Sym Wolf SB 250 Ni Service Manual

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Page 1

Wolf SB 250 Ni

SERVICE MANUAL

20120309

FOREWORD

HOW TO USE THIS MANUAL

CONTENTS

MECHANISM ILLUSTRATION

Page 2

Foreword

This service manual contains the technical data of each component inspection and repair for the SANYANG PD25A 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, PD25A 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.

Homepage

Contents

Page 3

How to use this manual

This service manual describes basic information of individual parts and system

inspection & service for SANYANG PD25A 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 chapter covers cooling systems.

The 11th to the 13th chapters contain the parts of vehicle frame.

The 14th chapter is electrical appliances. The 15th chapter is emission control system.

The 16th chapter is electrical diagram.

Please see index of content for brief information and quick guide.

Page 4

Content

Page Content Index

1-1 ~ 1-19

General Information

2-1 ~ 2-16

Maintenance Information

3-1 ~ 3-45

Injection System

4-1 ~ 4-14

Lubrication / Clutch / Transmission

5-1 ~ 5-8

AC Generator / Starting Clutch

6-1 ~ 6-8

Engine Removal

7-1 ~ 7-16

Cylinder Head / Valve

8-1 ~ 8-10

Cylinder / Piston

9-1 ~ 9-14

Crankshaft / Crankcase / Shifting Gear

10-1 ~ 10-14

Cooling System

11-1 ~ 11-10

Brake System

12-1 ~ 12-14

Steering / Front Wheel / Front Fork

13-1 ~ 13-12

Rear Wheel / Rear Cushion

14-1 ~ 14-26

Electrical System

15-1 ~ 15-10

Emission Control System

16-1 ~ 16-2

Wiring Diagram

Page 5

Mechanism Illustration

Start / Engine stop switch

Main Switch

RR brake pedal

Starter relay

Air cleaner

Fuel tank cap

Winker relay

Battery

Headlight dimmer / Winker / Horn

Ignition

ECU

Headlight

Fuse

Regulator/ Rectifier

Shifting pedal

Meter

FR. Brake lev

Clutch lever

Taillight

FR winker

RR. w

inker

Muffler

Page 6

1. General Information

Symbols and Marks ··················1-1 General Safety···························1-2 Service Precautions··················1-3 Specifications -··························1-9 Torque Values(Engine)

·············1-10

Torque Values(Frame) ··············1-11 Torque Values ···························1-11 Troubleshooting························1-12 Lubrication Points·····················1-17

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 in procedures is needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

Warning

Means that serious injury or even death may result if procedures are not followed.

Caution

Means that equipment damages may result if procedures are not followed.

Engine oil

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: Bramax G-3 oil)

Grease King Mate G-3 is recommended.

Gear oil

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140)

Locking

sealant

Apply sealant; medium strength sealant should be used unless otherwise specified.

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools Special tools

Correct Meaning correct installation.

Wrong 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 goes through the component (invisibility).

1-1

Page 7

1. General Information

General Safety

Carbon monoxide Battery 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 a ventilator.

Caution

1-2

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.

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.

‧ 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 compressed air 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.

Page 8

1. General Information

Service Precautions

 Always use with SANYANG genuine parts and

recommended oils. Using non-genuine parts for SANYANG vehicle may damage it.

1-3

 Special tools are designed for removal and

installation of components without damaging the part. Using wrong tools may result in damage.

 When servicing this bike, use only metric tools,

metric bolts, and nuts. Using wrong tools and fasteners may damage this vehicle.

 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.

 Wash and clean parts with high ignition point

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

 Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

 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.

 When loosening a component, which has

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

 Store complex components such as

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

 Note the reassemble position of the important

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

 Components not to be reused should be

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

Page 9

1. General Information

 The length of bolts and screws for assemblies,

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 outside the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.

1-4

 Tighten assemblies with different dimension

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

 When installing oil seal, 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.

 Remove residues of the old gasket or sealant

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

 The ends of rubber hoses (for fuel, vacuum, or

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

Groove

Clamp

 Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed

Connector

Boots

 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.

Manufacturer'

s name

Both of these examples can result in bearing damage.

Page 10

1. General Information

 Lubricate the rotation face with specified

lubricant on the lubrication points before assembling.

1-5

● Check if positions and operation of installed

parts are correct and proper.

● Make sure service safety each other when

conducting by two persons.

● Note that do not let parts fall down.

 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.

 After service completed, make sure all

connection points is secured.

Battery positive (+) cable should be connected

firstly.

And the two posts of battery have to be

greased after connected the cables.

● Make sure that the battery post caps are

located properly after the battery posts had

been serviced.

●

If a fuse is burned, it has to find out the cause

and solved it. And then replace with specified

capacity fuse.

Capacity verification

Page 11

1. General Information

● When separating a connector, its locker has to

be unlocked first. Then, conduct the service operation.

1-6

● Do not pull the wires as removing a connector

or wires. Hold the connector body.

● Make sure if the connector pins are bent,

extruded or loosened.

● Insert the connector completely.

● If there are two lockers on two connector sides,

make sure the lockers are locked in properly.

● Check if any wire loose.

● Check if the connector is covered by the twin

connector boot completely and secured properly.

● Before connecting terminals, check if the boot

is cracked or the terminal is loose

● Insert the terminal completely.

● Check if the boot covers the terminal.

● Do not let boot open facing up.

● Secure wires and wire harnesses to the frame

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

●

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

● Do not squeeze wires against the weld or its

clamp.

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1. General Information

● Do not let the wire harness contact with

rotating, moving or vibrating components when routing the harness.

1-7

●

Keep wire harnesses far away from the hot parts.

● Avoid wire harnesses from sharp edges or

corners, and also avoid the jutted-out ends of bolts and screws.

●

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

● Protect wires or wire harnesses with electrical

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

●

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

Never Touch

● Never use wires or harnesses which insulation

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

● Never clamp or squeeze the wire harness

when installing other components.

Never clamp or squeeze the wire harness

Never too tight

Page 13

1. General Information

● Do not let the wire harness be twisted when

installation.

1-8

●

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.

● Before operating a test instrument, the

operator should read the operation manual of the instrument, and then conducts test in accordance with the instruction.

● Use sand paper to clean connector

pins/terminals if rust is found. And then continue the connection operation.

Do you know how to set the

instrument to its measurement

position and the insert locations

of its two probes?

Clean rust

Page 14

1. General Information

1-9

Specifications

Maker SYM Model PD25A1

Overall Length

2005 mm

Front

TELESCOPIC FORK

Overall Width

790 mm

Suspension

System

Rear

UNIT SWING

Overall Height

1050 mm

Front

110/70-17 54H

Dimension

Wheel Base

1320 mm

Tire

Specifications

Rear

140/70-17 66H

Front

82 kg

Rear

91 kg

Front

DISK (ø 288 mm)

Curb

Weight

Total

173 kg

Brake System

Rear

DISK (ø 222 mm)

Passengers/Weight

Two / 150 kg

Max. Speed

> 140 km/hr

Front

112 kg

Performance

Climb Ability

< 28°

Rear

211 kg

Primary

Reduction

2.826 (65/23T)

Weight

Total

Weight

Total

323 kg

Final

Reduction

2.69 (35/13T)

Type/ Cooling

System

Water-cooled

4-stroke

gasoline engine

Clutch

Wet multi-plate

Installation and

arrangement

Vertical, below

center, incline

15°

Reduction

Transmission

6 speed, circulated

Fuel Used

Above 92 unleaded

Speedometer

0 ~ 199 km/hr

Fuel supply

injection Horn 1

Bore

Ø 71.0 mm

Muffler

Expansion & Pulse

Type

Stroke

63.0 mm

Exhaust Pipe Position and

Direction

Right side and

Backward

C yl

d e

Number/Arrangem

ent

Single Cylinder

Lubrication System

Forced / Wet sump

Displacement

249.4 cc

Solid Particulate

Compression Ratio

10.5 : 1

< 3.0 %

Max. HP

25 ps / 7500

rpm

Exh aust Con cent

rati

< 1600 PPM

Max. Torque

2.35 kg-m / 6000 rpm

E.E.C.

√

Ignition

Full transistor

Ignition

P.C.V.

√

Engine

Starting System

Electrical

starter

Catalytic reaction control

system

√

Page 15

1. General Information

1-10

Torque Values (Engine)

Item

Q’t

Thread Dia. (mm) Torque Value(kgf-m) Remarks

Cylinder stud bolt 4 10 1.0~1.4

Cylinder head nut 4 10 3.6~4.0

Cylinder head right bolt 2 6 1.0~1.4

Cylinder head side cover bolt 3 6 1.0~1.4

Cylinder head cover bolt 4 6 0.8~1.2 Cylinder head stud bolt (inlet

2 6 1.0~1.4

Cylinder head stud bolt (EX.

2 8 2.4~3.0

Air inject pipe bolt 4 6 1.0~1.4

Tappet adjustment screw nut 4 5 0.7~1.1

Lubricate with oil

Spark plug 1 10 1.0~1.2

Camshaft gear fix bolt 2 6 1.0~1.4

Camshaft setting plate bolt 1 6 0.8~1.2

Cam chain tensioning bolt 2 6 1.0~1.4

Throttle fix nut 2 6 0.8~1.2

Engine oil draining bolt 1 12 3.5~4.5

Engine oil strainer cap 1 30 1.3~1.7

Flywheel nut 1 14 8.5~10.5

R. crankcase cover bolt 12 6 0.8~1.2

L. crankcase cover bolt 11 6 0.8~1.2

L. crankcase rear cover bolt 2 6 0.8~1.2

Oil pump screw 2 6 0.7~1.1

Oil pump cover bolt 2 6 0.8~1.2

Water pump impeller 1 7 1.0~1.4

Water pump cover bolt 4 6 0.8~1.2

Crankcase bolt 11 6 0.8~1.2

Oil strainer cover bolt 2 6 0.8~1.2

Balancing shaft drive gear bolt 4 6 0.8~1.2

Primary drive gear nut 1 16 8.5~10.5

Balancing shaft fix nut 1 14 8.5~10.5

Clutch lifter plate bolt 6 6 1.0~1.4

Clutch fix nut 1 16 8.5~10.5

ACG fix bolt 3 6 0.8~1.4

Drive gear bolt 2 6 0.8~1.2

The torque values listed are important tightening torque values. Please see standard values for those not listed in the table.

Page 16

1. General Information

1-11

Torque Values (Frame)

Item

Q’tyThread Dia.

(mm)

Torque Value

(Kg-m)

Remarks

Mounting bolt for steering handle post 4 8 1.0~1.4

Lock nut for steering stem 1 22 6.0~8.0

Steering top cone race 1 22 0.15~0.25

Front wheel axle nut 1 12 6.0~8.0

Rear wheel axle nut 1 14 10.0~12.0

Rear drive sprocket nut 4 8 2.7~3.0

Front cushion mounting bolt 4 8 3.0~3.5

Rear cushion upper connection bolt 1 10 3.5~4.5

Rear cushion lower connection bolt 1 10 3.5~4.5

Brake lever bolt 2 6 0.8~1.2

Brake hose bolt 4 10 3.0~4.0

Brake air-bleeding valve 2 6 0.8~1.0

Front brake disc mounting bolt 3 6 3.7~4.3

Rear brake disc mounting bolt 2 8 2.4~3.0

Gear change bolt 1 6 0.8~1.2

Brake clipper mounting bolt 2 6 1.5~2.0

Engine suspension nut

2 8 2.4~3.0

upper part of engine &

Engine assembly nut

2 8 3.0~4.0

engine front part & engine

Engine assembly nut

1 10 4.5~5.5

engine rear part & frame

Special Bolt 8 8 1.5~2.5

Swing arm pivot nut 1 10 10.0~12.0

Muffler mounting nut 2 8 1.0~1.2

Muffler mounting bolt 2 8 3.2~3.8

The torque values listed in above table are for more important tightening torque values. Please refer to

standard values for those not listed in the table.

Torque Values

Type Tighten Torque Type Tighten Torque

5mm bolt, nut 0.45~0.60kgf-m 4mm screw 0.10~0.15kgf-m 6mm bolt, nut 0.80~1.20kgf-m 5mm screw 0.35~0.50kgf-m

8mm bolt, nut 1.80~2.50kgf-m 6mm screw, SH nut 0.70~1.10kgf-m 10mm bolt, nut 3.00~4.00kgf-m 6mm flange bolt, nut 1.00~1.40kgf-m 12mm bolt, nut 5.00~6.00kgf-m 8mm flange bolt, nut 2.40~3.00kgf-m

3mmscrew 0.05~0.08kgf-m 10mm flange bolt, nut 3.50~4.50kgf-m

Page 17

1. General Information

Troubleshooting

A. Engine cannot be started or difficult to be started

Check and adjustment

Fault condition Probable causes

1-12

Press the fuel injector feed pipe and confirm whether there is fuel in the feed

pip

The fuel supply to the fuel injector is sufficient

The fuel injector is not supplied with sufficient fuel

Check the spark plug ignition condition

Perform cylinder compression

pressure test

Sparks

1. Check the fuel amount in the fuel tank

Check if the fuel pipe and the vacuum tube are blocked or not

Malfunction of fuel pump relay or wiring

4. Evaporative Emission Control System clogged

5. Malfunction of fuel pump

The fuel strainer is blocked or not

Week sparks or no spark

Normal cylinder

compression pressure

Low or no compression

pressure

Piston ring seized

Malfunction of cylinder valves

Worn cylinder and piston ring

Cylinder gasket leakage

Sand hole in the compression parts

Malfunction of spark plug

Spark plug contamination

Malfunction of ECU

Malfunction of the AC Generator

Ignition coil is in open or short circuit

6. Ignition coil shorted or open circuit

7. Malfunction of main switch

Restart the engine

No ignition With signs of ignition but

the engine cannot be

started

Malfunction of throttle valve operation

Air sucked into intake manifold

Incorrect ignition timing

Remove and check the spark

plug

Dry spark plug

1. Contaminated or clogged fuel injector

Malfunction of throttle valve operation

Malfunction of fuel pressure regulator

Wet spark plug

Page 18

1. General Information

B. Engine runs sluggish (Speed does not go up, lack of power)

Check and adjustment

Fault condition

Accelerate gradually and check

Engine RPM can be increased

Engine RPM cannot be increased

Check ignition timing

Check cylinder compression

pressure (using pressure gauge)

Correct ignition timing Incorrect ignition timing

Normal compression pressure

Abnormal compression pressure

Check if the fuel injector is clogged or not

Not clogged

Clogged

Remove and check the spark plug

Check if the engine is over heated

No knocking Knocking

1. Clogged air cleaner

2. Poor fuel supply

(Test on level road)

1. Replace the fuel injector

Remove the dirt

2. Incorrect spark plug heat range

3. Incorrect spark plug gap

1. Worn out piston or cylinder

2. Abnormal fuel injector

3. Poor fuel quality

4. Carbon deposit in the combustion chamber

5. Abnormal ignition timing

6. clutch slippage

1. Carbon deposit in the combustion chamber

2. Malfunction of fuel injector

3. Poor fuel quality

4. Abnormal ignition timing

Continually drive in acceleration or high speed

Normal Engine overheated

1. Malfunction of ECU

2. Malfunction of AC Generator

Worn out cylinder or piston ring

2. Cylinder gasket leakage

3. and hole in compression parts

4. Valve deterioration

5. Jammed piston ring

Fuel tank emission control system clogged

4. Clogged exhaust pipe

5. Clogged fuel injector

Engine RPM cannot be

increased

3. clutch shoe damaged

1. clutch slippage

2. poor clutch contact surface

Probable causes

1-13

Page 19

1. General Information

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

Check and adjustment

Check ignition timing

(using ignition lamp)

Incorrect ignition timing (malfunction of

ECU or AC Generator)

1. Abnormal throttle body insulator gasket

Normal

Abnormal

Check for any air sucked in

through the throttle body insulator

Abnormal throttle body installation

3. Abnormal inlet pipe gasket

4. Malfunction of ECU

No air sucked in Air sucked in

Probable causes Fault condition

Contaminated spark plug

2. Malfunction of ECU

3. Malfunction of AC Generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

Good spark Poor spark

Remove the spark plug and check the spark condition

D. Engine runs sluggish (High speed)

Normal

Check the fuel pump supply

Check if fuel injector clogged

1. insufficient fuel

2. fuel hose clogged, pressed

3. EEC clogged

Good Poo

1. Malfunction of ECU

2. Malfunction of AC

Normal Abnormal

Clogged

1. Replace injector

Probable causes

Fault condition

Check and ad

ustment

1-14

Page 20

1. General Information

E. Starter Motor Malfunction

1. Starter Motor doesn’t rotate

Check the battery circuit by activating turning signal

Push the staring button and check if the starting relay is activated

Flashing normally

Not flashing or dimmed

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

Insufficient Battery capacity

(60~120 flashes per minute)

1. Abnormal wire harness

1. Worn carbon brushes

2. Broken or shorted rotor windings

3. Broken Starter motor sub wire

4. Loose coupler

Braking light activated Braking light not activated

1. Burnt Fuse

2. Insufficient Battery Voltage

3. Abnormal braking switch

4. Abnormal main switch

Check and adjustment

Fault condition Possible causes

Pull the brake handle or step on the braking pedal

1-15

Page 21

1. General Information

2. Starting Motor rotates slowly or spins without engagement with crankshaft

1-16

Check and adjustment Fault condition Possible causes

Flashing normally Not flashing or dimmed

Starting Motor Still rotating slowly

Rotates Normally

1. Loose coupler or terminals

2. Starting Relay bad contact

1. Engine Seized

2. Starting Motor shorted or damaged

Connect the starting motor to the battery

Insufficient Battery capacity

Check the battery circuit by activating turning signal

3. Starter motor won’t stop rotating

Turn the main switch off

Motor keeps running

Motor stops

1. Starting relay shorted

1. Starting switch shorted/ stuck

F. Abnormal Engine Noise

Fault condition Possible causes

Excessive valve clearance

2. Worn rocker arm

3. Worn camshaft

Rocker arm noise

Piston slapping

1. Worn piston and cylinder

2. Carbon deposit in the combustion chamber

3. Worn piston pin or connecting rod lower end

Worn camshaft bearings

2. Worn cam sprocket

3. Loose or worn cam chain

Cam chain noise

Worn or deteriorated rear wheel damping rubber

2. Gear surface worn

3. Worn transmission gear set

Transmission gear noise

cessive clutch plate clearance

Clutch knocking

Page 22

1. General Information

Lubrication Points

1-17

Throttle cable / Front brake lever pivot / clutch lever

Steering stem

Side stand bracket

Front wheel bearing

Driven chain

Rear wheel bearing

Page 23

1. General Information

1-18

NOTE:

Page 24

2. Maintenance Information

Precautions in Operation ········· 2-1 Periodical Maintenance Schedule

···················································· 2-2 Lubrication System··················· 2-3 Cylinder Compression Test ····· 2-4 Fuel System······························· 2-5 Air Filter ····································· 2-5 Throttle Operation····················· 2-6 Spark Plug ································· 2-6 PCV System······························· 2-7 Valve Clearance Adjustment···· 2-7 Drive Chain Adjustment ··········· 2-8

Steering Mechanism ················· 2-8 Suspension System·················· 2-9 Disk Brake System···················· 2-9 Tire·············································· 2-11 Battery········································ 2-12 Clutch Adjustment

···················· 2-12 Headlight Adjustment··············· 2-13 Brake Switch······························ 2-13 Nuts, Bolts Tightness

··············· 2-13

Special Tools····························· 2-14

Precautions in Operation

Specifications

Capacity 14000 c.c.

Fuel tank

capacity

Reserve 700 c.c.

Capacity 1700 c.c.

Engine Oil

Exchange 1500 c.c.

Throttle grip free play 2~6 mm Spark plug NGK CR8E Spark plug gap 0.7~0.8 mm Ignition timing BTDC 13º / 1650 rpm Idle speed 1650±100 rpm Cylinder compression pressure 12±2 kgf/cm²

In 0.10±0.02 mm

Valve

clearance

Ex 0.15±0.02 mm

Front 110/70-17 54H

Tire size

Rear 140/70-17 66H

Single ride

Front：2.0 kg/cm² / Rear：2.0 kg/cm²

Tire Pressure

Tandem ride

Front：2.0 kg/cm² / Rear：2.25 kg/cm²

Battery Type

GT12A-BS

(

12V 10Ah

)

2-1

Page 25

2. Maintenance Information

2-2

Periodical Maintenance Schedule

Items

Initial

300KM

1 month /

every1000

3 months / every3000

6 months / every6000

1year /

every12000K

☆Air filter element

I C C R

☆Gasoline filter

I I R

☆Engine oil filter

R R

☆Engine oil strainer

C C C

☆Engine oil replacement

R Change every 1000km

Tire pressure

I I

Battery inspection

I I

Brake lever free play check

I I

Steering handle integrity check

I I

Shock absorber performance check

I I

Bolts tightening check

I I

Check the engine for oil leakage

I I

☆Spark plug inspection or replacement

I I R

☆Change gear oil

R Change every 5000km

Lubrication of the whole bike

Exhaust pipe

I I

☆Ignition timing

I I

☆Idle emission check

A I A

☆Throttle operation

I I

☆Engine bolts torque

I I

☆Transmission / chain

I I/L R

☆Clutch free play inspection

I I

Light/electrical system//instrument readings

I I

Main stand/side stand spring

I I

Fuel lines

I I

Cam chain

I I

☆Valve clearance

I A

☆PCV

I C

☆Crankcase blow-by over-flow pipe

I Drain every 2000km

☆Evaporative control system

I 31 ☆Throttle body A I A C 32

ECUimput voltage

I 33

EFi sensor coupler

I I

Note: I-Inspection A-Adjust R-Replace C-Clean L-Lubricate

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. Whichever time 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 period ically fol lo wing the use r ma nua l instr uct ions . It’s prohibited to adjust or repair these emission control items by unauthorized people. Otherwise, SYM is no responsible.

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

2. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the

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.

Page 26

2. Maintenance Information

Lubrication System

2-3

Engine Oil quantity

Caution

 Turn off the engine; park the motorcycle on

level surface with main stand.

 Run the engine for 3-5 minutes, check oil

capacity after engine off for3-5

Check oil quantity from inspection window, if oil

level is near lower limit, fill in the recommended oil to upper limit.

Exchange engine oil

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

Caution

 Warm up the engine before draining oil; that

will make engine oil easily and thoroughly

drained.

Lower limit

Fill in the engine oil to the standard quantity.

Oil viscosity :SAE10W -30

Engine oil exchange volume

Full disassembly：1700 c.c. Regular exchange：1500 c.c.

Run the engine for several minutes, check for oil leakage.

Engine oil strainer cleaning

Drain engine oil completely，remove oil strainer cap, spring, and strainer from left side of

crankcase.

Clean oil strainer with solvent or compressed air. Check if O-ring is deformed or damaged, replace if

necessary.

Install strainer, spring, and oil strainer cap.

Torque value：1.3~1.7kgf-m

Oil strainer cap

Upper limit

Oil drain bolt

Page 27

2. Maintenance Information

Replace oil filter

2-4

Remo

ve bolts of oil filter chamber.

Remove the filter and replace it with a new one.

Caution

 Oil filter is paper type and cannot be cleaned

or reused.

Cylinder compression test

Warm up engine and turn it off.

Remove left cylinder head cover

Remove spark plug cap and spark plug. Install compression gauge into the spark plug hole,

full open the throttle, and rotate the engine.

Caution

Rotate the engine until the reading in the gauge

gains no more.

 Usually, the highest-pressure reading will

appear in 4~7 seconds.

Compression pressure：12 ±2 Kgf/cm²

Check the following items if the pressure is too low:

 Incorrect valve clearance.

 Valve leakage  Cylinder head leakage. Piston, piston ring,

cylinder damaged.

Over-high pressure means combustion chamber

r piston top deposit carbon. o

boltx2

Oil filter

Spark plug

Pressure

gauge

Page 28

2. Maintenance Information

Fuel System

2-5

Fuel lines

Check all fuel lines, and replace when they are

deteriorated, damaged or leaking.

Caution

 Gasoline is a highly flammable substance, so

any source of fire or spark is strictly prohibited when operation.

Fuel filter

Warning

 Any source of fire or spark is strictly

prohibited when operation.

 Fuel filter is sealed type, replace it if it is

clogged.

Remove seat, fuel tank, and fuel pump.

Check if fuel filter is clogged or broken; replace it

with a new one when necessary.

Check the fuel line for leakage.

Air filter

Air filter element

Remove the seat.

Remove the air filter cover (4 Screws)

Remove the air filter element

Check if the filter element is dirty or damaged.

If the air cleaner filter element is too dirty or

damaged, please replace with new parts.

Caution

 The air filter element is paper type and

cannot be soaked or washed, or engine performance will be affected.

 If the filter element is not installed correctly,

dust will be sucked into cylinder, which will result in decreased power and shortened engine life.

Fuel filter

Filter

Screw×4

Air filter element

Page 29

2. Maintenance Information

2-6

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 does not go smoothly, lubricate the

cable.

Measure the free play of the throttle grip, through

the inner side flange of it.

Free play：2~6 mm

Adjustment can be done on both side of throttle

cable.

Conduct secondary adjustment on upper side.

Loose fix nut and rotate it to adjust free play.

Spark plug

Recommended spark plug：CR8E

Remove cylinder head left cover. (boltX3) Remove spark plug cap.

Clean dirt around the spark-plug hole.

Remove spark plug.

Measure spark plug ignition gap.

Spark plug gap：0.7~0.8 mm

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

Install the spark plug cap.

2~6 mm

Adjustin

g nut

Lock nut

Spark plug cap

Ground electrode

Cente

r electrode

0.7~0.8mm

Page 30

2. Maintenance Information

PCV System

2-7

Unplug the drain tube, and leak the deposit off. Drain the tube every 2,000 km.

Caution

 Under rainy or full- throttle situation, the

maintenance period should be shortened.

You can check the deposit amount through

the transparent tube.

Valve clearance Adjustment

Caution

 The valve clearance should be adjusted

when the engine is cold. (Under 35°C)

Remove fuel tank. Remove cylinder head.

Remove 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)

Valve clearance inspection & adjustment

Check the intake and exhaust valve clearance by

inserting the feeler gauge between the adjusting

screw and the lock nut.

Valve clearance： IN: 0.10±0.02 mm EX: 0.15±0.02 mm

Adjust by loosening the lock nut first, and turning the adjusting screw.

Caution

 When adjusting valve clearance, make sure

all clearance on standard volume; recheck

after tightening lock nuts.

Install cylinder head, cylinder head side cover,

timing inspection cap, and the AC.G cap

Caution

 Before installing cylinder head side cover,

timing inspection cap, and the AC.G cap,

check if the O-ring is damaged, and apply

some oil on it.

Drain tube

〝T〞mark

TDC mark

Page 31

2. Maintenance Information

Drive chain adjustment

2-8

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

 Because the front and rear sprocket have

different wearing situations, 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 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.

Torque value：4.0~5.0kgf-m

After tightening the rear axle nut, please check the

sleeve nuts to prevent them from loosening.

Recheck the chain slack, and make sure the rear wheel rotates smoothly.

If the chain is too dirty, use high-flash point

solvents to clean the chain. (Kerosene or Diesel.)

Caution

 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.

Steering mechanism

Caution

 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.

Adjusting nut

Rear axle nut

Lock nut

Page 32

2. Maintenance Information

Suspension system

2-9

Caution

 Do not ride the motorcycle with poor cushion.

 Loosened, worn or damaged cushion will

make poor stability and maneuverability.

Front cushion

Press down the front cushion several times to

check its integrity.

Check if any oil leakage or damage. Replace relative parts if damaged.

Tighten all nuts and bolts.

Rear cushion

Press down the rear cushion several times to

check its integrity. Check if any oil leakage or damage.

Replace relative parts if damaged.

Start the engine and gradually rise R.P.M. to rotate the rear wheel; check if any looseness,

vibration; replace bushing if damaged.

Tighten all nuts and bolts.

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

 To keep the reservoir in horizontal position,

do not take off the brake fluid cap before keeping the steering handle steady.

 Do not operate the brake lever after the cap

removed. Otherwise, the brake fluid will be sprayed out.

 Do not mix non-compatible brake fluid.

Lower limit

Page 33

2. Maintenance Information

Air bleeding operation

2-10

Connect a transparent h

ose to air-bleeding 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 hose.

Caution

 Before closing the air bleed valve, do not

release the brake lever.

Add Brake Fluid

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

Caution

 Never mix or use dirty brake fluid to prevent

braking system from deterioration or reducing brake performance.

Brake Lining Wear

The indent mark on brake lining is the wear

limitation.

If the wear limit mark approximates the edge of

brake disc, replace the brake lining.

Caution

 It is not necessary to remove brake hose

when replacing the brake lining.

Master Cylinder Cap

Diaphragm

Upper limit

Brake fluid

Air-bleeding valve

Air Bubble

Transparent tube

Brake

Brake lining

wear limitation

Page 34

2. Maintenance Information

2-11

Tire

Check the pressure of the tire to see if it is in the specified pressure range.

Caution

 Tire pressure check should be done when the

tire is cold.

Specified tire pressure range

Tire pressure Front Rear

Single

riding

2.0 2.0

Tire pressure

when cold

(Kg/cm²)

Dual riding 2.0 2.25

Specified tire: Front：110/70-17 54H Rear：130/70-17 62H

Check if tire surface is stuck with nails, stones or

other objects. Check if tire surface and wall are damaged or

worn, replace when necessary.

Check tire tread depth with eye or tire depth gauge.

Replace the tire if it is uneven worn or insufficient

tread depth. If the wearing of the tire thread reaches triangle TWI mark index, the tire have to be replaced.

Measure tire thread depth from tire central surface, replace the tire, if the depth is not enough.

Minimum tread depth:

Front wheel: 1.5 mm Rear wheel: 2.0 mm

Caution

 The triangle TWI mark index is located along

the tire wall.

“△ ”TWI mark

Page 35

2. Maintenance Information

Battery

2-12

Battery removal

Remove the seat

Remove the〝─〞negative pole first, then remove the〝＋〞positive pole. Remove the battery holder and take out the battery.

Caution

 If the rust on the posts is very serious, spray

some hot water on them. Then, you can

remove the rust by steel brush more easily.

 Apply some grease on the posts after

cleaning rust to prevent from happening

again.

If there is some rust on battery posts, clean it with

steel brush.

Install the battery in the reverse procedures of removal.

Battery model : GT12A-BS

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.

Positive pole

Negative pole

10~20 mm

Adjusting nut Lock nut

Page 36

2. Maintenance Information

2-13

Headlight adjustment

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

Caution

 The factory setting of the beam height is

consistent with government orders.

 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.

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 will increase the free play.

Nuts, bolts tightness

Apply periodical maintenance in according with the

Periodical Maintenance Schedule.

Check if all the bolts and nuts on the frame are tightened within standard torque.

Check all fixing pins, snap rings, hose (pipe)

lamps, and wire holders for security. c

Headlight adjusting screw

RR brake switch adjusting nut

Brake switch

Page 37

2. Maintenance Information

Special tools

Name

Rocker arm shaft disassemble tool

Name Flywheel puller Name

Valve remove and assemble tool

SY No. SYM-1445100 SY No. SYM-3110000-HMA SY No. SYM-1471110/20

Name Valve spring compressor Name Tappet adjusting wrench Name Tappet adjusting tool

SY No. SYM-1471100 SY No. SYM-9001200 SY No. SYM-9001210

(6203/6004UZ)

(20*34*7)

Name Steering Nut Wrench Name 6203/6004UZ bearing Driver Name 20*32*6 oil seal driver

SY No. SYM-5320000 SY No. SYM-9620000 SY No. SYM-9120200

(6204)

(6301)

Name 6204 Bearing Driver Name 6301 Bearing Driver Name Digital clamp meter

SY No. SYM-9110400 SY No. SYM-9610000 SY No. SYM-HE07007-05

2-14

Page 38

2. Maintenance Information

Name Inner bearing puller set Name Outer bearing puller Name Bearing driver

SY No. SYM-6204020 SY No. SYM-6204001 SY No. SYM-6204024

Name Crankcase bush puller Name Cylinder pressure gauge Name Vacuum pressure gauge

SY No. SYM-1120310 SY No. SYM-HT07008 SY No. SYM-HT07011

Name EFi System Diagnostic tool Name Fuel pressure gauge Name Multi-meter

SY No. SY No. SYM-HT07010 SY No. SYM-HE07007-01

Name Vehicle circuit test tool kit Name Vehicle circuit test harness Name Fuel hose clamp

SY No. SYM-HE170008 SY No. SYM-HE170008-01 SY No. SYM-1950500

2-15

Page 39

2. Maintenance Information

Name EFI fuel hose pliers Name EFI fuel hose removal pliers Name

Water pump mechanical seal driver

SY No. SYM-1768100 SY No. SYM-1768110 SY No. SYM-1721700-H9A

Name

Water pump bearing driver

Name

Water pump oil seal driver

SY No. SYM-9100100 SY No. SYM-9120500-H9A

2-16

Page 40

3. Fuel Injection System

EFi System Diagram·································· 3-1

EFi System Operation ······························· 3-2

EFi System Introduction ··························· 3-3

Fuel System ··············································· 3-4

Ignition System·········································· 3-5

Sensors / Drives ········································ 3-6

Precautions in Operation·························· 3-12

EFi System Components Description ····· 3-13

EFi System Circuit····································· 3-29

ECU Pin Configuration······························ 3-30

Troubleshooting ········································ 3-31

Intergrated Troubleshooting Procedure·· 3-35

Fuel Tank ····················································3-37

Fuel Pump···················································3-38

Fuel Unit······················································3-39 Air Cleaner··················································3-39 EFi System Diagnosis Methods················3-40 Check Light Fault Codes Differentiation··3-41 Fault Codes and Sensors Table················3-42

Fault Code and Check Light Flashing Light

Identification Table···································3-43

Troubleshooting Table ······························3-44

Comprehensive Maintenance List ············3-45

EFi system diagram

ISC

(stepping motor)

ECT sensor

MAP

sensor

Injecto

TPS

TA sensor

Fuel pump

Rollover

sensor

Battery

ECU

Ignition coil

AISV

Diagnostic tool

EFi System Check L

Relay

CPS

O2 Sensor

amp

3-1

Page 41

3. Fuel Injection System

EFi system operation

3-2

ECU

Engine control

unit

CPS

Crankshaft Position Sensor

MAP

TPS

Throttle Pos

ition

Sensor

Manifold Absolute Pressure Sensor

K/S

LAMBDA

Engine Coolant Temperature Sensor

O2 sensor

Rollover sensor

INJECTOR

IGN COIL

FUEL PUMP

CHECK LIGHT

Injector

Ignition Coil

Fuel pump

AISV

Int

ake Air

Temperature Sensor

ISC

Idle Speed Control Valve

Tuning tools Diagnostic tool

VBATT

tepping motor)

Battery volt

age

Page 42

3. Fuel Injection System

3-3

EFi system introduction

Based on 4-stroke SOHC engine, displacement 250 c.c. electronically controlled fuel injection. Fuel vapor will be absorbed by carbon canister; blow-by gas from crankcase will be introduced to combustion chamber. The O2 sensor enhances the efficiency of the catalytic converter by dynamically controlling the air / fuel ratio.

Electrical fuel injection system

Electrical fuel injection system is constructed by fuel supply device: fuel tank, fuel pump, fuel filter, pressure regulator, and fuel control device: injector, ECU. The fuel is pumped by electrical fuel pump in the fuel tank to the injector on the intake manifold (inlet pipemanifold). The fuel pressure regulator keeps the pressure around 294±6kpa. The signals from ECU enable the injector to spray fuel into the combustion chamber once each two crankshaft-revolutions. The excessive fuel flows back to the fuel tank through the fuel pressure regulator. Fuel pump is placed inside the fuel tank to reduce the working noise and simplify the fuel system. Electrically controlled ignition and injection system effectively reduce fuel consumption rate and pollution.

In traditional gasoline engine, carburetor supplies the fuel. The engine vacuum generates negative pressure in the carburetor; then fuel mixed with air and together the mixed gas sent into combustion chamber. Under this condition, air-fuel ratio is determined by air and fuel sucked in. Thus, the three major processes are done simultaneously in the carburetor: air quantity measurement, the determination of fuel quantity, the mix of fuel and air.

Electrical fuel injection system checks intake air quantity and temperature; on this basis, the programmed air-fuel ratio in the ECU determines the amount of fuel to be injected; then the injector sprays the fuel. The difference between carburetor and electrical fuel injection is that the three mechanisms are independent which will lead to more precise fuel control and supply.

EFi engine uses computer-programmed fuel injection, the main features are: 1﹒ The quantity of fuel injected is determined according to the condition of the engine. The engine

RPM and throttle position determines the fuel quantity and injection time-length.

2﹒ The quantity of fuel injection, and the determination of injection time length, are all controlled by

16-bit microcomputer.

3﹒ The fuel pressure regulator maintains a 294±6kpa pressure difference between inlet pipe and

fuel pipe, raising the accuracy of fuel injection.

4﹒ By measuring the air pressure of inlet pipe, this system gives the vehicle better accommodation

to the environment.

5﹒ Idle speed control system supplies by-pass air to stabilize the idle running and cold starting.

6﹒ O2 sensor feeds back the signal to minimize the exhaust pollution.

Page 43

3. Fuel Injection System

Fuel system

Fuel pum

Injector

Fuel pump

relay

ECU

Powe

r relay

Battery

System description

1. After Key-on, the sensors send signals to ECU. ECU controls the fuel pump relay to make the fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in order to save electricity. Fuel pressure regulator maintains fuel pressure at 294 ± 6kPa (about 3 kg / cm ²). According to the operating conditions and environmental compensation coefficient, appropriate fuel will be injected. After Key-off or engine stops operating, the fuel pump stops running.

2. Fuel filter filtrates impurities in the fuel. Replace it periodically.

3. When the engine cannot be started, do not keep starting the motor, which may reduce battery power (less than 10 V), and the fuel pump will not be able to operate. The correct way is to use a new battery.

Injector

Ten-hole type injector provides fuel injection, enhances the effect of fuel atomization, and reduces HC emission. Short-type injector cap can easily fix the injector, receive the fuel from the fuel pump, and limit injector rotation sliding. The signals from ECU control the fuel pressure regulator, using the diaphragm and spring to maintain the fuel pressure in 294 ± 6kPa (about 3 kg / cm ²), and determine the fuel injection quantity by adjusting injection time width under different engine conditions.

Fuel pump

Electrical fuel pump is placed inside the fuel tank, powered by the battery and controlled by ECU. Fuel pressure: 294 ± 6kPa (about 3 kg / cm ²)

3-4

Page 44

3. Fuel Injection System

Ignition system

3-5

Principle

The computer programmed ignition system receives the signals from the crankshaft position sensor, throttle position sensor, O2 Sensor, MAP sensor, intake air temperature sensor, engine coolant temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines the appropriate ignition timing, controls the ignition coil and triggers the spark plug This way can not only make the engine achieve the maximum power output, but also help improve fuel consumption rate.

Specification

1. Ignition timing: BTDC 10 ° / 1650RPM

2. Spark plug: NGK CR8E Clearance:0.7~0.8mm

3. ACG crankshaft position sensor coil resistance: 120Ω±20% (green/white-blue/yellow)

4. Ignition coil primary circuit resistance: 2.8 Ω ± 15% Secondary circuit：with cap9.0KΩ±20% without cap14.0KΩ±20%

5. Battery Type / Capacity: GT12A-BS / 12V 10Ah

ACG/ Flywheel Gear (23+1 Long teeth)

Crankshaft

position

sensor

Throttle position

Manifold absolute pressure

Engine coolant temperature

REG. REC

ECU

Oxygen content

Battery

Intake air temperature

Power

relay

Ignition coil

Spark plug

Page 45

3. Fuel Injection System

Sensors / drives

Crankshaft position sensor (CPS) Function:

CPS identifies the teeth on the flywheel and sends voltage signal to ECU.

Crankshaft position

sensor

Long tooth

ECU

Flywhe

Description

Right after the engine is started; the crankshaft position sensor identifies the TDC position by detecting the long tooth on the flywheel and ignites at the fixed angle. When the engine RPM reaches the specified speed, the ignition timing will change to the software mode.

3-6

Page 46

3. Fuel Injection System

Manifold absolute pressure (MAP) / Engine water temperature (TW) / Intake air temperature (TA) sensor

W Sensor

TA Sensor

ECU

Map sensor

Engine water temperature / Intake air temperature sensor: Use the variable resistor of negative temperature coefficient (thermistor) to identify the outside temperature. The electrical resistance value goes down when the temperature rises. On the contrary, the electrical resistance value becomes higher when the temperature falls. Sensors provide the temperature of the engine coolant and intake air to ECU to determine the injection and ignition timing.

3-7

Manifold absolute pressure sensor: uses the piezoresistive resistor composed of silicon

diaphragm, forming the Wheatstone bridge circuit to measure the atmospheric pressure and the intake manifold pressure, which are both transmitted to ECU as reference of engine control.

Working voltage (5V)

Output voltage

Inlet pressure

sensor

ECU

Output voltage

Inlet pressure (kPa)

Page 47

3. Fuel Injection System

O2 Sensor

ECU

Powe

r relay

2 Sensor

Battery

O2 Sensor

3-8

Function

O2 Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts the air-fuel ratio by changing the fuel injection time. If the proportion of oxygen is too low, it means the air-fuel mixture is rich, the concentration of HC & CO in the exhaust gas will rise. If the proportion of oxygen is too high, it means the air-fuel mixture is thin, thin air-fuel mixture will result in higher combustion temperature and higher NOx concentration.

1. O

Sensor outputs feedback signal to ECU which keeps the air-fuel mixture near the

stoichometric ratio approximately 14.6 and forms the closed loop control system.

2. When the air-fuel mixture is near the stoichometic ratio, CO / HC / NOx are converted

most efficiently.

3. O

Sensor heater resistance: 6.7 ~ 10.5 Ω

4. O

Sensor amendment in the voltage value: between 100 ~ 900 mV

Output voltage

Ceramics tube

2. Electrode

3. Emissions

4. Atmosphere

Rich ← 14.7 → Lean

Page 48

3. Fuel Injection System

Throttle position sensor (TPS)

ECU

TPS

3-9

Battery

TPS

ECU

TPS output voltage

Basic Principle:

TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value will change, determining the throttle position.

Function:

TPS identifies the throttle valve position and sends signal to ECU as reference of engine control.

Voltage

VTA

100

150

Throttle valve opening angle

Page 49

3. Fuel Injection System

Idle speed control valve (ISC stepping motor)

ISC

3-10

Function:

ECU controls ISC stepping motor to adjust the bypass intake air quantity and stabilize the idle speed.

ECU

+Va

-Va +Vb

-Vb

Step

Battery

Page 50

3. Fuel Injection System

Air injection solenoid valve (AISV)

Function: AISV introduces appropriate air quantity to reduce pollutant emission. Basic principle: When the engine RPM and throttle opening are higher than the default value,

ECU controls AISV opening or closure.

AISV

Reed valve

3-11

Fre

sh air

Power relay

Battery

ECU

Power relay

AISV

ECU

Page 51

3. Fuel Injection System

Precautions in operation

General information

Warning

● Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and

flame is strictly prohibited when working with gasoline.

● Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to

prevent fuel from splashing.

Caution

● Do not bend or twist the throttle cable. Damaged cable will lead to unstable driving.

● When disassembling fuel system parts, pay attention to O-ring position, replace with new one

as re-assembly.

Method of releasing fuel pressure in fuel system:

After removing fuel pump relay, turn on the main switch, press start switch to start the engine till it stops to drain fuel in the fuel system.

Specification

Item Specifications

Idle RPM 1650±100 rpm

Throttle handle free play 2~6 mm

Fuel pressure 294±6kpa (3.0kg/cm²)

Torque value

Engine temperature sensor: 0.74~0.88kgf-m O

2 Sensor: 3.6~4.6kgf-m

Special Tools

Vacuum Gauge Fuel Pressure Gauge EFi System Diagnostic Scanner Fuel Pipe Pliers

3-12

Page 52

3. Fuel Injection System

EFi system components description

ECU(Electronic Control Unit)

Function Description:

● Powered by DC 8~16V, and has 36-pin socket on the unit.

● The hardware component consists of a 16-bit microcomputer that

is its control center. It contains the functional circuit interface of engine condition sensing and the driving actuator for the fuel injector, fuel pump, as well as ignition coil.

● Its major software is a monitor strategy operation program that

includes controlling strategy and self-diagnosis programs.

Testing Procedures:

1. Connect the diagnostic scanner to the diagnostic coupler on the

vehicle.

2. Key-on but do not start the engine, confirm the connection of ECU

and the diagnostic scanner.

3. Diagnostic scanner will automatically display Version

"certification" of the screen.

4. Confirm the application model, version is correct or not.

5. Check if the fault codes exist.

6. Remove the fault codes.

7. Start engine and check the parameters shown on the diagnostic

scanner.

Detection judge:

● Fault codes can be read and cleaned, and the fault codes will not

appear again after re-start.

Treatment of abnormal phenomena:

1. Can not connect→ First check whether the cartridge is correct

and ECU is normal or not. Replace with new parts and recheck.

2. Unable to start→ ECU or relevant parts abnormal. Replace with

new parts and recheck.

3. Fault codes appear→ ECU or relevant parts abnormal.

Troubleshoot and recheck.

3-13

Page 53

3. Fuel Injection System

Throttle body

Function description:

● Throttle body is an inlet air flow regulating device (similar to the

carburetor).

● Throttle valve pivot drives the throttle position sensor

synchronously and makes ECU detect the throttle opening immediately.

● Throttle valve positioning screw has been adjusted and marked

on the production line. Readjustment is not suggested.

● The ISC on throttle body functions to supply air making cold

starting easier; after engine warmed up, the air channel will be reduced according to engine conditions.

Treatment of abnormal phenomena:

● If all fuel injection associated components identified no fault, and

other traditional engine components are also normal, the engine is still not smooth, please confirm if too much carbon deposits in the throttle body.

● If there is too much carbon deposit in the throttle body, please

clean throttle body, and then adjust the injection system.

Throttle

positioning

screw

3-14

Page 54

3. Fuel Injection System

MAP sensor

Function description:

● Powered by 5V DC from ECU. It has 3-pin socket on the sensor. One

terminal is for power, and one terminal is for signal output. And, the rest one is for grounding.

● The major component of the intake pressure sensor is a variable

transistor IC. Its reference voltage is DC 5V, and output voltage range is DC 0~5V.

3-15

● It is a pressure-sensing sensor, and can measure the absolute pressure

in intake process. It also conducts fuel injection quantity correction based on environmental position level.

Testing Procedures

Working voltage measurement

Output voltage measurement

1. Connect inlet pressure sensor properly (using the probe tool).

2. Key-on but do not start the engine.

3. Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor voltage.

4. Working voltage check:

● Voltage meter negative access to the inlet pressure sensor third pin

(Green/Pink)

● Voltage meter positive access to the inlet pressure sensor first pin

(Yellow / Black).

5. Confirm output voltage values:

● Voltage meter negative access to the inlet pressure sensor third pin

(Green/Pink)

● Voltage meter positive access to the inlet pressure sensor second pin

(Black/Red)

Caution

● The probe tool should contact the inner terminals to measure

the correct value.

Detection judge:

● Working voltage value: 5.0±0.1V

● Output voltage values:2.87±0.03V (Conditions: Measure on level ground

101.3 kPa)

Caution

● The higher the elevation, the lower voltage will be measured.

● Sea-level atmospheric pressure = 1Atm = 101.3kPa = 760mmHg =

1013mbar

Treatment of abnormal phenomena:

● MAP sensor damaged, or poor contact couplers.

● Check if the wire harness abnormal.

● If MAP sensor fails, replace with a new one and recheck output

voltage.

● If ECU fails, replace with a new one and recheck output voltage.

Pin Wire color Function Left Y/B 5V voltage input

Center B/R Signal output

Right G/P Ground

Y/B B/R

G/P

Page 55

3. Fuel Injection System

TA se ns or

Function Description

● Powered by 5V DC from ECU. It has 2-pin socket on the sensor.

One terminal is for voltage output, the other is for grounding.

● The major component of TA sensor is a variable resistor of

negative temperature coefficient

● Installed in the air filter, the resistor in TA sensor varies with

temperature variation and sends voltage signals for ECU to calculate the intake air temperature; then, ECU adjusts injection time and ignition angle.

Testing Procedures:

Resistance value measurement:

● Dismantled TA sensor connector.

● Use the "Ohmmeter" Ohm stalls to inspect sensor resistance.

Detection judge:

3-16

Temperature( )℃ Resistance value(KΩ)

-20 18.8 ± 2.4 40 1.136 ± 0.1

100 0.1553 ± 0.007

Treatment of abnormal phenomena:

● Damaged TA sensor or poor connector contact.

● Check if the wire harness abnormal.

● If TA sensor possibly failed, it is suggested to replace with a new

one.

Resistance value measurement

Page 56

3. Fuel Injection System

TPS

Function description:

● Powered by 5V DC from ECU. It has 3-pin socket on the sensor.

One terminal is for power, and one terminal is for voltage output. And, the rest one is for grounding.

● Its main component is a sophisticated variable resistor.

3-17

● Installed on the throttle body. While throttle is rotated, TPS senses

the throttle position (opening) and sends voltage signals for ECU to judge the throttle position; then, ECU optimizes fuel injection and ignition timing.

Working voltage measurement

Throttle output signal measurement - close

Throttle output signal

measurement - full

Pin Wire color Function

Up White/Brown Signal output

Center Yellow/Black 5V voltage input

Low Green/Pink Ground

Y/B

W/BR

G/P

Testing Procedures:

1. Working voltage can be measured while sensor coupler is

connected (use probe tool) or removed (direct measurement).

2. Key-on but do not start the engine.

3. Use "voltage meter" DC stalls (DCV) to check voltage.

4. Working voltage check:

● Voltage meter negative access to TPS third pin.(green/pink)

● Voltage meter positive access to TPS second pin.(yellow/black)

5. Throttle output signal check: (using the probe tool)

● Voltage meter negative access to TPS third pin.(green/pink)

● Voltage meter positive access to TPS first pin.(white/brown)

● Measure the output voltages of both full-throttle and

close-throttle.

Caution

● The probe tool should contact the inner terminals to measure

the correct value.

Detection judge:

● Working voltage value:5.0±0.1V

● Close-throttle voltage value:0.6±0.02V

● Full-throttle voltage value:3.77±0.1V

Page 57

3. Fuel Injection System

Diagnostic tool can be used to check throttle output signals.

1. Connect the Diagnostic tool, key-on but do not start the engine.

2. Switch screen to “data analysis.”

3. Rotate the throttle and check the voltage.

3-18

Throttle output signal

measurement

-close

Treatment of abnormal phenomena:

● TPS damaged or coupler poor contact.

● Check if the wire harness abnormal.

● If TPS possibly failed, it is suggested to replace with a new one

and check again.

Warning

● It is prohibited to remove TPS from throttle body to conduct

any test.

Throttle output signal

measurement

-full

Page 58

3. Fuel Injection System

TW sensor:

Function Description:

● Powered by 5V DC from ECU. It has the two-pin socket on the

sensor. One terminal is for voltage output, and the other terminal is for ground.

● The major component of TA sensor is a variable resistor of

negative temperature coefficient

3-19

● Installed on the cylinder head, the resistor in TW sensor varies

with temperature variation and sends voltage signals for ECU to calculate the intake air temperature; then, ECU adjusts injection time and ignition angle.

Testing Procedures: Resistance value measurement:

● Remove the TW sensor from the vehicle.

● Use the "Ohmmeter" Ohm stalls to inspect sensor resistance.

Detection judge:

Resistance value measurement

Temperature ()℃ Resistance value (KΩ)

-20 18.8 ± 2.4 40 1.136 ± 0.1

100 0.1553 ± 0.007

Treatment of abnormal phenomena:

● Damaged TW sensor or poor connector contact.

● Check if the wire harness abnormal.

● If TA sensor possibly failed, it is suggested to replace with a new

one.

Page 59

3. Fuel Injection System

O2 Sensor

Function Description:

● Powered by 8-16V DC from ECU. It has the four-pin socket on the

sensor. One terminal is for heating power output, one for heating control, one for signal grounding, and one for signal.

● O2 sensor sends signal to ECU, and ECU control air / fuel ratio

around 14.5 – 14.7 to form a close loop.

● When the air-fuel mixture is near the stoichometic ratio, CO / HC /

NOx are converted most efficiently.

Testing Procedures:

1. Working voltage check

● Remove O2 sensor coupler from the wire harness.

● Key-on but do not start the engine.

● Use "voltage meter" DC stalls (DCV) to check the power supply of

wire harness to the heating circuit of the

O2 sensor.

● Working voltage check

Voltage meter negative access to the second pin of wire harness coupler.

(pink/white)

Voltage meter positive access to the first pin of wire harness. (red/yellow)

2. Resistance value check

● Remove O2 sensor coupler from the wire harness.

● Use the "Ohmmeter" Ohm stalls to inspect the heater sensor

resistance.

● Resistance value check

Ohmmeter negative access to the second pin of O2 sensor. (white)

Ohmmeter positive access to the first pin of O2 sensor. (white)

Working voltage check

3-20

G/P

P/B

P/W

R/Y

B GR

Resistance value check

Page 60

3. Fuel Injection System

3. Use of diagnosis tool to check O

sensor work situations

● Connect the Diagnostic tool, key-on and start the engine.

● Completely warm up the engine. (idle running for more than "5

minutes")

voltage changing condition.

● Switch screen to "DATA STREAM 01/01", select "O

Sensor" project, turn the throttle to achieve 4500 rpm. Observe O2 Sensor acting.

● Observe O

Sensor voltage changing condition.

Detection judge:

● Working voltage: above 10V

● Resistance value: 6.7~10.5Ω

● That Observe O

Sensor voltage between 100 ~ 900 mV means pollution close loop control system is normal. However, it is abnormal, if the value is a fixed one.

Treatment of abnormal phenomena:

● Damaged O

Sensor, damaged heater, or coupler poor contact.

● Check if the wire harness abnormal.

● If O

Sensor possibly failed, it is suggested to replace with a new

one and check again.

3-21

Page 61

3. Fuel Injection System

Rollover sensor

Function description

Normal

● Rollover sensor controls power of the power relay coil and has

three-pin socket.

● When the vehicle tilt angle is greater than 65 degrees, rollover

sensor will be the implementation of ECU system power-off. At this time, to restart the engine, the main switch has to be turn on again.

● It is a safety device, when the vehicle rolls over, it will cut off

power supply to ECU.

Rollover

Testing procedures:

● Rollover sensor is an electronic control mechanism. It is unable to

test while the sensor removed from the vehicle.

● In normal situation, key on, measure the voltage of white/brown

and green/pink (ground) wire of ECU, then the condition of the rollover sensor can be judged.

Detection judge: Voltage: Normal: 0.4~1.4V Rollover: 3.7~4.4V

Treatment of abnormal phenomena:

Vehicle state vertical, no power supply to power relay or ECU.

● Rollover sensor internal short circuit or open circuit, or coupler

poor contact.

● Check if the wire harness abnormal.

● If Rollover Sensor possibly failed, it is suggested to replace with a

new one.

3-22

Page 62

3. Fuel Injection System

ISC(stepping motor)：

Function description:

3-23

● Powered by 8-16V DC from ECU. ISC has a four-pin socket.

● The 4-pin socket is composed of power supply and grounding

circuits of two motors, ECU controls the acting of stepping motor by controlling the power supply and grounding circuit.

● Low-power-consuming DC motor drives the ISC. And the

movement of ISC controls the opening of idle speed air channel, thus the idle speed of cold or warmed engine can be adjusted.

Testing Procedures

Resistance value check:

● Remove ISC coupler from throttle body. (It is okay to test while

ISC installed on throttle body.)

● Use the "Ohmmeter" Ohm stalls to inspect the resistance of the

two motor circuits. A phase: ISCAP and ISCAN B phase: ISCBP and ISCBN

ISCAP

ISCBP

ISC pins

Resistance value measurement of

A phase

Resistance value measurement of

B phase

Movement test (This test can only be conducted while ISC installed on throttle body.)

● Key-off.

● Touch ISC with hand.

● Key-on.

ISCBN

ISCAN

● Feel if the ISC moves.

Caution

● The movement test can only be conducted while ISC installed

on throttle body.

Detection judge:

1. Resistance value:

A phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 )℃

B phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)

2. Movement test

Test in accordance with the test procedure illustrated above, ISC will vibrate slightly or sounds continuous “da…da…”

Treatment of abnormal phenomena:

● Damaged ISC, or coupler poor contact.

● Check if the wire harness abnormal.

● If ISC is abnormal, it is suggested to replace with a new one and

recheck its movement.

Page 63

3. Fuel Injection System

Fuel pump

Fuel pump working voltage

measurement

Fuel pump resistance

measurement

Function Description:

● Powered by 8-16V DC from ECU. Fuel pump has a four-pin

socket.

● The two pins are power supply and grounding. ECU controls the

movement of fuel pump by controlling the power.

● Low-power-consuming DC motor (12V) drives the vane pump to

keeps the pressure around 294±6kpa(3kg/cm2)in the fuel supply system.

● Fuel pump is placed inside the fuel tank. A fuel filter is installed

on the inlet front to prevent foreign material entering and damaging the fuel pump and injector.

Testing Procedures 1

Fuel pump working voltage check:

● Connect fuel pump coupler (use probe tools), or remove it to

measure working voltage. (direct test)

● Key-on but do not start the engine.

● Use "voltage meter" DC stalls (DCV) to check fuel pump voltage.

● Working voltage check

Voltage meter negative access to the second pin of fuel pump. (green) Voltage meter positive access to the first pin of fuel pump.

(

black/orange)

Caution

● While measuring fuel pump working voltage, if the engine is

not started, ECU will cut off power supply to fuel pump within 3 seconds.

Detection judge 1

1. Working voltage: above 10V

2. Resistance:1.5±0.5Ω

3. Fuel pressure:294±6kPa (3kg/cm

)

Testing Procedures 2

Fuel unit resistance check

● Remove fuel unit coupler.

● Use the "Ohmmeter" Ohm stalls to inspect the resistance of the

fuel unit. (yellow/white & green)

3-24

Page 64

3. Fuel Injection System

Testing Procedures 3

Fuel pressure measurement

● Connect fuel gauge between fuel tank and injector.

Caution

● To measure fuel pressure, fuel hoses, injector side or fuel

pump side, will be removed. After the measurement, please check if any fuel leaks.

Fuel system pressure

measurement

Detection judge 2

1. fuel pressure: 294±6kPa (3kg/cm

)

Treatment of abnormal phenomena:

1. Fuel pump internal circuit damaged, or coupler poor contact.

2. Clogged filter.

Pressure measurement-injector side

If fuel pump is abnormal, it is suggested to replace with a new one.

4. If fuel gauge is abnormal, it is suggested to replace with a new

one.

Pressure measurement -fuel pump side

3-25

Page 65

3. Fuel Injection System

Fuel injector

Function Description:

● Powered by 8-16V DC from ECU. Fuel pump has a two-pin

socket.

● Its major component is a high resistance voltage driven solenoid

valve.

● The two pins are power supply and grounding. Fuel injector is

controlled by ECU to decide the injection timing, and the injector pulse width.

Testing Procedures:

1. Resistance test

Use the "Ohmmeter" Ohm stalls to inspect the injector resistance.

2. Injector injection state check

Remove injector fix bolts, but do not disconnect the coupler. Hold injector and injector cap with hand, no leak should happen. Key-on and start the engine; inspect the injecting state.

Detection judge:

Injector resistance

measurement

1. Resistance between the two pins: 10.5±0.53Ω

2. Injection state

● Good fuel atomizing, with a clear scattering angle → judged as

normal.

● Injection-state resembles water drop, no obvious scattering

angle → judged as abnormal.

Treatment of abnormal phenomena:

1. Resistance NG→ abnormal injector, it is recommended to replace

with a new one.

good injection

2. Abnormal injection state, reasons:

● Clogged injector→ abnormal injector, it is recommended to

replace with a new one.

● Insufficient fuel pressure→ check fuel pressure, it is

recommended to replace with a new one and recheck.

Warning

● Fuel is highly flammable and explosive. Work in a

well-ventilated place, no flame or spark allowed.

● Properly store the fuel injected by injector while conducting

test.

abnormal injection

3-26

Page 66

3. Fuel Injection System

Transistor ignition coil

Function Description:

● Powered by 8-16V DC from ECU. Fuel pump has a two-pin socket.

● The two pins are power supply and grounding. Its major component is a

high conversion ratio transformer.

3-27

● The computer programmed ignition system receives the signals from

the Crankshaft position sensor, Throttle position sensor, O2 Sensor, MAP sensor, Intake air temperature sensor, Engine coolant temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines the appropriate ignition timing, controls the ignition coil and triggers the spark plug This way can not only make the engine achieve the maximum power output, but also help improve fuel consumption rate.

Testing Procedures

Resistance measurement:

● Remove primary circuit coupler from ignition coil.(red/yellow &

black/yellow)

● Use the "Ohmmeter" Ohm stalls to inspect the ignition coil resistance.

Primary circuit resistance

measurement

Detection judge:

● Ignition coil primary circuit: 2.8Ω±15%

● Ignition coil secondary circuit: without cap9.0KΩ±20% with cap14.0KΩ±

20%

Treatment of abnormal phenomena:

1. Ignition coil internal short circuit or open circuit, or coupler poor contact.

2. If ignition coil is abnormal or dose not ignite, it is recommended to replace with a new one.

Crankshaft position / RPM sensor

Function Description

● It does not need power supply, and has a two-pin plug.

Resistance measurement

● Its major component is a reluctance induction coil.

Long tooth

● The spacing of flywheel and sensor should be 0.7 to 1.1 mm.

● Magnetic induction sensor is the use of flywheel on the Gear (23

+1 long tooth) rotary cutting induction coil changes in the magnetic field sensor with the inductive voltage signal for ECU judgment, calculated at the engine speed and crankshaft position, and with a most appropriate time of fuel injection and ignition control.

Testing Procedures

Resistance measurement:

● Remove CPS coupler. (blue/yellow & green/white)

● Use the "Ohmmeter" Ohm stalls to inspect the CPS resistance.

Detection judge

● Resistance: 120Ω±20%

Treatment of abnormal phenomena

1. CPS internal circuit damaged, or coupler poor contact.

2. Check if the wire harness abnormal.

3. If CPS is abnormal, it is suggested to replace with a new one.

Page 67

3. Fuel Injection System

AISV

3-28

AISV working voltage

measurement

Resistance measurement

Function Description:

● AISV has two-pin socket, one is for power supply and the other is

for grounding.

● AISV acts while RPM under 3500.

● While idling, ECU controls AISV movements by controlling its

solenoid valve grounding circuit.

Testing Procedures

Resistance measurement:

● Use the "Ohmmeter" Ohm stalls to inspect the AISV resistance.

Detection judge Resistance: 22 ± 2Ω (20~30℃)

Treatment of abnormal phenomena

● AISV internal short circuit or open circuit, or coupler poor contact.

● Check if the wire harness abnormal.

● If CPS is abnormal, it is suggested to replace with a new one.

Page 68

3. Fuel Injection System

EFi system circuit

3-29

Te st switch

Engine-off relay

L/G

W/B

O/G

G/L

AISV

sensor

MAP

sensor

ISC

IG.

coil

sensor

O2 sensor

TPS

Rollover

sensor

CPS

ACG

Reg / Rec

Battery

Main

switch

i system

check light

Y/GY

G/W

L/Y

W/G

Diagnostic tool coupler

B/Y

L/O

Silicon controlled rectifier

Engine-off relay

Fan

Fuel

pump

Injector

Side stand indicato

Neutral gear indicato

G/BR

R/Y

G/P

LG/

Side stand relay

L/O

Side stand

switch

B/G

PU/R

R/GR

Sili

con controlled rectifier

G/R

P/B

Clutch switch

W W P/W

B/L

L/B

BR/B

Fan relay

G/B

B/O

O/L

Fuel pump relay

B/Y

ater temp. injector

Page 69

3. Fuel Injection System

ECU pin configuration

(on ECU)

ECU Pin Note

NO.

Wire color

code

Note

NO.

Wire color

code

Note

R/Y IGP

rive components Power +

R BAT

CU power +

B/W ROLL

Rollover sensor signal input

P TEST

Test switch signal (A/D)

L/Y CRK-P

rankshaft pos. Sensor+

Y/G MIL

arning Lights O/P

LG/R NLSW

Neutral gear switch signal 22

R/GR TW

ng. Water Temp. Sensor (A/D)

W/BR TH

hrottle position [A/D]

- -

No use

B/R PM

anifold Press. SNSR I/P [A/D]

G/P SG

ensor ground

P/B

HEGO

A/D

Sensor [A/D]

G/BR TA

ntake air temperature sensor A/D)

G LG

CU ground

o use

G/W CRK-M

rankshaft pos. Sensor-

PU FANR

Cooling fan drive

W/G K-LINE

equence transmission signal output

input

G/L TWL

Water temp. drive

O/G FLPR

uel pump relay O/P

- -

No use

O/L SOL

ISV O/P

- -

No use

Y/B VCC

ensor power + (DC 5V)

BR/B ISCAN

tep motor A phase power -

G/B ISCBP

tep motor A phase power +

B/W ISCBN

tep motor B phase power -

L/B ISCAP

tep motor B phase power +

o use

L/G INJ

uel injector O/P

G/R CLSW

Clutch switch signal

P/W

HEGO

Sensor heater ground

G PG1

rive components ground

B/Y IG

gnition coil O/P

G PG

rive components ground

3-30

Page 70

3. Fuel Injection System

Troubleshooting

EFi Circuit inspection

Main switch on

3-31

1. Bulbs blown?

2. Fuse blown?

3. Battery voltage too low?

4. ECU Power line bad contact?

5. Poor contact the main power

switch?

Warning lights extinguish after 2 seconds?

6. ECU fault？

1. Charging line anomaly?

Battery voltage above 12.5V?

2. Battery unable to store

electricity?

3. Short-circuit leakage?

Battery voltage & ECU voltage difference less than 0.2 V?

1. Main switch OFF

2. Remove ECU coupler

Main switch ON

1. Lines anomaly?

Use voltage meter to measure the

power-pin voltage difference

Confirmed ECU and battery supply

voltage difference within 0.2 V

Battery voltage & actuator voltage difference less than 0.2 V?

1. Main switch OFF

1. Lines anomaly?

2. Remove injector, fuel pump, O2 sensor,

rollover sensor, ig. coil couplers

KOK

3. Use voltage meter to measure the voltage

difference

4. Confirmed difference within 0.2 V

ECU 5V voltage - sensor voltage difference less than 0.1 V?

1. Main switch OFF

2. Use probe to insert TPS, engine temperature sensor,

MAP sensor couplers

3. Main switch ON

4. Use voltage meter to measure the sensor voltage

1. Lines anomaly?

2. ECU anomaly?

5. Voltage standard value: 5.0±0.1V

Battery voltage - fuel pump voltage difference less than 0.2 V?

1. Main switch OFF

1. Lines anomaly?

2. Removed fuel pump power coupler

3. Probe connects to two-pin connector of fuel

pump

2. Relay fault?

3. ECU anomaly?

4. Main switch ON

5. Record voltage values in three seconds

6. Confirm voltage difference within 0.2 V

End

Page 71

3. Fuel Injection System

Difficult or unable to start engine

3-32

Difficult or unable to start engine

Warning lights extinguish after 2 seconds?

Warning lights displays Fault Code?

Fuel system anomaly?

Circuit anomaly?

Engine anomaly?

1. Inspection process in accordance with

circuit inspection

1. Use diagnostic tool to view EMS fault

content

2. Troubleshoot in accordance with

procedures on troubleshooting

1. Fuel tank inadequate?

2. Fuel injector pressure less than 294 ±

6kpr?

3. Fuel system leaks?

4. Pressure Regulator anomaly?

5. Fuel pump hose leakage?

6. Fuel pump anomaly?

7. Fuel injector anomaly?

1. Spark plug sparks?

2. Wet spark plug?

3. Spark plug cap loose?

4. Crankshaft position sensor Short

Circuit

5. The high-voltage power wire loose?

6. ECU anomaly?

7. O2 sensor connector corrosion, short

circuit?

1. Without valve clearance?

2. Incorrect valve timing?

3. Valve seized?

4. Cylinder and piston ring worn?

5. Improper adjustment of air adjusting

screw on throttle body?

END

Page 72

3. Fuel Injection System

Idle flameout diagnosis

3-33

Idle Air Control Valve Actuation whether or failure?

If idle flameout cannot be solved after checking the EFi related mechanisms, it is recommended to check traditional engine mechanisms.

Idle flameout

Throttle line is jammed and unable to revert to full closure?

1. Link diagnostic tool to view EFI fault content

2. Troubleshoot in accordance with Troubleshooting procedures

Idle CO value beyond set range (1.5% ~ 2.5%)?

Enough Gasoline?

Throttle body whether coke seriously?

Battery wires loose?

Page 73

3. Fuel Injection System

CO value revised anomaly

In principle, system equipped with O2 Sensor, the CO value needs no adjustment. If CO value deviates from normal range, please check if O2 Sensor or other mechanisms is abnormal.

3-34

Link diagnostic tool to view if Idle CO value is abnormal

Enough gasoline?

Battery wires loose? Enough battery voltage?

Connect with the diagnostic tool, enter data steam screen.

If idle flameout cannot be solved after checking the EFi related mechanisms, it is recommended to check traditional engine mechanisms.

Throttle line is jammed and unable to revert to full closure?

Idle flameout

Start engine and warm to 70 º C ~ 95 º C, check if engine speed, idle control valve and fuel injection timing, O2 sensor is abnormal?

Idle CO value beyond the set range (1.5% ~ 2.5%)?

Idle running for 3 ~ 5 minutes, confirm the engine is running normally then shut off engine, eliminate fault codes

Page 74

3. Fuel Injection System

Intergrated troubleshooting procedure

3-35

Checking,

adjusting item

● Use meter to

measure battery voltage

Fault reasons

Fault status

determination

● Use diagnostic

tool to detect battery voltage

Parts specifications

Battery voltage

Detection items and

procedures

● Battery electricity

● Battery connector

loose

● Harness circuit

opening

● ECU coupler

disconnect

● Is battery

voltage above 10 V?

● Is diagnostic tool

showing voltage above 10 V?

● Diagnostic tool

should show voltage above 10 V.

YES

● Is fault code

shown on diagnostic tool?

● Fault Code is

show again after fault code elimination?

● TPS fault

● ETS fault

● CPS fault

● MAP fault

● O2 sensor fault

● ROS fault

● ECU fault

YES

● Use diagnostic

tool to detect existing fault code

● Eliminating fault

codes, and restart engine

Fault code

inspection

with

diagnostic

tool

Please refer to service manual for detection method and specification of each sensor.

● Does injector

inject?

● Is injecting angle

normal?

● Fuel pressure

enough?

● Removed injector

from intake manifold, but do not remove the hose. (Injector and injector cap tightly by hands, fuel spills should not be the case)

● Start the engine

● Examine whether

injector injects

● Connect pressure

gauge between the tank and injector

Fuel

quantity and

fuel

pressure

● Insufficient fuel in

fuel tank

● Fuel pressure

specifications:

Key-on three seconds but no start engine →more than 250 kPa

Idle speed→ 294±6kPa

● Injector fault

● Fuel pump relay

fault

● Fuel pump fault

● p filter

clogged

● ECU fault

Fuel pum

● Injector

resistance:

11.7±0.6Ω

● Check fuel

pressure

YES

● Remove the

spark plug from the cylinder head with ignition coil connected

● Start the engine

● Check spark

plug sparks

Ignition

situation

● Check if spark

plug ignites?

● Check if sparks

of spark plug strength is normal?

● Spark plug fault

● Rollover sensor fault

● ECU fault

● Ignition coil fault

● Crankshaft position

sensor fault

● Spark plug

specifications: NGK-CR8E

YES

Page 75

3. Fuel Injection System

3-36

Continued from previous page

● Observe O2

sensor voltage changes (Stand motorcycle and keep RPM abound 4500 to 5500

YES

● Whether O2

sensor voltage is maintained within a certain range in a long time

Close-loop

systems

mobility

● O2 sensor fault

● ECU fault

● O2 sensor

voltage specifications: 100 ~ 900 mV

● Use diagnostic

tool to detect the manifold pressure

Engine

vacuum

Is the value shown on diagnostic tool within set value?

● Valve clearance

abnormal

● Intake system leak

● Manifold

pressure Specification: 32~38 kPa

Normal starting

YES

Can not starting or starting

difficulties

Finish In traditional engine overhaul

way to maintenance

Page 76

3. Fuel Injection System

Fuel tank

3-37

Removal

Remove the rear seat. Remove the front seat (bolt x2).

Release the fuel pipe band, fuel pump coupler, EEC tube.

Bolt ×2

Caution

● Make sure the fuel is not too much in the fuel

tank. Pump out the fuel if necessary.

Fuel pipe

Fuel pump coupler

Remove the fuel tank rear bolt.

Bolt ×1

Remove the fuel tank.

Caution

● If the fuel tank is damaged or leaking, replace

with new one.

Installation

Install in the reverse order of removal.

Page 77

3. Fuel Injection System

3-38

Fuel pump

Removal

Remo

ve right and left turning signals and seat. Drain fuel from fuel tank. Remove EEC system and fuel hoses. Remove power wire of fuel pump and fuel unit.

Remove fuel tank. Remove fuel pump. (boltX8) 。

Fuel pump removal

Remove fuel pump power wire. Loosen the clamp.

Remove fuel hose by using fuel hose removal pliers.

ool number: SYM-1768110

bolt×8

Power

Clamp

Screw×

Remo

ve the fuel pump.

Caution

● Check if the gasket worn or damaged.

Replace with new one if it is abnormal.

Check if the rubber hose fastened well. Check if fuel filter contaminated or clogged. Replace with new one if it is too dirty.

Fuel hose removal pliers

Page 78

3. Fuel Injection System

Fuel unit

Fuel Unit

3-39

Remo

ve fuel unit screw. (screw×4)

Remove fuel unit.

Installation Install in the reverse order of removal.

Caution

● Do not bend the fuel unit float arm.

● Do not fill out too much fuel in the tank.

● Apply glue to the screw before

installation.

● Replace the washer with new one.

Air cleaner

Remove the rear and front seat. Remove the air cleaner cover (bolt x4).

Remove the air cleaner element.

Caution

● The air cleaner is paper-base; please

blow it clean with compressed air. Don’t use water or other solvent

● Replace it with new one if the dirt cannot

be removed.

Installation

Install in the reverse order of removal.

bolt×4

ower wire

screw×4

Element

Page 79

3. Fuel Injection System

EFi system diagnosis methods

When wrong signal occurs in motorcycle injection system, causing engine abnormal function or unable starting, the check light at the meter will be lighting to inform drivers to carry out maintenance.

While overhauling, diagnostic tool or meter flashing lighting identification can be applied to carry out fault detection.

After troubleshooting maintenance, the check light will be off, but ECU will record the fault code. Thus, fault code should be eliminated. There are two methods of fault elimination, one is using diagnostic tool and the other is manual elimination.

Using diagnostic tool

Connect diagnostic tool and the test switch and check in accordance with diagnostic tool using method. When EFi system or EFi parts malfunction is detected, replace or correct parts according to information shown on the screen. After maintenance, fault code should be eliminated, or the fault will exist in ECU.

Manual inspection

Use jumping wire (wire or paper clips, etc.) to ground test switch, check light on the meter will be flashing, meaning that the injection system or parts is abnormal. When no diagnostic tool is available, the long and short flashings can be used to tell the fault cause.

Test switch

coupler

Diagnostic tool coupler

Diag

nostic tool coupler and test switch coupler

3-40

Page 80

3. Fuel Injection System

Check light fault codes differentiation

Check light flashing mode

When there is no diagnostic tool for fault detection, wire jump the test switch and identify the

ault by check light flashing and then correct the fault. f

3-41

Fault Code manual elimination procedure:

Fault code can be eliminated manually without using diagnostic tool, procedures as following:

1. Main switch OFF

2. Wire jump the test switch.

3. Full throttle and do not release.

4. Main switch ON

5. Continue step 3 and 4 for five seconds, five seconds later the check light will flash twice quickly. Then the fault

code will be eliminated.

6 . Remove the jumping wire.

1 0.5

Unit: second

1 1 3

1 6

Fault code 22 Fault code 12 Continuous repeated

No wi

re-jump

Test switch

Wire-jump

No wire-jump

full

Throttle

clo

se close

At least 5 seconds

Main

switch

OFF OFF

Lighting

Check light flashes twice

Not lit

Che

Not lit

Page 81

3. Fuel Injection System

3-42

Fault codes and sensors table

No.

Fault

Fault Description

Parts Inspection

1 0120

Throttle position sensor fault TP Sensor and wire

2 0105

Manifold absolute pressure sensor fault MAP sensor and wire

3 0115

Engine temperature sensor fault (water) TW Sensor and wire

4 0110

Intake air temperature sensor fault TA Sensor and wire

5 1630

Roll over sensor fault Roll over sensor and wire

6 0130

O2 sensor fault O2 Sensor and wire

7 0201

ＩＮＪ #1 fault

Injector and wire

8 0351

IG #1 fault Ignition coil and wire

9 0230

Fuel pump fault Fuel pump and wire

10 0135

O2 sensor heater fault O2 Sensor and wire

11 1505

ISC Idle speed control motor fault ISC stepping motor and wire

12 1410

Exhaust 2nd air control solenoid valve fault AISV and wire

13 0335

Crankshaft position sensor fault Crankshaft position sensor and

14 1205

MAP wire fault MAP sensor and wire

15 0603

EEPROM fault EEPROM

16 0480

Fan relay fault Fan relay and wire

Page 82

3. Fuel Injection System

3-43

Fault code and check light flashing lighting identification table

No.

Fault

codes

Fault Description

Check

light

Check light flashing

state

Parts Inspection

Throttle position sensor fault Lighting

long 0，short 6

Throttle position sensor and wire

1 0120

Fault detection procedures Please refer to the "EFI System components description" throttle position sensor

(

TPS) chapte

Manifold Absolute Pressure sensor fault lighting

long 0，short 9

MAP sensor and wire

2 0105

Fault detection procedures Please refer to the "EFI System components description" manifold Absolute

Pressure senso

(

MAP) chapte

Engine temperature sensor fault (water) lighting

long 1，short 2

Engine temperature sensor and wire

3 0115

Fault detection procedures Please refer to the "EFI System components description" engine temperature

senso

(

WPS)chapter.

Intake temperature sensor fault lighting

long 1，short 3

Intake temperature sensor and wire

4 0110

Fault detection procedures Please refer to the "EFI System components description" intake temperature

senso

(

TAS)chapter.

Roll over sensor fault lighting

long 1，short 5

Roll over sensor and wire

5 1630

Fault detection procedures Please refer to the "EFI System components description" Roll over sensor chapter.

O2 sensor fault lighting

long 1，short 7

O2 Sensor and wire

6 0130

Fault detection procedures Please refer to the "EFI System components description" O2 sensor chapter.

ＩＮＪ #1 fault

lighting

long 3，short 3

Injector and wire

7 0201

Fault detection procedures Please refer to the "EFI System components description" fuel injector chapter.

IG #1 fault lighting

long 3，short 7

Ignition coil and wire

8 0351

Fault detection procedures to adhere to the traditional way

Fuel pump fault lighting

long 4，short 1

Fuel pump and wire

9 0230

Fault detection procedures Please refer to the "EFI System components description" fuel pump chapter.

O2 sensor heater fault lighting

long 4，short 5

O2 Sensor and wire

10 0135

Fault detection procedures Please refer to the "EFI System components description" O2 Sensor chapter.

ISC motor fault lighting

long 4，short 9

Step motor and wire

11 1505

Fault detection procedures Please refer to the "EFI System components description" idle speed control valve

(

ISC)chapter.

Exhaust 2nd air solenoid valve fault lighting

long 5，short 4

2nd air control valve and wire

12 1410

Fault detection procedures Please refer to the "EFI System components description" 2

air solenoid valve

cha

pter

Crankshaft position sensor fault lighting

long 6，short 6

Crankshaft position sensor and wire

13 0335

Fault detection procedures Please refer to the "EFI System components description" Crankshaft position

senso

chapter.

MAP sensor wire fault lighting

long 6，short 8

MAP sensor wire

14 1205

Fault detection procedures Please refer to the "EFI System components description" MAP sensor chapter.

EEPROM fault Not lit

long –，short –

EEPROM

15 0603

This fault Please direct replacement ECU

Cooling fan relay fault lighting

long 4，short 3

Cooling fan relay and wire

16 0480

Fault detection procedures Please refer to the "EFI System components description" cooling fan relay chapter.

Page 83

3. Fuel Injection System

3-44

Troubleshooting table

Comprehensive testing program Parts

Test items

Abnormal phenomena

Power

voltage

Fuel

press.

Ignition

state

Engine

vacuum

Injection

state

closed-

loop control system

Fault Code

Detection

ECU

Throttle position

sensor

Engine

temp.

sensor

Can’t start

    

 

Start state

Difficult to

start

 



 

Without

idle

  



 

Idle not smooth

   

ˇ

RPM NG

 

Idle

state

CO NG



   

Not smooth

   

Acceler-

ation

Inability

and slow

   

Idle

flameout



Flameo-

Acceleratio

n flameout

 

Related parts

Roll over

sensor

Fuel pump

Ignition

coil

Inlet pipe Injector O2 sensor

Power

relay

Fuel

pressure

adjustment

valve

Spark plug

Cylinder

head

Fuel pump

Secondary

air injection solenoid

valve

Main

switch

Fuel

pump

relay

MAP

sensor

Fuel

pressure

adjustment

valve

Battery

Fuel filter

Note: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation.

2. Spare parts, according to the "EFI System components description" implementation.

Page 84

3. Fuel Injection System

3-45

Comprehensive maintenance list

Maintenance Project

Testing Procedures Test items Determine benchmarks Fault reasons

Power and

voltage

● Use meter direct

measurement battery voltage

● Use diagnosis tool detection

of battery voltage

● Battery voltage ● Battery voltage = 10V Above ● Battery electricity

● Battery connector loose

● Harness circuit opening

 ECU coupler not

connected properly

Fuel

pressure

● Use fuel pressure gauge,

connected in series between the injector and the Pressure Regulating Valve

● Main switch ON, but not

start engine

● Check fuel pressure

● Start engine (idle)

● Check change of the fuel

pressure

● throttle several rotation

● check to the change of fuel

pressure again

● Open the main

switch, but not to start the engine of pressure

● Pressure in idle

● Rotating throttle,

situation of pressure changes

● Open main switch, but not

srart:

pressure = 250kPa

(Stable

value)

● Idle state:

pressure = 294±6kPa (Beating situation from top to bottom)

● rotation throttle moment:

pressure = 294±6kPa (Slightly beating)

● Fuel not enough

● Security switch not disarm

● Ruel pump relay fault

● Ruel pump fault

● Injector fault

1. ECU fault

Ignition state

● The spark plug removed from

the cylinder head, but the power lines still ring

● Start engines or use for the

diagnosis tool of output View spark plug ignition conditions

● Spark plug

specifications

● Whether the spark

plug ignition

● Spark plug sparks

whether it is normal strength

● Specifications: NGK-CR8H

● Ignition conditions:

With traditional engines found ways

● Spark plug fault

● Roll over sensor fault

● ECU No. 5 pin fault

● Ignition coil fault

 Crankshaft position

sensor fault

Engine

vacuum

● Diagnosis tool to detect the

use of

● Manifold pressure of

diagnosis tool

● Manifold pressure

=32~38kPa

● Valve clearance abnormal  Intake system leak

Injection

state

● The injector removed from

the throttle body, but not dismantle pipeline

● Main switch ON, but not

start engine

● Investigation the injector it’s

leaking fuel?

● Once again start engines or

use for the diagnosis tool of output function

● Check injector fuel injection

and the injection situation

● Open the main

switch, but did not start engine the injection situation

● Injector state when

start

● Not started, injector not

leaking fuel

● In started, the injection state

must show fan shape

● Security unit is configured

not disarm

● Fuel pump relay fault

● Fuel pump fault

● Injector fault

 ECU fault

Closed -

loop control

system

● Use of diagnostic tool

observation O2 Sensor voltage changes

● Stable condition,

sensor voltage variation (Idle continued 5 minutes later to measurement)

● Idle stable condition: O2

Sensor voltage = 50 ~ 200mV (Show from top to bottom beating phenomenon)

● O2 Sensor fault  ECU fault

Fault Code

Detection

● Use of the diagnosis tool

existing fault-detection code or historical Fault Code

● Elimination of the

implementation of fault codes, check can be eliminated

● Once again start engine

● Check fault is it happen

again

● Diagnosis tool of the

fault code is it can be eliminated

● Start again, the fault

is it will happen again

● Without any residual Fault

Code

● If residual Fault Code,

according to the "Fault Code Maintenance Form" implementation of troubleshooting

● throttle position sensor fault

● Engine temperature sensor

fault

● Intake temperature sensor

fault

● Manifold pressure sensor

fault

● O2 Sensor fault

● Crankshaft position sensor

fault

● ECU fault  Roll over sensor fault

Notes:

1. Fuel pressure gauge connected between the fuel tank and injector, open the main switch to repeatedly shut down, fuel system makes pressure stability.

2. Injector and injector cap tightly by hands, fuel spills should not be the case.

Page 85

4. Lubrication System / Clutch / Transmission

Mechanism Diagram ........................... 4-1

Precautions in Operation.................... 4-2

Troubleshooting.................................. 4-3

Engine Oil ............................................ 4-4

Engine Oil Strainer Cleaning.............. 4-4

Clutch Disassembly.............................4-5

Clutch Inspection.................................4-6

Clutch Installation................................4-7

Oil Pump...............................................4-9

Gear Shift Linkage Mechanism...........4-11

Mechanism diagram

0.8~1.2kgf-m

0.8~1.2

kgf-m

8.5~10.5kgf-m

1.0~1.4

kgf-m

0.8~1.2kgf-m

8.5~10.5kgf-m

0.8~1.2kgf-m

0.8~1.2

kgf-m

0.1~0.3kgf-m

4-1

Page 86

4. Lubrication System / Clutch / Transmission

Precautions in Operation

General information

 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 viscosity

Engine oil quantity：

Full disassembly：1700 c.c. Regular maintenance：1500 c.c. Recommended engine oil viscosity:

SAE 10W-30 (The Bramax series oil is recommended)

Measurement: mm

Item Standard Service Limit

Clearance between inner rotor and outer rotor

0.15 0.20

Clearance between outer rotor and the pump body

0.15~0.20 0.25

Oil pump

Rotor to pump cover clearance

0.04~0.09 0.12

Lever free play 10~20 Spring free length 44.65~44.80 41.70 Friction disk thickness 3.00 2.50

Clutch

Clutch plate warp - 0.20

Torque value

4-2

Oil pump cover bolts: 0.8~1.2kgf-m Oil pump screw: 0.7~1.1kgf-m Primary drive gear nut 8.5~10.5kgf-m

R. Crank case bolts: 0.8~1.2kgf-m Clutch fix nut 8.5~10.5kgf-m Clutch lifter plate bolt 1.0~1.4kgf-m

Special tools

Page 87

4. Lubrication System / Clutch / Transmission

4-3

Troubleshooting

Insufficient engine oil

 Oil leaks  Valve guides or seals worn out  Worn piston rings

Insufficient oil pressure

 Insufficient oil amount  Clogged oil strainer, oil route, oil tubes  Abnormal oil pump

Engine oil dirty

 Engine oil is not exchanged periodically.  Cylinder head gasket damaged  Worn piston rings

Clutch slips when accelerating

 Insufficient clutch free play  Worn clutch disks  Weak clutch springs

Unable to disengage the clutch; or the bike trembles while clutch disengaged

 Excessive clutch free play settings  Warped clutch plates

Excessive clutch lever pulling force

 insufficiently lubricated clutch cable  Damaged clutch cable  Clutch lifter mechanism damaged

Hard to shift gear

 Excessive clutch free play settings  Twisted or bent shifting forks

Gearshift pedal won’t return

 Broken or weak return spring  Bent shift spindle

Gear jumps out

 Broken stopper arm spring  Bent shift spindle

Page 88

4. Lubrication System / Clutch / Transmission

Engine oil

4-4

Turn off the engine; park the motorcycle on level surface with main stand. Check oil level 3-5minutes later. Check oil quantity from window, if oil level is near lower limit, fill in the recommended oil to upper limit.

Exchange engine oil

Caution

 Drain oil when the engine is fully warmed

up, so the oil can be drained completely.

Upper limit

Lower limit

Place an oil basin under the bike, and remove oil drain bolt. Check if the washer damaged, replace when necessary. Fill in new engine oil after installing oil drain bolt.

Torque value：3.5~4.5kgf-m

Engine oil strainer cleaning

Remove engine oil strainer cap. Remove engine oil strainer and spring. Clean oil strainer with compressed air. Check if O-ring can be re-used. If it’s damaged, please replace with a new one Install engine oil strainer and spring. Install engine oil strainer cap.

Torque value：1.3~1.7kgf-m

Fill in engine oil (oil viscosity SAE 10W-30) Recommended using Bramax series oil. Install dipstick, run the engine for several minutes. Then turn off engine, and check oil level again. Check if engine oil leaks.

Oil drain boltEngine oil strainer cap

Engine oil strainer

Page 89

4. Lubrication System / Clutch / Transmission

Clutch disassembly

4-5

Drain all engine oil. Remove clutch cable.

Remove right crankcase cover(bolt×12)。

Remove clutch lifter(boltX6)。 Remove clutch spring.

Remove clutch lock nut. Remove clutch center, friction disks, clutch plates, and pressing plate.

Clutch lock nut

bolt×6

bolt×12

Clutch cable

Page 90

4. Lubrication System / Clutch / Transmission

4-6

Remove washer, clutch outer, and center guide.

Washer

Disassemble the clutch center, clutch plates, clutch friction disks, and pressing plate.

Clutch inspection

Clutch spring inspection

Measure the free length of the 6 clutch springs.

Service limit：41.70mm

Clutch friction disk inspection

Measure the thickness of each clutch friction disk. If it’s under service limit or damaged, please replace it with a new one.

Service limit：2.50mm

Clutch center

Pressing plate

Friction disk

Clutch plate

Page 91

4. Lubrication System / Clutch / Transmission

4-7

Clutch plate inspection

Use a feeler gauge to measure the warp of each clutch plate.

Service limit：0.2mm

Clutch outer inspection

Check if the clutch outer is cracked or damaged.

washer

Clutch installation

Install clutch washer, center guide.

Install clutch outer and washer.

Washer

Center guide

Page 92

4. Lubrication System / Clutch / Transmission

4-8

Install clutch center, clutch plate, friction disk,

and pressing plate.

Clutch lock nut

Tighten clutch lock nut.

Install clutch spring, clutch lifter; tighten 6 bolts.

Install right crankcase cover. (bolt×12)。 Install clutch cable.

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.

Clutch lifter

10~20mm

Adjusting nut

Decrease free play

Lock nut

Increase free play

Page 93

4. Lubrication System / Clutch / Transmission

4-9

Oil pump

Drain all engine oil. Remove clutch cable. Remove right crankcase cover. Remove clutch assembly. Remove initial driven gear lock nut. Remove initial driven gear.

Remove oil pump cover. (boltX2)。

Remove oil pump drive gear fix circlip. Remove oil pump gear and chain.

Remove oil pump. (holding screwX2) 。

Caution

 It is recommended to remove the oil

pump holding screw with impact screw driver.

Lock nut

bolt×2

Initial driven gear

Circlip

Holding screw

Page 94

4. Lubrication System / Clutch / Transmission

4-10

Oil pump disassembly

Remove oil pump cover. (screw×1) Disassemble oil pump.

Oil pump inspection

Check the clearance between oil pump body and outer rotor.

Service limit: under 0.25 mm

Check clearance between inner and outer rotors.

Service limit: under 0.20mm

Check the unevenness between rotor face and pump body.

Service limit: under 0.12 mm

Page 95

4. Lubrication System / Clutch / Transmission

Gear shift linkage mechanism

Gear shift linkage disassembly

Remove shifting lever. (bolt×1)

4-11

bolt×1

Remove cultch cable. Remove right crankcase cover. Remove cultch assembly.

Take out the gear shifting spindle.

Remove the shifting drum stopper arm and the return spring. (bolt×1) Remove shifting drum retainer. (boltx2)

Gear shifting spindle

Shifting drum stopper

Retainer

Page 96

4. Lubrication System / Clutch / Transmission

Remove shifting cam. (bolt×1) Remove alignment pin.

4-12

Shifting cam

Inspection

Check if shifting spindle and the fork assembly damaged or worn.

Check if shifting drum stopper arm and the return spring damaged or worn.

Check if gear shifting cam damaged or worn.

Page 97

4. Lubrication System / Clutch / Transmission

Gear shift linkage mechanism installation

Install alignment pin. Install the gear shifting cam by matching the alignment pin.

Tighten gear shifting cam lock bolt. (bolt×1)。

Torque value：0.8~1.2kgf-m

4-13

Install shifting drum stopper and the return spring. (bolt X 1) Install shifting drum retainer. (boltx2)

Torque value：0.8~1.2kgf-m

Caution

 Check if the stopper is working smoothly

after assembly.

Install the gear shifting spindle and the fork assembly. Then install the shifting pedal (bolt X1)

Caution

 The return spring on the shifting spindle

should contact the salient on the crankcase.

Install cultch assembly. Install alignment pin and another new right crankcase gasket, then the right crankcase cover. Connect clutch cable, and adjust the clutch free play. Fill in specified engine oil.

Gear shifting cam

Shifting drum stopper

Retainer

Page 98

4. Lubrication System / Clutch / Transmission

4-14

NOTE:

Page 99

5. AC Generator / Starting Clutch

Mechanism Diagram ···················5-1

Precautions in Operation ···········5-2

ACG Stator Disassambly············ 5-3

ACG Flywheel/ Starter Clutch ····5-5

Mechanism diagram

0.8~1.2

f-m

2.8~3.2kgf-m

8.5~10.5kgf-m

0.3~0.4

kgf-m

0.7~1.1

f-m

0.3~0.5

kgf-m

0.15~0.25

kgf-m

0.8~1.2

kgf-m

5-1

Page 100

5. AC Generator / Starting Clutch

5-2

Precautions in operation

General information

 For engine troubleshooting and inspection, please refer to the first chapter.  Starting Motor repairing process and cautions please refer to Chapter 14

Specifications measurement：mm

Item Standard Service limit

Start Driven Gear exterior diameter

42.192~42.208 42.100

Starting Clutch interior diameter

25.026~25.045 25.050

Torque value

Flywheel nut 8.5~10.5kgf-m Left crankcase cover bolt 0.8~1.2kgf-m Starting clutch inner-hexagon bolt 2.8~3.2kgf-m with screw adhesive

Special tool

Flywheel puller SYM-3111000-HMA

Sym Wolf SB 250 Ni Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual