SYM Mio User Manual

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Mechanism Illustrations

Mio 50 / 100

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG Mio 50 / 100 scooters. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the scooter, Mio 50 / 100, 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 Mio 50 / 100 scooters. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information 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 contents 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 ~ 2-18 3-1 ~ 3-8 4-1 ~ 4-12 5-1 ~ 5-8 6-1 ~ 6-18 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

8-1 ~ 8-14 9-1 ~ 9-8

10-1 ~ 10-8 11-1 ~ 11-8 12-1 ~ 12-16 13-1 ~ 13-14 14-1 ~ 14-12 15-1 ~ 15-4 16-1 ~ 16-26

“V” Type Belt Driving System / Kick-Starter Final Driving Mechanism Alternator Crankshaft / Crankcase Body Cover Brake Steering / Front Wheel / Front Cushion Rear Wheel / Rear Cushion Electrical Equipment

10 11 12 13 14 15 16

17-1 ~ 17-8

18-1 ~ 18-2

Emission Control System Electrical Diagram

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Contents

Mechanism Illustrations

HU05U / HU10U / HU10W

Front winker

Oil gauge Fuel tank

Fuel tank cap

Battery / Fuse / C.D.I. unit

Helmet hook

Headlight

Back mirror

Front brake lever

Rear brake lever

Luggage box

Luggage box lock

Air cleaner

Winker / Horn / Hazard or Seat open switch

Start / headlight switch

Main switch

Rear winker

Tail light

Exhaust muffler

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Contents

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

Torque Values ···································· 1-11 Troubles Diagnosis···························· 1-13

Lubrication Points ····························· 1-17

1. General Information

Specifications ·····································1-9

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)

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. Keeps 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 ATV may damage the ATV.

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 ATV, 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 ATV. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to 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 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, and 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 HU05U

Overall Length

Overall Width

Dimension

Weight

Overall Height

Wheel Base

Front

Curb

Weight

Passengers/Weight

Rear Total

Front

1710 mm

700 mm

1005 mm

1170 mm

31 kg

49 kg

80 kg

Two / 110 kg

53 kg

Suspension

System

Tire

Specifications

Brake System

Performance

1. General Information

Front

Rear

Front

Rear

Front

Rear

Max. Speed

Climb Ability

TELESCOPE

UNlT SWING

3.0-10 42J

90/90-10 50J

DRUM (ø 110 mm)

DRUM (ø 95 mm)

Above 60 km/hr

Below 20°

Total

Weight

Type

Installation and

arrangement

Fuel Used

Cycle/Cooling

Bore

Stroke

Cylinder

Number/Arrange

Engine

Displacement

Compression Ratio

ment

Max. HP

Rear Total

137 kg

190 kg

4-STROKE ENGINE

Vertical, below center,

incline 80°

Above 92 unleaded

4-stroke/ forced air

cooled

37 mm

46 mm

SINGLE CYLINDER

49.5 cc

12.6 : 1

3.8 ps /8000 rpm

Primary

Reduction

Secondary

Reduction

Speedometer

Exhaust Pipe Position and

Direction

Lubrication System

Solid Particulate

Exhaust

Concentratio

Reduction

Clutch

Transmission

Horn

Muffler

CO HC

Belt

Gear

Centrifugal, dry type

C.V.T., auto speed

change

0 ~ 90 km/hr

70~90 dB/A

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

Below 3.0 % 以下

Below 2000 ppm

Max. Torque

Ignition

Starting System

0.38 kg-m / 6500 rpm

C.D.I.

Power & Foot

Catalytic reaction control

E.E.C. P.C.V.

system

√

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1. General Information

Specifications

MAKER SANYANG MODEL HU10U/W

Overall Length

Overall Width

Dimension

Weight

Overall Height

Wheel Base

Front

Curb

Weight

Passengers/Weight

Rear

Total

Front

Two / 110 kg

1710 mm

700 mm

1020 mm

1220 mm

32.5 kg DRUM (ø 110 mm)

55 kg

87.5 kg

54.5 kg

Suspension

System

Tire

Specifications

Brake System

Performance

Front

Rear

Front

Rear

Front

Rear

Max. Speed

Climb Ability

TELESCOPE

UNlT SWING

90/90-10 50J

DISK (ø 160 mm)

DRUM (ø 110 mm)

Above 90 km/hr

Below 26°

Total

Weight

Type

Installation and

arrangement

Fuel Used

Cycle/Cooling

Bore

Stroke

Cylinder

Number/Arrange

Engine

Displacement

Compression Ratio

ment

Max. HP

Rear

Total

143 kg

197.5 kg

4-STROKE ENGINE

Vertical, below center,

incline 80°

Above 92 unleaded

4-stroke/ forced air

cooled

50 mm

51.5 mm

SINGLE CYLINDER

101 cc

10.5 : 1

7.7 ps /8000 rpm

Primary

Reduction

Secondary

Reduction

Speedometer

Exhaust Pipe Position and

Direction

Lubrication System

Solid Particulate

Exhaust

Concentratio

Reduction

Clutch

Transmission

Horn

Muffler

CO HC

Belt

Gear

Centrifugal, dry type

C.V.T., auto speed

change

0 ~ 120 km/hr

70~90 dB/A

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

Below 3.0 % 以下

Below 2000 ppm

1-10

Max. Torque

Ignition

Starting System

0.77 kg-m / 6500 rpm

C.D.I.

Power & Foot

E.E.C. P.C.V.

Catalytic reaction control

system

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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 Tighten Torque Type Tighten Torque

5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut

Engine Torque Values

Item Q’ty

Cylinder stud bolt 4 8 0.7~1.0 Tighten to crankcase Cylinder head nut 4 8 1.8~2.2 Apply oil to thread Cylinder head left bolt 2 6 1.0~1.4 Cylinder head side cover bolt 2 6 1.0~1.4 Valve adjustment cap 2 30 1.3~1.7 Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread Spark plug 1 10 1.0~1.4 Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.0 Cylinder head stud bolt (EX. pipe) 2 6 0.7~1.0 Tensioner lifter bolt 2 6 1.0~1.4 Tensioner bolt 1 6 0.8~1.2 Socket bolt Carburetor insulator bolt 2 6 0.7~1.0 Oil pump screw 2 3 0.1~0.3 Engine left cover bolt 7 6 1.0~1.5 Engine oil draining bolt 1 12 3.5~4.5 Engine oil strainer cap 1 30 1.3~1.7 Mission draining bolt 1 8 0.8~1.2 Mission filling bolt 1 10 1.0~1.4 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 ACG. Flywheel nut 1 12 5.0~6.0 Crankcase bolts 7 6 1.5~2.0 Mission case bolt 7 8 2.0~2.4 One-way clutch tighten bolts 3 6 1.0~1.4 Apply locking sealant One-way clutch tighten nut 1 22 9.0~10.0 Apply oil to thread Exhaust pipe bolts 2 8 3.0~3.6 Exhaust pipe connection nuts 2 6 1.0~1.4

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

Thread Dia.

(mm)

6 mm screw、SH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut

Torque Value(kgf-m) Remarks

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 (Kg-m) Remarks

Mounting bolt for steering handlebar

Mounting nut for steering rod 1 25.4 1.0~2.0 Cone seat for steering rod 1 25.4 0.2~0.3 Front wheel shaft nut 1 12 5.0~7.0 Rear wheel shaft nut 1 16 11.0~13.0 Wheel hub/rim mounting nuts 8 8 2.8~3.2 Speedometer cable locking screw 1 5 0.15~0.3

Front shock absorber mounting bolts Rear shock absorber upper connection bolt Rear shock absorber upper connection bolt

Brake lever bolts 2 6 0.8~1.2 Front brake hose bolts 2 10 3.3~3.7 Front brake air-bleeding valve 1 6 0.8~1.0 Front brake disc mounting bolts 4 10 4.0~4.5 Front brake clipper mounting bolts 2 10 3.1~3.5 Drum brake arm bolts (front/rear) 2 6 0.8~1.2 Engine suspension bracket bolts 2 10 4.5~5.5 On frame side Engine connection bolt 1 10 4.5~5.5 On engine side Main standard nut 1 10 3.5~4.5 Foot-starting lever bolt 1 6 1.6~1.8 Air cleaner bolts 2 6 1.0~1.4

1 10 4.0~5.0

4 8 2.4~3.0 1 10 3.5~4.5 1 8 2.4~3.0

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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 carbureto

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

Perform cylinder

compression pressure test.

No fuel is supplied to

carburetor

at 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

Check ignition timing (Using ignition lamp)

Engine speed can be

increased.

Ignition timing correct Incorrect ignition timing

Check cylinder compression

pressure (using compression

pressure gauge)

Compression pressure

correct

Engine speed can not be

increased.

No compression pressure

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

Check if carburetor jet is

clogged

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

1. Remove foreign

1. Remove dirt

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

2. Lean mixture

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

6. Poor circuit on the cooling system

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 ad

Check ignition timing (Using ignition lamp)

Adjust the air screw of

Air sucked through

carburetor gasket

Remove spark plug, install

spark plug into spark plug

cap and perform spark test

against engine ground

ustment Fault condition Probable causes

Normal Abnormal

carburetor

Good Poor

No air sucked Air sucked

1. Incorrect ignition timing (malfunction

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. General Information

of CDI or AC alternator)

Good spark Poor

D. Engine runs sluggish (High speed)

Check and adjustment

Check ignition timing

Normal Abnormal

Check for fuel supplying

system in automatic fuel cup

Good Poor

Check if carburetor clogged

Fault condition Probable causes

1. Spark plug fouled

2. Malfunction of CDI

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug

leads

6. Malfunction of main switch

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

No clogged Clogged

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)

PROBABLE CAUSES

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damaged

1. Clutch ling spring broken

2. Clutch outer cover stickled with clutch balance weights

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

1. Driving belt worn out or deformation

Poor initial driving

(Poor climbing performance)

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

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Lubrication Points

Steering shaft bearing

Acceleration cable/ Front & rear brake lever pivot

1. General Information

Seat locker

Speedometer gear/ front wheel bearing

Side stand shaft

Main stand shaft

Clutch bearing

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1. General Information

Note:

1-18

Home page

Contents

Precautions in Operation...................... 2-1

Periodical Maintenance Schedule........ 2-2

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

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

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

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

Crankcase Blow-By Ventilation............ 2-6

Valve Clearance Adjustment................ 2-6

Carburetor Idle Speed Adjustment...... 2-7

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

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

Cylinder Compression Pressure..... 2-9

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

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

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

Front Disk Brake System................. 2-11

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

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

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

Headlight Adjustment...................... 2-15

Nuts、Bolts Tightness..................... 2-15

Special Service Tools Catalogue.... 2-16

2. Maintenance Information

Precautions in Operation

Specification

Model HU05U HU10U/W

Fuel Tank Capacity 4800c.c. 4800 c.c. Engine Oil

Transmission Gear oil

Clearance of throttle valve 2~6 mm

capacity 800 c.c. 750 c.c. change 700 c.c. 600 c.c. capacity 100 c.c. 110 c.c. change 90 c.c. 100 c.c.

Spark plug NGK C6HSA Clearance:0.6~0.7 mm 〝F〞Mark in idling speed

Full timing advanced TDC 26º / 4000 rpm TDC 22º / 4000 rpm Idling speed 2000±100 rpm 1700±100 rpm Cylinder compression pressure 9 kgf/cm²

Valve clearance Tire dimension Front / Rear 3.00-10/ 90-90 10 90-90 10 50J

Tire pressure (cold)

Battery 12V4Ah (MF battery) YTX5L-BS / GTX5L-BS Play of drum brake lever 10~20 mm

IN 0.05±0.02 mm EX 0.1±0.02 mm

single

Two persons

TDC 13º / 1700 rpm

Front:1.5 kg/cm²

Rear:2.25 kg/cm²

Front:1.5 kg/cm²

Rear:2.50 kg/cm²

TDC 13º / 1700 rpm

12 kgf/cm²

0.12±0.02 mm

Front:2.00 kg/cm²

Rear:2.25 kg/cm²

Front:2.00 kg/cm²

Rear:2.50 kg/cm²

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2. Maintenance Information

Periodical Maintenance Schedule

No item

☆Air cleaner

☆2nd air jet leaner

☆Fuel filter

☆Oil filter

☆Engine oil change

Tire pressure

Battery inspection

Brake & free play check

Steering handle check

Cushion operation check

Every screw tightening check

Gear oil check for leaking

☆Spark plug check or change

☆Gear oil change

Frame lubrication

Exhaust pipe

☆Ignition timing

☆emission check in Idling

☆Throttle operation

☆Engine bolt tightening

☆CVT driving device(belt﹞

☆CVT driving device(roller)

22 23 24 25 27 28 29 30 31 32

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

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first. Remarks: 1. These marks” ☆” in the schedule are emission control items. According to EPA regulations, these items must be

Lights/electrical equipment/ mutli-meters Main/side stands & springs Fuel lines Shock absorbers

Cam chain

☆Valve clearance ☆Crankcase vapor control System ☆Crankcase blow-by over-flow pipe ☆2nd air jet system

C ~ Cleaning (replaced if necessary) L ~ Lubrication

perform normally periodical maintenance following the use r manual instructions. They are prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment.

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

4. Preventive maintenance a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn,

overheating occur.

b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power

is obvious lower. Than ever

c. Replace worn out pistons, cylinder head.

300KM

Initial

1 Month

every

1000KM

I C C R I C C R

I I R C C C R Replacement for every 1000km

I I

I I R R Replacement for every 5000km

L I I I I

A I

I I I I

I R

C I I I I I I I I I A I C I Replacement for every 2000km I I C

3 month

every

3000KM

6 month

every

6000KM

1 year

every

12000KM

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Lubrication System

Engine Oil Capacity

Caution

y The vehicle must be parked on a level

ground when checking oil capacity.

y Run the engine for 2-3 minutes then stop,

wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.

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

Oil change

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

Torque value: 3.5~4.5kgf-m

2. Maintenance Information

Caution

z Warm up the engine. This will make the oil

flow out easily.

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

Engine oil capacity: Disassembly HU10U/W 750c.c.

Change HU10U/W 650c.c.

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

HU05U 800c.c.

HU05U 700c.c.

Cleaning the oil strainer

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

Torque value: 1.3~1.7kgf-m

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2. Maintenance Information

Gear Oil Inspection

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

Replacement

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

Torque value: 0.8~1.2kgf-m

Caution

z Inspect if washer is in good condition.

Replace it with new one if it was deformed or damaged.

Check if the seal washer is good, and replace it if deformed or damaged.

Torque value: 1.0~1.4 kgf-m Quantity: HU10U/W 100 c.c.

Recommended: King-Mate HYPOID GEAR OIL ( #140 ).

Fuel System

Fuel Lines

Remove trunk, side cover, central cover, body frame cover, and pedal, as well as front glove box Check all lines, and replace it when they are deterioration, damage or leaking

HU05U 90 c.c.

Oil draining bolt

Oil refilling bolt

Warning

z Gasoline is a low ignition material so any kind

of fire is strictly prohibited as dealing.

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Air Cleaner

Element

Remove the air cleaner cover (7 screws)

Remove element. Check the element if dirt or damaged. Replace it with new one if dirt or damaged.

2. Maintenance Information

Throttle Valve Operation

Have a wide open of throttle valve as handle bar in any position and release it to let back original (full closed) position. Check handle bar if its operation is smooth. Check throttle valve cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part.

Free play：2~6 mm

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

2~6 mm

Rubber boot

Adjustment nut

Fixing nut

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2. Maintenance Information

Primary adjustment is conducted from cable button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition.

Crankcase Blow-By Ventilation

Pull out the plug from draining hose to clean deposits

Caution

z When always riding in rainy area or full

throttle position, maintenance travel must be shorted. The deposits can be seen in the transparent section of draining hose.

Adjustment nut

Valve Clearance Adjustment

Caution

z Checks and adjustment must be performed

when engine is cold (below 35℃).

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

Caution

z The model that equipped with starting

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

Blow-by hose

TDC mark

Ignition timing mark

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Valve clearance inspection and adjustment

Check & adjust valve clearance with feeler gauge after open the valve adjustment hole cap.

Valve clearance: HU10U/W 0.12±0.02mm (IN/EX) HU05U IN: 0.05±0.02mm EX: 0.10±0.02mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

z It has to make sure that valve rock-arm is be

adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.

Carburetor Idle Speed Adjustment

Caution

z Inspection & adjustment for idle speed

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

z Idle speed check and adjustment have to

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

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

Specified idle speed: HU10U/W 1700±100 rpm HU05U 2000±100 rpm

Emission adjustment in Idle speed

Warm up the engine for around 10 minutes and then conduct this adjustment.

1. Connect the tachometer onto engine.

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

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

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

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

Emission standard: CO: below 3.0%

HC: below 2000 P.P.M.

2. Maintenance Information

High voltage coil cable

Throttle valve stopper screw

Mixture adjustment screw

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2. Maintenance Information

Ignition System

Ignition Timing

Caution

z C.D.I ignition system is set by manufacturer

so it can not be adjusted

z 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 on the cooling fan cap. Or remove the cooling fan cover. Connect tachometer and ignition lamp. Start engine Set engine idle speed in1700 rpm, and if the mark aligns with the “F”, then it means that ignition timing is correct. Increase engine speed to 4000 rpm to check ignition timing advance. If the detent aligns with advance mark “II”, then it means ignition timing advance is in functional. If not, check CDI set, pulse flywheel, and pulse generator. Replace these components if malfunction of these parts are found.

“F” Mark

Spark Plug

Appointed spark plug：CR6HSA (NGK) Remove luggage box.

Remove center cover Remove spark plug cap Clean dirt around the spark plug hole. Remove spark plug Measure spark plug 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 washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed.

Torque value: 1.0~1.2kgf-m

Connect spark plug cap.

Side electrode

Center electrode

Plug cap

2-8

0.6~0.7mm

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Cylinder Compression Pressure

Warn up engine and then turn off the engine. Remove the trunk and 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 stepping the foot-starting lever

Caution

y Rotate the engine until the reading in the

gauge no more increasing.

y Usually, the highest pressure reading will be

obtained in 4~7 seconds.

Compression pressure: HU10U/W 12±2 Kg/cm²

HU05U 9±2 Kg/cm²。

Check following items if the pressure is too low:

˙ Incorrect valve clearance ˙ Valve leaking ˙ Cylinder head leaking, piston, piston ring and

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

Driving System

DRIVING BELT

Remove left side cover Remove mounting bolt located under air cleaner. Remove 8 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: 16.5mm

2. Maintenance Information

Spark plug cap

Cylinder pressure gauge

Gear teeth

Width

Clutch pad

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

Clutch pad

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2. Maintenance Information

Steering System

Caution

z 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.

Suspension System

Caution

z Do not ride the motorcycle with poor shock

absorber.

z Looseness, wear or damage shock absorber

will make poor stability and drive ability.

Front shock absorber

Hold front brake lever and press down the front shock absorber for several times to check its operation. Hold front brake lever and push forward the front shock absorber for several times to check its locking status. Check if it is scratched or leaking. Replace damaged and non-repairable components. Tighten all nuts and bolts.

Rear Shock absorber

Press down the rear shock absorber for several times to check its operation. Check if it is scratched or leaking. Replace damaged and non-repairable components. Park the motorcycle with main standard. Start engine and let the rear wheel rotate after increased engine rpm. Check engine for any parts loose or shaking. Also check the engine suspension bushing for wear out. Replace the bushing if worn out. Tighten all nuts and bolts.

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Front Disk Brake System

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.

Caution

z In order to maintain brake fluid in the

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

z Do not operate the brake lever after the cap

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

z Do not mix non-compatible brake fluid

together.

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.

2. Maintenance Information

Lower limit

Master cylinder cap

Upper limit

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

z Before closing the air bleed valve, do not

release the brake lever.

Bubbles

Brake fluid

Draining valve

Transparent draining hose

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2. Maintenance Information

ADDED BRAKE FLUID

Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid

Caution

z 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.

Master cylinder cap

Upper limit

Brake fluid

Brake lining wear limit

Caution

z It is not necessary to remove brake hose

when replacing the brake lining.

Remove the brake clipper bolt, and take out the clipper.

Caution

z 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 be clipped.

Remove brake lining bolt.

Brake clipper bolts

Brake lining

Brake disc

Brake clipper

Take out the lining

Caution

z In order to maintain brake power balance, the

brake lining must be replaced with one set.

2-12

Pin bolts

To this chapter contents

Drum Brake System

Front Brake Free Play: (Drum brake)

Measure free play of rear brake level at the end of the lever.

Free play: 10~20mm

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

2. Maintenance Information

10∼20mm

“△”mark

Rear Brake Free Play: (Drum Brake Type)

Measure the free [lay of the front brake lever at the end of the lever.

Free play: 10~20 mm

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

Brake Confirmation

Caution

z After brake adjustment, it has to check the

brake operation to make sure the front and rear wheel can be braked.

z Pull the brake lever, and make sure that the

wear limit marks of brake ling on the both front & rear brake arm are closer and touch to the △’ marks. If so, replace the brake ling

with new one.

Decreasing free play

Increasing free play

Adjustment nut

Increasing free play

Decreasing free play

Adjustment nut

“△”mark

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2. Maintenance Information

BRAKE LAMP SWITCH

The brake light switch lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying.

Wheel / Tire

Check if the tire pressure of front & rear wheel is within standard.

Caution

z Tire pressure check should be done as cold

tire.

Appointed tire pressure (HU05U)

Tire size Front tire Rear tire

Tire pressure

as cold tire

(Kg/cm²)

Single 1.5 2.25

Two persons 1.5 2.50

Brake light switchfront disc brake

Rear brake light switch

Appointed tire pressure (HU10U/W)

Tire size Front tire Rear tire

Tire pressure

Single 1.75 2.25

as cold tire

(Kg/cm²)

Two persons 1.75 2.50

Appointed Tire: HU05U Front/Rear wheel: 3.00-10/ 90-90 10 HU10U/W Front & Rear wheel: 90/90 50J

Check if tire surface is ticked with nails, stones or other materials. Check if tire surface or wall for crack or damaged, and replace it if necessary. The tire tread depth can be checked by visual inspection or depth gauge.

• Replace the tire if tire tread dent or unusual

wearing out.

• The tire should be replaced if the wear limit

mark “△” is in visible.

Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:

Front tire：1.5 mm Rear tire：2.0 mm

“△”mark

Caution

z The wear limit marks “△” are located around

the tire wall even for inspection.

2-14

Wear limit indictor

To this chapter contents

Battery

Battery Removal

Open the seat cushion and then the battery cap. (2 screws)

Battery cables removal:

1. At first, remove the negative “-“ cable.

2. Then, remove the positive “+” cable

3. Remove the battery. 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 there is rust on the posts very serious,

spray some hot water on the posts. Then, clean it with steel brush so that can remove rust for more easily.

z Apply some grease on the posts after rust

removed to prevent from rust again.

Headlight Adjustment

Turn on main switch Turn the headlight adjustment screw to adjust headlight beam height.

2. Maintenance Information

Caution

z To adjust the headlight beam follows related

regulations.

z Improper headlight beam adjustment will

make in coming driver dazzled or insufficient lighting.

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 (pipe) clamps, and wire holders for security.

Headlight adjustment screw

2-15

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2. Maintenance Information

Special Service Tools Catalogue

(ø28mm) (ø20mm)

Name

Parts no. SYM-1120310 Parts no. SYM-1120320 Parts no. SYM-1471110/20

Puller/presser for crankcase bushing

Name

Puller/presser for crankcase bushing

Name

Valve spring compressor

Name

Parts no. SYM-1471100 Parts no. SYM-9001200 Parts no. SYM-9001210

Valve spring compressor

Name

Parts no. SYM-9121600 Parts no. SYM-9120200 Parts no. SYM-9125500

Oil seal tapping installer

Name

Valve clearance adjustment wrench

(20*32*6) (25*37*6) (27*42*7)

Valve spring compressor

Name

Valve clearance adjuster

Valve spring compressor

(6204)

(6301)

(6203/6004UZ)

Name

Parts no. SYM-9110400 Parts no. SYM-9610000 Parts no. SYM-9620000

2-16

Bearing installer

Name

Bearing installer

Name

Bearing installer ψ17mm

To this chapter contents

2. Maintenance Information

Name

Parts no. SYM-6204002 Parts no. SYM-6204001 Parts no. SYM-2301000

Bearing remover (inner type)

Name

Bearing remover (outer type)

Name

clutch spring compressor

Name

Parts no. SYM-9020200 Parts no. SYM-2210100 Parts no. SYM-3110A01

Name

Parts no. SYM-ALL23461 Parts no. SYM-1445100-A1A

Clutch mounting nut wrench

Cylinder head/oil filter cap wrench

Name

Name Valve rocker arm puller

Universal fixer

Name

Alternator flywheel remover

2-17

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2. Maintenance Information

NOTE:

2-18

Home page

Contents

Mechanism Illustrations ····················· 3-1 Operational Precautions····················· 3-2 Trouble Diagnosis······························· 3-2 Engine OIL ··········································· 3-3

Mechanism Illustrations

Rock Arm

Scoop lubrication

3. Lubrication System

Cleaning Engine Oil Strainer··············· 3-4 Oil Pump··············································· 3-5 Gear Oil················································· 3-8

Forcedly lubrication

Cam Shaft

Connecting rod

Forcedly lubrication

Crankshaft

Inner passage

Oil strainer

Oil pump

3-1

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3. Lubrication System

Operational Precautions

General Information

z This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.

Specifications

Engine oil quantity

Disassembly: HU10U/W 750c.c.

HU05U 800c.c.

Replacement: HU10U/W 650c.c.

HU05U 700c.c. Oil viscosity: SAE 10W-30 or equivalent (Recommended King-Mate serial oils)

Gear Oil

Disassembly: HU10U/W 110c.c.

HU05U 100c.c. Replacement: HU10U/W 100c.c.

HU05U 90c.c. Oil viscosity of gear oil: SAE 85W-140 (Recommended King-Mate gear oil series SYM HYPOID GEAR OIL)

Oil viscosity

Unit: mm

Items Standard(mm) Limit(mm)

Inner rotor clearance - 0.12

Oil pump

Clearance between outer rotor and body - 0.12 Clearance between rotor side and body 0.05~0.10 0.20

Torque value

Oil draining plug 3.5~4.5kgf-m Oil screen cap 1.3~1.7kgf-m Gear oil draining bolt 0.8~1.2kgf-m Gear oil filling bolt 1.0~1.4kgf-m Oil pump connection screw 0.1~0.3kgf-m

Special Service Tools

Strainer cap wrench SYM-ALL12361 One way clutch socket SYM-9020100 Universal fixer SYM-2210100

Trouble Diagnosis

Low engine oil level

Oil leaking Valve guide or seat worn out Piston ring worn out

Low Oil Pressure

Low engine oil level Clogged in oil strainer, circuits or pipes Oil pump damage

Dirty oil

No oil change in periodical Cylinder head gasket damage 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 Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

Oil Replacement

Caution

z Drain oil as engine warmed up so that make

sure oil can be drained smoothly and completely.

Place an oil pan under the motorcycle, and remove oil strainer cap. Make sure if the aluminum washer of the draining bolt is damaged. If so, replace it with new one. Install the drain bolt and tighten it.

Torque value: 3.5~4.5kgf-m Engine oil replacement quantity:

HU10U/W 650c.c. HU05U 700c.c.

3. Lubrication System

Draining bolt

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3. Lubrication System

Cleaning Engine Oil Strainer

Remove the oil strainer cap. Remove oil strainer and spring Clean oil strainer (recommended using compressed air to clean dirty foreign.) Check if the strainer and O-ring of the oil strainer are broken. Replace with new one if found. Install the oil strainer and spring. Install the oil strainer cap and tighten it.

Special Service Tools: Strainer cap wrench SYM-ALL12361 Torque value：1.3~1.7kgf-m

Fill out oil to the oil filler (Oil viscosity SAE 10W-30) (Recommended King-Mate serial oils)

After oil replaced, insert ignition key into the re-set bottom under instrument panel so that the oil indicator is changed from red to green and set oil replacement mileage to zero. Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again if within standard level after 3-5 minutes. Check if engine oil leaks.

Re-set bottom

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Oil Pump

Oil Pump Removal

Remove the alternator (refer to chapter 10). Remove the engine right cover. Remove the one-way clutch and starting gear (1 nut)

Special Service Tools: One way clutch socket SYM-9020100 Universal fixer SYM-2210100

Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 screws).

Remove the oil pump.

Oil Pump Disassembly

Remove the oil pump screw (1 screw) Take out the oil pump cover, inner & outer rotors. Check these parts after cleaned.

3. Lubrication System

Universal fixer

One way clutch socket

2 screws

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3. Lubrication System

Oil Pump Inspection

Check the clearance between oil pump body and outer rotor

Limit：below 0.12mm

Check clearance between inner and outer rotors.

Limit：below 0.12mm

Check clearance between rotor side face and pump body

Limit：below 2.0 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 the oil pump cover and fixing pin properly and then tighten screw. (1 screw)

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Install driving gear and clamp.

Caution

z Make sure if the oil pump can be rotated

smoothly.

Oil Pump Installation

Install the oil pump (2 screws).

Install oil pump drive gear.

Install the one-way clutch and starting gear (1nut) Install the engine right cover. Install the alternator (refer to chapter 10).

Special Service Tools: One way clutch socket SYM-9020100 Universal fixer SYM-2210100

Oil pump drive gear

Universal fixer

3. Lubrication System

2 screws

One way clutch socket

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3. Lubrication System

Gear Oil

Oil Level Inspection

Park the motorcycle on flat surface with main stand Turn off engine and remove both engine oil filling bolt and oil draining plug.

Remove gear oil filling hole bolt and place a measurement cup under the draining plug. Remove the oil draining plug and the pour gear oil into the measurement cup. Measure the gear oil quantity if within standard value. Add specified gear oil if the oil level too low.

Standard quantity: HU10U/W 110c.c. / replacement: 100c.c. HU05U 100c.c. / replacement: 90c.c.

Gear Oil Replacement

Remove the gear oil filling bolt and its draining plug and then drain oil completely. Install the draining plug and tighten it (Make sure if the plug washer is damaged. If so, replace it with new one.)

Torque Value：0.8~1.2kgf-m

Add new gear oil from the gear oil filling hole and then install the gear oil filling hole bolt after added oil. And then, tighten the bolt.

Torque Value：1.0~1.4kgf-m ※Recommended to apply with SYM HYPOID

GEAR OIL (SAE 85W-140)

Start engine and run it for 2~3 minutes. Turn of f engine and check if oil leaking.

Draining plug

Refill plug of gear oil

3-8

Home page

Contents

Mechanism Illustration ......................4-1

Operational Precautions....................4-2

Trouble Diagnosis..............................4-3

Carburetor...........................................4-4

Mechanism Illustration

Fuel unit

Idle Speed Adjustment ...................... 4-8

Fuel Tank............................................ 4-9

Air Cleaner.......................................... 4-11

Fuel vapor separator

4. Fuel System

Fuel tank cap

Fuel tank

Fuel hose

Carburetor

Throttle valve stopper screw

Vacuum type fuel coke

Vacuum hose

Fuel drain screw

Mixture adjustment screw

4-1

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4. Fuel System

Operational Precautions

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 Do not bend or twist throttle valve cable. Damaged cable will make unstable drive ability. 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 automatic by-starter and air cut-off valves arbitrarily.

Specification

Item

HU10U/W HU05U

Venturi diameter 20 mm 16.6 mm I.D. number 049B 001 Fuel level 16.0mm 17.75mm Main injector # 95 # 88 Idle injector # 38 # 35 Idle speed 1700±100 rpm 2000±100 rpm Throttle handle free play 2~6 mm 2~6 mm Fuel quantity adjustment screw 2 5/8±3/4 turns 2±1/2 turns

Torque value

Fuel valve tightening nut: 1.5~2.0Kgf-m

Special service tools

Vacuum/air pressure pump

General service tools

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 automatic by-starter y Malfunction of throttle valve operation

Stall after started

y Malfunction of automatic 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

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

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

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

Mixture too rich

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

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4. Fuel System

Carburetor

Carburetor Removal

Remove the luggage box and seat. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Remove air cut-off valve hose Disconnect automatic by-starter connectors. Release the clamp strip of air cleaner. Release the clamp strip of carburetor isolator. Take the carburetor out.

Vacuum Chamber Removal

Loosen drain screw, and drain out residual fuel in float chamber. Remove screws (2 screws) of vacuum chamber cover and the cover.

Air cleaner clamp

Adjustment nut

2 Screws

Heat-isolator clamp

Remove compress spring and vacuum piston.

Remove fuel needle seat, spring, and injector needle. Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack.

Caution

z Do not damage vacuum diaphragm.

Installation

Install in reverse order of removal procedures.

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Air Cut-off Valve Removal

Removal the throttle cable seat (screws x 2)

Remove the screws (screw x 2) of the air cut-off valve and its cover.

4. Fuel System

2 screws

Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack.

Installation

Install the valve as reverse order of removal.

Caution

z Do not damage the vacuum diaphragm or in

opposite installation direction.

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4. Fuel System

AUTOMATIC BY-STARTER Inspection

Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter.

Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes)

Replace the automatic by-starter with a new one if resistance value exceeds standard.

Remove the carburetor, allow it to cool off for 30 minutes. Connect a pressure tester form air pump. Connect fuel rich circuit. Pump compressed air to the circuit. Replace the automatic by-starter if the circuit clogged.

Connect battery posts (12V) to starter’s connectors. After 5 minutes, test the rich circuit with compressed air. If air flow through the circuit, then replace the by-starter.

Removal

Remove fixing plate screw, and then remove the plate and automatic by-starter from carburetor.

Valve inspection

Check if automatic by-starter and valve needle for damage or wear out.

Installation

Install automatic by-starter to the carburetor body. Install fixing plate to the upper groove of automatic by-starter, and install its flat surface to carburetor. Install screw and tighten it.

Caution

z Align the round point of the starter with the

screw hole of air intake side.

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FLOAT CHAMBER Disassembly

Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve.

Checking

Check float needle valve and valve seat for drop difference damage, wear out, dirty or clogged.

Caution

z 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, nozzle, idle jet, air-fuel mixture adjustment screw.

Caution

z Take care not to damage jets and adjust

screw.

z Before removing adjustment screw, turn it all

the way down and note the number of turns.

z Do not turn adjustment screw forcefully to

avoid damaging valve seat face.

4. Fuel System

Drain screw

Float valve

Float pin

Float

Main jet

Idle jet

Fuel needle holder

Nozzle

Air-fuel mixture adjustment screw

Clean jets with cleaning fluid. Then use compressed air to blow dirt off. Blow carburetor body passages with compressed air.

Nozzle

Idle jet

Fuel needle holder

Main jet

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4. Fuel System

Assembly

Install main jet, fuel needle jet holder, nozzle, idle jet and air-fuel mixture adjustment screw.

Caution

z Set the adjustment screw in according to

number of turns noted before it was removed.

Install the float valve, float, and float pin.

Checking Fuel Level

Caution

z Check again to ensure float valve, float for

proper installation.

z 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：16.0 mm

Air-fuel mixture

Installation of carburetor

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

y Throttle valve cable clearance adjustment. y Idle speed adjustment.

Idle Speed Adjustment

Caution

z Air amount adjust 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.

z Never screw in forcedly to avoid damaging

the screw seat.

z 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. After warm up engine, then adjust the stopper screw of throttle valve to standard RPM. Connect the sampling hose of exhaust analyzer to exhaust front end. Press test key on the analyzer. Adjust the fuel amount adjustment screw and read CO reading on the analyzer

CO standard value：1.3~2.0 %

Accelerate in gradual increments, and make sure both rpm and CO value are in standard values after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above

Float level gauge

The stopper screw of throttle valve

Adjustment nut of throttle cable

Air-fuel mixture adjustment screw

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Fuel Tank

Fuel meter gauge removal

Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove fuel unit coupler.

Remove the rear bracket (4 bolts & 3 screws)

Turn fuel unit setting plate to the left, and then remove fuel unit.

Special Service Tools:

Each side 2 bolts

4. Fuel System

Fuel unit coupler

3 screws

Universal fixer SYM-2210100

Check if the float and washer is damaged. Replace it with new ones if damaged.

Caution

z Do not bend the float arm of fuel metering

gauge.

z Do not fill out too much fuel to fuel tank

before operation.

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4. Fuel System

Fuel tank removal

Remove the fuel tank mounting bolts (4 bolts). Remove the all lines from the fuel tank.

Each side 2 bolts

3 screws

Fuel vapor separator

Remove fuel tank cap open cable (2 screws).

Remove the fuel tank.

Caution

Vacuum hose / Fuel hose

2 screws

4 bolts

z Replace the fuel tank immediately if it is

broken or leakage.

Fuel Tank Installation

Install the tank in the reverse order of removal.

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Air Cleaner

Removal the element of the air cleaner

Remove the air cleaner cover (7 screws).

Remove air cleaner element.

7 screws

4. Fuel System

Installation

Install the air cleaner in the reverse order of removal.

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4. Fuel System

Removal of Air Cleaner

Open the seat. Remove the luggage box (chapter 12). Remove the left side cover (chapter 12). Loose the air cleaner adapting-pipe clamp.

Remove the EEC, PCV, AI system hoses. Remove the mounting bolts of the air cleaner body. (2 bolts)

Remove the air cleaner assembly.

Installation

2 bolts

Install the air cleaner in the reverse order of removal.

4-12

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Contents

Mechanism Illustrations ····················· 5-1 Operational Precautions····················· 5-2 Engine Removal ·································· 5-3

Mechanism Illustrations

5. Removal & Installation of Engine

Removal of Engine Bush·····················5-6 Engine Hanger······································ 5-7 Installation of Engine··························· 5-8

3.5~4.5kgf-m

4.5~5.5kgf-m

2.4~3.0kgf-m

4.5~5.5kgf-m

5-1

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5. Removal & Installation of Engine

Operational Precautions

General Information

y Engine must be supported by a bracket or adjustable tool in height. y The following parts can be serviced with the engine installed on the frame.

1. Carburetor

2. Driving disk, driving belt, clutch, and transporting disk

3. Final reduction gear mechanism

Specification

Item

MIO 50 MIO 100

Replacement 700 c.c. 650 c.c.

Engine Oil Capacity

Disassemble 800 c.c. 750 c.c.

Replacement 90 c.c. 100 c.c.

Gear Oil Capacity

Disassemble 100 c.c. 110 c.c.

Torque Values

Engine hanger bolt (frame side) 4.5~5.5kgf-m Engine hanger nut (engine side) 4.5~5.5kgf-m Bolt of rear cushion upper connection 3.5~4.5kgf-m Bolt of rear cushion lower connection 2.4~3.0kgf-m

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Engine Removal

Open the seat. Remove the luggage box (Bolt× 4, Nut×1). Remove battery cover. Remove the battery negative (-) cable. Remove the battery positive (+) cable.

Remove right and left side covers (1 screw on each side.).

Remove the power connector of auto by-starter. Remove the generator power wire and pulse generator connector. Remove the starter motor wire.

Remove the spark plug cap.

5. Removal & Installation of Engine

Each side 1 screw

Connectors of the by-starter and the pulse generator

Spark plug cap

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5. Removal & Installation of Engine

Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and then the air cleaner guide.

Remove the exhaust muffler (2 Bolts, 2 Nuts).

Remove the air cleaner connection bolts (2 bolts).

Remove the rear brake cable nut and cable.

2 Bolts

2 Nuts

5-4

Rear brake cable nut

To this chapter contents

Remove the rear cushion lower bolt (1 bolt).

Remove the engine hanger nuts and bolts (engine side), and then remove the engine.

With a bracket to support the engine to prevent from it damage by falling down as removing the engine. Remove the rear wheel with air tools after the engine removed.

5. Removal & Installation of Engine

1 bolt

螺栓×1

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5. Removal & Installation of Engine

Removal of Engine Bush

If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then, with the bush remover / presser, ø28mm & ø20mm, to press the bush out, and replace it with new one.

Engine hanger bush: ø 28mm Rear cushion bush: ø 20mm

Pressing out

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.

Special Service Tools:

Crankcase bush remover/presser SYM-1120310 Crankcase bush remover/presser SYM-1120320

Pressing In

Place the flat section of the remover toward the bush, and then drive the bush, pressing ring, and bolt in to install the bush.

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Engine Hanger

Removal

Remove the right side bolt of engine hanger. (1 bolt on each side)

Remove the engine hanger.

Check if the engine hanger bush and cushion rubber for damage. If so, replace with new ones.

Installation

Tighten the bolts and nuts of engine hanger.

Engine hanger nut: Torque Value: 4.5~5.5kgf-m

5. Removal & Installation of Engine

1 bolt on each side

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5. Removal & Installation of Engine

Installation of Engine

Install the engine according to the reversing order of removal.

Caution

z Note both feet and hands safety for

squeezing as engine installation.

z Do not bent or squeeze each wires or hose. z Route all cables and wires in accordance with

the routine layout.

Engine hanger nut: Torque Value: 4.5~5.5kgf-m

Rear cushion bolt: Torque Value: upper：3.5~4.5kgf-m

Rear wheel axle nut: Torque Value: 11.0~13.0kgf-m

under：2.4~3.0kgf-m

5-8

Home page

Contents

Mechanism Illustrations ····················· 6-1 Operational Precautions····················· 6-2 Troubleshooting·································· 6-3 Cylinder Head Removal······················ 6-4 Cylinder Head Disassembly (HU05U) 6-6 Cylinder Head Disassembly (HU10U/W)

······························································ 6-7

Valve Disassembly······························ 6-9

Mechanism Illustrations

6. Cylinder Head / Valve

Cylinder Head Inspection·················· 6-10 Valve Seat Inspection and Service··· 6-12 Cylinder Head Reassembly··············· 6-14 Cylinder Head Installation················· 6-15 Valve Clearance Adjustment············· 6-16

1.0~1.4kgf-m

1.8~2.2kgf-m

1.0~1.4kgf-m

0.7~1.1kgf-m

6-1

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6. Cylinder Head / Valve

Operational Precautions

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 cannot be carried out when engine is in frame.

Specification Unit: mm

Model HU10U/W HU05U

Item Standard Limit Standard Limit

Valve clearance (intake/exhaust valve

as cold engine)

Compression pressure

Camshaft height of cam

lobe

Rocker

arm

ID of valve rocker arm

OD of valve rocker arm shaft

Intake

Exhaust

0.12 ± 0.02 ─ 0.05/ 0.10 ± 0.02 ─

12 ± 2 kg/cm² ─ 9 ± 2 kg/cm² ─

25.969 25.570 24.100 23.761

25.891 25.410 23.850 23.369

10.000~10.015 10.100 10.000~10.015 10.100

9.972~9.987 9.910 9.987~9.978 9.910

Intake

OD of valve stem

Exhaust

Guide seat

Valve

Connection Flatness of cylinder head

Clearance

between valve

stem and guide

Valve seat width

Intake

Exhaust

4.975~4.985 4.900 4.980~4.970 4.900

4.955~4.970 4.900 4.970~4.955 4.900

5.000~5.012 5.300 5.000~5.012 5.300

0.010~0.037 0.080 0.010~0.037 0.080

0.030~0.057 0.100 0.030~0.057 0.100

1.000 1.600 1.000 1.600

- 0.050 - 0.050

Torque Value

Cylinder head bolt (LH) 1.0~1.4kgf-m Cylinder head left side bolt 1.0~1.4kgf-m Cylinder head Nut 1.8~2.2kgf-m Sealing bolt of timing chain auto-tensioner 0.8~1.2kgf-m Bolt of timing chain auto-tensioner 1.0~1.4kgf-m Valve adjustment nuts 0.7~1.1kgf-m (apply with oil on bolt thread & seat) Spark plug 1.0~1.4kgf-m

Special service tools

Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve cover wrench SYM-ALL12361 Valve spring compressor SYM-1471100 0r Valve spring compressor/installer SYM-1471110/20 Valve clearance adjustment wrench SYM-9001200 or Valve clearance adjuster SYM-9001210

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6. Cylinder Head / Valve

Troubleshooting

Engine performance will be affected by troubles on engine top end. The troubles usually can be

determinate or by performing cylinder compression test and judging the abnormal noise generated.

Rough Idle

Low compression pressure

1. Valve

y Improper valve adjustment y Burnt or bended valve y Improper valve timing y Valve spring damaged y Valve carbon y Poor sealing on valve seat y Improper spark plug installation

2. Cylinder head

y Cylinder head gasket leaking or damage y Tilt or crack cylinder surface

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 Cam chain wear out or looseness y Auto-tensioner wear out or damage of cam chain y Camshaft sprocket wear out y Rocker arm or rocker arm shaft wear out

White smoke

y Valve guide or valve stem wear out y Valve stem seal wear out

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6. Cylinder Head / Valve

Cylinder Head Removal

Remove the right cooling shroud from the engine outer cover. (5 screws)

Remove the left cooling shroud (1 bolt). Remove the crankcase blow-by system hose from the cylinder head.

Remove the cam chain tensioner (2 bolts).

Remove the cylinder head side cover. (2 bolts)

5 Screws

1 bolt

Blow-by system hose

Tensioner

6-4

2 bolts

To this chapter contents

Turn the flywheel in counter clockwise motion with T type wrench until the “Timing” mark on camshaft aligned with the mark on the cylinder head. Remove camshaft sprocket mounting bolt and remove the sprocket. Remove the left side cylinder head and cylinder connection bolts (2 bolts)

Remove the cylinder head mounting nuts (4 nuts).

Remove the cylinder head. Clean up residues from the matching surfaces of cylinder and cylinder head.

4 nuts

6. Cylinder Head / Valve

1 bolt

2 bolts

Timing mark

Caution

z Do not damage the matching surfaces of

cylinder and cylinder head.

z Avoid residues of gasket or foreign materials

falling into crankcase as cleaning.

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6. Cylinder Head / Valve

Cylinder Head Disassembly (HU05U)

Remove the valve cover from the cylinder head.

Special Service Tool:

Cylinder head wrench: SYM-ALL12361

Remove the camshaft stopper of the rocker arm shaft (1 bolt).

With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker arm.

Special Service Tool: Valve rocker arm shaft puller: SYM-1445100-A1A

Take out the rocker arm and shaft.

Camshaft stopper

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Cylinder Head Disassembly (HU10U/W)

Remove the valve cover from the cylinder head.

Special Service Tool:

Cylinder head wrench: SYM-ALL12361

Remove the camshaft stopper of the rocker arm shaft (1 bolt).

With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker arm.

Special Service Tool: Valve rocker arm shaft puller: SYM-1445100-A1A

Take out the rocker arm and shaft.

Exhaust rocker arm shaft

6. Cylinder Head / Valve

固定擋板

Intake rocker arm shaft

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6. Cylinder Head / Valve

Remove the camshaft.

Camshaft Inspection

Inspect cam lobe height for damaged.

Service Limit: (Refer to page 2)

Inspect the camshaft bearing for looseness or wear out. If any damaged, replace whole set of camshaft and bearing.

Measure the cam rocker arm I.D.

Service Limit: (Refer to page 2)

Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.

Service Limit: (Refer to page 2)

Calculate the clearance between the rocker arm shaft and the rocker arm.

Service Limit: (Refer to page 2)

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Valve Disassembly

Remove the valves

Special Service Tool:

Valve remover/installer SYM-1471110/20

Caution

z Place a rag under the bottom of the

combustion chamber as disassembling to prevent from valve stem deformation.

Remove the valve spring retainer, valve springs and valves.

Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.

6. Cylinder Head / Valve

Valve stem

Caution

z Do not damage the matching surface of

cylinder head.

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6. Cylinder Head / Valve

Cylinder Head Inspection

Cylinder Head

Check if spark plug and valve holes are crack. Measure cylinder head wrap age with a straightedge and flat feeler gauge.

Service limit: 0.05mm

Valve spring free length

Measure the free length of intake and exhaust valve springs.

Service limit: 31.5mm

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: (Refer to page 2)

Valve guide

Caution

z Before measuring the valve guide, clean

carbon deposits with reamer.

Special Service Tool:

5.0mm valve guide reamer Measure and record each valve guide inner diameters.

Service limit: 5.03mm

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: (Refer to page 2)

The narrow pitch of the spring shall face to the

combustion chamber.

5.0mm valve guide reamer

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Caution

z 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

z 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

z Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed as heating it.

z 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.

Special Service Tool: Valve guide driver: 5.0mm

Caution

z Check if new valve guide is deformation after

pressed it in.

z 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 13mm. Press in new valve guide from rocker arm side.

Special Service Tool: Valve guide driver: 5.0mm

Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.

Caution

z Using cutting oil when correcting valve guide

with a reamer.

z Turn the reamer in same direction when it be

inserted or rotated.

Correct valve seat, and clean up all metal residues from cylinder head.

Special Service Tool: Valve reamer: 5.0mm

6. Cylinder Head / Valve

13 mm (0.15in)

Valve guide driver 5.0mm

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6. Cylinder Head / Valve

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

z Do not let emery enter into between valve

stem and valve guide.

z Clean up the emery after corrected, and

apply with red paint onto contact faces of valve and valve seat.

Remove the valve and check its contact face.

Caution

z Replace the valve with new one if valve seal

is roughness, wear out, or incomplete contacted with valve seat.

z If the valve and the valve seat still can not be

matched sealing after grinded, replace it with new one.

Valve seat inspection

If the valve seat is too width, narrow or rough, corrects 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 grinded 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.

Valve seat width

Roughness

45°

Old valve seat width

Caution

z After valve guide had been replaced, it has to

be grinded with 45° valve seal chamfer cutter to correct its seat face.

Use 32° cutter to cut a quarter upper parts out.

6-12

32°

To this chapter contents

Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat.

Use 45° cutter to grind the valve seat to specified width.

Caution

z Make sure that all roughness and uneven

faces had been grinded.

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.

6. Cylinder Head / Valve

Old valve seat width

60°

1.0mm

45°

Contact surface too high

Old valve seat width

Caution

z The contact surfaces of valve and valve seat

are very important to the valve sealing capacity.

If the contact surface is too high, grind the valve seat with 32° cutter. Then, grind the valve seat to specified width with 45° cutter.

If the contact surface is too low, grind the valve seat with 60° cutter. Then, grind the valve seat to specified width with 45° cutter.

Contact surface too low

32°

Old valve seat width

60°

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6. Cylinder Head / Valve

After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded.

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

z The closed coils of valve spring should face

down to combustion chamber.

Valve split lock

Valve spring retainer

Valve spring

Valve stem oil seal

Valve

Install the valves with the valve remover/installer.

Special Service Tool: Valve remover / installer SYM-1471110/20.

Caution

z Place a rag under the bottom of the

combustion chamber as disassembling to prevent from valve stem deformation.

Tap valve stem with a plastic hammer to make valve retainer and valve stem sealing properly.

Caution

z Place and hold cylinder head on to working

table so that can prevent from valve damaged.

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Assembly the cylinder head.

Caution

z The tangent of rocker shaft of intake valve

should match with the bolt hole of camshaft mounting seat.

Cylinder Head Installation

Install the lock pins and new cylinder head gasket onto the cylinder. Install the camshaft chain plate.

Tighten the cylinder head nuts (4 nuts) At first, tighten the 4 nut on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.

With T type wrench to turn crankshaft in a clockwise motion so that the “T” mark on the generator flywheel aligns with the mark on crankcase. (piston is at TDC position)

Place the TDC marks of the cam sprocket at same level of the top-end of cylinder head. The other single hole of the cam sprocket is in upward. Then, install the cam chain onto the cam sprocket. (bolts x2)

Torque value: 1.8~2.2kgf-m

Install the spark plug and tighten it.

Torque value: 1.0~1.4kgf-m

Lock pins

4 Nuts

6. Cylinder Head / Valve

Chain plate

1 bolt

Gasket

Caution

z Apply with oil onto the thread of cylinder head

bolts and tighten the bolts in diagonally for 2-3 sequences.

z Do not over tightening the bolts to avoid the

cylinder head deformation, noise created or leaking so that effects motorcycle’s performance.

2 bolts

Timing mark

6-15

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6. Cylinder Head / Valve

Valve Clearance Adjustment

Install the auto-chain tensioner.

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: (Refer to page 2) Special Service Tool: Valve clearance adjustment wrench SYM-9001200 or valve clearance adjuster SYM-9001210.

Install the side cover of the cylinder head. (2 bolts)

Install the left cooling shroud of the engine body outer cover. (1 bolt)

Auto-chain tensioner

2 bolts

1 bolt

6-16

Blow-by system hose

To this chapter contents

Install the cooling shroud of the engine body outer cover. (5 bolts)

Install the engine onto the frame. (Refer to chapter 5)

6. Cylinder Head / Valve

5 Screws

6-17

To this chapter contents

6. Cylinder Head / Valve

Notes:

6-18

Home page

Contents

Mechanism Illustrations ····················· 7-1 Operational Precautions····················· 7-2 Trouble Diagnosis······························· 7-2 Cylinder Removal································ 7-3

Mechanism Illustrations

0.8~1.2kgf-m

7. Cylinder / Piston

Piston Removal····································7-5 Piston Ring Installation·······················7-7 Piston Installation································7-8 Cylinder Installation·····························7-8

7-1

To this chapter contents

7. Cylinder / Piston

Operational Precautions

General Information

y Both cylinder and piston service cannot be carried out when engine mounted on frame.

Specification Unit: mm

Model HU10U/W HU05U

Cylinder

Item ID Bend / wrap age Cylindrical roundness Cylindrical roundness

Clearance between piston rings

top ring 0.015~0.050 0.090 0.015~0.050 0.090

top ring 0.100~0.250 0.500 0.100~0.250 0.500

ring 0.015~0.050 0.090 0.015~0.050 0.090

Standard Limit Standard Limit

49.995~50.015 50.500 37.015~36.995 37.500

－－－

0.050

－－－

0.050

Ring-end gap

Piston/

Piston ring

OD of piston pin Clearance between piston and piston pin ID of connecting rod small-end

OD of piston Piston OD measurement

position Clearance between piston

and cylinder ID of piston pin boss

2nd ring 0.100~0.250 0.500 0.100~0.250 0.500

oil ring 0.300~0.900

Trouble Diagnosis

Low or Unstable Compression Pressure

Cylinder or piston ring worn out High compression Pressure

Carbon deposit onto piston and combustion chamber

Knock or Noise

Cylinder or piston ring worn out Carbon deposits on cylinder head top-side Piston pin hole and piston pin wear out

－

49.970~49.990 49.900 36.985~37.005 36.900

Lower-end up 9mm

of piston skirt

0.005~0.015 0.100 0.005~0.015 0.100

13.002~13.008 13.040 10.002~10.008 10.040

12.994~13.000 12.960 10.000~10.006 9.966

0.002~0.014 0.020 0.002~0.014 0.020

13.016~13.034 13.060 10.016~10.034 10.060

Smoking in Exhaust Pipe

Piston or piston ring worn out Piston ring installation improperly Cylinder or piston damage

Engine Overheat

Carbon deposits on cylinder head top side

－

0.2~0.7

Lower-end up 9mm

of piston skirt

－

7-2

To this chapter contents

Cylinder Removal

Remove cylinder head. (Refer to chapter 6) Remove cam chain plate.

Remove cylinder.

Remove cylinder gasket and lock pins.

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.

7. Cylinder / Piston

Cam chain plate

Caution

z To soap the residues into solvent so that the

residues can be removed more easily.

7-3

To this chapter contents

7. Cylinder / Piston

Inspection

Check if the inner diameter of cylinder is worn out or damaged. In the 3 positions (top, center and bottom) of cylinder, measure the X and Y direction values respective in the cylinder.

Service limit: (Refer to page 2)

Calculate both the real roundness (the difference between X and Y motion values) and the cylindrical roundness (the difference in the top, center or bottom positions of X or Y motion values.) Then, determinate by the max. value

Service limit: Real roundness: correct or replace as over

0.05mm Cylindrical roundness: correct or replace as over 0.05mm

Check Cylinder Wrap age.

Service limit: 0.05mm

Exhaust side

Top

Center

Bottom

Intake side

7-4

To this chapter contents

Piston Removal

Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts 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.

Remove piston rings.

Caution

z Pay attention to remove piston rings because

they are fragile.

Disassemble the piston rings. Check if the piston rings are damaged or its grooves are worn. Cleaning carbon deposit onto the piston ring grooves.

Install the piston rings and then measure clearance between piston ring and its grooves.

Service Limit: Top ring: replace if over 0.09mm

Take out the piston rings and place them respective into cylinder below 20mm of cylinder top. Measure each piston ring gaps.

ring: replace if over 0.09mm

7. Cylinder / Piston

Piston ring

Push in

Piston

Feeler gauge

Caution

z Push the piston rings into cylinder with piston

top-end in parallel motion.

Service Limit: Top ring: replace if over 0.5mm

2nd ring: replace if over 0.5mm

Piston rings

7-5

To this chapter contents

7. Cylinder / Piston

Measure the outer diameter of piston pin.

Service Limit: (Refer to page 2)

Measure the inner diameter of connecting rod small end.

Service Limit: (Refer to page 2)

Measure the inner diameter of piston pin hole.

Service Limit: (Refer to page 2)

Calculate clearance between piston pin and its hole.

Service Limit: (Refer to page 2)

Measure piston outer diameter.

Caution

z The measurement position is 10 mm distance

from piston bottom side, and 90° to piston pin.

Service Limit: (Refer to page 2)

Compare measured value with service limit to calculate the clearance between piston and cylinder.

7-6

To this chapter contents

Piston Ring Installation

Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown below.

Caution

z Do not damage piston and piston rings as installation. z All marks on the piston rings must be forwarded to up side. z Make sure that all piston rings can be rotated freely after installed.

7. Cylinder / Piston

Top groove

2nd groove

Oil groove

Over 20mm

120°

Top ring

2nd ring

Side ring Spacer

Side ring

Oil ring

7-7

To this chapter contents

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

z Do not let the opening of piston pin snap ring

align with the opening piston ring.

z Place a piece of cloth between piston skirt

section 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

z To soap the residues into solvent so that the

residues can be removed more easily.

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

z Do not push piston into cylinder forcefully

because this will cause the piston and the piston rings to be damaged.

Install the cam chain plate, the cylinder gasket and lock pins. Install cylinder head (refer to Chapter 6) Install the cam chain auto-tensioner. (2 bolts)

7-8

Home page

Contents

Mechanism Illustrations ····················8-1 Operational Precautions····················8-2 Trouble Diagnosis······························8-2 Left Crankcase Cover ························8-3

Mechanism Illustrations

8. V-Belt Drive System / Kick Starter

Kick Starter········································· 8-3 Drive Belt············································ 8-5 Movable Drive Face ··························· 8-7 Clutch / Driven Pulley························ 8-10

5.0~6.0kgf-m

1.0~1.5kgf-m

8-1

To this chapter contents

8. V-Belt Drive System / Kick Starter

Operational Precautions

General Information

y Movable drive face, clutch, and driven pulley can be serviced on the motorcycle. y Drive belt and driven pulley surface must be free of grease.

Specification Unit: mm

HU10U/W HU05U

Item Standard value Limit Standard value Limit

Drive belt width ID of movable drive face OD of drive face boss OD of roller ID of clutch outer Thickness of clutch lining Free length of driven pulley spring OD of driven pulley

17.800~18.200 17.200 17.800~18.200 17.200

23.989~24.052 24.060 23.964~23.985 24.015

23.960~23.974 23.940 23.910~23.926 23.890

15.920~16.080 15.400 15.920~16.080 15.400

112.000~122.200 112.500 107.000~107.200 107.500

2.000 1.500 2.00 1.500

──

33.965~33.985 33.940 33.965~33.985 33.940

156.000

──

87.900

ID of sliding driven pulley

34.000~34.025 34.060 34.000~34.025 34.060

Torque value:

Movable drive face nut: 5.0~6.0kgf-m Clutch outer nut: 5.0~6.0kgf-m Driven pulley nut: 5.0~6.0kgf-m

Trouble Diagnosis

Engine can be started but motorcycle can not be moved

1. Worn drive Belt

2. Worn ramp plate

3. Worn or damaged clutch lining

4. Broken driven pulley

Shudder or misfire when driving

1. Broken clutch lining

2. Worn clutch lining

Special Service Tools

Clutch spring compressor SYM-2301000 Bearing puller (inner type) SYM-6204002 Clutch mounting nut wrench SYM-9020200 Universal fixture SYM-2210100

Insufficient horsepower or poor high speed performance

1. Worn drive belt

2. Insufficient spring capacity of driven pulley

3. Worn roller

4. Driven pulley operation un-smoothly

8-2

To this chapter contents

Left Crankcase Cover

Left crankcase cover removal

Remove body cover Remove air cleaner (2 bolts)

Remove left crankcase cover (8 bolts).

Installation of the left crankcase cover

Install the left crankcase cover (8 bolts) Tighten the air cleaner (2 bolts)

Kick Starter

Disassembly

Remove left crankcase cover. Remove kick starter arm (1 bolt).

Remove snap ring and thrust washer from left crankcase cover.

8. V-Belt Drive System / Kick Starter

2 bolts

8 bolts

1 bolt

Snap ring

8-3

To this chapter contents

8. V-Belt Drive System / Kick Starter

Remove the inner plate inside of left crankcase cover. (6 screws)

Install kick starter arm, rotate the lever slightly and then remove driven gear and washer. Remove the kick starter arm, kick starter spindle, spindle bush and return spring as well as socket.

Return spring

6 screws

Inspection

Check if kick starter spindle, kick spindle bush, kick driven gear for wear or damage. Replace it with new one if necessary. Check the return spring and friction spring for spring force or damaged. Replace it with one if poor parts found.

Reassembly

Install socket, return spring and starter shaft as diagram shown. Install thrust washer and snap ring onto starter shaft. Install kick starter lever temporary. Rotate the lever and then align driving gear with width-tooth on the starter shaft. Install the friction of driving gear onto convex part of the cover. Install the left crankcase cover.

Kick starter spindle

Driven gear

8-4

To this chapter contents

Drive Belt

Removal

Remove left crankcase cover Hold drive face with universal fixture, and remove nut and drive face.

Special Service Tool: Universal fixture SYM-2210100

Hold the clutch outer with the universal fixture, and the remove the nut and the clutch outer.

Caution

z Using special service tools for tightening or

loosening the nut. Fixed rear wheel or rear brake only will damage reduction gear system.

Special Service Tool: Universal fixture SYM-2210100

8. V-Belt Drive System / Kick Starter

Universal fixture

Nut

Universal fixture

Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove. Drive belt and clutch at same time.

Inspection

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

Service Limit: 17.2mm

Caution

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

free of grease.

z Clean up all grease or dirt before installation.

Drive belt

Tooth

Width

8-5

SYM Mio User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual