect idle speed settings.

Unstable idle speed

z Abnormal ignition system z Incorrect idle settings. z Abnormal carburetor z Impure fuel

Misfire during acceleration

z Malfunction of ignition system

Late ignition timing

z Malfunction of ignition system z Malfunction of carburetor

Weak engine power

z Fuel system clogged z Malfunction of ignition system

Fuel / Air Mixture too lean

z Clogged carburetor jet z Carburetor parts stick and closed z Malfunction of float valve z Fuel level too low in float chamber z Clogged fuel tank cap vent z Clogged fuel filter z Obstructed fuel pipe z Clogged air vent hose z Air leakage into inlet manifold

Fuel / Air Mixture too rich

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

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3. Fuel System

3-4

3BCarburetor Removal

Removal

Remove the body side cover. Put a container near the fuel drain screw, and loosen it. Drain all the fuel of the float chamber.

Warning

z Gasoline should stay away from fire, and

avoid getting on the frame. If gasoline gets on the frame, please wash it off immediately.

Disconnect the auto by-starter coupler.

Disconnect the fuel pipe.

Disconnect the breather pipe and remove the winker relay.

Auto by-starter coupler

Breather pipe

Winker relay

Fuel pipe

Fuel drain screw

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3. Fuel System

3-5

Remove the carburetor top cover by turning it counterclockwise. Remove the top cover, throttle cable, and throttle valve.

Loosen the clamp from the air cleaner side and remove the pipe.

Remove the carburetor lock bolts. Remove the insulator and the carburetor.

Installation

Install as the reversed order of removal procedures.

Torque value： Carburetor holding nuts：0.7~1.1kgf-m

After installation, the following adjustment is required:

● Throttle cable free play.

● Idle speed adjustment.

Adjusting nut

Locknut

Throttle valve

Air cleaner clamp

Top cover

2 bolts

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3. Fuel System

3-6

4BThrottle Valve

Disassembly

Compress the throttle spring and disassemble the throttle cable, and the spring.

Turn the jet needle seat counterclockwise to remove the jet needle and the seat from the throttle valve.

Check the throttle valve and the jet needle to see if they are damaged or not.

Assembly

Assemble as reversed order of removal procedures.

Jet needle

Jet needle seat

Throttle valve

Top cover

Spring

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3. Fuel System

3-7

5BFloat Chamber / Jet Set

Remove 2 mounting screws and remove float chamber cover.

Warning

z Please fill the gasoline in float chamber

into the fuel tank.

Remove the float pin. Remove the float and float valve.

Inspection

Check the float valve and valve seat for any damage or blocking.

Caution

z In case of worn out or dirty, the float valve

and valve seat will not close tightly. The fuel will overflow. A worn out or dirty float valve must be replaced with a new one to fix the problem.

Check if worn out

Float valve

Float

Float pin

2 screws

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3. Fuel System

3-8

Cleaning

Remove the main jet, main jet seat and slow jet.

Remove the air adjusting screw.

Caution

z Be careful not to damage jets and

adjusting screw.

z Before removing the adjusting screw, turn

it all the way in clockwise and record the number of circles.

z Do not turn the adjusting screw forcefully,

or the valve seat may be damaged.

z When the air adjusting screw is removed,

take out the inner washer with it.

Clean the jets with Carburetor conditioner. Then use compressed air to blow the dirt off.

Air adjusting screw

Main jet

Slow jet

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Main jet

Slow jet

Air adjusting screw

Main jet seat

Spring

Main fuel passage

Slow fuel passage

Slow air passage

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3. Fuel System

3-9

Assembly

Before assembling, please blow the fuel passages with compressed air.

Assemble the air adjusting screw.

Caution

● Please assemble the air adjusting screw

with the same setting circles as removal.

Assemble the main jet seat, main jet and slow jet.

Assemble the float valve, float and float pin.

Main jet

Slow jet

Air adjusting screw

Float pin

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3. Fuel System

3-10

Fuel level inspection

Caution

y Check the float valve and float for proper

installation.

y To get the correct reading, position the fuel

level gauge in the way that float chamber face is vertical to the main jet.

Fuel level：10.2mm

Assemble the fuel cup after confirming the fuel level.

6BCarburetor Installation

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

● Throttle cable free play adjustment.

● Idle speed adjustment

Fuel level gauge

2 screws

Adjusting nut

Locknut

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3. Fuel System

3-11

7BIdle Speed Adjustment

Caution

y Air-screw was set at factory, so no

adjustment is needed. For easy installation, count the number of circles it takes to screw the air-screw to the bottom.

y The idle adjustment process must be done

while the bike is on its main stand.

Use a tachometer while adjusting engine RPM. Screw in air adjusting screw gently, then back up to standard circles.

Standard setting：1 3/4 circles

Warm up the engine fully; adjust the throttle stopper screw of throttle valve to achieve the standard idle RPM.

Standard idle speed：1600rpm±100

Connect the hose of exhaust analyzer to exhaust front end. Press test key on the analyzer.

Adjust the air adjustment screw and read CO reading on the analyzer. Standard value of CO emission：1.0~1.5 %

Gradually increase the throttle, make sure rpm and CO value are within the standard range after engine running stable. If rpm and CO value fluctuated, repeat the procedures above for achieving the standard value.

Idle adjusting screw

Air adjusting screw

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3. Fuel System

3-12

8BFuel Tank

Fuel tank removal

Remove the license plate bracket (2 bolts).

Remove the rear right / left winkers, and the rear fender (1 bolt, 1 screw). Remove the rear top cover.

Disconnect the fuel unit wire coupler.

Open the seat. Disassemble the fuel-vapor tube to the carbon canister.

1 screw

2 bolts

Wire coupler

Fuel-vapor tube

1 bolt

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3. Fuel System

3-13

Remove the right body cover, and remove

the battery.

Remove the fuel outlet pipe and the vacuum pipe from the Vacuum operated automatic fuel cock.

Lift the fuel tank with the fuel tank cover. Remove the lock bolts to separate the cover from the fuel tank.

Fuel unit removal

Remove the fuel unit (3 screws). Refer to the chapter 12 for the detailed inspection for the fuel unit.

Fuel outlet tube

3 screws

Vacuum operated automatic fuel cock

Vacuum tube

2 bolt for both sides

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3. Fuel System

3-14

9BAir Cleaner

Air filter element

Remove the body cover. Loosen the air duct clamp (1 screw). Remove the air cleaner cover screws.

Open the air cleaner lock clip and remove the air cleaner cover.

Remove the air filter element. Check if the air filter element is dirty or damaged.

Wash the air filter element with non-flammable or high flash-point solvent (Like kerosene or diesel). After washing, squeeze it and dump into motor oil, and squeeze again. If the element is too dirty or damaged, please change a new one.

Caution

y Don’t use gasoline or other flammable

solvents to clean the element.

wash squeeze

dump into engine oil squeeze

4 screws for both sides

1 screw

Lock clip

Air filter element

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3. Fuel System

3-15

Air cleaner removal

Remove the body cover. Remove the air cleaner connecting tube and the fuel vapor recycle tube.

Loosen the air cleaner duct band, and remove the air cleaner ducts (both sides). Remove the air cleaner (2 bolts on both sides).

Installation

Install as the reversed order of removal.

2 bolts on both sides

1 clamp

Fuel vapor recycle tube

Air cleaner duct band

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3. Fuel System

3-16

Note:

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4. Lubrication / Clutch / Transmission

4-1

Mechanism Diagram .................... 4-1

Mechanism Diagram .................... 4-2

Precautions in Operation ............ 4-3

Troubleshooting........................... 4-4

Engine Oil ..................................... 4-5

Engine Oil Strainer Cleaning....... 4-5

Clutch Removal ............................ 4-6

Clutch Inspection ......................... 4-8

Clutch Installation ........................ 4-9

Gear Shift Mechanism.................. 4-12

Oil Pump Removal / Inspection...4-16 Oil Pump Assembly / Installation 4-18

Mechanism Diagram

Anti loose nut

3.8~4.5kgf-m

Clutch outer

Primary drive gear

Clutch weight

Clutch spring

Clutch set ring

Clutch friction dick B

Clutch plate A

Clutch center

Clutch outer cover

Flexible washer

Lock washer

Primary driven gear

Oil pump drive gear

Oil pump

Oil pump driven gear

Oil filter screen

Oil drain bolt

Clutch plate B

Clutch plate C

Clutch friction disk A

Drive gear outer

Drive plate Clutch damper spring

Bearing 6000

Homepage Contents

Clutch free spring

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4. Lubrication / Clutch / Transmission

4-2

Mechanism Diagram

Shift drum retainer

Shift drum cam

Clutch lever

Clutch lifter plate

Gear shift spindle

Gear shift arm

Clutch cam plate

Ball retainer

Cam plate spring

Clutch adjusting bolt

Gear shift arm return spring

Gear shift arm pivot pin

Shift drum stopper

Shift drum stopper spring

Shift drum pin

Shift drum pin guide

Shift drum plate

Bearing 6805

Gear shift drum

Shift fork

Shift fork shaft

hift fork shaft

Gear change switch

Gear indication drill

Gear indication drill spring

Gear shift arm master

Gear shift arm master spring

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4-3

Precautions in Operation：

General Information

z This chapter covers the engine oil pump and the oil replacement. z The disassembly of the clutch and the shifting linkage is covered. All these operations can be

done while the engine is still on the motorcycle.

Specification

Engine Oil Capacity：

After disassembly：1000 c.c. After draining：800 c.c.

Recommended engine oil viscosity: SAE 10W-30

(The Bramax series oil is recommended)

Engine oil viscosity

Measurement: mm

Item Standard Service Limit

Clearance between inner rotor and

outer rotor

0.30 0.35

Clearance between outer rotor and the pump body

0.30~0.36 0.40

Oil pump

Clearance between rotor and pump cover

0~0.06 0.11

Clutch pedal free play 10~20 Spring free length 16.35 15.50 Clutch friction disk A thickness 2.55~2.68 2.20 Clutch friction disk A thickness 3.35~3.45 3.00

Clutch

Clutch plate warp - 0.20

Torque value

Oil drain bolt 1.5~2.0kgf-m Oil filter cover bolt 0.8~1.2kgf-m Oil pump cover screw 0.3~0.4kgf-m

Oil pump screw 0.4~0.6kgf-m Clutch anti-loosen nut 3.8~4.5kgf-m Right crankcase bolt 0.8~1.2kgf-m

Special tool

Clutch anti-loosen nut socket wrench SYM-9023100-SY125

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4. Lubrication / Clutch / Transmission

4-4

Troubleshooting

Engine oil level too low

y Oil leakage y Worn valve guide or stem seal y Worn piston ring

Engine oil pressure too low

y Oil level low y Clogged oil filter, passage y Damaged oil pump

Engine contamination

y Oil or filter not changed regularly y Damaged cylinder head gasket y Worn piston ring

Clutch slips during acceleration

y Worn clutch plate y Weak clutch spring

Bike trembles y Bent clutch plate

Hard to shift gear

y Improper y bent shift fork shaft

Gear shift pedal won’t return

y Broken or weak gear shift arm return spring y Bent shift fork shaft

Gear jumps out

y Bent shift fork y Bent shift fork shaft y Damaged shift drum stopper spring

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4. Lubrication / Clutch / Transmission

4-5

Engine Oil

Turn off the engine, and park the motorcycle on flat surface with main stand. Check the oil level with the oil dipstick. Do not screw the dipstick in while checking. If oil level is low, fill into recommended oil to reach the upper limit.

Engine oil replacement

Caution

z Drain the engine oil when the engine is

fully warmed up, so the oil can be drained out completely.

Place an oil basin under the bike, and remove oil drain bolt. After all oil is drained, make sure washer can be re-used, and re-install oil drain bolt. If the Oil drain bolt washer is damaged, it should be replaced.

Torque value：1.5~2.5kgf-m

Oil Filter Screen Cleaning

Remove the oil filter screen cover (2 bolts). Remove the oil filter screen. Clean the oil filter screen with compressed air. Check the cover washer and the oil filter screen for any damage. Replace it with new one if necessary. Install the oil filter screen and the cover.

Torque value：0.8~1.2kgf-m

Fill in engine oil (oil viscosity SAE 10W-30) Recommended using Bramax series oil.

Engine oil capacity: 800 c.c. Regular exchange.

Install dipstick, run the engine for several minutes. Then turn off the engine, and check the oil level again. Check if engine oil leaks.

Drain bolt

Upper limit

Lower limit

2 bolts

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4. Lubrication / Clutch / Transmission

4-6

Clutch Removal

Drain the engine oil. Remove the footrest, exhaust pipe and kick-starter. Remove the right crankcase cover (8 bolts).

Remove the clutch lift plate, ball retainer and clutch cam plate spring.

Remove the clutch lever and clutch cam plate.

Remove the clutch outer cover (4 screws).

8 bolts

Clutch cam plate spring

Clutch ball retainer

4 screws

Clutch lever

Clutch cam plate

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Clutch outer cover

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4. Lubrication / Clutch / Transmission

4-7

Open the location foot of the lock washer. Remove the anti-loose locknut. Remove the flexible washer, lock washer and the whole clutch assembly.

Special tool： Anti-loosen locknut socket wrench

SYM-9023100-SY125

Remove the clutch set ring.

Remove the drive gear outer, clutch center, clutch plates and clutch friction disks from the clutch outer.

Disassemble the drive gear outer, clutch center, clutch plates and clutch friction disks.

Location foot

Clutch set ring

Clutch plate

Clutch center

Drive gear outer

Clutch friction disk B

Anti-loose nut

Clutch free spring

Clutch friction disk A

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4. Lubrication / Clutch / Transmission

4-8

Remove the clutch drive plate screws (4 screws) and disassemble the clutch drive plate from the clutch outer.

Remove the clutch spring.

Clutch Inspection

Clutch spring inspection

Measure the free length of four clutch springs.

Service limit：15.5mm

Clutch friction disk inspection

Measure the thickness of each clutch friction disk. If it’s under service limit or it’s damaged, replace it with a new one.

Service limit：Friction disk A 2.2mm

Friction disk B 3.0mm

Clutch outer

4 screws

Clutch damper spring

Clutch spring

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4. Lubrication / Clutch / Transmission

4-9

Clutch plate inspection

Use a feeler gauge to measure the warp of each clutch plate.

Service limit：0.2mm

Clutch outer inspection

Check the clutch outer to see if any cracks or damage can be found.

Clutch Installation

Assemble the clutch drive plate onto the clutch outer (4 screws) and install the clutch damper spring in the clutch outer.

Reinstall the clutch plate, clutch friction disks, clutch center and drive gear outer.

4 screws

Clutch damper spring

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4. Lubrication / Clutch / Transmission

4-10

Reinstall the clutch set ring.

Assemble the clutch assembly to the crankshaft. Put the anti-loose lock washer first and then the flexible washer. After the anti-loose locknut is installed, bend any one location foot of the lock washer to fit in the locknut.

Install the clutch outer cover (4 screws).

Install the clutch cam plate. Make the clutch lever aim at the breach of the clutch cam plate and install the clutch lever onto the gear shift spindle.

Clutch set ring

Location foot

Anti-loose locknut

4 screws

Clutch lever

Clutch cam plate

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4. Lubrication / Clutch / Transmission

4-11

Install the clutch cam plate side spring, ball retainer, and clutch lifter plate onto the clutch cam plate.

Install the right crankcase cover (8 bolts). Reinstall the kick starter, gear shift pedal, footrest and exhaust pipe. Refill the specified engine oil.

Loosen the locknut of the clutch adjusting bolt. Turn the clutch adjusting bolt counterclockwise to the end and then turn it clockwise 1/8~1/4 circle to adjust the clutch free play. After the clutch clearance adjustment, lock the adjusting bolt and then the locknut.

Caution

z Increase or decrease the clutch

clearance according to the real circumstance.

Turn clockwise 1/8~1/4 circle

8 bolts

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4. Lubrication / Clutch / Transmission

4-12

Gear Shift Linkage Mechanism

Gear shift linkage mechanism removal

Remove the gear shift pedal (1 bolt).

Drain out the engine oil. Remove the footrest, kick starter and exhaust pipe. Remove the right crankcase cover. Remove the clutch lever and the clutch assembly.

Remove the primary driven gear cir clip. Remove the primary driven gear.

Remove the shift drum stopper and stopper spring (1 bolt). Remove the shift drum cam and shift drum pin guide (1 bolt).

Shift drum cam

Cir clip

1 bolt

Shift drum stopper

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4. Lubrication / Clutch / Transmission

4-13

Pull out the gear shift spindle and gear shift arm.

Remove the shift drum pin guide and gear shift drum pins.

Remove the shift drum plate location pin and prevent it from being lost.

Inspection

Check the gear shift spindle and gear shift arm for wear or damage.

Gear shift spindle

Shift drum pin guide

Shift drum plate location pin

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4. Lubrication / Clutch / Transmission

4-14

Check the shift drum stopper and stopper spring for wear or damage.

Check the shift drum cam for wear or damage.

Check the shift drum plate and shift drum pin for wear or damage.

Gear shift linkage mechanism assembly

Install the shift drum plate location pin onto the gear shift drum.

Shift drum plate location pin

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4. Lubrication / Clutch / Transmission

4-15

Install the shift drum plate and shift drum pin onto the gear shift drum.

Install the gear shift spindle and gear shift arm.

Caution

z The gear shift spindle location finger must

pass through movement limit hole of the gear shift arm.

z The claw of gear shift arm must hook up

with shift drum pins.

Install the shift drum pin guide and shift drum cam (1 bolt). Install the shift drum stopper and stopper spring (1 bolt).

Torque value：0.8~1.2kgf-m

Caution

z After the shift drum stopper is reinstalled,

make sure it operates well.

Install the primary driven gear and put on the cir clip. Install the primary drive gear, clutch assembly, and linkage mechanism. Install the crankcase location pin, new crankcase gasket and right crankcase cover. Install the kick starter, gear shift pedal, footrest and exhaust pipe. Fill in the specified engine oil.

Shift drum plate

Claw of gear shift arm

Movement limit hole

Shift drum cam

Shift drum stopper

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Gear shift spindle location finger

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4. Lubrication / Clutch / Transmission

4-16

Oil Pump Removal / Inspection

Drain out the engine oil. Remove the footrest and exhaust pipe. Remove the kick starter (1 bolt). Remove the right crankcase cover (8 bolts) and clutch assembly. Remove the primary drive gear.

Special tool： Special nut socket wrench

SYM-9023100-SY125

Remove the oil pump (3 screws).

Caution

z Impact screwdriver is allowed to be used

to remove the oil pump lock screws.

Oil pump disassembly

Remove the cir clip, washer and oil pump driven gear

Remove the oil pump driven gear location pin.

Location pin

Oil pump drive gear

3 screws

Primary drive gear

Cir clip

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4-17

Remove the oil pump cover and washer (3 screws).

Oil pump inspection

Check the clearance between the oil pump and outer rotor.

Service limit：Under 0.35 mm

Check the clearance between the inner and outer rotor.

Service limit：Under 0.40mm

Check the clearance between the surface of oil pump and rotor.

Service limit：Under 0.11 mm

3 screws

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4. Lubrication / Clutch / Transmission

4-18

Oil Pump Assembly / Installation

Assemble the inner and outer rotor into the oil pump body. Install the oil pump drive shaft. Install the oil pump cover and washer (3 screws).

Torque value：0.3~0.4kgf-m

Caution

z Make sure the oil pump rotate smoothly.

Install new o-rings.

Install the oil pump driven gear location pin.

Install the oil pump driven gear and cir clip.

O ring

3 screws

Cir clip

Location pin

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4-19

Install the oil pump (3 screws).

Torque value：0.4~0.6kgf-m

Install the oil pump drive gear onto the crankshaft and make the teeth of oil pump drive gear and driven gear coordinate.

Install the primary drive gear.

Install the clutch assembly and clutch lever.

Install the location pin and new right crankcase cover gasket. Install the right crankcase cover (8 bolts).

Torque value：0.8~1.2kgf-m

Oil pump drive gear

3 screws

Primary drive gear

Clutch lever

Clutch cam plate

8 bolts

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4-20

Note:

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5. AC. Generator / Starting Clutch

5-1

Mechanism Diagram····················· 5-1 Precautions in Operation············· 5-2

AC. Generator Stator Removal········5-3 AC. Generator / Starting Clutch ······5-6

Mechanism Diagram

1.0~1.4kgf-m

0.8~1.2kgf-m

3.5~4.3kgf-m

Homepage Contents

Starter motor

Flywheel

ACG Stator

Starter reduction gear shaft

Starter reduction gear

Starter clutch gear

Starter clutch outer body

Clutch outer cover

Clutch roller 9*10mm

Spring cap

Roller spring

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5. AC. Generator / Starting Clutch

5-2

Precautions in Operation

General information

z For engine troubleshooting and inspection, refer to the first chapter. z For starting Motor repairing process and cautions, refer to Chapter 13.

Specification Measurement unit：mm

Item Service limit Starter clutch gear exterior diameter 35.91 Starter clutch outer interior diameter 37.8

Torque value

Flywheel locknut 3.5~4.3kgf-m Left crankcase cover bolt 0.8~1.2kgf-m Starter clutch inner-hexagon bolts 1.0~1.4kgf-m with screw adhesive

Special tool

Flywheel puller SYM-3110A00

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5. AC. Generator / Starting Clutch

5-3

ACG Stator Replacement

Stator replacement

Remove the body cover. Disconnect the ACG coupler. Disconnect the gear change switch coupler.

Remove the gear shift pedal (1 bolt).

Remove the left crankcase rear cover (2 bolts).

Remove the left crankcase cover (7 bolts).

Rubber cover

1 bolt

7 bolts

2 bolts

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5. AC. Generator / Starting Clutch

5-4

Remove the foreign objects and gasket residue on the interface of crankcase and cover.

Remove the pulse coil (2 screws) and ACG stator (2 bolts).

ACG stator inspection

Check the following circuit for electricity conductivity. White ~ Green 0.7Ω±10%

Yellow ~ Green 0.5Ω±10% Black / Red ~ Green 780Ω±10% Blue / Yellow ~ Green 110Ω±10%

2 screws

2 bolts

Yellow

Black / Red

Blue / Yellow

White

Green

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5. AC. Generator / Starting Clutch

5-5

ACG stator assembly

Assemble the ACG stator (2 bolts) and pulse coil (2 screws). Assemble the stator wire correctly onto the left crankcase cover with the rubber seal.

Install the location pins and new left crankcase gasket.

Install the left crankcase cover (7 bolts).

Rubber seal

7 bolts

Location pins

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5. AC. Generator / Starting Clutch

5-6

ACG Flywheel / Starting One-way Clutch

ACG flywheel / starting clutch removal

Remove the flywheel / starting one-way clutch with flywheel puller.

Special tool： ACG flywheel puller SYM-3110A00

Remove the starter clutch gear and needle bearing

Remove the cir clip and starter reduction gear.

Remove the starter reduction gear shaft (2 screws).

Flywheel puller

Starter clutch gear

Cir clip

Starter reduction gear

2 screws

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5. AC. Generator / Starting Clutch

5-7

Check the starter reduction gear and shaft for any wear or damage. Measure the inner diameter of starter reduction gear.

Service limit： Inner diameter：Under 13.02 mm

Measure the exterior diameter of starter reduction gear shaft.

Service limit： Exterior diameter：Over 12.96 mm

Starter clutch inspection

Install the starter clutch gear onto the starter clutch outer. Hold the starter clutch and turn the starter clutch gear. Make sure the starter clutch gear can only be turned counterclockwise.

Check the starter clutch gear for any wear or damage. Measure the exterior diameter of the starter clutch gear.

Service limit： Exterior diameter：over 35.91 mm

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Starter clutch gear

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5. AC. Generator / Starting Clutch

5-8

Starter clutch disassembly

Remove the starter clutch inner-hexagon bolts. Separate the starter clutch outer body and the clutch outer cover. Disassemble the clutch rollers, spring caps, and springs. Check if the rollers and spring caps are worn or damaged. Assemble the rollers, spring caps, and springs.

Measure the inner diameter of the starter clutch outer.

Service limit： Inner diameter：under 37.8 mm

Assembly

Assemble in the reversed process of disassembly.

Caution

z Apply some screw- adhesive on the

thread of inner-hexagon bolts.

Torque value：1.0~1.4kgf-m

Roller spring

Clutch roller

Spring cap

Clutch outer body

Clutch outer cover

Roller spring

Clutch roller

Spring cap

Clutch outer body

Clutch outer cover

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5. AC. Generator / Starting Clutch

5-9

Flywheel / starter clutch installation

Install the starter reduction gear shaft (2 bolts).

Install the starter reduction gear and cir clip.

Install the ACG flywheel, starter clutch and starter clutch gear (1 locknut).

Torque value：5.0~6.0kgf-m

Install the location pins and new gasket onto the crankcase.

2 screws

Cir clip

Locknut

Location pins

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5. AC. Generator / Starting Clutch

5-10

Assemble the stator wire correctly onto the left crankcase cover with the rubber seal.

Install the left crankcase cover (7 bolts).

Torque value：1.5~2.0kgf-m

Install the left crankcase rear cover (2 bolts).

7 bolts

Rubber seal

2 bolts

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6. Engine Removal

6-1

Precautions in Operation ···········6-1 Engine Removal··························6-2

Engine Intallation ························6-5

Precautions in Operation

General information

● During maintenance of a removed engine, you need to use an adjustable rack or cart to

support the engine.

● The following parts can be repaired with the engine staying on the frame:

1. Carburetor

2. AC. Generator

3. Starting clutch

4. Clutch

5. Gear shift mechanism

6. Cylinder / Piston

7. Cam chain tensioner

8. Cam shaft / Rocker arm

● You must remove the engine for repairing the following parts:

1. Crankshaft

2. Gear box

3. Kick starter mechanism

Specification

Item Specification

Regular replacement 800 c.c.

Engine oil capacity

Fully disassembly 1000 c.c.

Torque value

Engine suspension nut 3.0~3.5kgf-m Left crankcase rear cover bolt 0.8~1.2kgf-m Driven sprocket bolt 0.8~1.2kgf-m Step bar lock bolt 2.4~3.0kgf-m

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6. Engine Removal

6-2

Engine Removal

Drain the engine oil.

Remove the right body cover. Remove the battery ventilation pipe. Remove the battery cable, first negative then positive pole. Remove the battery (2 bolts).

Caution

z To prevent short circuit, always connect

the positive pole before the negative one.

Remove the starter motor power cable.

Remove the AICV pipe.

Engine oil drain bolt

Ventilation pipe

2 bolts

AICV pipe

Starter motor power cable

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6. Engine Removal

6-3

Remove the spark plug cap. Remove the high tension cord from the cord clamp.

Remove the step bar (4 bolts).

Remove the exhaust pipe (3 locknuts)

Disconnect the ACG wire and gear change switch.

2 locknuts

ACG wire and gear

Spark plug capCord clamp

4 bolts

1 locknut

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6. Engine Removal

6-4

Remove the PCV breather tube. Remove the PCV drain pipe from the drain pipe clamp.

Remove the inlet pipe lock bolts.

Loosen the rear wheel axle nut, and the sleeve nut. Loosen the adjusting nut and push the rear wheel forward.

Remove the left crankcase rear cover. Remove the driving sprocket holding bolts. Turn slightly and take out the stopping plate, then remove the driving sprocket and chain.

PCV breather pipe

2 bolts

PCV drain pipe

Stopping plate

Sleeve nut

Rear wheel axle nut

Adjusting nut

2 bolts

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6. Engine Removal

6-5

Use a rack to hold the engine. Remove the engine locknuts. Pull out the engine holding bolts and remove the engine.

Engine Installation

Install the engine in the reversed procedure of removal

Caution

z During installation, always pay attention

to the possible injuries.

z All the wires and cables can’t be bent or

pressed.

z Please align the wires and cables in

accordance with the setting diagram.

Torque value： Engine locknut (rear part of engine and

frame) 3.0~3.5kgf-m Step bar lock bolt 2.4~3.0kgf-m Left crankcase rear cover lock bolt 0.8~1.2kgf-m Drive sprocket lock bolt 0.8~1.2kgf-m

After installation and filling in engine oil, adjust clutch free play, drive chain wave clearance and idle speed.

2 nuts

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Sym MB10A7-A series, Symba 100 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual