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
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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
To this chapter contents
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
To this chapter contents
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
To this chapter contents
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
To this chapter contents
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
To this chapter contents
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
To this chapter contents
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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2. Maintenance Information
Air Filter
Air filter element
Remove the right side cover.
Remove the air filter cover (5 Screws, 1 Bolt)
Remove the air filter element
Check the filter element for dirty or damaging.
Wash the air cleaner filter with high flash point
solvent (for example, kerosene or diesel)
Squeeze out the cleaning solvent thoroughly,
Bolt×1
Screw×5
soak the element into gear oil, and squeeze
out the excessive.
Re-install the filter and the cover.
If the air cleaner filter element is too dirty or
damaged, please exchange with new parts.
Caution:
y Never use gasoline or other low-flash
point solvent for cleaning the element.
Throttle Operation
Operate the throttle grip to see if the throttle
cable is going smoothly.
If the throttle cable is deteriorated, twisted or
damaged, please exchange it.
If the cable is not going smoothly, apply some
lubrication oil onto it.
Air filter element
2~6 mm
Measure the free play of the throttle grip,
through the inner side flange of it.
Free play：2~6 mm
Please loosen the lock nut and adjust the
throttle cable nut to reach the normal free play.
2-6
Throttle cable nut
Lock nut
To this chapter contents
PCV System
Unplug the drain tube, and leak the deposit off.
Drain the tube every 2,000 km.
Caution:
z Under rainy or full- throttle situation, the
maintenance period should be shortened.
You can check the deposit amount
through the transparent tubes.
Valve Clearance Adjustment
Caution:
z The valve clearance should be adjusted
when the engine is cold. (Under 35
degrees Celsius)
Remove the valve clearance-adjusting cap.
〝T〞mark of AC.G
2. Maintenance Information
PCV Drain tube
Remove the cylinder head side cover.
Remove the timing inspection cap and the
AC.G cap on the crankcase L cover.
Use a T socket wrench to rotate the
crankshaft counterclockwise. Align the “T”
mark on the AC.G flywheel with the crankcase
sign, and simultaneously, the cam- chain
sprocket TDC mark aligning with the cylinder
head mark (That means the piston is in the
upper end of compression stroke)
TDC mark
2-7
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2. Maintenance Information
Valve clearance inspection and
adjustment.
Check the intake and exhaust valve clearance
by inserting the feeler gauge between the
adjusting screw and the lock nut.
Valve clearance：
IN 0.05±0.02 mm
EX 0.05±0.02 mm
Adjust by loosening the lock nut first, and
turning the adjusting screw until you feel slight
drag on the feeler gauge.
Hold the adjusting screw and tighten the lock
nut.
Caution:
z Check the valve clearance after the
adjustment.
Install the valve clearance-adjusting cap,
cylinder head side cover, and the timing
inspection cap and the AC.G cap on the
crankcase L cover.
Caution:
z Before installing the O-ring, you should
check if the O-ring is damaged, and apply
some oil on it to prevent damage when
assembly.
2-8
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Idle Adjustment
Caution:
z You should finish all the other
configurations before idle speed
adjustment.
z The engine must be fully warmed before
idle adjustment.
Use the main stand of the bike, and warm up
the engine.
Clip on the RPM sensor (Clip the RPM sensor
clamp on the spark plug cap wire)
Turn the idle adjusting screw to reach the
recommended idle RPM.
Recommended idle RPM：1500±100rpm
Emission adjustment in idle speed
Spark plug cap
2. Maintenance Information
Idle adjustment screw
Warm up the engine for around 10 minutes
and then conduct this adjustment.
Connect the tachometer onto engine.
Adjust the throttle valve stopper screw and let
engine runs in 1500±100 rpm.
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.
Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4
procedures until measured value within
standard.
Air adjustment screw
Emission standard CO: 3. 0 %↓
HC: 2,000 P.P.M.↓
2-9
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2. Maintenance Information
Ignition System
Ignition timing
Caution:
z C.D.I ignition system is set by
manufacturer so it cannot be adjusted.
z Ignition timing check procedure is for
checking whether CDI function is
normal or not.
Remove ignition timing hole cap located in
front upper side of crankcase left cover.
Connect tachometer and ignition lamp and
start the engine.
When engine runs in idle speed, if the “F”
mark meets with the ignition lamp. Then, it
means that ignition timing is correct.
Re- install the spark plug cap.
“F” Mark
Ignition advance indent ”װ”
Increase engine RPM to check ignition
advance degree. If the illustrated indent is
within the ignition advance degrees, it means
that the ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set,
pulse rotor and pulse generator. Replace
defective parts if malfunction is found.
Standard idle：1500±100rpm
Ignition Advance：4000±100rpm
Spark Plug
Recommended spark plug: D7EA
Remove spark plug cap.
Clean dirt around the spark-plug hole.
Remove spark plug.
Measure spark plug ignition gap.
Spark plug gap：0.6~0.7 mm
Spark plug cap
Ground electrode
Center electrode
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug and install the spark plug by
screwing it with hand, after tightening the plug
by hands, use plug socket to tighten it to the
standard torque value.
Standard torque：1.0~1.2kgf-m
2-10
0.6~0.7mm
To this chapter contents
Cylinder Compression Test
Warm up engine and turn it off.
Remove spark plug cap and spark plug.
Install compression gauge into the spark plug
hole, full open the throttle, and kick the kick
starter for several times.
Caution:
Rotate the engine until the reading in the
gauge gains no more.
z Usually, the highest-pressure reading
will appear in 4~7 seconds.
Compression pressure：12 ±1 Kg/cm²
Check the following items if the pressure
reading is too low:
2. Maintenance Information
Spark plug hole
Compression
gauge
y Incorrect valve clearance.
y Valve leaking.
y Cylinder head leaking, piston, piston ring
and cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston
head.
Cam Chain Adjustment
Start the engine, and let the engine idle.
Remove the rubber cap of the adjusting
screw and loosen the lock nut. Turn the
adjusting screw in or out to find a most silent
cam chain setting.
If you want to tighten the chain, turn the
screw counterclockwise, or turn the screw
clockwise to loosen the cam chain. After
finding a best set of cam chain, tighten the
ck nut and re-install the rubber cap. lo
Cam-chain adjusting screw
Lock nut
2-11
To this chapter contents
2. Maintenance Information
Clutch Adjustment
Clutch lever free play inspection
Slightly pull the clutch lever to check the free
play before clutch disengagement.
Free play：10~20 mm
Clutch lever free play adjustment
Before adjusting the clutch lever free play,
please loosen the lock nut first. Then turn
the adjusting screw to achieve the
recommended clutch free play.
If you want to decrease the free play of
clutch lever, turn it clockwise. If you want to
increase the free play, turn it
counterclockwise.
After adjustment, tighten the adjusting nut
with lock nut.
Lubricate the clutch cable.
10~20 mm
Adjusting nut
Lock nut
2-12
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Drive Chain Adjustment
Drive chain inspection.
Place the bike on its main-stand with its
neutral gear.
Check the drive chain slack by moving
the chain up and down by fingers, and
measure the amount of chain slack.
Standard chain slack：10~20 mm
Caution:
z Because the front and rear sprocket has
different wearing situation, so please
rotate the rear wheel to find the minimum
chain slack for the measurement.
Drive chain adjustment
If you need to adjust the chain slack, please
loosen the rear axle nut and sleeve nut first.
Turn the left side and the right side
adjusting nut evenly to make the chain slack
within the standard range. (Turn the nuts
clockwise to tighten the chain, or
counterclockwise to loosen the chain)
Tighten the sleeve nuts, then the rear axle
nut.
Torque value：4.0~5.0kgf-m
After tightening the rear axle nut, please
check the sleeve nuts to prevent them from
loosening.
Check the chain slack again, and make
sure the rear wheel rotates smoothly.
2. Maintenance Information
Rear axle nut
10~20 mm
Sleeve nut
Adjusting nut
If the chain is too dirty, use high-flash point
solvents to clean the chain. (Kerosene or
Diesel.)
Caution:
y Don’t use gasoline when cleaning the
chain. The gasoline will damage the
O-ring in the chain.
After cleaning, lubricate the chain with chain
lubricant.
2-13
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2. Maintenance Information
Steering Mechanism
Caution:
z Check all wires and cables if they are
interfered with the rotation of steering
handle bar.
Lift the front wheel off the ground.
Turn handle from right to left and check if
turning is smoothly.
If handle is uneven or bending, or the
handle can be lifted through vertical direction,
adjust the handle top bearing.
Lock nut
2-14
To this chapter contents
Suspension System
Caution:
z Do not ride the motorcycle with poor
cushion.
z Looseness, wear or damage cushion
will make poor stability and
maneuverability.
Front cushion
Press down the front cushion for several times
to check its integrity.
Check if any oil leaks or damage found.
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
2. Maintenance Information
Press down the rear cushion for several times
to check its integrity.
Check if any oil leaks or damage found.
Replace rear cushion if any damage found.
Park motorcycle with main stand.
Move the rear wheel sideways forcefully to
see if the swing arm bushing and pivot nut are
loosened.
Tighten all nuts and bolts.
2-15
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2. Maintenance Information
Disk Brake System
Brake System Hose
Check the brake hoses for corrosion or brake
fluid leaking.
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 fluid
level found.
Caution:
z In order to prevent the brake fluid
overflow by accidental shaking of the
steering handle, keep the reservoir in
horizontal position and hold the
steering handle firmly. Don’t take off
Lower limit
the brake fluid cap before keeping the
steering handle steady.
z Do not operate the brake lever after the
cap had been removed. Otherwise,
the brake fluid will spray out.
z Do not mix non-compatible brake fluid
together.
2-16
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Air Bleed Operation
Connect a transparent hose to draining valve.
Hold the brake lever and turn the air-bleeding
valve open. Perform this operation several
times until there is no air bubble inside the
transparent hoses.
Caution:
z Before closing the air bleed valve, do not
release the brake lever.
Add 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 braking system deterioration or
reducing brake performance.
Brake Lining Wear
The indent mark on brake lining is the wear
Master Cylinder Cap
Air Bubble
2. Maintenance Information
Diaphragm
Upper limit
Brake fluid
Transparent tube
Brake Disk
limitation.
If the wear limit mark approximates the edge
of brake disc, replace the brake lining.
Caution:
z It is not necessary to remove brake hose
when replacing the brake lining.
Brake lining
wear limitation
2-17
To this chapter contents
2. Maintenance Information
Drum Brake System
Rear brake pedal free play
Press down the brake pedal slightly, and
measure the free play before brake
engagement.
Free play：20~30 mm
Turn the brake-adjusting nut clockwise to
decrease the free play. Or turn the nut
counterclockwise to increase the free play.
Brake lining inspection
When pulling the brake lever, if the arrow
mark on the braking arm reaches the triangle
20~30mm
Triangle mark
Arrow mark
mark on the brake panel, it means that the
brake lining needs to be changed.
Please refer to Chapter 11 and 12 for brake
lining exchange process.
Brake system integrity check
Caution:
z After changing the brake lining or the
brake fluid, you must check the brake
system to see if it works well or not.
Adjusting nut
2-18
To this chapter contents
Tire
Check the pressure of the tire to see if it’s in
the specified pressure range.
Caution:
z Tire pressure check should be done
when the tire is cold.
Specified tire pressure range
Tire pressure FR RR
Tire pressure when
cold (Kg/cm²)
Specified tire：
Front wheel：2.75-18-42P
Rear wheel：3.00-17-45P
Single ride
With
passenger
1.8 2.0
1.8 2.4
2. Maintenance Information
Check if tire surface is ticked with nails,
stones or other objects.
Check if front and rear tires pressure is
normal.
If the wearing of the tire thread reaches
triangle TWI mark index, the tire also have to
be changed.
Measure tire thread depth from tire central
surface, and if the depth is not enough, please
change the tire.
Front tire thread：1.5 mm
Rear tire thread：2.0 mm
Caution:
z The triangle TWI mark index is located
along the tire wall.
“△” TWI mark
2-19
To this chapter contents
2. Maintenance Information
Battery
Battery removal
Remove the left side cover.
Remove the〝─〞negative pole first, then
remove the〝＋〞positive pole.
Unplug the ventilation tube
Remove the battery holder and take out the
battery.
If the battery liquid level is too low, please
remove the top plug, and fill in distilled water
to the upper limit.
Caution:
z Don’t fill in too much distilled water, or the
electrolyte may overflow and corrode the
frame.
z Only distilled water is allowed. If any
impure water is filled in, it will shorten the
battery life.
Negative pole
Warning:
z The electrolyte contained sulfuric acid.
Please avoid touching the eyes, skin, or
clothes. If any contact by accident, please
flush with plenty of water.
If there is some rust on battery posts, clean
it with steel brush
Install the battery in the reverse procedures
of removal
Caution:
z If the rust on the posts is very serious,
spray some hot water on them. Then,
more easily you can remove the rust by
steel brush.
z Apply some grease on the posts after
cleaning rust to prevent from
happening again.
2-20
To this chapter contents
Headlight Adjustment
Turn on main switch. Loosen the headlight
adjustment screw to adjust headlight beam
height.
Caution:
z The factory setting of the beam height is
consistent with government orders.
z Improper headlight beam setting will
make driver in the opposite lane dazzled
and cause danger.
Brake Switch
Inspection on the brake switch
When brake lever is pulled, brake switch will
light up the brake lamp.
2. Maintenance Information
headlight adjust. screw
Make sure that electrical starter can be
activated only under braking condition.
Adjustment of rear brake switch.
Turn on the main switch.
When the brake pedal is stepped down for
20mm，the brake lamp should be activated.
If the brake lamp is not activated or
activated too early, please adjust through the
rear-brake-switch adjusting nut.
Turning clockwise will decrease the free
play, and counterclockwise to increase the
free play.
Nuts, Bolts Tightness
RR brake switch
adjust nut
Brake switch
Apply periodical maintenance in according
with the Periodical Maintenance Schedule.
Check if all the bolts and nuts on the frame
are tightened well.
Check all fixing pins, snap rings, hose (pipe)
lamps, and wire holders for security. c
2-21
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2. Maintenance Information
Special Tools
Name
SY No. SYM-1445100 SY No.
Rocker arm shaft disassemble tool
Name
Valve cover wrench
SYM-1236100
Name
SY No. SYM-1471110/20
Valve remove and assemble tool
Name Valve spring compressor Name
SY No. SYM-1471100 SY No. SYM-9001200 SY No. SYM-9001210
Tappet adjusting wrench
Name ACG Puller Name
SY No. SYM-3111000 SY No. SYM-9023100-SY125 SY No. SYM-9120200
Oil pump fix nut socket
Name
Name 20*32*6 oil seal driver
TAPPET ADJUSTING
TOOLS
(20*32*6)
(6204)
Name 6204 Bearing Driver Name 6301 Bearing Driver Name 6203/6004UZ bearing Driver
SY No. SYM-9110400 SY No. SYM-9610000 SY No. SYM-9620000
(6301)
(6203/6004UZ)
2-22
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2. Maintenance Information
Name Inner bearing puller set Name Outer bearing puller Name Steering Nut Wrench
SY No. SYM-6204025 SY No. SYM-6204001 SY No. SYM-5320000
Name Crankcase bush puller 30mm Name Electrical Gauge Name
SY No. SYM-1120310 SY No. SYM-HE07007-01 SY No.
2-23
To this chapter contents
2. Maintenance Information
Note:
2-24
Homepage
Contents
Mechanism Diagram ·················3-1
Precautions in Operation ········· 3-2
Troubleshooting························3-3
Carburetor Removal··················3-4
Throttle Valve ····························3-6
Float Chamber / Jet Set ············3-6
Mechanism Diagram
Fuel tank cap
3. Fuel System
Carburetor Installation··············3-8
Air Cut-off Valve························3-9
Idle Speed Adjustment ············· 3-10
Fuel Tank ··································· 3-11
Air Cleaner·································3-13
Fuel Tank
3
Air Cut-off Valve
To the Carbon
canister
Vacuum type
fuel cock
Fuel Vapor
Collector
Fuel outlet tube
Carburetor
Vacuum
tube
3-1
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3. Fuel System
Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated
place and strictly prohibit flame when working with gasoline.
Caution
z Do not bend off throttle cable. Damaged throttle 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 air cut valve arbitrarily.
Specification
Item Specification
Carburetor diameter Ø 35 mm
I.D. number PTG043B
Fuel level 14.8 mm
Main injector # 98
Idle injector # 35
Idle speed 1500±100 rpm
Throttle handle clearance 2~6 mm
Pilot screw 1 1/2 turns
Torque Value:
Carburetor holding nut: 0.7~1.1kgf-m
Special service tools
Vacuum/air pressure pump
General Tool
Float Chamber fuel level gauge
3-2
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Troubleshooting
Engine won’t start Late ignition timing
y No fuel in fuel tank
y Clogged fuel tube
y Excessive fuel in cylinder
y No spark from spark plug (malfunction of
ignition system)
y Clogged air cleaner
y Malfunction of carburetor chock
y Throttle cable damaged
Engine stall after started
y Malfunction of carburetor chock
y Incorrect ignition timing
y Malfunction of carburetor
y Improper engine oil
y Air leakage into inlet manifold
y Incorrect idle speed settings.
Unstable Idle speed
z Abnormal ignition system
z Incorrect idle settings.
z Abnormal carburetor
z Impure fuel
y Malfunction of ignition system
y Malfunction of carburetor
Weak engine power
y Fuel system clogged
y Malfunction of ignition system
Fuel / Air Mixture too lean
y Clogged carburetor jet
y Carburetor parts 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 leakage into inlet manifold
Fuel /Air Mixture too rich
y Clogged air injector
y Malfunction of float valve
y Fuel level too high in float chamber
y Malfunction of carburetor chock
y Dirty air cleaner
3. Fuel System
Misfire when accelerates
z Malfunction of ignition system.
3-3
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3. Fuel System
Carburetor Removal
Removal
Turn the fuel cock switch to the S position ( If
the fuel cock is vacuum type, it won’t be
necessary)
Put a container near the fuel drain screw, and
loosen it. Drain all the fuel of the float
chamber
Manual fuel
cock
Automatic Fuel
cock (Vacuum)
Warning
z Gasoline should stay away from fire, and
avoid getting on the frame. If gasoline
gets on the frame, please wash it off
immediately.
Loosen the choke wire clamp screw, and
remove the choke wire.
Remove the carburetor top cover by turning it
counterclockwise. Remove the top cover,
throttle cable, and throttle valve.
Fuel drain screw
Choke wire clamp screw
Top cover
3-4
Throttle valve
To this chapter contents
Remove the carburetor fuel tube. Loosen the
clamp from the air- cleaner side, and unplug
the fuel tube. Remove the carburetor holding
nuts.
Remove the carburetor.
Installation
Install as the reversed order of removal
procedures.
Torque value：
Carburetor holding nuts: 0.7~1.1kgf-m
After installation, the following adjustment is
required:
● Throttle cable free play.
● Idle speed adjustment.
Fuel tube
A/F clamp
3. Fuel System
Carb holding screw ×2
Adjust screw
Lock nut
3-5
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3. Fuel System
Throttle Valve
Disassembly
Compress the throttle spring and disassemble
the throttle cable, and the spring.
Disassemble the needle seat and the needle
from the throttle valve.
Check the throttle valve and the needle to see
if they are damaged or not.
Installation
Install as reversed order of removal
procedures.
Float Chamber/ Jet Set
Remove 2 mounting screws and remove float
chamber cover.
Top cover
Needle Seat Needle
Throttle valve
Warning
z Please fill the gasoline in float chamber
into the fuel tank.
Remove the fuel level plate, float pin, float and
float valve.
Float pin
3-6
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Inspection
Check the float valve and valve seat to see if
any damage or blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.
Caution
z In case of worn out or dirty, the float valve
and valve seat will not close tightly. The
fuel will overflow. A worn out or dirty
float valve must be replaced with a new
one to fix the problem.
Remove main jet, needle jet holder, needle jet,
Check if worn out
Float
3. Fuel System
Float pin
Float valve
slow jet and air adjustment screw.
Caution
z Be careful not to damage jets and adjust
screw.
z Before removing adjustment screw, turn it
all the way in and record the number of
circles.
z Do not turn adjust screw forcefully, or the
valve seat may be damaged.
z When airscrew is removed, please also
take out the inner washer with it.
Clean jets with Carburetor conditioner. Then
use compressed air to blow the dirt off.
Slow jet
Air adjustment
screw
Spring
Main jet
Air adjustment
screw
Washer
Slow jet
Main jet
Jet holder
Nozzle
3-7
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3. Fuel System
Assemble
Before assembling, please blow the fuel
passages with compressed air.
Assemble the main jet, jet holder, nozzle, slow
jet, and the air screw.
Caution
● Please assemble the air screw with the
same setting circles as removal.
Slow jet
Main jet
Assemble the float valve, float, float pin. After
confirming the fuel level, assemble the float
chamber cover (3 screws).
Checking fuel level
Caution
y Check the float valve and float for proper
installation.
y To get the correct reading, position the
float meter in the way that float chamber
face is vertical to the main jet.
Fuel level：14.8mm
Carburetor Installation
Install carburetor in the reverse order of
removal.
Following adjustments must be made after
installation.
● Throttle cable free play adjustment.
● Idle adjustment
Air adjustment
Float pin
3-8
Float level
gauge
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Air Cut-off Valve
Removal
Removal the throttle cable seat (2 screws)
Remove the screws (2 screws) of the air
cut-off valve and the cover.
Remove the spring and vacuum diaphragm
Check the diaphragm to see if deterioration or
crack found.
Install
Install the valve as reverse order of removal.
3. Fuel System
螺絲
×2
Caution
z Do not damage the vacuum diaphragm or
in opposite installation direction.
3-9
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3. Fuel System
Idle Speed Adjustment
Caution
y Air-screw was set at factory, so no
adjustment is needed. For easy installation,
count the number of circles it takes to screw
the air-screw to the bottom.
y The idle adjustment process must be done
while the bike is on its main stand.
Use a tachometer while adjusting engine
RPM.
Screw in air adjustment screw gently, then
back up to standard circles.
Standard setting：1 ½ circles
Warm up engine fully; adjust the throttle
stopper screw of throttle valve to achieve the
standard idle RPM.
Standard idle RPM：1500rpm±100
Connect the hose of exhaust analyzer to
exhaust front end. Press test key on the
analyzer.
Adjust the air adjustment screw and read CO
reading on the analyzer.
The standard value of CO emission：
1.0~1.5 %
Gradually increase the throttle, make sure rpm
and CO value are within the standard range
after engine running stable. If rpm and CO
value fluctuated, repeat the procedures above
for achieving the standard value.
Air adjusting screw
Idle adjusting screw
3-10
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Fuel Tank
Fuel tank removal
Manual fuel cock
Turn off the fuel cock switch, and disassemble
the outlet fuel tube.
Vacuum operated automatic fuel cock
Disassemble the outlet fuel tube and the
vacuum tube.
Remove the seat(Bolts×2)。
Disassemble the fuel-vapor tube to the carbon
canister.
Take out the fixing rubber cushion behind the
fuel tank.
Outlet fuel
tube
One bolts on each side
3. Fuel System
Vacuum tube
Fuel vapor tube
Rubber cushion
3-11
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3. Fuel System
Slightly pull the fuel tank back toward the
tail of the bike. This will help the fuel tank to
separate from the frame.
Disassemble the fuel gauge coupler.
Remove the fuel tank.
Caution
z If the fuel tank is broken or leaking,
please change a new one immediately.
Fuel amount warning sensor/ Fuel
gauge disassembly.
Remove the protective cover of fuel amount
warning sensor or Fuel gauge sensor.
Remove the holding screws (screw ×4)
Take out the fuel amount warning sensor or
fuel gauge sensor.
Please refer to the 13th chapter for the
detailed inspection for the gauges.
Sensor cover
Screw ×4
Fuel gauge coupler
3-12
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Air Cleaner
Remove the air filter cover
(Screw x 5, bolt x 1)
Remove the air filter element.
Remove the air filter holding plate and take
out the air filter element. (Screw×1)。
Wash the air filter element with non-flammable
or high flash-point solvent. (Like kerosene or
diesel)
After washing, squeeze it and dump into motor
oil, and squeeze again.
Install the holding plate and the air filter cover
If the element is too dirty or damaged, please
change a new one.
Bolt×1
Air filter
element
Screw×1
3、Fuel System
Screw ×5
Caution
y Don’t use gasoline or other flammable
solvents to clean the element.
Installation
Install as reverse order of removal.。
Cleanse
Dump Engine Oil
Squeeze
Squeeze
3-13
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3、Fuel System
Air filter assembly removal
Remove the right body cover
Remove the cushion.
Loosen and remove t he air filter tunnel clamp
and unplug the fuel vapor recycle tube.
Remove the air filter box mounting bolts.
(Bolts X 2)
Remove the air filter box upper mounting bolt
(bolt×1)。
Remove the air filter assembly.
Installation
Install as the reversed order of removal.
Air filter tunnel clamp
Bolts×2
Fuel vapor recycle
tube
3-14
Bolt×1
Homepage
Contents
4、Lubrication / Clutch / Transmission
Mechanism Diagram-Lubrication
System .......................................4-1
Mechanism Diagram-Clutch /
Transmission.............................4-2
Precautions in Opeartion ......... 4-3
Troubleshooting........................4-4
Engine Oil ..................................4-5
Engine Oil Strainer Cleaning.... 4-5
Mechanism Diagram-Lubrication system
Oil Pump Removal / Inspection4-6
Oil pump Assembly / Installation
....................................................4-9
Clutch Disassembly..................4-12
Clutch Inspection......................4-13
Clutch Installation.....................4-14
Gear Shift Linkage Mechanism 4-16
Rocker
4
Transmission gear
main shaft
Transmission gear
sub shaft
Camshaft
Inner oil route
Con. Rod
Crankshaft
Centrifugal
oil strainer
Engine oil
strainer
Oil pump
4-1
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4、Lubrication / Clutch / Transmission
Mechanism Diagram – clutch/transmission
Shifting Cam
Shifting fork
Clutch Outer
Clutch pressure
Gear shift drum
stopper
Clutch plate
Clutch friction
disk
plate
Primary driven gear
Clutch Center
Clutch lever
Anti-loosen nut
5.0~6.0kgf-m
Clutch lifter rod cam
Clutch lifter rod
Centrifugal oil
strainer
Clutch spring
Clutch lifter
Clutch lifter guide pin
Oil pump
4-2
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4、Lubrication / Clutch / Transmission
Precautions in Operation
General information
z This chapter covers the engine oil pump and the oil exchange, also the disassembly and the
shifting linkage is covered. All these operations can be done while the engine is still on the
bike.
Specification
Engine oil quantity：
Full disassembly：1200 c.c.
Regular maintenance：1000 c.c.
Recommended engine oil viscosity:
SAE 10W-30
(The Bramax series oil is recommended)
Engine Oil viscosity
Measurement: mm
Item Standard Service Limit
Oil pump
Clutch
Clearance between inner
rotor and outer rotor
Clearance between
outer rotor and the
pump body
Rotor to pump cover
clearance
Lever free play 10~20 Spring free length 35.50 32.40
Friction disk thickness 3.00 2.50
Clutch plate warp 0 0.20
0.30 0.35
0.30~0.36 0.40
0~0.06 0.11
Torque value:
Oil drain bolt: 1.5~2.5kgf-m
Oil strainer cover: 1.5~3.0kgf-m
Oil pump cover bolts: 0.4~0.6kgf-m
Oil pump screw: 0.3~0.4kgf-m
Centrifugal strainer cover screw: 0.3~0.4kgf-m
Centrifugal strainer nut: 5.0~6.0kgf-m
R. Crank case bolts: 0.8~1.2kgf-m
Special Tools
Centrifugal oil strainer nut socket wrench: SYM-9023100-SY125
Cylinder head/ oil strainer cover wrench: SYM-ALL23461
4-3
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4、Lubrication / Clutch / Transmission
Troubleshooting
Insufficient engine oil Clutch slips when accelerating
y Oil leaks
y Valve guides or seals worn out.
y Worn piston rings.
Insufficient oil pressure
y Insufficient oil amount.
y Clogged oil strainer, oil route, oil tubes
y Abnormal oil pump
Engine oil dirty
y It’s not exchanged properly on time.
y Cylinder head gasket damaged.
y Worn piston rings.
y Insufficient clutch free play.
y Worn clutch disks
y Weak clutch springs.
Unable to disengage the clutch, or the
bike trembles while clutch disengaged
y Excessive clutch free play settings.
y Warped clutch plates.
Excessive clutch lever pulling force
y Twisted or insufficiently lubricated clutch
cable
y Damaged clutch cable
y Clutch lifter mechanism damaged.
Hard to shift gear
y Excessive clutch free play settings.
y Twisted or bent shifting forks.
Gearshift pedal won’t return
y Broken or weak return spring.
y Bent shift spindle.
Gear jumps out
y Broken stopper arm spring.
y Bent shift spindle.
4-4
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4、Lubrication / Clutch / Transmission
Engine Oil
Turn off engine, and park the scooter on flat
surface with main stand.
Check oil level with oil dipstick.
Do not screw the dipstick in while checking.
If oil level is low, fill into recommended oil to
reach the upper limit.
Oil Change
Caution
z Drain oil when the engine is fully warmed
up, so the oil can be drained completely.
Place an oil basin under the bike, and remove
oil drain bolt.
After all oil is drained, make sure washer can
be re-used, and re-install oil drain bolt.
If the Oil drain bolt washer is damaged, it
should be replaced.
Torque value：1.5~2.5kgf-m
Engine Oil Strainer Cleaning
Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer with compressed air.
Check if O-ring can be re-used. If it’s
damaged, please change a new one.
Install oil strainer and spring.
Install oil strainer cap.
Torque value：1.5~3.0kgf-m
Upper
limit
Lower
limit
Oil drain bolt
Strainer cap
Fill in engine oil (oil viscosity SAE 10W-30)
Recommended using Bramax series oil.
Engine oil capacity: 1000c.c. Regular
exchange.
Install dipstick, run the engine for several
minutes. Then turn off engine, and check oil
level again.
Check if engine oil leaks.
Engine oil strainer
4-5
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4、Lubrication / Clutch / Transmission
Oil Pump Removal / Inspection
Drain all the engine oil.
Disassemble the kick-starter, exhaust muffler
Disassemble the kick-starter lever (bolt×1)
Remove the engine R case(bolts×11)。
Remove the centrifugal oil strainer cover.
(screw×3)。
Remove the centrifugal oil strainer anti-loosen
nut, and remove the oil strainer.
Special tool：
Centrifugal oil strainer special nut socket:
SYM-9023100-SY125
Bolt×1
Clutch cable
Bolt×11
Screw×3
4-6
Anti-loosen nut
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Remove the initial driven gear
Remove the oil pump gear protective cover
(bolts×2)
Remove the driven gear and driven shaft.
Remove the oil pump(screw×2)。
4、Lubrication / Clutch / Transmission
Bolts×2
Driven shaft
Caution
z It’s recommended to remove the oil pump
holding screw with impact screw driver.
Remove the two O-rings on the oil pump seat.
screw×2
O-ring
4-7
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4、Lubrication / Clutch / Transmission
Oil pump disassembly
Remove the oil pump cover(screw×2)。
Remove the oil pump cover and the gasket.
Oil Pump Inspection
Check the clearance between oil pump body
and outer rotor.
Service limit: under 0.35 mm
Check clearance between inner and outer
rotors.
Service limit: under 0.40 mm
screw×2
4-8
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Check the unevenness between rotor face
and pump body
Service limit: 0.11 mm
4、Lubrication / Clutch / Transmission
Oil Pump Assembly / Installation
Install inner and outer rotors into the pump
body.
Align the pump cover and the gasket and
assemble it properly. Then tighten the holding
screws. (Screw×2)。
Install new O-rings.
Install the oil pump(screw×2)。
Torque value：0.3~0.4kgf-m
Screw×2
O-Rings
Screw×2
4-9
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4、Lubrication / Clutch / Transmission
Match the driven shaft indent with the inner
rotor indents, and assemble the driven shaft.
Make sure that oil pump shaft can be rotated
freely. Then assemble the driven gear.
Caution
z Make sure that oil pump can rotate
smoothly.
Install the oil pump gear protective cover.
(Bolt×2)
Torque value：0.4~0.6kgf-m
Install the centrifugal oil strainer, and tighten
the anti-loosen nut.
Torque value：5.0~6.0kgf-m
Special tool：
Centrifugal oil strainer special nut socket:
SYM-9023100-SY125
Install the centrifugal oil strainer cover.
(screw×3)。
Torque Value：0.3~0.4kgf-m
Anti-loosen nut
4-10
Screw×3
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Install the alignment pin and a new right
crankcase gasket.
Install the right crankcase cover. ( Bolt X 11 )
Torque Value：0.8~1.2kgf-m
Assemble the clutch cable.
Assemble the kick-starter, lever, and the
exhaust pipe.
Fill in the specified engine oil.
Adjust the clutch lever free play.
Free play：10~20mm
4、Lubrication / Clutch / Transmission
Bolt×1
Alignment pin
Bolts×11
Clutch cable
10~20mm
4-11
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g
4、Lubrication / Clutch / Transmission
Clutch Disassembly
Drain all the engine oil.
Remove the kick-starter lever, exhaust pipe.
Remove the clutch cable.
Disassemble the right crankcase cover
(Bolt×11)
Disassemble the clutch lifter.
Disassemble the centrifugal engine oil strainer
cover. (Screw×3)。
Remove the centrifugal oil strainer anti-loosen
nut, and remove the strainer.
Special tool：
Centrifugal oil strainer special nut socket:
SYM-9023100-SY125
Remove the clutch lifter plate holding bolts.
(Bolts X 4) Remove the lifter plate and spring.
Remove the 20 mm holding ring.
Disassemble the clutch center, friction disks,
clutch plates, and pressing plate.
Clutch lifter Centrifugal oil
Bolt×11
strainer
Bolt×4
4-12
Holding
Rin
To this chapter contents
Turn the 20mm washer to match the indent on
the main shaft with that on the washer.
Remove the washer and disassemble the
clutch outer
Disassemble the clutch center, clutch plates,
clutch friction disks, and the pressing plate.
4、Lubrication / Clutch / Transmission
Clutch Inspection
Clutch spring inspection
Measure the free length of the four clutch
springs.
Service limit：Above 32.4mm
Clutch friction disk inspection
Measure the thickness of each clutch friction
disk. If it’s under service limit or it’s damaged,
please replace with a new one.
Service Limit：Above 2.5mm
Clutch center
Friction disk
20mm Washer
Clutch pressing plate
Clutch plate
4-13
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4、Lubrication / Clutch / Transmission
Clutch plate inspection
Use a feeler gauge to measure the warp of
each clutch plate.
Service limit：under 0.2mm
Clutch outer inspection
Check the clutch outer to see if any cracks or
damage can be found.
Clutch Installation
Install the clutch outer and the 20mm washer.
Caution
z You can slightly rotate or sway the 20mm
washer to make it fit into the main shaft
groove.
Install the clutch pressing plate, friction disks,
clutch plates, and the clutch center. Then
install the 20mm holding ring.
Holding Ring
Washer
4-14
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Install the clutch spring, lifter plate, and tighten
the holding bolts. (Bolt X 4)
Install the lifter rod.
Install the centrifugal oil strainer
Assemble the right crankcase cover.
(Bolt X 11)
Connect the clutch cable
Install the Kick-starter, kick-starter lever, and
exhaust pipe.
Fill in specified engine oil.
Turn the adjustment nut to optimize the clutch
free play.
Free play：10~20mm
After achieving the correct free play, tighten
the adjusting nut and the lock nut.
4、Lubrication / Clutch / Transmission
Lifter rod
Adjusting nut
Bolt×4
Oil strainer
10~20mm
Lock nut
Decrease free play
Increase the
free play
4-15
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4、Lubrication / Clutch / Transmission
Gear Shift Linkage Mechanism
Gearshift linkage disassembly
Remove the shifting lever. (Bolt X 1)
Drain all the engine oil.
Disassemble the kick-starter, exhaust pipe,
and the starting lever.
Disassemble the clutch cable
Remove the right crankcase cover.
Remove the clutch lifter rod.
Remove the centrifugal oil strainer.
Remove the clutch outer.
Take out the gear shifting spindle.
Remove the shifting drum stopper arm and the
return spring. (Bolt×1)。
Bolt×1
Gear shifting spindle
4-16
Stopper arm
To this chapter contents
Disassemble the shifting cam. (Bolt×1)
Remove the 4×10mm alignment pin.
4、Lubrication / Clutch / Transmission
Inspection
Check the shifting spindle and the fork
assembly to see if any damage.
Check the shifting drum stopper arm and the
return spring to see if any damage or worn.
Check the gear shifting cam to see if any worn
or damage can be found.
Shift cam
4-17
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4、Lubrication / Clutch / Transmission
Gear shift linkage mechanism installation
Install the shifting cam by matching the
4×10mm alignment pin.
Tighten the holding bolt for shifting cam.
(BoltX1)
Torque value：0.8~1.2kgf-m
Assemble the shifting drum stopper and the
return spring. (Bolt X 1)
Torque value：0.8~1.2kgf-m
Alignment pin
Caution
z Check if the stopper is working smoothly
after assembly.
Assemble the gear shifting spindle and the
fork. Then install the shifting pedal. (Bolt X1 )
Caution
z The return spring of the shifting spindle
should be matched and fixed on the
crankcase convex.
Assemble the clutch, centrifugal oil strainer,
and clutch lifter.
Assemble the alignment pin and another new
right crankcase gasket, then the right
crankcase cover.
Connect the clutch cable, and adjust the
clutch free play.
Assemble the kick-starter, kick-starter lever,
and the exhaust pipe.
Fill in specified engine oil.
Shifting cam
Shifting drum stopper
4-18
Gear shifting spindle set
Homepage
Contents
Mechanism Illustration ···············5-1
Precautions in Operation ···········5-2
Mechanism Illustration
1.0~1.4kgf-m
1.0~1.4kgf-m
5. AC Generator / Starter Clutch
ACG Stator Disassambly············5-3
ACG Flywheel/ Starter Clutch ···5-6
5
5.0~6.0kgf-m
0.8~1.2kgf-m
5-1
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5. AC Generator / Starter Clutch
Precautions in Operation
General Information
z For engine troubleshooting and inspection, please refer to the first chapter.
z Starting Motor repairing process and cautions, please refer to Chapter 13
Specifications measurement：mm
Item Service Limit
Start Driven Gear exterior diameter
Starting Clutch interior diameter
54.060
54.940
Torque Value
Flywheel Bolt 5.0~6.0kgf-m
R crankcase cover bolts 0.8~1.2kgf-m
Starting clutch inner-hexagon bolts 1.0~1.4kgf-m with screw adhesive
Special Tool
Flywheel puller SYM-3111000
th
.
5-2
To this chapter contents
ACG Stator Disassembly
ACG Stator Disassembly
Remove the seat (bolts×2).
Remove the ACG coupler.
Remove the gear shift pedal (Bolt×1)。
Remove the left crankcase chain cover (Bolts
×2).
Remove the neutral gear sensor and the
wiring.
5. AC Generator / Starter Clutch
Stator Coupler
Bolt×1
Bolt×2
Neutral gear sensor
5-3
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5. AC Generator / Starter Clutch
Remove the left crankcase cover(Bolt×9)。
Remove foreign objects and gasket residue on
the interface of crankcase and cover.
Remove the ACG stator holding screws
(screw×2).
Remove the stator composition.
Bolt×9
Screw×2
5-4
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ACG stator inspection
Check the following circuit for electricity
conductivity.
Yellow ~ Pink 0.9Ω±10%
Black/White ~ Grounding 420Ω±10%
Green/White ~ Blue/White 105Ω±10%
Light Green/ Red (for the neutral gear sensor)
ACG Stator assembly
Assemble the ACG stator holding screws.
(Screw×2)。
Assemble the stator wire correctly onto the
L-crankcase cover with the rubber seal.
Insert the dowel pin, set the L crankcase cover
gasket to the correct position.
Assemble the L crankcase cover (Bolt×9).
5. AC Generator / Starter Clutch
Green/White
Black/ red
Blue/White
Pink
Bolt×9
Light Green/ Red
Yellow
Rubber seal
5-5
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5. AC Generator / Starter Clutch
ACG Flywheel/ Starter Clutch
ACG Flywheel/ Starting clutch
disassembly
Remove the flywheel with special toolFlywheel puller, starting clutch, and the
start driven gear.
Special Tool：
ACG Flywheel puller SYM-3111000
Remove the start driven gear, and its shaft.
Inspection on starting clutch
Assemble the start driven gear onto the
starting clutch.
Hold the starting clutch and turn the start
driven gear.
Start driven gear should only be able to turn
counterclockwise.
Check if the start gear is worn or damaged.
Measure the exterior diameter of the start
driven gear
Service limit：
Exterior diameter： over 54.06 mm
Start driven gear
Flywheel puller
5-6
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Check if the start driven gear is damaged or
worn.
Measure the inner diameter of start driven
gear.
Service limit：
Inner diameter：under 10.05 mm
Measure the exterior diameter of the start
driven gear shaft.
Service limit：
Over 9.94 mm
Disassembly
Remove the start clutch inner-hexagon bolts.
(Bolt×3).
Separate the clutch body and the clutch cover.
Disassemble the clutch rollers, guides, and
springs.
Check if the rollers and the guides are worn or
damaged.
Assemble the rollers, guides, and springs.
Measure the starting clutch body inner
diameter.
Service limit：
Inner diameter：over 54.94 mm
Assembly
Assemble in the reversed process of
disassembly.
5. AC Generator / Starter Clutch
Spring
Guide
Rolle
Clutch body
Clutch cover
Spring
Caution
z Apply some screw- adhesive on the
thread of inner-hexagon bolts.
Torque Value：1.0~1.4kgf-m
Guide
Roller
Clutch cover
Clutch cover
5-7
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5. AC Generator / Starter Clutch
ACG flywheel/ Start clutch assembly
Assemble the start driven gear and its gear
shaft.
Install the ACG flywheel, start clutch, and start
gear. Tighten the ACG flywheel (Bolt×1).
Torque Value：5.0~6.0kgf-m
Insert the dowel pin, set the L crankcase cover
gasket to the correct position. Assemble the R
crankcase cover onto the R crankcase.
(Bolt×9).
Torque Value：1.5~2.0kgf-m
Assemble the left crankcase chain cover
(Bolt×2).
Start driven gear
Bolt×9
5-8
Bolt×2
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Contents
6. Engine Removal
Precautions in Operation ···········6-1
Engine Installation ······················6-7
Engine Removal··························6-2
Precautions in Operation
General information
● During maintenance of a removed engine, you need to use an adjustable rack or cart to
support the engine.
● The following parts can be repaired with the engine staying on the frame:
1. Carburetor
2. AC generator
3. Starting clutch
4. Clutch
5. Transmission mechanism
● You must remove the engine for repairing the following parts:
1. Piston
2. Crankshaft
3. Transmission mechanism
4. Cam-chain tensioner.
6
5. Camshaft and Rocker arm.
6. Kick starter mechanism.
Specification
Model Specification
Engine oil capacity
Regular
exchan
disassembly
e
Fully
800 c.c.
1000 c.c.
Torque value
Engine suspension nut (the upper part of engine and frame) 2.4~3.0kgf-m
Engine hanger nut (the front end of the frame) 2.4~3.0kgf-m
Engine assembly nut (the front part of engine and engine hanger) 2.4~3.0kgf-m
Engine assembly nut (the back part of the engine and frame) 4.5~5.5kgf-m
L crankcase chain cover bolts 0.8~1.2kgf-m
Driven sprocket bolts 0.8~1.2kgf-m
Kick-starter holding bolt 2.2~3.0kgf-m
6-1
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6. Engine Removal
Engine Removal
Drain all the engine oil out.
Remove the left body cover.
Remove the battery cable, first negative then
positive pole.
Remove the battery
Engine oil drain bolt
Negative pole
Positive pole
Caution
z To prevent short circuit, always connect
the positive pole before the negative one.
Remove the seat cushion, separate the wire
band, and remove the AC.G coupler.
Remove the starting motor power cable.
ACG coupler
6-2
Starting motor power cable
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6. Engine Removal
Remove the PCV tube.
Remove the AICV tube.
Loosen the choke cable holder screw
(screwX1), and remove the choke cable.
Disassemble the carburetor top cover by
turning counterclockwise. Then remove the
top cover, throttle cable, and the throttle
PCV tube
AICV tube
Choke cable
Top cover
body.
Throttle body
6-3
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6. Engine Removal
Remove the fuel tube of carburetor.
Loosen the air filter pipe strainer, and
separate the pipe.
Remove the carburetor holding nuts. (Nut X
2)
Remove the carburetor.
Loosen the rear wheel axle nut, and the
sleeve nut. Then loosen the adjusting nut and
push the rear wheel forward.
Remove the L crankcase chain cover.
Remove the driving sprocket holding bolts.
(Bolt X 2). Turn slightly and take out the
stopping plate, then remove the driving
sprocket and chain.
Remove the spark plug cap and the cable.
Fuel tube
Air filter pipe strainer
Rear wheel axle nut
Stopper plate
Holding nut×2
Sleeve nut
Adjusting nut
Bolt×2
6-4
IG coil cable
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6. Engine Removal
Remove the front exhaust pipe holding nuts.
(Nut X 2)
Remove the rear exhaust pipe holding nuts.
(Nut X 2)
Remove the exhaust pipe.
Remove the footrest (bolt×4)
Loosen the clutch cable holding nut and
adjusting nut. Pull the clutch lever and
release the clutch cable.
Bolt×4
Clutch lever
Nut×2
Nut×1
Adjusting nut
Holding nut
6-5
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6. Engine Removal
Settle the engine on a rack.
Remove the engine front hanger.
(Nut X 4)
Remove the engine rear holding bolts.
(Nut X 2, bolt X 2)
Remove the engine upper holding nut.
(Nut X1, bolt×1)
Pull out the bolt and remove the engine.
Nut×1
Nut×4
Nut×2
6-6
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6. Engine Removal
Engine Installation
Assemble the engine in the reversed
procedure of disassembly
Caution
z When assembly, always pay attention to
the possible injuries.
z All the wires and cables can’t be bent or
pressed.
z Please align the wires and cables in
accordance with the setting diagram.
Torque value：
Please refer to the General information in
the head of this chapter.
6-7
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6. Engine Removal
Note:
6-8
Homepage
Contents
Mechanism Illustration ············· 7-1
Precautions in Operation ········· 7-2
Troubleshooting························ 7-3
Cylinder Head···························· 7-4
Camshaft···································· 7-6
Valve Rocker Arm ····················· 7-6
Mechanism Illustration
1.0~1.2kgf-m
1.3~1.7kgf-m
7. Cylinder Head / Valve
Valve···········································7-7
Valve Seat Inspection and Refacing
···················································· 7-11
Cylinder Head Assembly··········7-14
Cylinder Head Installation········7-15
Valve Clearance Adjustment···· 7-17
2.8~3.0kgf-m
0.8~1.2kgf-m
1.3~1.7kgf-m
7
0.7~1.0kgf-m
0.7~1.1kgf-m
0.7~1.1kgf-m
0.8~1.2kgf-m
7-1
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g
7. Cylinder Head / Valve
Precautions in Operation
General Information
This chapter includes the repair information of cylinder head, valve, camshaft, and rocker arm.
The engine must be removed before the repairing of Cylinder head.
Specification Measurement unit :mm
Specification
Subject
Standard Service Limit
Valve Clearance (IN/EX valve when
engine is cold)
Compression pressure 12 ± 1 kg/cm² ─
IN 31.983 30.800
Camshaft
Cam Lift
EX 31.119 30.020
Rocker
Arm
Inner Diameter 12.000~12.018 12.100
Outer Diameter 11.984~11.966 12.000
0.05 ± 0.02 ─
Valv e
IN 5.450~5.465 5.420
stem outer
EX 5.430~5.455 5.400
IN 5.4750~5.485 5.500
EX 5.4750~5.485 5.500
IN 0.010~0.035 0.080
EX 0.030~0.055 0.100
Valv e
Guide
diameter
Valv e
guide
Clearance
between
Valve stem
uide
and
Valve seat width 1.200 1.600
Warpage/clearance between cylinder head
and cylinder.
─ 0.050
Torque Value
Cylinder head nuts 2.8~3.0kgf-m Cylinder head tensioner bolt 1.0~1.4kgf-m
Cylinder head left bolts 0.8~1.2kgf-m Tappet adjusting cap 1.3~1.7kgf-m
Cylinder head side cover bolts 0.8~1.2kgf-m Valve adjusting holding nut 0.7~1.1kgf-m
(Apply engine oil on threads and seats.) Cam chain sprocket bolt 0.8~1.2kgf-m
Rocker arm shaft setting plate bolts
Spark plug 1.0~1.2kgf-m
0.8~1.2kgf-m
Special tools
Valve Guide reamer 5.0mm
Valve Guide driver 5.0mm
Rocker arm shaft/ Camshaft Disassemble tool
SYM-1445100
Valve Spring Compressor SYM-1471100
Valve Spring Assemble/Disassemble Tool
7-2
SYM-1471110/20
Cylinder Head/ Engine Oil Strainer Cap
Wrench SYM-ALL23461
Valve Clearance Adjustment Wrench
SYM-9001200
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7. Cylinder Head / Valve
Troubleshooting
Engine performance will be affected by troubles on cylinder-head perimeter parts. The trouble
usually can be determined or by performing cylinder compression test or judging the abnormal
noise.
Poor Idling
Compression pressure is too low.
Low compression pressure
1. Valve
y Improper valve clearance adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
y Valve seat warpage
y Spark plug not tightened of badly assembled.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston rings worn out.
High compression pressure
y Too much carbon deposit on combustion chamber or piston head
Abnormal noise
y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Chain wear out or looseness
y Auto-tensioner wear out or damage
y Camshaft sprocket
y Rocker arm or rocker arm shaft wear out
Smoke from exhaust pipe:
z Valve guide or stem worn
z Valve guide oil seal worn
7-3
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