Sym PA12B, PA12C, wolf 125, Wolf Classic 125, Wolf Classic 125R Service Manual
PA12B
PA12C
SERVICE MANUAL
FOREWORD CONTENTS
HOW TO USE THIS MANUAL MECHANICAL LAYOUT
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Contents
Foreword
This service manual contains the technical data of each component inspection and
repair for the SANYANG PA12B & PA12C 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.
Copyright reserved.
If the style and construction of the motorcycle, PA12B & PA12C series motorcycle,
are different from that of the photos, pictures shown in this manual, you should
follow the actual vehicle layout. Specifications may be changed 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 individual parts and system
inspection & service for SANYANG PA12B&PA12C series motorcycle. In addition,
please refer to the manual contents for detailed information for the model year.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 9th chapters cover engine and driving systems.
The 10th to the 12th chapters contain the parts of vehicle frame.
The 13th chapter is electrical appliances.
The 15th chapter is wiring diagram.
Please see index of content for brief information and quick guide.
There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and
“Mechanical Layout” on the PDF version homepage, and can access these items
by clicking of the mouse.
If technician wants to see the content of one specific chapter, click on the title of
each chapter on the Index page. There are two buttons on the upper part of each
page, “Homepage” and “contents”. The user can click on the “Homepage” button or
the “Contents” button to go back to the homepage or contents index. Therefore, to
check one paragraph inside the chapter, click on the paragraph index to go to the
desired paragraph. In addition, there is a “To This Chapter Contents” button at the
upper side of each page, by clicking the button; you can go back to the paragraph
selection index of this specific chapter.
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Page Content Index
1-1 ~ 1-20
2-1 ~ 2-24
3-1 ~ 3-14
4-1 ~ 4-18
5-1 ~ 5-8
6-1 ~ 6-8
General Information
Maintenance Information
Fuel System
Lubrication / Clutch / Transmission
AC Generator / Starter Clutch
Engine Removal
Contents
1
2
3
4
5
6
7-1 ~ 7-18
8-1 ~ 8-10
9-1 ~ 9-16
10-1 ~ 10-14
11-1 ~ 11-22
12-1 ~ 12-16
13-1 ~ 13-26
14-1 ~ 14-10
Cylinder Head / Valve
Cylinder / Piston
Crankshaft / Crankcase / Shifting Gear / Kick Starter
Brake System
Steering / Front Wheel / Front Fork
Rear Wheel / Rear Cushion / Swingarm
Electrical System
Emission Control System
7
8
9
10
11
12
13
14
15-1 ~ 15-2
Wiring Diagram
15
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Contents
Mechanical Layout
Headlight/starting
/Hazard switch
FR winker
Headlight dimmer
switch/Signal light
/ Horn switch
Headlight
RR brake pedal
Kick-starter
Engine Oil Dipstick
RR. winker
C.D.I.
Air filter
Fuel tank cap
Regulator/
Rectifier
Ignition coil
Winker relay
FR Brake lever
Clutch lever
Tail light
Battery/ Fuse
Shifting pedal
Choke lever
Main Switch
Muffler
Homepage
Contents
Symbols and Marks···················1-1
General Safety···························1-2
Service Precautions··················1-3
Torque Values ···························1-11
Trouble Diagnosis·····················1-13
Lubrication Points·····················1-19
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
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
1
Engine oil
Grease
Gear oil
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Correct
Wrong
damage that caused by not apply with the limited engine oil.
(Recommended oil: Bramax G-3 oil)
King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
# 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.
Indication Indication of components.
Directions
Indicates position and operation directions
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt go through
the component (invisibility).
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1. General Information
General Safety
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 ventilator.
Caution
Exhaust contains toxic gas, which may cause one
to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark allowed in the work place or where
gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified.
We recommend you to wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Battery Carbon monoxide
Caution
‧ Battery emits explosive gases; flame is strictly
prohibited. Keeps the place well ventilated
when charging the battery.
‧ Battery contains sulfuric acid (electrolyte),
which can cause serious burns, so be careful
not to get the sulfuric acid on your eyes or
skin. If you get battery acid on your skin, flush
it off immediately with water. If you get battery
acid in your eyes, flush it off immediately with
plenty of water and then go to hospital to
consult an ophthalmologist.
‧ If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as
vegetable oil and then go to see a doctor.
‧ Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Brake fluid
Caution
Hot components
Caution
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until the vehicle is cooling down.
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-genuine parts for
SANYANG vehicle may damage it.
y Special tools are designed for remove and
install of components without damaging the part.
Using wrong tools may result in damage.
y When servicing this bike, use only metric tools.
Metric bolts, nuts, using wrong tools and
fasteners may damage this vehicle.
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 easy to be damaged by solvent and oil.
Check these parts before installation to make
sure that they are in good condition, replace if
necessary.
y When loosening a component, which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
y Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
y Clean the outside of the parts or the cover
before removing it from the bike. Otherwise, dirt
and deposit accumulated on the part's surface
may fall into the engine, chassis, or brake
system, and cause damage.
y Wash and clean parts with high ignition point
solvent, and blow-dry with compressed air. Pay
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on
them.
y 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 assembly,
cover plates or boxes is different from one
another, make sure they are correctly installed.
In case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length out side the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
y Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
y 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, you have to
remove the battery negative (-) cable first.
Avoid using tools like open-end wrench, which
may contact with body or create spark.
y 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 first. Then, conduct the service
operation.
y Do not pull the wires as removing a connector
or wires. Hold the connector body.
y Make sure if the connector pins are bent,
extruded or loosen.
y Insert the terminal completely.
Check if the boot covers the terminal.
Do not let boot open facing up.
y Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
y 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 when 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 Avoid wire harnesses from sharp edges or
corners, and also avoid the jutted-out ends of
bolts and screws.
y Route harnesses so that they neither pull too
tight nor have excessive slack.
y Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
y Never clamp or squeeze the wire harness when
installing other components.
Never 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 when
installation.
y Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, use rubber covering against adjacent or
surrounding parts in all steering perimeters.
y Use sand paper to clean connector
pins/terminals if rust is found. And then
continue the connection operation.
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 PA12B
Overall Length
Overall Width
Dimension
Weight
Overall Height
Wheel Base
Front
Curb
Weight
Passengers/Weight
Rear
Total
Front
1910 mm
760 mm
1030 mm
1210 mm
53 kg
70 kg
123 kg
Two / 110 kg
75 kg
Suspension
System
Tire
Specifications
Brake System
Performance
1. General Information
Front
Rear
Front
Rear
Front
Rear
Max. Speed
Climb Ability
TELESCOPIC FORK
SWING ARM
2.75-18-4PR
3.00-17-4PR
DISK (ø 240 mm)
DRUM (ø 130 mm)
Above 94 km/hr
Below 28°
Total
Weight
Type
Installation and
arrangement
Fuel Used
Cycle/Cooling
Bore
Stroke
Cylinder
Number/Arrange
Engine
Displacement
Compression Ratio
ment
Max. HP
Rear
Total
158 kg
233 kg
Air cooled 4-stroke
gasoline engine
Vertical, below center,
incline 15°
Above 92 unleaded
4-stroke/ forced air
cooled
Ø 56.5 mm
49.5 mm
SINGLE CYLINDER
124 cc
9: 1
12.5 ps / 9500 rpm
Primary
Reduction
Secondary
Reduction
Speedometer
Exhaust Pipe Position and
Direction
Lubrication System
Solid Particulate
n
Exhaust
Concentratio
Reduction
Clutch
Transmission
Horn
Muffler
CO
HC+Nox
4.06
2.73
wet mutiplate
5 speed, circulated
0 ~ 140 km/hr
80~112 dB/A
Expansion & Pulse
Type
Right side, and
Backward
forced and wet sump
-
Below 3.0 %
Below 2000 PPM
Max. Torque
Ignition
Starting System
1.0 kg-m / 7500 rpm
C.D.I.
kick & electrical
starter
Catalytic reaction control
E.E.C. √
P.C.V. √
system
√
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1. General Information
MAKER SANYANG MODEL PA12C
Overall Length
Overall Width
Dimension
Weight
Overall Height
Wheel Base
Front
Curb
Weight
Passengers/Weight
Total
Weight
Installation and
arrangement
Rear
Total
Front
Rear
Total
Type
Two / 110 kg
Air cooled 4-stroke
gasoline engine
Vertical, below center,
1940 mm
715 mm
1085 mm
1235 mm
52.5 kg
66 kg
118.5 kg
75 kg
158 kg
228.5 kg
incline 15°
Suspension
System
Tire
Specifications
Brake System
Performance
Reduction
Front
Rear
Front
Rear
Front
Rear
Max. Speed
Climb Ability
Primary
Reduction
Secondary
Reduction
Clutch
Transmission
TELESCOPIC FORK
SWING ARM
2.75-18-4PR
3.00-17-4PR
DISK (ø 240 mm)
DRUM (ø 130 mm)
Above 94 km/hr
Below 28°
4.06
2.73
wet mutiplate
5 speed, circulated
Fuel Used
Cycle/Cooling
Bore
Stroke
Cylinder
Number/Arrange
Engine
Displacement
Compression Ratio
Max. Torque
Starting System
ment
Max. HP
Ignition
Above 92 unleaded
4-stroke/ forced air
cooled
Ø 56.5 mm
49.5 mm
SINGLE CYLINDER
124 cc
9: 1
12.5 ps / 9500 rpm
1.0 kg-m / 7500 rpm
C.D.I.
kick & electrical
starter
Exhaust Pipe Position and
Speedometer
Horn
Muffler
Direction
Lubrication System
Solid Particulate
n
Exhaust
Concentratio
Catalytic reaction control
CO
HC+Nox
E.E.C. √
P.C.V. √
system
0 ~ 140 km/hr
80~112 dB/A
Expansion & Pulse
Type
Right side, and
Backward
forced and wet sump
-
Below 3.0 %
Below 2000 PPM
√
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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
alues for those not listed in the table. v
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
3 mm screw 0.05~0.08kgf-m
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder head nut 4 8 2.8~3.0
Cylinder head left bolt 1 6 0.8~1.2
Cylinder stud bolt 4 8 0.7~1.0
Cylinder head side cover bolt 2 6 0.8~1.2
Cylinder head cover bolt 2 30 1.3~1.7
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Tensioner lifter bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 6 0.3~0.4
1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
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 14 5.0~6.0
Drive face nut 1 14 8.5~10.5
ACG. Flywheel nut 1 14 5.0~6.0
Crankcase bolt 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
Muffler mounting bolt 3 10 3.2 ~3.8
Muffler mounting nut 2 8 1.0 ~1.2
0.45~0.6kgf-m 4 mm screw 0.10~0.15kgf-m
0.8~1.2kgf-m 5 mm screw 0.35~0.5kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
6 mm screw、SH nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
0.7~ 1.10kgf-m
1.0 0~1.40kgf-m
2.40 ~3.00kgf-m
3.50~4.50kgf-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 handle
post
Lock nut for steering stem 1 BC1 1.0~2.0
Steering top cone race 1 BC1 2.0~3.0
Front wheel axle nut 1 12 5.0~7.0
Rear wheel axle nut 1 16 11.0~13.0
Front cushion mounting bolt 4 10 3.5~4.5
Rear cushion upper connection bolt 1 10 3.5~4.5
Rear cushion under connection bolt 1 8 2.4~3.0
Rear fork mounting bolt 2 10 4.0~5.0
Brake hose bolt 2 10 3.0~4.0
Brake air-bleeding valve 1 6 0.8~1.0
Front brake disc mounting bolt 5 8 4.0~4.5
Rear brake disc mounting bolt 5 8 4.0~4.5
Brake clipper mounting bolt 2 8 2.9~3.5
Engine hanger link bolt 2 12 7.5~9.5 On frame side
Engine hanger link nut 1 12 7.5~9.5 On engine side
Main standard nut 1 10 4.0~5.0
Air cleaner bolts 2 6 1.0~1.4
4 8 3.0~3.5
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r
1. General Information
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Possible causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carbureto
Fuel supplied to
carburetor sufficient
Remove spark plug, install it
into spark plug cap, and
perform a spark test.
Good 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 damaged
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil wire open or short circuit
7. Main switch malfunction
Cylinder compression
pressure normal
Re-start by following the
starting procedures
No ignition
Remove the spark plug again
and check it.
Dry spark plug
Start with choke applied
Low compression
pressure or no pressure
There are some signs of
ignition; but engine
cannot 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 leaking through intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
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1. General Information
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Possible causes
Try gradual acceleration and
check engine speed
Engine speed increases.
Check ignition timing
(Using ignition lamp)
Ignition timing correct Incorrect ignition timing
Check cylinder compression
pressure (using compression
pressure gauge)
Compression pressure
correct
Engine speed cannot
increase.
No compression pressure
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 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
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
Clogged
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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1. General Information
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment Fault condition Probable causes
Check ignition timing
(Using ignition lamp)
Adjust the air screw of
carburetor
Normal Abnormal
Good Poor
Air sucked through
carburetor gasket
No air sucked
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
Air sucked
1. Incorrect ignition timing (malfunction
of CDI or AC alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
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. Starter Motor Malfunction
1. Starter Motor doesn’t rotate
Check and adjustment
Pull the brake handle or step
on the braking pedal
Braking light is activated
Check the battery circuit by
activating turning signal
Push the staring button
and check if the starting
relay is activated
Flashing normally
Fault condition Possible causes
Braking light not activated
Not flashing or dimmed
(60~120 flashes per minute)
1. Burnt Fuse
2. Insufficient Battery Voltage
3. Braking Switch abnormal
4. Main switch abnormal
1. Insufficient Battery capacity
Starting relay activated Starting relay not activated
Connect the starting motor
to the battery
Starter Motor rotates Starter Motor doesn’t
rotate
1. Bad contact in the starter switch
2. Abnormal Starter relay
3. Loose coupler or terminals
1. Worn carbon brushes
2. Broken or shorted rotor windings
3. Broken Starter motor sub wire
4. Loose coupler
1. Loose coupler
1-16
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g
1. General Information
2. Starting Motor rotates slowly or spins without engagement with crankshaft
Check and adjustment
Check the battery circuit by
activating turning signal
Connect the starting
motor to the battery
Kick the kick starter
Flashing normally
Starting Motor Still
rotatin
slowly
Fault condition Possible causes
Not flashing or dimmed
Rotates Normally
1. Insufficient Battery capacity
1. Loose coupler or terminals
2. Starting Relay bad contact
Works smoothly
3. Starter motor won’t stop rotating
Turn the main switch off
F. Abnormal Engine Noise
Rocker arm noise
Cam chain noise
Motor keeps running
Fault condition
Piston slapping
Jammed
1. Engine Seized.
1. Starting Motor shorted or damaged
Motor stops
Possible causes
1. Excessive valve clearance
2. Worn rocker arm
3. Worn camshaft
1. Worn piston and cylinder
2. Carbon deposit in the combustion chamber
3. Worn piston pin or connecting rod lower end
1. Worn camshaft bearings.
2. Worn cam sprocket.
3. Loose or worn cam chain.
1. Starting switch shorted/ stuck
1. Starting relay shorted
1-17
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1. General Information
Clutch knocking
Transmission gear noise
1. Excessive clutch plate clearance
1. Worn or deteriorated rear wheel damping rubber.
2. Gear surface worn
3. Worn transmission gear set
1-18
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Lubrication Points
Steering shaft
bearing
1. General Information
Throttle cable / Front braking lever /
clutch lever
Speed sensor gear /
FR wheel bearing
Side stand bracket
Min stand bracket
Driven chain
Rear wheel
bearing
1-19
1. General Information
Note:
To this chapter contents
1-20
Homepage
Contents
Precautions in Operation ········· 2-1
Periodical Maintenance Schedule
···················································· 2-2
Lubrication System··················· 2-3
Fuel System ······························· 2-5
Air Filter ····································· 2-6
Throttle Operation····················· 2-6
PCV System ······························· 2-7
Valve Clearance Adjustment···· 2-7
Idle Adjustment ························· 2-9
Ignition System ························· 2-10
Spark Plug ································· 2-10
Cylinder Compression Test ····· 2-11
2. Maintenance Information
Cam Chain Adjustment············· 2-11
Clutch Adjustment ···················· 2-12
Drive Chain Adjustment············ 2-13
Steering Mechanism ················· 2-14
Suspension System ·················· 2-15
Disk Brake System···················· 2-16
Drum Brake System ·················· 2-18
Tire·············································· 2-19
Battery········································ 2-20
Headlight Adjustment ··············· 2-21
Brake Switch······························ 2-21
Nuts, Bolts Tightness ··············· 2-21
Special Tools ····························· 2-22
2
Precautions in Operation
Specification
Items
Fuel tank
capacity
Engine oil
Throttle grip free play 2~6 mm
Spark Plug NGK D7EA
Spark plug gap 0.6~0.7 mm
Ignition timing BTDC 10º / 1500 rpm
Ignition advance BTDC 34º / 4000 rpm
Idle speed 1500±100 rpm
Cylinder compression pressure 12±1 kgf/cm²
Valve clearance Intake/ex 0.05±0.02 mm
Capacity 9300 c.c.
Reserve 700 c.c.
Capacity 1200 c.c.
Exchange 1000 c.c.
Specification
Tire size
Tire pressure
(Cold)
Battery Type 12N7A (12V 7Ah)
Front brake lever clearance 10~20 mm
Rear brake pedal clearance 20~30 mm
FR/RR wheel 2.75-18-42P / 3.00-17-45P
Single ride
Tandem ride
Front：1.8 kg/cm² / Rear：2.0 kg/cm²
Front：1.8 kg/cm² / Rear：2.4 kg/cm²
2-1
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2. Maintenance Information
Periodical Maintenance Schedule
NO
☆Air filter element
1
☆AICV filter
2
☆Gasoline filter
3
☆Engine oil filter
4
☆Engine oil replacement
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
27
28
29
30
31
32
Tire pressure
Battery Inspection
Brake lever free play check
Steering handle integrity check
Shock absorber performance check
Bolts tightening check
Check the engine for oil leakage
☆Spark plug inspection or replacement
☆Change gear oil
Lubrication of the whole bike
Exhaust pipe
☆Ignition timing
☆Idle emission check
☆Throttle operation
☆Engine bolts torque
☆Transmission / Chain
☆Clutch free play inspection
Light/ electrical system/ instrument readings.
Main stand/ side stand springs.
Fuel lines
Cam chain
☆Valve clearance
☆PCV system integrity
☆Crankcase blow-by over-flow pipe
☆Second air injection system (filter)
☆E.E.C. Device check
Items
Initial
300KM
1 month or
every
1000KM
3 months or
every
3000KM
6 months or
every
6000KM
1 year or
every
12000KM
I C C R
I C C R
I I R
C C C
R Exchange every 1000 km
I I
I I
I I
I I
I I
I I
I I
I I R
R Exchange every 5000 km
L
I I
I I
A I A
I I
I I
I I/L R
I I
I I
I I
I I
I I
I A
I C
I Drain every 2000km
I I C
I
Note：I- inspection A- Adjust R- Replace C-Clean L-Lubrication
Please have your periodical maintenance data recorded by your SYM Authorized Dealer to maintain the motorcycle in excellent
condition. The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference. Whichevertime or mileage- comes first will be regarded as an index for maintenance.
Remark：These marks “☆” in the schedule are emission control items. According to EPA regulations, these item checks
must be performed periodically following the use r manual instructions. It’s prohibited to adjust or repair
these emission control items by unauthorized people. Otherwise, SYM is no responsible.
1. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
2.
motorcycle has accumulated a higher mileage.
3. Preventive maintenance：
a. Ignition system－Perform maintenance or check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is decreasing.
c. Replace worn out pistons, cylinder head.
2-2
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Lubrication System
Engine oil quantity
Caution
z Turn off engine, and park the
motorcycle in flat surface with main
stand.
z Check oil level with oil dipstick. (Do not
screw the dipstick into engine when
checking.)
If oil level is near lower limit, fill in the
recommended engine oil to upper limit.
Exchange the engine oil
Engine off and disassemble the oil dipstick.
Remove the oil drain bolt under the crankcase
to drain the engine oil.
After completely drain the engine oil, clean the
drain bolt and the washer. If the washer is
deformed or cracked, please change a new
one
Engine oil drain bolt torque：3.5~4.5kgf-m
2. Maintenance Information
Oil drain bolt
Caution:
z Warm up the engine before drain oil, that
will make engine oil easily drained
thoroughly
Fill in the engine oil to the standard quantity.
Add oil to crankcase (oil viscosity SAE
10W-30) Recommended using Bramax series
engine oil.
Engine oil exchange volume
Full disassembly：1200 c.c.
Regular exchange：1000c.c.
Install the dipstick, run the engine for several
minutes.
Turn off the engine, and check oil level again.
Check if engine oil leaks.
2-3
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2. Maintenance Information
Engine Oil Strainer Cleaning
Drain engine oil completely.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring is deformed or damaged.
If not, it can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value：1.3~1.7kgf-m
Oil strainer
2-4
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Fuel System
Fuel Lines
Check all fuel lines, and replace when they
are deteriorated, damaged or leaking.
Caution
z Gasoline is a highly flammable
substance, so any source of fire or spark
is strictly prohibited when operation.
Fuel filter cleaning
Warning:
z Any source of fire or spark is strictly
prohibited when operation.
If gasoline filter is clogged, please drain all
2. Maintenance Information
Fuel filter
the gasoline into a clean container, and wash
the fuel tank.
After the cleaning of filter and fuel tank, refill
the tank with clean gasoline.
Check the fuel line for leakage.
Filter
2-5
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