SYM Orbit User Manual

SERVICE MANUAL

SYM FORWARD

This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle. The manual is shown with illustrations and focused on 「Service Procedures」, 「Operation Key

Points」, and 「Inspection Adjustment」 so that provides technician with service guidelines.

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

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

SERVICE DEPARTMENT

SAN YANG INDUSTRY CO., LTD.

HOW TO USE THIS MANUAL SYM

This service manual describes basic information of different system parts and system inspection & service for SYM series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance. The third to the eleventh chapters cover engine and driving systems. The twelfth to fifteenth chapters are contained the parts set of assembly body. The sixteenth chapter is electrical equipment.

The seventh chapter is for wiring diagram. Please see index of content for quick having the special parts and system information.

SYM CONTENTS

CONTENTS

GENERAL INFORMATION/TROUBLE DIAGNOSIS...................................1

MAINTENANCE INFORMATION .................................................................2

LUBRICATION SYSTEM..............................................................................3

FUEL SYSTEM.............................................................................................4

ENGINE REMOVAL......................................................................................5

CYLINDER HEAD/VALVE............................................................................6

CYLINDER/PISTON......................................................................................7

"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......................8

FINAL DRIVING MECHANISM.....................................................................9

A.C. GENERATOR/STARTING CLUTCH....................................................10

CRANKCASE/CRANKSHAFT .....................................................................11

BODY COVER..............................................................................................12

BRAKE SYSTEM..........................................................................................13

STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER........................14

REAR WHEEL/SUSPENSION......................................................................15

ELECTRICAL EQUIPMENT.........................................................................16

ELECTRICAL DIAGRAM .............................................................................17

MECHANISM ILLUSTRATIONS SYM

brake lever

Rea

Front turn signal light

Horn/REG.REC

Head light/ Position light

Front disk brake

Meter

Frame numbe

High&Low beam/Seat open/turn signal/horn

Start magnetic switch

Fuel tank / Fuel unit

Tail light

RR. turning signal light

cleane

Gearoil filling bolt

Gear oil draining bolt

Engine number/engine oil draining bolt

Engine control switch

Tail light

Rear turn signal light

Exhaust muffler

Ignition coil

Oil level

Light/starter switch

Battery/Fuse/CDI

Winker relay

Front brake lever

Front turn signal light

Ignition switch

A.C. Generator

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYMBOLS AND MARKS....................1-1

GENERAL SAFETY............................1-2

SERVICE PRECAUTIONS.................1-3

SPECIFICATIONS..............................1-9

TORQUE VALUES (ENGINE)..............1-10

TORQUE VALUES (FRAME)...............1-11

TROUBLES DIAGNOSIS..................... 1-12

LUBRICATION POINTS....................... 1-16

SYMBOLS AND MARKS

Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

Warning

Caution

Engine oil

Grease

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 SH/CD class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil.

King Mate G-3 is recommended.

Locking sealant

Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

Indication

Directions

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 service tools.

Meaning correct installation.

Meaning wrong installation.

Indication of components.

Indicates position and operation directions.

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility).

1-1

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

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 verdict.

Hot components

Battery

Caution

 Battery emits explosive gases; flame is

strictly prohibited. Keep the place well ventilated when charging the battery.

 Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water, 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 compressed air or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid asbestos dust flying.

Caution

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

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.

1-2

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 brake fluid beyond reach of children.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SERVICE PRECAUTIONS

 Always use with SANYANG genuine parts

and recommended oils. Using non-designed parts for SANYANG motorcycle may damage the motorcycle.

 Never bend or twist a control cable to prevent

stiff control and premature worn out.

 Special tools are designed for remove and

install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.

 When servicing this motorcycle, use only

metric tools. Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.

 Clean the outside of the parts or the cover

before removing it from the motorcycle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause a damage.

 Wash and clean parts with high ignition point

solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.

 Rubber parts may become deteriorated when

old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.

 When loosening a component which has

different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.

 Store complex components such as

transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.

 Note the reassemble position of the important

components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).

 Components not to be reused should be

replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

1-3

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

 The length of bolts and screws for

assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.

 Tighten assemblies with different dimension

fasteners as follows:

 Tighten all the fasteners with fingers, then

tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.

 When oil seal is installed, fill the groove with

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

Manufacturer's name

 Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if the contact surface has any damage.

 The ends of rubber hoses (for fuel, vacuum,

or coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.

Groove

Clamp

Connector

 Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

 The tool should be pressed against two (inner

and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.

Boots

Both of these examples can result in bearing damage.

1-4

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

 Lubricate the rotation face with specified

lubricant on the lubrication points before assembling.

 Check if positions and operation for installed

parts is in correct and properly.

 Make sure service safety each other when

conducting by two persons.

 Note that do not let parts fall down

 Before battery removal operation, it has to

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

 After service completed, make sure all

connection points is secured. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.

 Make sure that the battery post caps are

located in properly after the battery posts had been serviced.

 If fuse burned, it has to find out the cause

and solved it. And then replace with specified capacity fuse.

capacity verification

1-5

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

 When separating a connector, it locker has to

be unlocked firstly. Then, conduct the service operation.

 Do not pull the wires as removing a

connector or wires. Hold the connector body.

 Make sure if the connector pins are bent,

extruded or loosen.

 Insert the connector completely. If there are

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

 Check if the connector is covered by the twin

connector boot completely and secured properly.

 Before terminal connection, check if the boot

is crack or the terminal is loose.

 Insert the terminal completely. Check if the

terminal is covered by the boot. Do not let boot open facing up.

 Secure wires and wire harnesses to the

frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

 Wire band and wire harness have to be

clamped secured properly.

 Do not squeeze wires against the weld or its

clamp.

1-6

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

 Do not let the wire harness contact with

rotating, moving or vibrating components as routing the harness.

 Keep wire harnesses far away from the hot

parts.

 Route wire harness to avoid sharp edges or

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

 Route harnesses so that they neither pull too

tight nor have excessive slack.

Do not extend it too much.

Do not touch it.

 Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied.

 Secure the rubber boot firmly as applying it

on wire harness.

 Never use wires or harnesses which

insulation has been broken. Wrap electrical tape around the damaged parts or replace them.

 Never clamp or squeeze the wire harness as

installing other components.

Please do not clip or squeeze the wire.

1-7

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

 Do not let the wire harness been twisted as

installation.

 Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

 Before operating a test instrument, operator

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

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

 With sand paper to clean rust on connector

pins/terminals if found. And then conduct connection operation later.

Clean rust.

1-8

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SPECIFICATIONS

MAKER SANYANG MODEL AAA(AV05W-6)

Overall Length 1906mm Front Telescopic fork

Overall Width 694mm

Overall Height 1138 mm Front 120/70-12(56J)

DIMENSION

Wheel Base 1327mm

Front 40kg

Rear 59kg

Curb Weight

WEIGHT

Total Weight

Installation and

Cycle/Cooling

Total 99kg

Passengers/

Weight

Front 84kg

Rear 125kg Primary Reduction BELT

Total 209kg

Type 4-STROKE ENGINE Clutch Centrifugal, dry type

arrangement

Fuel Used Petrol Speedometer 0 ~ 140 km/hr

Two men/150 kg Max. Speed 45km/h

Vertical, below center,

incline 80°

4-stroke/forced air

cooled

sion

System

Suspen

Tire

Specifi

cations

Brake

System

nce

Performa

Deceleration

Climb Ability 20° Below

Secondary

Reduction

equipment

Transmission C.V.T.

Horn 95~115dB(A)

Rear Single swing arm

Rear 130/70-12(56J)

Front DISK (ø 190 mm)

Rear DRUM (ø 110 mm)

GEAR

ENGINE

Bore φ39.0 mm Muffler Expansion & Pulse Type

Stroke 41.5 mm

Cylinder

Number/Arran

gement

Displacement 49.5 cc CO <1.0 g/km

Compression

Ratio

Max. HP 2.35KW/8500 rpm

Max. Torque 2.91N.m /6500 rpm Air Filtration Paper filter

Ignition C.D.I. Noise Emission < 71dB

Starting System Electrical & foot type

Single Cylinder/

horizontal

11.8:1 HC <1.2 g/km

Exhaust Pipe Position

and Direction

Lubrication System

Exhaust

Emission

Engine Weight(dry

weight)

NOx <1.2 g/km

Right side, and

Backward

forced-circulation&

splashing

23kg

1-9

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

TORQUE VALUES (ENGINE)

ITEM Q'TY

Cylinder head bolts 4 6 0.8~1.2 Cylinder head nuts 4 8 1.8~2.2 Apply oil to thread Cylinder/cylinder head two-ends bolts 4 7 0.7~1.1 Tighten to crankcase Cam holder nut 4 7 0.8~1.2 Right crank case cover bolts 10 6 0.8~1.2 Pulse generator bolts 2 5 0.35~0.5 Valve adjustment fixing nuts 2 6 0.7~1.1 Apply oil to thread Spark plug 1 10 1.0~1.4 Engine oil strainer cap 1 30 1.0~2.0 Gear oil draining plug 1 10 1.0~1.4 Gear oil filling bolt 1 10 1.0~1.5 Oil pump bolts 3 6 0.8~1.2 Oil pump drive sprocket nuts 1 6 0.8~1.2 Left crankcase cover bolts 10 6 0.8~1.2 Cylinder head cover bolts 4 6 0.8~1.2 Camshaft chain tensioner pivot 1 6 0.8~1.2 Hex socket bolt

THREAD DIA

(mm)

TORQUE

VALUE(Kg-m)

REMARKS

Camshaft chain adjuster bolts 2 6 1.0~1.4 Cooling fan bolts 4 6 0.8~1.2 Shroud A/B 2 6 0.8~1.2 RR. brake fixing nut 1 8 1.5~2.0 Flywheel nut 1 10 3.5~4.5 Transmission(Gear box) bolts 7 8 2.6~3.0 RR. brake arm bolt 1 6 0.7~1.1 Drive face nut 1 12 5.0~6.0 Drive pulley nut 1 10 3.5~4.5 A.C. generator flange bolt 2 6 0.8~1.2 Air/C connect bracket bolts 2 6 0.8~1.2 Start motor bolts 2 6 0.8~1.2 Brake arm bolt 1 6 0.7~1.1 Kick starter arm bolt 1 6 0.8~1.2 Carburetor nut 2 6 0.8~1.2 A.I. fixing hex cap nut 2 6 0.8~1.2 Crankcase bolts 1 6 0.8~1.2 Exhaust pipe bolts 2 8 3.0~3.6 Exhaust pipe connecting nuts 2 6 1.0~1.4

1-10

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

TORQUE VALUES (FRAME)

ITEM Q'TY

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 Speedometer cable locking screw 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 Front brake disc mounting bolts Front brake clipper mounting bolts

Drum brake arm bolts (front/rear)

Engine suspension bracket bolts

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

8 8 2.8~3.2 1 5 0.15~0.3 4 8 2.4~3.0 1 10 3.5~4.5 1 8 2.4~3.0

1 6 0.8~1.0 4 10 4.0~4.5 2 10 3.1~3.5

2 6 0.8~1.2

2 10 4.5~5.5 On frame side

THREAD DIA

(mm)

TORQUE

VALUE(Kg-m)

REMARKS

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

Standard Torque Values for Reference

TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE

5mm bolt、nut 6mm bolt、nut

8mm bolt、nut 10mm bolt、nut 12mm bolt、nut

0.45~0.60kgf-m

0.80~1.20kgf-m 4mm screw 0.10~0.15kgf-m

1.80~2.50kgf-m 5mm screw 0.35~0.50kgf-m

3.00~4.00kgf-m

5.00~6.00kgf-m

3mm screw

6mm screw、SH nut

6mm bolt、nut 8mm bolt、nut

10mm bolt、nut

0.05~0.08kgf-m

0.70~1.10kgf-m

1.00~1.40kgf-m

2.40~3.00kgf-m

3.50~4.50kgf-m

1-11

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

TROUBLES DIAGNOSIS

A. Engine hard to start or can not be started

Check and adjustment Fault condition

Loosen carburetor drain bolt to check if there is gasoline inside the carburetor

Fuel supplied tom carburetor sufficient

No fuel is supplied to carburetor

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

Check if sparks Weak sparks, no spark

at all

perform cylinder compression pressure test.

Probable causes

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

Remove the spark plug again and check it.

Dry 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

There are some signs of ignition, nut engine can not be started

Wet spark plug

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Sand hole in compression parts

1. Malfunction of throttle valve operation

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Fuel level in carburetor too high

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

1-12

Blowing in normal

Blowing clogged

1. Malfunction of automatic bystarter

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

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

Check and adjustment

Fault condition

Probable causes

Try gradual acceleration and check engine speed

Engine speed can be increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if carburetor jet is clogged

Engine speed can not be increased.

Incorrect ignition timing

No compression

1. Air cleaner clogged

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

5. Fuel level too low in carburetor

6. Fuel nozzle clogged in

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

No clogged Clogged

1. Remove foreign

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

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

No knock

Knock

combustion chamber

2. Lean mixture

3. Poor fuel quality

4. Ignition timing too advanced

1-13

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

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

Check and adjustment Fault condition Probable causes

Check ignition timing

(using ignition lamp)

Normal

Adjust the air screw of carburetor

Abnormal

1. Incorrect ignition timing (malfunction of CDI or AC alternator)

Good Poor

Air sucked through

carburetor gasket

No air sucked Air sucked

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

Good spark Poor

1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket

2. Carburetor lock loose

3. Poor intake gasket

4. Poor carburetor O-ring

5. Vacuum hose crack

1. Spark plug fouled

2. Malfunction of CDI

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

D. Engine runs sluggish (High speed)

Check and adjustment Fault condition Probable causes

1-14

Check ignition timing

Normal Abnormal

Check for fuel supplying system in automatic fuel cup

Good

Check if carburetor clogged

No clogged Clogged

Poor

1. Malfunction of CDI

2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel filter clogged

3. Restricted fuel tank vent

1. Cleaning

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

E. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITIONS PROBABLE CAUSES

Engine can be started but motorcycle can not be moved.

1. Driving belt worn out or deformation

2. Driving disk damaged

3. Driving pulley spring broken

4. Clutch ling broken

5. Driving slide-shaft gear groove broken

6. Transmission gear damaged

Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)

1. Clutch ling spring broken

2. Clutch outer stick with clutch balance weights

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

Poor initial driving ( Poor climbing performance)

1. Driving belt worn out or deformation

2. Balance weight roller worn out

3. Driving sliding gear shaft worn out

4. Driving disk spring deformation

5. Driving sliding gear shaft worn out

6. Greased in driving belt and sliding gear.

1-15

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

LUBRICATION POINTS

Steering shaft bearing

Acceleration cable/ Front & rear brake lever pivot

Seat lock

Speedometer gear /

Front wheel bearing

Side stand shaft

Main stand shaft

Rear wheel bearing

1-16

SYM 2. MAINTENANCE INFORMATION

PRECAUTIONS IN OPERATION .......2-1

PERIODICAL MAINTENANCE SCHEDULE........2-2

LUBRICATION SYSTEM....................2-3

FUEL SYSTEM...................................2-4

AIR CLEANER....................................2-5

THROTTLE VALVE OPERATION ......2-5

VALVE CLEARANCE INSPECTION & ADJUSTMENT ......2-6

CARBURETOR IDLING SPEED ADJUSTMENT .2-7

IGNITION SYSTEM/SPARK PLUG ..2-8

CYLINDER COMPRESSION PRESSURE

.2-9

PRECAUTIONS IN OPERATION

Specification

Fuel Tank Capacity

Engine Oil

Main 5200 c.c.

auxiliary 1500 c.c.

capacity 850 c.c.

change 750 c.c.

DRIVING SYSTEM.............................2-9

STEERING SYSTEM .........................2-10

SUSPENSION SYSTEM .................... 2-10

FRONT DISK BRAKE SYSTEM ......... 2-11

DRUM BRAKE SYSTEM.................... 2-13

WHEEL/TIRE......................................2-14

BATTERY........................................... 2-15

HEADLIGHT ADJUSTMENT.............. 2-15

NUTS、BOLTS TIGHTEN.................. 2-15

Transmission Gear oil

capacity 110 c.c.

change 100 c.c.

Clearance of throttle valve 2~6 mm Spark plug A7RC Gap: 0.6~0.7 mm “F” Mark in idling speed Before TDC 13º / 2200 rpm Full timing advanced Before TDC 26º / 8000 rpm Idling speed 2100±100 rpm Cylinder compression pressure 11.8±0.2 kg/cm² Valve clearance: IN/EX 0.03/0.05±0.02 mm

Tire dimension front / rear 120/70-12 / 130/70-12

single Front: 1.75 kg/cm² rear: 2.00 kg/cm²

Tire pressure (cold)

Two persons Front: 1.75 kg/cm² rear: 2.25 kg/cm²

Battery 12V6Ah (MF battery)

Play of drum brake lever 10~20 mm

2-1

2. MAINTENANCE INFORMATION SYM

PERIODICAL MAINTENANCE SCHEDULE

Mainte nance

Code

☆Air cleaner

☆2nd air jet leaner

☆Fuel filter

☆Oil filter

☆Engine oil change

5 6 Tire pressure 7 Battery inspection 8 Brake & free play check

9 Steering handle check 10 Cushion operation check 11 Every screw tightening check 12 Gear oil check for leaking

☆Spark plug check or change

☆Gear oil change

14 15 Frame lubrication 16 Exhaust pipe

☆Ignition timing

☆Emission check in Idling

☆Throttle operation

☆Engine bolt tightening

☆CVT driving device (belt﹞

☆CVT driving device (roller)

22 23 Lights/electrical equipment/mutli-meters 24 Main/side stands & springs 25 Fuel pipes 27 Cam chain

☆Valve clearance

☆Crankcase vapor control System

☆Crankcase blow-by over-flow pipe

☆2nd air jet system

☆vapor control system

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication

Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

Remarks:

1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items

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

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

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

4. Preventive maintenance

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

overheating occur.

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

obvious lower than ever.

c. Replace worn out pistons, cylinder head.

Item Initial 300KM

I C C R I C C R

I I R C C C R

I I

I I R R

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 I I C

1 Month

Every1000KM

3 month

Every3000KM

Replacement for every 1000km

Replacement for every 5000km

Replacement for every 2000km

6 month

Every6000KM

1 year

Every12000K

2-2

SYM 2. MAINTENANCE INFORMATION

LUBRICATION SYSTEM

Engine Oil Capacity

Caution

 The vehicle must be parked on a level

ground when checking oil capacity.

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

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

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 value1.0~1.5 kgf-m

Dipstick

Caution

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: 850cc Change: 750cc

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

Cleaning the oil strainer

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

Torque value: 1.0~2.0 kgf-m

Oil drain plug

strainer cove

oil straine

spring

2-3

2. MAINTENANCE INFORMATION SYM

Gear Oil Inspection

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

Replacement

At first, remove the gear oil refilling bolt, and then remove the draining plug.

Install the draining plug after drained oil out.

Torque value: 1.0~1.5 kgf-m

Caution

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

Fill out gear oil to specified quantity from the engine oil filling hole. Install the oil filling bolt.

Torque value: 1.0~1.5 kgf-m Quantity: 90 c.c.

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

Fuel System

Fuel Pipe

Remove luggage box, rear center cover, body cover, and rear fender, as well as front inner box. Check all pipes, and replace it when they are deterioration, damage or leaking.

Gear oil refilling bolt

Gear oil draining plug

Warning

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

Fuel filter

Remove the fuel tank. Remove fuel pipe from the fuel filter. Replace the fuel filter with new one. Install the fuel filter.

Caution

The arrow on the fuel filter means the flow direction of fuel and check it if leaking after installation.

2-4

Fuel filte

SYM 2. MAINTENANCE INFORMATION

AIR CLEANER

Element

Remove 7 screws from the air cleaner cover. Remove element of air cleaner (2 screws). Check the element if dirt or damaged. Replace it with new one if dirt or damaged.

Caution

 Air cleaner element contains a paper

made filter so do not try to clean it.

 Make sure that the air cleaner cover had

been installed properly after installation.

screws×7

THROTTLE VALVE OPERATION

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

Free play：2~6 mm

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

Air cleaner element

2~6 mm

Rubber boot

Fixing nut

Adjustment nut

2-5

2. MAINTENANCE INFORMATION SYM

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

Caution

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

Adjustment nut

Fixing nut

VALVE CLEARANCE ADJUSTMENT

Caution

Checks and adjustment must be performed

when engine is cold (below 35℃).

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

Caution

The crankshaft can not be rotated in counter-clockwise to prevent from damage so that valve clearance can not be measured.

Inspection hole

TDC mark

Ignition timing mark

2-6

SYM 2. MAINTENANCE INFORMATION

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX): 0.03/0.03±0.2 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

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

CARBURETOR IDLE SPEED ADJUSTMENT

Caution

 Inspection & adjustment for idle speed

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

 Idle speed check and adjustment have to

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

Park the motorcycle with main stand and warn up engine. Open the carburetor cover from the luggage box. Turn the throttle valve stopper screw to specified idle speed.

Specified idle speed: 2100±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 2100±100 rpm.

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

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

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

Exhaust Emission: CO: ＜1.0g/km

HC: ＜1.2g/km

NOx:＜1.2g/km

Feeler gauge

Fixing nut

Ignition coil cable

Throttle valve stopper screw

Air adjustment screw

2-7

2. MAINTENANCE INFORMATION SYM

IGNITION SYSTEM

Ignition timing

Caution

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

Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap. Check ignition timing with ignition light. Start engine and set engine idle speed in 1700 rpm, and if the mark aligns with the “F”, then it means that ignition timing is correct. Increase engine speed to 8000 rpm to check ignition timing advance. If the detent aligns with advance mark “װ”, then it means ignition timing advance is in functional. If not, check CDI set, pulse flywheel, and pulse generator. Replace these components if malfunction of these parts are found.

F mark

Ignition light

SPARK PLUG

Appointed spark plug: TORCH A7RC

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. Screw the park plug into the plug hole with hands, then tighten the plug with a wrench to prevent from damaging the spark plug's thread.

Torque value: 1.0~1.4 kgf-m

Connect spark plug cap.

Spark plug

Side electrode

Center electrode

2-8

0.6~0.7mm

SYM 2. MAINTENANCE INFORMATION

CYLINDER COPMRESSION PRESSURE

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

Caution

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

Compression pressure: 12 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.

Spark plug

Cylinder pressure gauge

DRIVING SYSTEM

DRIVING BELT

Remove left side cover. Remove mounting bolt located under air cleaner. Remove 9 bolts of the engine left crankcase. Remove the left crankcase 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: above 18.5 mm

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.

Gear teeth

Width

Clutch pad

Clutch

2-9

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