SYM VS150, VS2 User Manual

VS150 / VS2

SERVICE MANUAL

1. FORWARD

This service manual contains the technical data of each component inspection and repair for the VS150 / VS2 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the motorcycle, VS150 / VS2, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

Service Department

VMEP COMPANY

					2.CONTENTS
		Page			Content	Index
	3-1 ~ 3-18				GENERAL INFORMATION	3
	4-1 ~ 4-13				SERVICE MAINTENANCE INFORMATION	4
	5-1 ~5-8				LUBRICATION SYSTEM	5
	6-1	~ 6-12			FUEL SYSTEM	6
	7-1	~ 7-8			ENGINE REMOVAL	7
	8-1	~ 8-14			CYLINDER HEAD/VALVE	8
	9-1	~ 9-8			CYLINDER/PISTON	9
	10-1 ~10-14				“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER	10
	11-1 ~11-10				FINAL DRIVING MECHANISM	11
	12-1 ~			12-8	ALTERNATOR	12
	13-1 ~			13-9	CRANKSHAFT/ CRANKCASE	13
	14-1 ~			14-16	BODY COVER	14
	15-1 ~			15-14	BRAKE SYSTEM	15
	16-1		~	16-11	STEERING/FRONT WHEEL/SUSPENSION	16
	17-1		~	17-6	REAR WHEEL/SUSPENSION	17
	18-1		~	18-18	ELECTRICAL EQUIPMENT	18
	19-1		~	19-2	ELECTRICAL DIAGRAM	19

MECHANISM ILLUSTRATIONS

VS150/VS2

ٛLight switch	Front winker
ٛStart switch

Key set

Head light

Battery cover ass’y

	ٛDimmer switch
	ٛOpen switch
	ٛWinker switch
Handle lever	ٛHorn switch

Fuel cap ass’y ٛTail light

ٛStop light

Air cleaner

Kick starter

Luggage box

Fuel tank

HOW TO USE THIS MANUAL

This service manual describes basic information of different system parts and system inspection & service VS150 / VS2 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance information and special tools manual.

The third to the 11th chapters cover engine and driving systems.

The 12th to the 17th chapter is contained the parts set of assembly frame body and body cover.

The 18th chapter is electrical equipment. The 19th chapter is wiring diagram.

Please see index of content for quick having the special parts and system information.

3. GENERAL INFORMATION

...............................Symbols and Marks	3-1	.....................................Specifications	3-10
General safety........................................	3-2	Torque Values ....................................	3-11
Service Precautions ..............................	3-3	Troubles Diagnosis............................	3-13
Specifications........................................	3-9	Parts to Be Greased...........................	3-17

Symbols and Marks

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

Warning

Caution

Engine oil

Grease

Gear oil

Locking sealant

Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

Indication

Directions

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 SHARK 4T (SAE 20W-50 API SG) class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: SHARK 4T oil)

SHARK 4T is recommended.

SHARK gear oil serials are recommended. (SUPER HYPOID GEAR OIL # 150)

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 of components.

Indicates position and operation directions

Components assembly directions each other.

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

3

3-1

3. GENERAL INFORMATION

General safety

Carbon monoxide

If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.

Caution

Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.

Gasoline

Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode under some conditions, keep it away from children.

Used engine oil

Caution

Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified.

We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.

Hot components

Caution

Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.

Battery

Caution

Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery.

Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist.

If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor.

Keep electrolyte beyond reach of children.

Brake shoe

Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying.

Caution

Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system

Brake fluid

Caution

Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children.

3-2

3. GENERAL INFORMATION

Service Precautions

yAlways use with VMEP genuine parts and recommended oils. Using non-designed parts for VMEP motorcycle may damage the motorcycle.

ySpecial tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.

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

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

yWash 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.

yNever bend or twist a control cable to prevent unsmooth control and premature worn out.

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

yWhen 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.

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

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

yComponents not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

3-3

3. GENERAL INFORMATION

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

yTighten 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.

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

Manufacturer's name

yRemove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage.

yThe 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

yRubber and plastic boots should be properly reinstalled to the original correct positions as designed.

Boots

yThe 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.

3-4

3. GENERAL INFORMATION

yLubricate the rotation face with specified lubricant on the lubrication points before assembling.

yCheck if positions and operation for installed parts is in correct and properly.

yMake sure service safety each other when conducting by two persons.

y Note that do not let parts fall down.

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

yAfter service completed, make sure all connection points is secured.

Battery positive (+) cable should be connected firstly.

yAnd the two posts of battery have to be greased after connected the cables.

yMake sure that the battery post caps are located in properly after the battery posts had been serviced.

yIf fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse.

Capacity verification

3-5

3. GENERAL INFORMATION

yWhen separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation.

yDo not pull the wires as removing a connector or wires. Hold the connector body.

yMake sure if the connector pins are bent, extruded or loosen.

yInsert 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.

yCheck if the connector is covered by the twin connector boot completely and secured properly.

yBefore terminal connection, check if the boot is crack or the terminal is loose.

yInsert the terminal completely.

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

ySecure 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.

yWire band and wire harness have to be clamped secured properly.

yDo not squeeze wires against the weld or its clamp.

3-6

3. GENERAL INFORMATION

yDo not let the wire harness contact with rotating, moving or vibrating components as routing the harness.

yKeep wire harnesses far away from the hot parts.

yProtect 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.

ySecure the rubber boot firmly as applying it on wire harness.

Never Touch

yRoute wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws.

yRoute harnesses so that they neither pull too tight nor have excessive slack.

Never too tight

yNever use wires or harnesses which insulation has been broken. Wrap electrical tape around the damaged parts or replace them.

yNever clamp or squeeze the wire harness as installing other components.

Never clamp or squeeze the wire harness

3-7

3. GENERAL INFORMATION

yDo not let the wire harness been twisted as installation.

yWith sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later.

Clean rust

yWire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

yBefore 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?

3-8

3. GENERAL INFORMATION

Specifications
		MAKER		VMEP	MODEL			HA15A6-4 (VS2)
Dimension		Overall Length		1910 mm	Suspension		Front	Telescopic Fork
		Overall Width		740 mm	System		Rear	Twin Unit Swing
		Overall Height		1125 mm	Tire Specifications		Front	110 / 80 – 12 61L
		Wheel Base		1345 mm			Rear	130 / 70 – 12 64L
			Front	58 kg			Front	Disk (ψ273 mm)
	Curb Weight		Rear	75 kg	Brake System		Rear	Drum (ψ130 mm)
			Total	133 kg
Weight	Passengers/Weight			Two /110 kg	Performance	Max. Speed		Above 100 km/h
			Front	88 kg		Climb Ability		Below 28°
						Primary
	Total Weight		Rear	155 kg				Belt, 2.56 ~ 0.8
						Reduction
			Total	243 kg		Secondary		Gear
					Reduction	Reduction
		Type		4-Stroke Engine		Clutch		Centrifugal, dry type
		Installation and		Vertical, below center,		Transmission		C.V.T
		arrangement		incline 80°
		Fuel Used		Unlead gasoline	Speedometer			0 ~ 140 km/h
		Cycle/Cooling		4-stroke/water cooled	Horn			93~112 dB/A
		Bore		57.4 mm	Muffler			Expansion & Pulse Type
	Cylinder	Stroke		57.8 mm	Exhaust Pipe Position and			Right side, and
Engine					Direction			Backward
		Number/Arrange		Single Cylinder	Lubrication System			Forced circulation &
		ment						splashing
		Displacement		149.6 cm3	Solid Particulate
	Compression Ratio			11.2 : 1	Exhaust Concentrati on	CO		Below 5.5 g/ km
		Max. HP		9 Kw / 8000 r.p.m		HC		Below 1.2 g/ km
		Max. Torque		12.16 Nm / 6500 r.p.m	E.E.C.			─
		Ignition system		C.D.I. electronic ignition	P.C.V.			─
		Starting System		Kick and electrical	Catalytic reaction control			Yes
				starter	system
								3-9

3. GENERAL INFORMATION

Specifications

Dimension

Weight

Engine

	MAKER			VMEP	MODEL			VS3
	Overall Length			1910 mm	Suspension System		Front	Telescopic Fork
	Overall Width			740 mm			Rear	Twin Unit Swing
	Overall Height			1125 mm	Tire Specifications		Front	110 / 80 -12 61L
	Wheel Base			1345 mm			Rear	130 / 70 -12 64L
			Front	58 kg			Front	Disk (ψ273 mm)
Curb Weight		Rear		75 kg	Brake System			Drum (ψ130 mm)
			Total	133 kg			Rear
Passengers/ Weight				Two/110 kg	Performance	Max. Speed		Above 100 km/h
			Front	88 kg		Climb Ability		Below 28°
Total Weight			Rear	155 kg		Primary		Belt
						Reduction
			Total	243 kg		Secondary		Gear
					Reduction	Reduction
	Type			4-Stroke Engine		Clutch		Centrifugal, dry type
	Installation and			Vertical, below center,		Transmission		C.V.T.
	arrangement			incline 80°
	Fuel Used			Unlead gasoline	Speedometer			0 ~ 140 km/h
	Cycle/Cooling			4-Stroke/Water Cooled	Horn			93~112 dB/A
	Bore			52.4 mm	Muffler			Expansion & Pulse
								Type
Cylinder
	Stroke			57.8 mm	Exhaust Pipe Position and			Right side, and
					Direction			Backward
	Number /			Single Cylinder	Lubrication System			Forced circulation &
	Arrangement							splashing

	Displacement	124.6 cm3	Exhaust	Concentr	ation	Solid Particulate
	Compression Ratio	11.2 : 1				CO	Below 5.5 g/km
	Max. HP	11.1PS / 8000 rpm				HC	Below 1.2 g/km
	Max. Torque	10.12Nm / 6500 rpm				E.E.C.	─
	Ignition	C.D.I.				P.C.V.	─
	Starting System	Power & Foot	Catalytic Reaction Control				Yes
						System

3-10

3. GENERAL INFORMATION

Torque Values

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

Standard Torque Values for Reference

Type	Tighten Torque	Type	Tighten Torque
5 mm bolt nut	0.45~0.6kgf-m	5 mm screw	0.35~0.5kgf-m
6 mm bolt nut	0.8~1.2kgf-m	6 mm screw SH nut	0.7~ 1.1kgf-m
8 mm bolt nut	1.8~2.5kgf-m	6 mm bolt nut	1.0 ~1.4kgf-m
10 mm bolt nut	3.0~4.0kgf-m	8 mm bolt nut	2.4 ~3.0kgf-m
12 mm bolt nut	5.0~6.0kgf-m	10 mm bolt nut	3.5~4.5kgf-m

Engine Torque Values

Item	Q’ty	Thread Dia. (mm)	Torque Value(kgf-m)	Remarks
Cylinder head nut	4	8	2.0~2.4
Cylinder head right bolt	2	8	2.0~2.4
Cylinder head stud bolt (inlet pipe)	2	6	0.7~1.1
Cylinder head stud bolt (EX. pipe)	2	7	0.5~1.0
Tappet adjustment hole cap bolt	6	6	1.0~1.4
Tappet adjustment screw nut	4	5	0.7~1.1	Apply oil to thread
Spark plug	1	10	1.0~1.2
Carburetor insulator bolt	2	6	0.7~1.1
Cylinder stud bolt	4	8	0.7~1.1
Engine left cover bolt	7	6	1.1~1.5
Engine oil draining bolt	1	12	1.1~1.5
Engine oil strainer cap	1	30	1.3~1.7
Mission draining bolt	1	8	0.8~1.2
Mission filling bolt	1	10	0.8~1.2
Clutch driving plate nut	1	28	5.0~6.0
Clutch outer nut	1	12	5.0~6.0
Drive face nut	1	12	5.0~6.0
Flywheel nut	1	12	5.0~6.0
Crankcase bolts	7	6	0.8~1.2
Mission case bolt	7	8	2.0~2.4

3-11

3. GENERAL INFORMATION

Frame Torque Values

Item	Q’ty	Thread Dia. (mm)	Torque Value(kgf-m)	Remarks
Stopper nut for engine hanger	1	8	1.8~2.2
rubber
Engine hanger nut	2	12	4.0~5.0
Engine hanger bolt	1	12	4.0~5.0
Engine connection bolt	1	10	3.5~4.5
Front wheel axle nut	1	12	5.0~7.0
Rear wheel shaft nut	1	14	10.0~12.0
Rear fork	2	8	4.0~5.0
Rear cushion upper bolt	2	10	3.5~4.5
Rear cushion under bolt	2	8	2.4~3.0
Nut for steering post	1	10	4.0~5.0
Front cushion	4	8	2.4~3.0
Brake lever nut	2	6	0.8~1.2
Nut for the rear brake arm	1	6	0.5~0.6
Front brake hose bolt	4	10	3.0~4.0
Front brake caliper bolt	4	6	3.0~3.5
Front brake disk mounting bolt	7	8	4.0~4.5
Air-bleed valve	1	5	0.5~0.6
Speedometer cable locking screw	1	5	0.15~0.3
Exhaust muffler bolt	3	8	3.2~3.8
Exhaust muffler connection nut	2	7	1.0~1.2

3-12

3. GENERAL INFORMATION

Troubles Diagnosis

A. Engine hard to start or can not be started

Check and adjustment		Fault condition

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

Fuel supplied tom		No fuel is supplied to
carburetor sufficient		carburetor

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

Check if sparks		Weak sparks, no spark at
		all

Perform cylinder compression pressure test.

Cylinder compression		Low compression
pressure normal		pressure or no pressure

Re-start by following the starting procedures

No ignition

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

Remove the spark plug again and check it.

Dry spark plug		Wet spark plug

Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air

Blowing in normal		Blowing clogged

Probable causes

1.No fuel in fuel tank

2.Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.

3.Float valve clogged

4.Lines in fuel tank evaporation system clogged

5.Malfunction of fuel pump

6.Loosen or damaged fuel pump vacuum hose

7.Fuel filter clogged

1.Malfunction of spark plug

2.Spark plug foul

3.Malfunction of CDI set

4.Malfunction of AC generator

5.Ignition coil is in open or short circuit

6.Ignition coil leads open or short circuit

7.Malfunction of main switch

1.Piston ring seized

2.Malfunction of cylinder valves

3.Worn cylinder and piston ring

4.Cylinder gasket leak

5.Sand hole in compression parts

1.Malfunction of throttle valve operation

2.Air sucked into intake manifold

3.Incorrect ignition timing

1.Fuel level in carburetor too high

2.Malfunction of throttle valve operation

3.Throttle valve opening too wide

1. Malfunction of automatic bystarter

3-13

3. GENERAL INFORMATION

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

Check and adjustment		Fault condition

Try gradual acceleration and check engine speed

Engine speed can be		Engine speed can not be
increased.		increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct		Incorrect ignition timing

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure		No compression pressure
correct

Probable causes

1.Air cleaner clogged

2.Poor fuel supply

3.Lines in fuel tank evaporation system clogged

4.Exhaust pipe clogged

5.Fuel nozzle clogged 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					Clogged				1. Remove foreign
Remove spark plug
										1. Remove dirt
	No foul or discoloration					Fouled and discoloration
								2.			Incorrect spark plug heat range
Check if engine over heat										1.	Piston and cylinder worn out
										2.	Lean mixture
										3.	Poor fuel quality
	Normal					Engine overheat				4. Too much carbon deposited in
										5.	combustion chamber
											Ignition timing too advanced
										6.	Poor circuit on the cooling system
Continually drive in acceleration
	or high speed									1.	Too much carbon deposited in
											combustion chamber
	No knock					Knock				2. Lean mixture
										3.	Poor fuel quality
										4.	Ignition timing too advanced

3-14

3. 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)

Normal				Abnormal

Adjust the air screw of carburetor

Good				Poor

Air sucked through carburetor gasket

No air sucked				Air sucked

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

Good spark			Poor

D. Engine runs sluggish (High speed)

Check and adjustment		Fault condition

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

1.Rich mixture (loosen the screw)

2.Lean mixture (tighten the screw)

1.Poor heat insulation gasket

2.Carburetor lock loose

3.Poor intake gasket

4.Poor carburetor O-ring

5.Vacuum hose crack

1.Spark plug fouled

2.Malfunction of CDI

3.Malfunction of AC generator

4.Malfunction of ignition coil

5.Open or short circuit in spark plug leads

6.Malfunction of main switch

Probable causes

Check ignition timing

										1. Malfunction of CDI
	Normal					Abnormal
										2.	Malfunction of AC alternator
Check for fuel supplying system
in automatic fuel cup										1.	Insufficient fuel in fuel tank
	Good					Abnormal				2. Fuel filter clogged
										3.	Restricted fuel tank vent
Check if carburetor clogged											Cleaning
								1.
	No clogged					Clogged

3-15

3. GENERAL INFORMATION

E. Clutch, driving and driving pulley

FAULT CONDITIONS

Engine can be started but motorcycle can not be moved.

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

Poor initial driving ( Poor climbing performance)

PROBABLE CAUSES

1.Drive belt worn out or deformation

2.Ramp plate of movable drive face damaged

3.Driving pulley spring broken

4.Clutch weights broken

5.Drive slide-shaft gear groove broken

6.Transmission gear damaged

1.Clutch weights spring broken

2.Clutch outer stuck with clutch weights

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

1.Drive belt worn out or deformation

2.Weight roller worn out

3.Movable drive face shaft worn out

4.Driven pulley spring deformation

5.Driven pulley shaft worn out

6.Greased in drive belt and driven face.

3-16

3. GENERAL INFORMATION

Parts to Be Greased

Acceleration cable/ Front & rear brake lever pivot

Steering shaft bearing

Seat catch

	Speedometer gear/			Rear wheel bearing
	front wheel bearing	Side stand pivot	Main stand pivot

3-17

3. GENERAL INFORMATION

Notes:

3-18

4. MAINTENANCE INFORMATION

Precautions in Operation ······················ 4-1 Periodical Maintenance Schedule ········ 4-2 Fuel Lines / Cable ·································· 4-3 Air Cleaner·············································· 4-4 Spark Plug·············································· 4-4 Valve Clearance ····································· 4-5 Carburetor Idle Speed Adjustment······· 4-6 Ignition System ······································ 4-7 Cylinder Compression Pressure ·········· 4-7 Drive Belt················································ 4-8 Brake System (Front Disk Brake) ········· 4-8

Brake Light Switch/Starting Inhibitor Switch ················································· 4-10

Headlight Beam Distance ·················· 4-10 Clutch Disc Wear································ 4-10 Side Stand··········································· 4-11 Cushion··············································· 4-11 Nuts, Bolts Tightness ························ 4-11 Wheel/Tire··········································· 4-12 Steering Handle Top Bearing ············ 4-12

Precautions in Operation	4
Specification

	Fuel Tank Capacity			6000 c.c.
	Engine Oil		Capacity	1000 c.c.
			Change	900 c.c.
	Transmission Gear oil		Capacity	150 c.c.
			Change	120 c.c.
	Clearance of throttle valve			2~6 mm
	Spark plug		Type	NGK CR8E
			Gap	0.6~0.7 mm
	“F” Mark in idling speed			BTDC 13º / 1700 rpm
	Full timing advanced			BTDC 28º / 4000 rpm
	Idling speed			1600±100 rpm
	Cylinder compression pressure			12.0 ±0.2 kgf/cm²
	Valve clearance: IN/EX			0.12 ± 0.02 mm
	Tire dimension		Front	110/80-12 61L
			Rear	130/70-12 64L
	Tire pressure (cold)		Single	Front: 1.75 kg/cm²	rear : 2.25 kg/cm²
			Two persons	Front: 1.75 kg/cm²	rear : 2.50 kg/cm²
	Battery			12V8Ah (MF battery) type: TTZ10S

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4. MAINTENANCE INFORMATION

Periodical Maintenance Schedule

	Maintenance	Item	Every	1 Month	3 month	6 month	1 year	15 month
				every	every	every	every	every
	Code		300KM
				1,000KM	3,000KM	6000KM	12,000KM	14,500KM
	1	Air cleaner	I		C		R
	2	2nd air jet leaner	I		C		R
	3	Fuel filter	I			I	R
	4	Oil filter	C			C
	5	Engine oil change	R		Replacement for every 1000 km
	6	Tire pressure	I	I
	7	Battery inspection	I	I
	8	Brake & free ply check	I	I
	9	Steering handle check	I			I
	10	Cushion operation check	I			I
	11	Every screw tightening check	I	I
	12	Gear oil check for leaking	I	I
	13	Spark plug check or change	I		I	R
	14	Gear oil change	R		Replacement for every 5000 km
	15	Frame lubrication				L
	16	Exhaust pipe	I	I
	17	Ignition timing	I	I
	18	emission check in Idling	A	I
	19	Throttle operation	I		I
	20	Engine bolt tightening	I		I
	21	CVT driving device(belt)				I	R
	22	CVT driving device(roller)				C
	23	Lights/electrical	I	I
		equipment/multi-meters
	24	Main/side stands & springs	I			I
	25	Fuel lines	I		I
	26	Cushions			I
	27	Cam chain	I		I
	28	Valve clearance	I		A
	29	Crankcase evaporative control	I		C
		system
	30	Crankcase blow-by over-flow			Replacement for every 2000 km
	31	2nd air jet system	I		I	C

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

Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

Remarks: 1. There marks “ ” in the schedule are emission control items. According to EPA regulations, these items must be performed normally periodical maintenance following the use r manual instructions. They are prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.

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

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

4.Preventive maintenance

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

b.Carbon deposit removal Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious lower. Than ever

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4. MAINTENANCE INFORMATION

Fuel Lines / Cable

Remove luggage box. Remove rear carrier. Remove body covers.

Check all lines, and replace it when they are deterioration, damage or leaking.

Warning

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

Acceleration Operation

Have a wide open of throttle valve as handle in any position and release it to let back original (full closed) position.

Check handle if its operation is smooth. Check acceleration cable and replace it if deteriorated, twisted or damaged.

Lubricate the cable if operation is not smooth Measure the throttle grip free play in its flange part.

Adjustment can be done in either end.

Secondary adjustment is conducted from top side. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment nut.

Primary adjustment is conducted from bottom side.

Loosen fixing nut, and adjust by turning the adjustment nut.

Tighten the fixing nut, and check acceleration operation condition.

Free play: 2~6 mm.

Fuel filter		Vacuum hose

Fuel hose

Return Fuel hose

Fuel tank

Throttle grip

Adjustment nut

Adjustment nut

Lock nut

2~6 mm

4-3

4. MAINTENANCE INFORMATION

Air Cleaner

Air Cleaner Element

Remove 6 screws from the air cleaner cover and then remove the cover.

Remove 6 screws, and then remove the air cleaner element.

Caution

The air cleaner element is made of paper so do not soap it into water or wash it with water.

6 screws

6 screws

Spark Plug

Remove central cover. Remove spark plug cap.

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

Measure the spark plug gap. Spark plug gap 0.6÷0.7 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary.

Hold spark plug washer and install the spark plug by screwing it.

Tighten torque: 1.0~1.2kgf-m

Connect spark plug cap. Recommended spark plug: NGR CR8E

Spark plug cap

0.6÷0.7 mm

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4. MAINTENANCE INFORMATION

Valve Clearance

Caution

Checks and adjustment must be performed when the engine temperature is below 35 .

Remove trunk. Remove central cover.

Remove valve adjustment cap. Remove cylinder head side cover.

Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.

Caution

Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.

Valve clearance inspection and adjustment. Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX): 0.12 ± 0.02 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

Re-check the valve clearance after tightened the fixing nut.

Timing mark

4-5

4. MAINTENANCE INFORMATION

Carburetor Idle Speed Adjustment

Caution

yInspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted.

yIdle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.)

Park the motorcycle with main stand and warm up engine.

Connect tachometer (the wire clamp of tachometer is connected to the high tension cable).

Open carburetor cover from the luggage box. Turn the throttle valve stopper screw to specified idle speed.

Specified idle speed: 1600 ± 100 rpm

Emission adjustment in idle speed

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

1.Connect the tachometer onto engine.

2.Adjust the idle speed adjustment screw and let engine runs in 1600±100 rpm.

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

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

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

Emission standard CO: below 2.5~3.5% HC: below 2000ppm

Ignition cable

Stopper screw

Air adjustment screw

4-6

4. MAINTENANCE INFORMATION

Ignition System

Caution

yC.D.I ignition system is set by manufacturer so it can not be adjusted.

yIgnition timing check procedure is for checking whether CDI function is in normal or not.

Remove right side cover.

Remove ignition timing hole cap located in front upper side of engine right cover.

Connect tachometer and ignition lamp. Start engine.

As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition lamp. Then, it is means that ignition timing is correct.

Increase engine speed to 6000 rpm to check ignition advance degree. If indent is located within the ignition advance degrees, it is means that the ignition advance degree is in normal.

If ignition timing is incorrect, check CDI set, pulse rotor and pulse generator. Replace it if malfunction of these parts is found.

Cylinder Compression Pressure

Warm up engine. Turn off the engine. Remove the trunk.

Remove the central cover.

Remove spark plug cap and spark plug. Install compression gauge.

Full open the throttle valve, and rotate the engine by means of starter motor.

Caution

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

Usually, the highest pressure reading will be obtained in 4~7 seconds.

Compression pressure: 12 ± 0.2 Kg/cm²

Check following items if the pressure is too low:

yIncorrect valve clearance.

yValve leaking.

yCylinder 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.

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