Sym Joyride 125, Joyride 200i EVO, X'PRO RV125, 200 EFi, Joyride 125 EVO Service Manual
...
Foreword
How to Use This Manual
Contents
Mechanism Illustration
Joyride 125 / 200i EVO
X’PRO RV125 / 200 EFi
SERVICE MANUAL
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Contents
Foreword
This service manual contains the technical data of each component inspection
and repair for the Sanyang JOYRIDE 125/200i EVO, X’PRO RV 125/200 EFi
motorcycle. The manual is shown with illustrations and focused on “Service
Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that
provides technician with service guidelines.
If the style and construction of the motorcycle, JOYRIDE 125/200i EVO, X’PRO
RV 125/200 EFi, are different from that of the photos, pictures shown in this
manual, the actual vehicle shall prevail. Specifications are subject to change
without notice.
Service Department
Sanyang Industry Co., LTD.
Homepage
Contents
How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for Sanyang JOYRIDE 125/200i EVO, X’PRO RV
125/200 EFi motorcycles. In addition, please refer to the manual contents in
detailed for the model you serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information.
Th third to the thirteenth chapter covers the engine and driving systems.
The fourteenth to the seventeenth is contained the parts set of assembly body.
The eighteenth chapter is electrical equipment.
The nineteenth chapter is special tool.
The twentieth chapter is wiring diagram
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and
“Mechanism Illustration” in the PDF version, and can be access to these items
by clicking on the buttons.
If user wants to look for the content of each chapter, selecting the words of
each chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, on the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back
the homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the
content. In addition, there is a “To this Chapter Contents” button at the second
page of each content so that clicking the button can back to the contents of this
chapter.
Homepage
Contents
Contents
Page Content Index
1-1 ~ 1-20 General Information
1
2-1 ~ 2-12 Maintenance Information
3-1 ~ 3-8 Lubrication System
4-1 ~ 4-12 Fuel System-Carburetor
5-1 ~ 5-56 Fuel Injection System
6-1 ~ 6-14 Engine Removal
7-1 ~ 7-14 Cylinder Head / Valve
8-1 ~ 8-8 Cylinder / Piston
9-1 ~ 9-14 V-Belt Drive System
10-1 ~ 10-8 Final Drive Mechanism
11-1 ~ 11-8 AC Generator / Starting Clutch
2
3
4
5
6
7
8
9
10
11
12-1 ~ 12-8 Crankshaft / Crankcase
13-1 ~ 13-12 Cooling System
14-1 ~ 14-10 Body Cover
15-1 ~ 15-10 Brake System
16-1 ~ 16-12 Steering / Front Wheel / Front Cushion
17-1 ~ 17-6 Muffler / Rear Wheel / Rear Cushion
18-1 ~ 18-22 Electrical System
19-1 ~ 19-12 Special Tools
20-1 ~ 20-4 Wiring Diagram
12
13
14
15
16
17
18
19
20
Home page
Contents
Mechanism Illustration
Light switch / start switch /
engine stop (hazard) switch
Front winker
Fuel tank /
Dimmer switch / winker switch /
horn switch / seat open (passing)
switch
fuel pump
ECU /
throttle body
Coolant filler
cap
Ignition / Seat open
switch
Front brake
lever
Rear brake
lever
Side stand
Fuel tank
cap
Taillight /
rear winker
Luggage box
Air cleaner
Main stand
Main switch
Reserved tank
cap
Battery
Muffler
Homepage
Contents
1. GENERAL INFORMATION
Symbols and Marks .............................. 1-1
General Safety....................................... 1-2
Service Precautions.............................. 1-3
Specifications ........................................ 1-5
Cables and Harness Routing..............1-11
Troubleshooting-Carburetor model ...1-12
Troubleshooting-EFi model ................1-16
Lubrication Points ...............................1-20
Torque Values ....................................... 1-9
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information is procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Warning
Caution
Engine oil
Grease King Mate G-3 is recommended.
Means that serious injury or even death may result if procedures are not
followed.
Means that equipment damages may result if procedures are not
followed.
Limits to use SAE 20 JASO FC class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: MAX-2 serial oils)
1
Gear oil
Locking sealant
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.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
OIL # 140)
Apply sealant, medium strength sealant should be used unless
otherwise specified.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
1-1
To this chapter contents
1. GENERAL INFORMATION
General Safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if
you have to run your engine in a closed area, be
sure to use an extractor.
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no
flame or spark should be allowed in the work
place or where gasoline is being stored.
Caution
Gasoline is highly flammable, and may
explode under some conditions, keep it away
from children.
Battery
Caution
‧ Battery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
‧ Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be
careful do not be spray on your eyes or
skin. If you get battery acid on your skin,
flush it off immediately with water. If you get
battery acid in your eyes, flush it off
immediately with water and then go to
hospital to see an ophthalmologist.
‧ If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such
as castor oil or vegetable oil and then go to
see a doctor.
‧ Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verified.
We recommend that you wash your hands
with soap and water right after contacting.
Keep the used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust
system can become extremely hot after
engine running. They remain very hot even
after the engine has been stopped for some
time. When performing service work on these
parts, wear insulated gloves and wait until
cooling off.
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.
1-2
1. GENERAL INFORMATION
Service Precautions
To this chapter contents
z Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
z Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools
may result in parts damaged.
z When servicing this motorcycle, use only
metric tools. Metric bolts, nuts, and screws
are not interchangeable with the English
system, using wrong tools and fasteners may
damage this vehicle.
z Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on
the part's surface may fall into the engine,
chassis, or brake system to cause a damage.
z Wash and clean parts with high ignition point
solvent, and blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most cleaning agents have an
adverse effect on them.
z Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
z Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
z 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.
z Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
z Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
z Components not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.
Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.
1-3
To this chapter contents
1. GENERAL INFORMATION
z The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed.
In case of confusion, Insert the bolt into the
hole to compare its length with other bolts, if
its length out side the hole is the same with
other bolts, it is a correct bolt. Bolts for the
same assembly should have the same length.
z 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.
z When oil seal is installed, fill the groove with
grease, install the oil seal with the name of
the manufacturer facing outside, check the
shaft on which the oil seal is to be installed for
smoothness and for burrs that may damage
the oil seal.
Manufacturer's
name
z Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
z 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
Connection
z Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
z The tool should be pressed against two (inner
Boots
and outer) bearing races when removing a
ball bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Both of these examples can result in bearing damage.
z Lubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.
1-4
1. GENERAL INFORMATION
g
Specifications
Maker SANYANG MODEL LF12W-6/F
To this chapter contents
Overall Length 2100 mm Front Telescopic Fork
Overall Width 760 mm
Overall Height 1390 mm Front 110 / 90-13 56P
Wheel Base 1440 mm
Front 63 kg Front
ht
Curb
Passengers/
WEIGHT DIMENSION
Total Weight
Position and
arrangement
Rear 93 kg
Wei
Total 156 kg
Two /170 kg Max. Speed >100 km/hr
Weight
Front 97 kg Climb Ability 28°
Rear 229 kg Primary Reduction Belt
Total 326 kg
Type Gasoline Clutch
Horizontal, below
center, CYL incline 80°
Suspension
System
Tire
Specifications
Brake System
Secondary
Reduction
PERFORMANCE
Transmission C.V.T.
Rear Unit Swing
Rear 130 / 70-12 64L
Disk (ψ273mm)
Rear
Disk (ψ200mm)
Gear
3-piece centrifugal, dry
type
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 57 mm Muffler Expansion & Pulse Type
Stroke 48.8 mm
Cylinder
ENGINE
Number/Arran
gement
Displacement 124.5 cc Co
Compression Ratio 10.5 : 1 HC
Max. HP 13 ps / 8500 rpm
Max. Torque 1.1 kg-m / 6500 pm E.E.C. -
Ignition C.D.I P.C.V. -
Starting System Kick & Electrical Starter Catalytic Converter Equipped
Single Cylinder Lubrication System
Exhaust Pipe Position
and Direction
Exhaust
Concentratio
n
NOx
Right Side & Backward
Forced Circulation &
Splashing
〈 2.0 g/km
〈 0.8 g/km
〈 0.15 g/km
1-5
g
To this chapter contents
1. GENERAL INFORMATION
Specifications
Maker SANYANG MODEL LF12W2-7
Overall Length 2100 mm Front TELESCOPIC FORK
Overall Width 760 mm
Overall Height 1390 mm Front 110 / 90-13 56P
Wheel Base 1440 mm
Front 63 kg Front
ht
Curb
WEIGHT DIMENSION
Total Weight
arrangement
Rear 93 kg
Wei
Total 156 kg
Passengers/
Weight
Front 97 kg Climb Ability 28°
Rear 229 kg Primary Reduction BELT
Total 326 kg
Type Gasoline Clutch
Position and
Two /170 kg Max. Speed >100 km/hr
Horizontal, below
center, CYL incline 80°
Suspension
System
Tire
Specifications
Brake System
Secondary
Reduction
PERFORMANCE
Transmission C.V.T.
Rear Unit SWING
Rear 130 / 70-12 64L
DlSK (ψ273mm)
Rear
DlSK (ψ200mm)
GEAR
3-piece centrifugal, dry
type
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 57 mm Muffler Expansion & Pulse Type
Stroke 48.8 mm
Cylinder
ENGINE
Number/Arran
gement
Displacement 124.5 cc Co
Compression Ratio 10.5 : 1 HC
Max. HP 13 ps / 8500 rpm
Max. Torque 1.1 kg-m / 6500 pm E.E.C. -
Ignition Full Transistor Ignition P.C.V. Equipped
Starting System Electrical Starter Catalytic converter Equipped
Single Cylinder Lubrication System
Exhaust Pipe Position
and Direction
Exhaust
Concentratio
n
NOx
Right Side & Backward
Forced pressure and wet
sump
〈 2.0 g/km
〈 0.8 g/km
〈 0.15 g/km
1-6
1. GENERAL INFORMATION
Specifications
Maker SANYANG MODEL LF18W-A/W3-H/W5-C
To this chapter contents
Overall Length 2100 mm Front TELESCOPIC FORK
Overall Width 760 mm
Overall Height 1390 mm Front 110 / 90-13 56P
Wheel Base 1440 mm
Front 63 kg Front
Net
Passengers/
WEIGHT DIMENSION
Total Weight
Position and
arrangement
Rear 93 kg
Weight
Total 156 kg
Two /170 kg Max. Speed >109 km/hr
Weight
Front 97 kg Climb Ability 28°
Rear 229 kg Primary Reduction BELT
Total 326 kg
Type Gasoline Clutch
Horizontal, below center,
CYL incline 80°
Suspension
System
Tire
Specifications
Brake System
Secondary
Reduction
PERFORMANCE
Transmission C.V.T.
Rear UNlT SWING
Rear 130 / 70-12 64L
DlSK (ψ273mm)
Rear
DlSK (ψ200mm)
GEAR
3-piece centrifugal, dry
type
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 61 mm Muffler Expansion & Pulse Type
Stroke 58.6 mm
Cylinder
ENGINE
Number/Arran
gement
Displacement 171.2 cc Co
Compression Ratio 10 : 1 HC
Max. HP 13 / 8000 ps/rpm
Max. Torque 1.2 / 6000 kg-m/rpm E.E.C. -
Ignition C.D.I. P.C.V. Equipped
Starting System Kick & Electrical Starter Catalytic converter Equipped
Single Cylinder Lubrication System
Exhaust Pipe Position
and Direction
Exhaust
Concentratio
n
NOx
Right Side & Backward
Forced pressure and wet
sump
〈 12.0 g/km
〈 1.0 g/km
-
1-7
g
To this chapter contents
1. GENERAL INFORMATION
Specifications
Maker SANYANG MODEL LF18W-6/W1-9/W2-7/W4-8
Overall Length 2100 mm Front TELESCOPIC FORK
Overall Width 760 mm
Overall Height 1390 mm Front 110 / 90-13 56P
Wheel Base 1440 mm
Front 63 kg Front
ht
Curb
Passengers/
WEIGHT DIMENSION
Total Weight
arrangement
Rear 93 kg
Wei
Total 156 kg
Two /170 kg Max. Speed >109 km/hr
Weight
Front 97 kg Climb Ability 28°
Rear 229 kg
Total 326 kg
Type Gasoline Clutch 3-piece centrifugal, dry type
Position and
Horizontal, below
center, CYL incline 80°
Suspension
System
Tire
Specifications
Brake System
Primary
Reduction
Secondary
Reduction
PERFORMANCE
Transmission C.V.T.
Rear UNlT SWING
Rear 130 / 70-12 64L
DlSK (ψ273mm)
Rear
DlSK (ψ200mm)
BELT
GEAR
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 61 mm Muffler Expansion & Pulse Type
Stroke 58.6 mm
Cylinder
Number/Arran
ENGINE
Compression Ratio 10 : 1 HC
Starting System Electrical Starter Catalytic converter Equipped
gement
Displacement 171.2 cc Co
Max. HP 15 / 8000 ps/rpm
Max. Torque 1.35 / 6500 kg-m/rpm E.E.C. -
Ignition Full Transistor Ignition P.C.V. - / Equipped
Single Cylinder Lubrication System
Exhaust Pipe Position
and Direction
Exhaust
Concentratio
n
NOx
Right Side & Backward
Forced pressure and wet
sump
〈 2.0 g/km
〈 0.3 g/km
〈 0.15 g/km
1-8
1. GENERAL INFORMATION
Torque Values
Item Q’ty
To this chapter contents
Thread Dia.
(mm)
Torque Value
Remarks
(Kgf-m)
Cylinder head bolt
Valve clearance adjust nut
Spark plug
L. Crankcase cover bolts
Crankcase bolts
Oil drain bolt
Oil strainer cap
Gear oil drain bolt
Gear oil inspection bolt
Transmission cover bolt
Flywheel bolt
Clutch driving plate bolt
Driving disc nut
Clutch outer cover nut
Transmission cover bolts
Stopper nut for engine hanger
bracket
Nut for engine hanger bracket
Bolt for engine hanger bracket
Engine mounting bolt
Front wheel shaft nut
Rear wheel shaft nut
Bolt for rear shock absorber (upper)
Bolt for rear shock absorber (under)
Bolt for steering rod
Front shock absorber
Brake arm bolts
Brake hose bolts
Bolt for brake caliper
Bolts for the lining guide pin
Brake disk bolts
Mounting screw for speedometer
cable
Muffler bolts
Mounting bolts for exhaust pipe
connection
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
4 8 2.0-2.4
4 5 0.7-1.1
1 10 1.0-1.4
7 6 1.1-1.5
7 6 0.8-1.2
1 8 1.1-1.5
1 30 1.3-1.7
1 6 1.0-1.4
1 6 1.0-1.4
7 6 1.0-1.4
1 14 5.0-6.0
1 28 5.0-6.0
1 12 5.0-6.0
1 10 3.5-4.5
7 6 1.0-1.4
1 8 1.8-2.2
1 10 4.0-5.0
1 10 4.0-5.0
1 10 3.5-4.5
1 12 5.0-7.0
1 14 11.0-13.0
2 10 3.5-4.5
2 8 2.4-3.0
1 10 4.0-5.0
4 8 2.4-3.0
2 6 0.8-1.2
4 10 3.3-3.7
4 10 3.0-3.5
4 6 1.6-2.0
7 10 4.0-4.5
1 5 0.15-0.3
4 8 3.2-3.8
2 7 1.0-1.2
Apply oil to thread
1-9
To this chapter contents
1. GENERAL INFORMATION
Standard Torque Values for Reference
Type Torque value kgf-m
5 mm Bolt, Nut 0.45 - 0.6
6 mm Bolt, Nut 0.8 - 1.2
8 mm Bolt, Nut 1.8 - 2.5
10 mm Bolt, Nut 3.0 - 4.0
12 mm Bolt, Nut 5.0 - 6.0
5 mm Screw 0.35 - 0.5
6 mm Screw & 6mm bolt with 8mm head 0.7 - 1.1
6 mm Flange bolt, nut 1.0 - 1.4
8 mm Flange bolt, nut 2.4 - 3.0
10 mm Flange bolt, nut 3.5 - 4.5
1-10
1. GENERAL INFORMATION
Cables and Harness Routing
Note the following when routing cables
and wire harnesses:
• A loose wire, cable or harness may cause
safety hazard. After clamping, check each
wire to make sure it is secured.
• Do not squeeze wires against the weld or its
clamp.
• 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.
• 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.
• Route wire harnesses to avoid sharp edges
or corners.
• Avoid the projected ends of bolts and screws.
• Keep wire harnesses far away from the
exhaust pipes and other hot parts.
• Be sure grommets are seated in their groves
properly.
• After clamping, check each harness to be
certain that it is not interfered with any
moving or sliding parts.
• After routing, check that the wire harnesses
are not twisted or kink.
• Wire harnesses routed along the handlebar
should not be pulled too tight or have
excessive slack, be rubbed against or
interfere with adjacent or surrounding parts in
all steering positions.
• Thoroughly clean the surface where tape is to
be applied.
• Wrap electrical tape around the damaged
parts or replace them.
To this chapter contents
○：correct
╳：wrong
1-11
r
p
To this chapter contents
1. GENERAL INFORMATION
Troubleshooting-Carburetor model
A. Engine hard to start or can not be started
Check and adjustment Failure condition Possible causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carbureto
.
Fuel supplied to
carburetor sufficient.
Remove spark plug, install it
into spark plug cap, and
perform a spark test against
engine ground.
Check if sparks Weak sparks, no
Perform cylinder compression
pressure test.
No fuel is supplied to
carburetor.
s
ark at all.
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum
hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
7. Malfunction of main switch
Cylinder compression
pressure normal.
Re-start by following the
starting procedures.
No ignition
Remove the spark plug again
and check it.
Dry spark plug Wet spark plug
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then
blow the hose with air.
Low compression
pressure or no
pressure.
There are some signs of
ignition, but engine can
not be started.
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
Blowing in normal Blowing clogged
1. Malfunction of automatic by- starter
1-12
To this chapter contents
1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
Try gradual acceleration and
check engine speed.
Check ignition timing
(Using ignition lamp)
Engine speed can be
increased.
Engine speed can not be
increased.
1. Air cleaner clogged
1. Poor fuel supply
2. Lines in fuel tank evaporation system
clogged
3. Exhaust pipe clogged
4. Fuel level too low in carburetor
5. Fuel nozzle clogged in carburetor.
Ignition timing correct Incorrect ignition timing
Check cylinder compression
pressure (using compression
pressure gauge)
Compression pressure
correct
Check if carburetor jet is
clogged
No clogged Clogged
Remove spark plug
No foul or discoloration Fouled and discoloration
No compression pressure
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
1. Remove foreign
1. Remove dirt
2. Incorrect spark plug heat range
Check if engine over
Normal Engine overheat
Continually drive in
acceleration or high speed.
No knock Knock
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling system
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced
1-13
To this chapter contents
1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment Fault condition Probable causes
Check ignition timing
(Using ignition lamp)
Adjust the air screw of
carburetor
Normal Abnormal
Good Poor
Air sucked through
carburetor gasket
No air sucked Air sucked
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground.
Good spark Poor
D. Engine runs sluggish (High speed)
1. Incorrect ignition timing (malfunction
of CDI or AC alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
Check and adjustment
Check ignition timing
Check for fuel supplying
system in automatic fuel cup
Normal Abnormal
Good Poor
Check if carburetor clogged
No clogged Clogged
1-14
Fault condition Probable causes
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
1. Cleaning
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1. GENERAL INFORMATION
E. Clutch, Driving And Driving Pulley
FAULT CONDITIONS
PROBABLE CAUSES
Engine can be started but
motorcycle can not be moved.
1. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damaged
Engine running and misfire as
motorcycle initial forward moving or
jumping suddenly (rear wheel
rotating as engine in running)
1. Clutch ling spring broken
2. Clutch outer cover stickled with clutch balance
weights
3. Connection parts in clutch and shaft worn out or
burned
1. Driving belt worn out or deformation
Poor initial driving
(Poor climbing performance)
2. Balance weight roller worn out
3. Driving sliding gear shaft worn out
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.
1-15
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1. GENERAL INFORMATION
Troubleshooting-EFi model
A. Engine cannot be started or difficult to be started
Check and adjustment Fault condition Probable causes
Press the fuel injector feed pipe and confirm
whether there is fuel in the feed pipe
1. Check the fuel amount in the fuel tank
2. Check if the fuel pipe and the vacuum
The fuel supply to the fuel injector is
sufficient
Check the spark plug ignition
condition
The fuel injector is not
supplied with sufficient fuel
tube are blocked or not
3. Malfunction of fuel pump relay or wiring
4. Malfunction of fuel pump
5. The fuel strainer is blocked or not
Sparks
Perform cylinder compression
ressure test
Normal cylinder compression pressure
Restart the engine
No ignition With signs of ignition but
Remove and check the
spark plug
Week sparks or no spark
Low or no compression
pressure
the engine cannot be
started
1. Malfunction of spark plug
2. Spark plug contamination
3. Malfunction of ECU
4. Malfunction of the AC Generator
5. Ignition coil is in open or short circuit
6. Malfunction of main switch
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leakage
5. Sand hole in the com
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
ression parts
1. Contaminated or clogged fuel injector
Dry spark plug Wet spark plug
1-16
2. Malfunction of throttle valve operation
3. Malfunction of fuel pressure regulator
f
A
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1. GENERAL INFORMATION
B. Engine runs sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
Accelerate gradually and
check engine RPM
Engine RPM can be
increased
Engine RPM cannot be
increased
1. Clogged air cleaner
2. Poor fuel supply
3. Clogged exhaust pipe
4. Clogged
uel injector
Check ignition timing
(Using ignition lamp)
Correct ignition timing Incorrect ignition timing
Check cylinder compression
pressure (using compression
pressure gauge)
Normal compression pressure Abnormal compression
pressure
Check if the fuel injector is
clogged or not
Not clogged Clogged
Remove and check the
spark plug
No contamination or discoloration
Check if the engine is over
Contaminated or discolored
1. Malfunction of ECU
2. Malfunction of AC Generator
1. Worn out cylinder or piston ring
2. Cylinder gasket leakage
3. Sand hole in compression parts
4. Valve deterioration
5. Jammed piston ring
1. Replace the fuel injector
1. Remove the dirt
2. Incorrect spark plug heat range
1. Worn out piston or cylinder
Normal Engine overheated
Continually drive in
acceleration or high speed
No knocking Knocking
2. Abnormal fuel injector
3. Poor fuel quality
4. Carbon deposit in the combustion chamber
5. Abnormal ignition timing
1. Carbon deposit in the combustion chamber
2. Malfunction of fuel injector
3. Poor fuel quality
4.
bnormal ignition timing
1-17
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1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check for any air sucked in through
the throttle body insulator gasket
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes
Check ignition timing
(using ignition lamp)
Normal
No air sucked in
Remove the spark plug and
check the spark condition
Good spark Poor spark
Check and adjustment Fault condition Probable causes
Check ignition timing
Abnormal
Air sucked in
1. Incorrect ignition timing (malfunction of
ECU or AC Generator)
1. Abnormal throttle body insulator gasket.
2. Abnormal throttle body installation
3. Abnormal inlet pipe gasket
4. Damaged ABV pipe
1. 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
Normal Abnormal
Check the fuel pump
su
condition
Good Poor
Check if fuel injector clogged
Normal Clogged
1. Malfunction of ECU
2. Malfunction of AC Generator
1. Insufficient fuel in the fuel tank
2. Pressed or clo
1. Replace the fuel injector
ed fuel pipe
1-18
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1. GENERAL INFORMATION
E. CLUTCH AND DRIVING PULLEY
FAULT CONDITION PROBABLE CAUSES
Engine can be started but the
vehicle cannot run
Engine shuts down or trembles
when the vehicle is running (rear
wheel rotates during engine idling).
1. Worn out or damaged drive belt
2. Damaged movable drive face
3. Damaged driven face spring
4. Broken clutch weight
5. Broken drive shaft groove
6. Worn out or damaged transmission gear
1. Broken clutch spring
2. Clutch outer stuck with clutch weights
3. Connection parts between clutch and shaft worn out or
burned
Poor initial driving (poor climbing
performance)
1. Worn or deformed drive belt
2. Worn weight roller
3. Worn driven face
4. Deformed driven face spring
5. Grease on drive belt or drive / driven face
1-19
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1. GENERAL INFORMATION
Lubrication Points
Steering stem
bearin
Throttle cable / front &
rear brake lever pivot
Seat catch
1-20
Front wheel bearing
Side stand pivot
Main stand pivot
Rear wheel bearing
p
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Homepage
Contents
2. Maintenance Information
Precautions in Operation..................2-1
Periodical Maintenance
Schedule ............................................2-2
Fuel Lines ..........................................2-3
Throttle Operation.............................2-3
Air Cleaner.........................................2-4
Spark Plug .........................................2-4
Valve Clearance.................................2-5
Ignition System..................................2-6
Cylinder Compression Pressure......2-7
Drive Belt ...........................................2-7
Brake System (front/rear
disk brake) .........................................2-8
Brake Hose ........................................2-8
Precautions in Operation
Brake Fluid ........................................ 2-8
Filling out brake fluid........................ 2-8
Air bleed operation........................... 2-9
Add brake fluid.................................. 2-9
Brake lining ....................................... 2-9
Brake light switch............................. 2-10
Headlight beam distance.................. 2-10
Clutch weight .................................... 2-10
Side Stand ......................................... 2-11
Front / Rear Cushion ........................ 2-11
Nut, bolts tightness. ......................... 2-11
Wheel / Tire........................................ 2-12
2
Model
Fuel Tank Capacity 7,600 c.c.
Engine Oil
Transmission
Gear oil
Capacity of
Clearance of throttle valve 2~6 mm
Spark plug CR7E CR7E CR8E CR7E
〝F〞Mark in idling speed
Full timing advanced BTDC 27º BTDC 24º BTDC 27º BTDC 24º
Idling speed 1,800±100 rpm
Cylinder compression pressure 12 ± 2 Kg/cm²
Valve
clearance
coolant
capacity 1,000 c.c.
change 800 c.c.
capacity 110 c.c.
change 100 c.c.
Engine + radiator 780 c.c.
Reservoir upper 420 c.c.
IN 0.12±0.02 mm
EX 0.12±0.02 mm
LF12W-6/F
BTDC 13º /
1800r
LF12W2-7
BTDC 10º
m
1800rpm
LF18W-A/W3-H
/W5-C
BTDC 13º
1800rpm
LF18W-6/W1-9
/W2-7/W4-8
BTDC 10º
1800rpm
Tire dimension Front 110/90-13 56P
Tire dimension Rear 130/70-12 64L
Tire pressure
(cold)
Battery 12V8Ah (MF battery) YTX9-BS / GTX9-BS
single Front: 1.75 Kg/cm² Rear: 2.25 Kg/cm²
Load 90 Kg
(full load)
Front: 1.75 Kg/cm² Rear: 2.5 Kg/cm²
2-1
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2. Maintenance Information
Periodical Maintenance Schedule
Mainte
nance
Code
item
Every
300KM
1 ☆Air cleaner I C C R C
2 ☆Fuel filter I I R
3 ☆Oil filter C C C
4 ☆Engine oil cha nge R Replacement for every 1000 km
5 Tire pressure I I I I I I
6 Battery inspection I I I I I I
7 Brake & free play check I I I I I I
8 Steering handle check I I I
9 Cushion op eration che ck I I I
10 Every screw tightening
I I I I I I
check
11 Gear oil check for leaking I I I I I I
12 ☆Spark plug check or change I I R R R
13 ☆Gear oil change R Replacement for every 5000 km
14 Frame lubrication L L
15 Exhaust pipe I I I I I I
16 ☆Ignition timing I I I I I I
17 ☆emission check in Idling A I I I I I
18 ☆Throttle operation I I I I I
19 ☆Engine bolt tightening I I I I I
20 ☆CVT driving device(belt) I R I
21 ☆CVT driving device(roller) C C C
22 Lights/electrical
I I I I I I
equipment/multi-meters
23 Main/side stands & springs I I I
24 Fuel lines I I I I I
25 Shock absorbers I I I I
26 Cam chain I I I I I
27 ☆Valve clearance I A A A A
28 Lines & connections in
I I I I I I
cooling system
29 Coolant reservoir I I I I I I
30 Coolant I Replacement for every 1 year
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~
Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes
first.
Remarks: 1. These marks “ ☆” in the schedule are emission control items. According to EPA regulations, these items
must be performed normally perio dical ma inte nance foll owing the use r manua l instr ucti ons. They are
prohibited to be adjusted or re paired by una uthorize d pe ople . Otherwise, SYM is no responsible for the
charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequentl y oper ated in high speed and after
the motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating
occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is
obvious lower. Than ever
c. Replace worn out pistons, cylinder head.
1 Month
every
1000KM
3 month
every
3000KM
6 month
every
6000KM
1 year
every
12000KM
15 month
every
14500KM
2-2
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Fuel Lines
Remove trunk
Remove side cover.
Remove central cover.
Remove body frame cover.
Remove pedal.
Remove front glove box.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any
kind of fire is strictly prohibited as dealing it.
Throttle Operation
Have a wide open of throttle valve as handle bar
in any position and release it to let back original
(full closed) position.
Check handle bar if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure handle bar free play in its flange part.
Free play: 2~6 mm.
Adjustment can be done in either end.
Secondary adjustment is conducted from top
side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.
Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
2. Maintenance Information
Fuel pump
Filler hole
Fuel tank
2~6 mm
2-3
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2. Maintenance Information
Air Cleaner
Remove trunk.
Remove side cover.
Remove 8 screws from the air cleaner cover and
then remove the cover.
Caution
Air cleaner element contains a paper made
filter so do not try to clean it.
Spark Plug
Recommended spark plug: CR7E / CR8E
Remove trunk.
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap：0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark
plug by screwing it.
Tighten the plug by turning 1/2 turn more with
plug socket after installed.
Connect spark plug cap.
Ground electrode
Central electrode
0.8 mm
2-4
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Valve Clearance
Caution
Checks and adjustment must be performed
when the engine temperature is below 35℃.
Remove trunk.
Remove central cover.
Remove valve adjustment cap.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the
“T” mark on the camshaft sprocket align with
cylinder head mark so that piston is placed at
TDC position in compression stroke.
2. Maintenance Information
Caution
Do not turn the bolt in C.C.W. direction to
prevent from camshaft bolt looseness.
Check & adjust valve clearance with feeler
gauge.
Valve clearance (IN/EX): 0.12 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened
the fixing nut.
2-5
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