Sym Citycom 300i (En)

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HOW TO USE THIS MANUAL
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Ci t yc o m .3 0 0 i SERVICE MANUAL
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Foreword
This service manual contains the technical data of each component inspection and repairment for the SANYANG LH30W series scooter. The manual is shown with illustrations and focused on Service Procedures, Operation Key Points, and Inspection Adjustment, providing technicians with service guidelines. If the style or the mechanical structures of the scooter, LH30W series scooter, are different from those of the photos or pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to changes without notice.
Service Department SANYANG INDUSTRY CO., LTD.
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Contents
How To Use This Manual

This service manual describes the basic information of different system parts and system inspection & service for SANYANG LH30W series scooter. In addition, please refer to the manual contents in detail for the model you serviced in inspection and adjustment. The first chapter covers the general information and the trouble diagnosis. The second chapter covers the periodic maintenance information and the special tool models. The third to the 11th chapters cover the engine and the driving systems. The 12th chapter is the cooling system. The 13th to the 16th chapter contain the relative parts of the body frame assembly. The 17th chapter is the electrical system. The 18th chapter is the emission control system. The 19th chapter is the 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 Illustrations on the CD-R version, and can be access to these items by click the mouse. 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, onto 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 contents so that clicking the button can back to the contents of this chapter.
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1-1 ~ 1-16 2-1 ~ 2-17 3-1 ~ 3-8 4-1 ~ 4-60 5-1 ~ 5-11 6-1 ~ 6-16 7-1 ~ 7-8 8-1 ~ 8-14 9-1 ~ 9-8 10-1 ~ 10-10 11-1 ~ 11-8 12-1 ~ 12-14 13-1 ~ 13-16 14-1 ~ 14-12 15-1 ~ 15-10 16-1 ~ 16-6 17-1 ~ 17-23 18-1 ~ 18-7 19-1
Content
General Information Maintenance Information Lubrication System Fuel Injection System Engine Removal Cylinder Head/ Valve Cylinder/ Piston V Type Belt Driving System/ Kick-Starter Final Drive Mechanism Alternator Crankshaft/ Crankcase Cooling System Body Cover Brake System Steering/ Front Wheel/ Front Cushion Rear Wheel/ Rear Fork/ Rear Cushion Electrical Equipment Emission Control System Electrical Diagram
Index
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
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1. GENERAL INFORMATION
Symbols and Marks............................ 1-1 General Safty1-2 Service Precautions ........................... 1-3 Specifications ..................................... 1-9 Torque Values .................................... 1-10 Troubles Diagnosis............................ 1-12 Parts to Be Greased ........................... 1-16
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 needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks only. Warning Caution Means that serious injury or even death may result if procedures are not followed. Means that equipment damages may result if procedures are not followed. Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the Engine oil damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil) Grease Gear oil Locking sealant Oil seal Renew Brake fluid Special tools Correct Wrong Indication Directions King Mate G-3 is recommended. King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140) Apply sealant, medium strength sealant should be used unless otherwise specified. Apply with lubricant. . Replace with a new part before installation. Use recommended brake fluid DOT3 or WELLRUN brake fluid. Special tools Meaning correct installation. Meaning wrong installation. Indication of components. Indicates position and operation directions Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility).
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To this chapter contents
General safety
Carbon monoxide If you have to run your engine, make sure that 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. stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.
Battery Caution
Battery emits explosive gases; flame is strictly prohibited. Keep the places well ventilated when charging the battery. Battery fluid 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 fluid on your skin, flush it off immediately with water. If you get battery fluid in your eyes, flush it off immediately with water and then go to a hospital. If you swallow the battery fluid 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 the battery fluid beyond the reach of children.
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.
Brake pad
Do not use compressed air or a cleaning brush to clean the brake system; use a vacuum cleaner to prevent the asbestos fiber from drifting in the air.
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.
Caution
Inhaling asbestos fiber may result in lung disease or cancer.
Brake fluid Caution

Brake fluid may cause damage to the surface of the painted parts, or even the structure of the plastic or rubber parts. Place a clean cloth for protection when servicing the brake system. Keep the brake fluid beyond reach of children.
Hot components Caution

Components of the engine and exhaust system can become extremely hot after running. They remain very hot even after the engine has been
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unsmooth control and premature worn out.
Service Precautions
Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle.
Special tools are designed for remove and install of components without damaging the parts being work ed on. Using wrong tools may result in parts damaged.
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. 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 togethe r with a wire for ease of installation later.
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. 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. 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.
Note the reassemble position of the important components before disassembling them to ensure they wil l 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.
Never bend or twist a control cable to prevent
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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. 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 en larged ends for tightening the clamps.
Groove
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 unles s otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.
Clamp
Connector
Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.
Boots
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
The tool should be pressed against two (inner and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.
Both of these examples can result in bearing damage.
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Lubricate the rotation face with specified lubricant on the lubrication points before assembling. 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.
Check if positions and operation for installed parts is in correct and properly.
Make sure that the battery post caps are located in properly after the battery posts had been service d. Make sure service safety each other when conducting by two persons.
If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse. Note that do not let parts fall down.
Capacity verification
Before battery removal operation, it has to remove the battery negative (-) cable firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create sp ark.
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When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. Insert the terminal completely. Check if the terminal is covered by the boot. Do not let boot open facing up.
Do not pull the wires as removing a connector or wires. Hold the connector body.
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.
Make sure if the connector pins are bent, extruded or loosen.
Wire band and wire harness have to be clamped secured properly.
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. Do not squeeze wires against the weld or its clamp.
Check if the connector is covered by the twin connector boot completely and secured properly.
Before terminal connection, check if the boot is crack or the terminal is loose.
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Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. 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.
Keep wire harnesses far away from the hot parts.

Never Touch
Secure the rubber boot firmly as applying it on wire harness.
Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws.
Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the damaged parts or replace them.
Route harnesses so that they neither pull too tight nor have excessive slack.
Never clamp or squeeze the wire harness as installing other components.

Never clamp or squeeze the wire harness
Never too tight
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Do not let the wire harness been twisted as installation. With sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later.
Clean rust
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.
Before operating a test instrument, operator should read the operation manual of the instrument. And then, conduct test in accordance with the instruction.
Do you know how to set the instrument to its measurement position and the insert locations of its two probes?
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Specifications
MAKER SANYANG 2210 mm 785 mm 1445 mm 1500 mm 77 kg 107 kg 184 kg Two /150 kg 104 kg 230 kg 334 kg 4-Stroke Engine Vertical, below center, incline 80 Unleaded gasoline 4-stroke/water cooled 73 mm 62.8 mm Single Cylinder 262.8 cc 10.0 : 1 15.4 kw / 7000 rpm 23.5 Nm / 5500 rpm Full transistor Ignition(ECU) electrical starter Performance Brake System MODEL Suspension System Tire Specifications Front Rear Front Rear Front Rear LH30W-6 Telescopic Fork Unit Swing 110 /70-16 52P 140 /70-16 65P Disk ( 260 mm) Disk ( 260 mm) Overall Length Overall Width Overall Height Wheel Base Front Curb Weight Rear Total
Weight
Dimension
Passengers/Weight Front Total Weight Rear Total Type Installation and arrangement Fuel Used Cycle/Cooling Bore
Max. Speed Climb Ability Primary Reduction
Above 128 km/hr Below 27 Belt Gear Centrifugal, dry type C.V.T. 0 ~ 160 km/hr 93~112 dB/A Expansion & Pulse Type Right side, and Backward Forced circulation & splashing Below 2.0 g/ km Below 0.3g/ km
Reduction
Secondary Reduction Clutch Transmission
Speedometer Horn Muffler Exhaust Pipe Position and Direction Lubrication System
Cylinder
Engine
Stroke Number/Arrange ment Displacement
Exhaust Concentrati on
Solid Particulate CO HC EEC PCV
Compression Ratio Max. HP Max. Torque Ignition Starting System
Catalytic Converter
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Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table.
Standard Torque Values for Reference

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

Item Cylinder head nut Cylinder head right bolt Cylinder head stud bolt (inlet pipe) Cylinder head stud bolt (EX. pipe) Tappet adjustment hole cap bolt Tappet adjustment screw nut Spark plug Carburetor insulator bolt Cylinder stud bolt Engine left cover bolt Engine oil draining bolt Engine oil strainer cap Mission draining bolt Mission filling bolt Clutch driving plate nut Clutch outer nut Drive face nut Flywheel nut Crankcase bolts Mission case bolt Qty Thread Dia. (mm) Torque Value(kgf-m) 4 2 2 2 6 4 1 2 4 7 1 1 1 1 1 1 1 1 7 7 8 8 6 7 6 5 10 6 8 6 12 30 8 10 28 12 12 12 6 8 2.0~2.4 2.0~2.4 0.7~1.1 0.5~1.0 1.0~1.4 0.7~1.1 1.0~1.2 0.7~1.1 0.7~1.1 1.1~1.5 1.1~1.5 1.3~1.7 0.8~1.2 0.8~1.2 5.0~6.0 5.0~6.0 5.0~6.0 5.0~6.0 0.8~1.2 2.0~2.4 Remarks
Apply oil to thread
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Frame Torque Values
Item Stopper nut for engine hanger rubber Engine hanger nut Engine hanger bolt Engine connection bolt Front wheel axle nut Rear wheel shaft nut Rear fork Rear cushion upper bolt Rear cushion under bolt Nut for steering post Front cushion Brake lever nut Nut for the rear brake arm Front brake hose bolt Front brake caliper bolt Front brake disk mounting bolt Air-bleed valve Speedometer cable locking screw Exhaust muffler bolt Exhaust muffler connection nut Qty Thread Dia. (mm) Torque Value(kgf-m) 1 2 1 1 1 1 2 2 2 1 4 2 1 4 4 7 1 1 3 2 8 12 12 10 12 14 8 10 8 10 8 6 6 10 6 8 5 5 8 7 1.8~2.2 4.0~5.0 4.0~5.0 3.5~4.5 5.0~7.0 10.0~12.0 4.0~5.0 3.5~4.5 2.4~3.0 4.0~5.0 2.4~3.0 0.8~1.2 0.5~0.6 3.0~4.0 3.0~3.5 4.0~4.5 0.5~0.6 0.15~0.3 3.2~3.8 1.0~1.2 Remarks
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Troubles Diagnosis (Electronic Fuel Injection System) A. Engine cannot be started or difficult to be started
Check and adjustment Fault condition Probable causes
Press the fuel sprayer feed pipe and confirm whether there is petrol in the feed pipe 1. 2. fuel fuel tank gasoline hose
3. Malfunction of fuel pump relay fuel for 4. 5. E.E.C system tube 6. Malfunction of fuel pump Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. 1. Malfunction of spark plug. 2. Check if sparks Week sparks or no spark at all of spark plug 7. The fuel strainer is
3. Malfunction of ECU. 4. Malfunction generator
5. Ignition coil is in open or short circuit Perform cylinder compression pressure test. 6. Ignition coil leads open or short circuit
7. Malfunction of main switch

Low compression pressure or no pressure Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression parts
cylinder compression pressure normal
Re-start by following the starting procedures
No ignition
There are some signs of ignition, but engine can not be started
1. Malfunction of throttle valve operation 2. Air sucked into intake manifold 3. Incorrect ignition timing
Remove the spark plug again and check it.
1. Dry spark plug Wet spark plug 2. Malfunction of throttle valve operation 3. Malfunction of a
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B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Fuel injector clogged.
Engine speed can be increased.
Engine speed can not be increased.
Check ignition timing (Using ignition lamp)
Ignition timing correct
Incorrect ignition timing
Malfunction of ECU Malfunction of AC generator
Check cylinder compression pressure (using compression pressure gauge) Cylinder & piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration piston can not be moved.
Compression pressure correct
No compression pressure
Check fuel injector clogged or not
No foul or discoloration
Fouled and discoloration
1. change the fuel injector
Remove spark plug
No foul or discoloration
foul and discoloration
Remove dirt Incorrect spark plug heat range
Check if engine over heat Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber Ignition timing too advanced
Normal
Engine overheat
Continually drive in acceleration or high speed Too much carbon deposited in combustion Malfunction of fuel injector. Poor fuel quality Ignition timing too advanced
No knock
Knock
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Engine runs sluggish (especially in low speed and idling)
Check ignition timing (using ignition lamp)
Normal
Abnormal
Incorrect ignition timing (malfunction of ECU or AC generator)
throttle body or not
1. Suck the air
gasket.
2. Throttle body wrongly attached 3. Inlet pipe gasket abnormal 4. ABV pipe cracked
Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground
Good spark
Poor
Spark plug fouled Malfunction of E.C.U. Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch
Engine runs sluggish (High speed)

Check ignition timing
Normal
Abnormal
Malfunction of ECU. Malfunction of AC generator
good
poor
Insufficient fuel in fuel tank Fuel filter clogged Restricted fuel tank vent
Check if fuel injector clogged
Normal
Clogged
1. change the fuel injector
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E. CLUTCH AND DRIVING PULLEY
FAULT CONDITION PROBABLE CAUSES
Engine can be started but motorcycle can not run
Driving belt worn out or deformation Driving disk damaged Driving pulley spring broken Clutch lining broken Driving shaft groove broken Transmission gear damage Transmission gear worn out or burned
Engine running and misfire as motorcycle initial forward moving or jumping sudden (rear wheel rotating as engine in running)
Clutch lining spring broken Clutch outer stuck with clutch balance weights Connection parts in clutch and shaft worn out or burned
Poor initial driving (Poor climbing performance)
Driving belt worn out or deformation Balance weight roller worn out Driving sliding gear shaft worn out Driving disk spring deformation Driving sliding gear shaft worn out Greased in driving belt and sliding gear.
1-15
Parts to Be Greased
Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing
Seat catch
Speedometer gear/ front wheel bearing
Side stand pivot
Main stand pivot
Rear wheel bearing
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2. Maintenance Information
Precautions in Operation2-1 Periodical Maintenance Chart 2-2 Engine Oil 2-3 Engine Oil Strainer Clean 2-3 Gear Oil 2-4 Fuel Line / Cable2-4 Air Cleaner 2-5 P.C.V. system 2-6 Valve Clearance2-6 Ignition System 2-7 Spark Plug 2-7 Cylinder Compression Pressure2-8 CVT System 2-8 Steering Mechanism2-9 Suspension System 2-9 Disk Brake System 2-10 Brake Light Switch/Starting Inhibitor Switch2-12 Headlight Beam Distance 2-12 Wheel / Tire 2-12 Battery 2-13 Nuts, Bolts Tightness2-13 Special Tools List 2-14
Precautions in Operation
Specification Fuel Tank Capacity Engine Oil Transmission Gear oil capacity change capacity change 10,000 c.c. 1,400 c.c. 1,200 c.c. 180 c.c. 160 c.c. 1400 c.c. 2~6 mm CR8E (gap:0.6~0.7 mm) BTDC 10 / 1,650 rpm BTDC 30 1,650100 rpm 12 2 Kg/cm 0.10.02 mm 0.150.02 mm 110/70-16 52P 140/70-16 65P Front: 1.75 Kg/cm Front: 2.0 Kg/cm Rear: 2.0 Kg/cm Rear: 2.25 Kg/cm IN EX Front Rear single Load 90 Kg (full load)
Capacity of coolant (Engine + radiator +Reservoir upper) Clearance of throttle valve Spark plug F Mark in idling speed Full timing advanced Idling speed Cylinder compression pressure Valve clearance Tire dimension Tire dimension Tire pressure (cold) Battery
12V10Ah (MF battery) / YTX12-BS
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Periodical Maintenance Chart
No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 item Air cleaner 2nd air jet cleaner Fuel filter Oil filter Engine oil change Tire pressure Battery inspection Brake & free ply check Steering handle check Cushion operation check Every screw tightening check Gear oil check for leaking Spark plug check or change Gear oil change Frame lubrication Exhaust pipe Ignition timing emission check in Idling Throttle operation Engine bolt tightening CVT driving device(belt CVT driving device(roller) Lights/electrical equipment/multi-meters Main/side stands & springs Fuel lines Shock absorbers Cam chain Valve clearance Crankcase evaporative control system Crankcase blow-by over-flow pipe 2nd air jet system Evaporative control system Lines & connections in cooling system Coolant reserve tank Coolant ECU input voltage signal EMS sensor couplers Every 300KM I I I C R I I I I I I I I R I I A I I 1 Month 3 month every every 1,000KM 3,000KM C C 6 month 1 year every every 6,000KM 12,000KM C R C R I R C C Replacement for every 1,000 km I I I I I I I I I I I I I I I I I I I I I I I I I R R Replacement for every 5,000 km L L I I I I I I I I I I I I I I I I I I I R C C I I I I I I I I I I I I I I I A A A C C C Replacement for every 2,000 km I C C I I I I I I I I I I I Replace I I
I I I I I I I I I I I
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 1,000 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 periodical maintenance following the use r manual instructions. They are prohibited to be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge. 2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment. 3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage. 4. Preventive maintenance
a. Ignition system Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur. b. Carbon deposit removal Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious lower. Than ever c. Replace worn out pistons, cylinder head.
2-2
Engine Oil
Turn off the engine, and situate the motorcycle vertically by main stand. Check the oil level with oil filler plug. Do not screw the oil filler plug into the engine when checking. If oil level is nearly low level, pour in the recommended oil to the upper level. Oil Change
Caution
Drain oil as engine warmed up to make sure oil can be drained smoothly and completely. Place an oil pan under the engine, and remove the oil drain bolt. After draining oil, make sure the drain bolt gasket can be re-used. Tighten the oil drain bolt. Torque value: 3.5~4.5kgf-m Pour in the oil (viscosity SAE 10W-30) Recommended oil: King series oil. Engine oil capacity: Disassembly 1400c.c. Replacement 1200c.c. Screw the oil filler plug; start the engine and run it for several minutes. Turn off the engine, and check the oil level again. Check if the engine oil leaks or not.
Engine Oil Strainer

Drain the engine oil. Unscrew the oil filter cap and remove the oil strainer and the spring. Clean the oil strainer. Check if the O-ring can be re-used or not. Install the oil strainer and the spring. Tighten the oil filter cap. Torque value 1.3~1.7kgf-m
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Gear Oil
Situate the motorcycle vertically by the main stand. Turn off the engine. Inspect the gear oil level through the oil inspection bolt.
Gear oil inspection bolt
Gear Oil Change

Unscrew the gear oil filler bolt. Unscrew the drain bolt and drain the gear oil. Screw the drain bolt. Torque value: 0.8~1.2kgf-m Pour in the specified type and amount of gear oil. Screw the oil filler bolt. Torque value: 1.0~1.4kgf-m Gear Oil Capacity: 170 cc. Make sure that the bolt washer can be re-used. Start engine and run the engine for 2-3 minutes. Make sure that no oil leaking.
Drain bolt
Fuel Line / Cable

Remove luggage box. Remove rear carrier. Remove body covers. Remove floor panel. Check all lines, and replace them when they are deteriorated, damaged or leaking.
Warning
Gasoline is a low flashpoint fuel, so any fire is strictly prohibited when dealing with it.
2~6 mm
Throttle Control System

Check if the throttle grip operation is smooth or not. Check the throttle cable and replace it if its deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth Measure the throttle grip free play. Throttle grip free play: 2~6 mm. Adjustment can be carried out at both ends of the throttle cable. Loosen the locknut, and then adjust the throttle grip free play by turning the adjuster.
Adjuster
2-4
Primary adjustment should be carried out from bottom end of the throttle cable. Loosen the locknut, and adjust by turning the adjuster. Tighten the locknut, and check throttle operation condition.
Adjuster
Locknut
Air Cleaner
Air Cleaner Element
Remove 9 screws from the air cleaner cover and then remove the cover.
9 screws
Remove the air cleaner element.
Caution
The air cleaner element is made of paper, so do not wash it by water or solvent.
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P.C.V. system
Remove the plug from the P.C.V. drain hose. Drain the internal deposit and reinstall the plug. Inspection should be carried out every 2,000 kilometers.
P.C.V drain hose
Caution
The P.C.V. drain hose is transparent so that the deposit is visible. Inspection of the P.C.V drain hose should be carried out more often in the rainy place or under the situation of full throttle frequently.
Valve Clearance
Caution
Inspection and adjustment should be carried out when the engine temperature is under 35 . Remove the luggage box. Remove the cylinder head cover & the side cover. Remove ignition timing inspection cap located on the right cover of the engine. Turn the camshaft bolt clockwise and let the T mark on the camshaft sprocket align with the cylinder head mark so that piston is placed at TDC in compression stroke.
2 bolts Timing mark
Caution
Do not turn the bolt counterclockwise to prevent the camshaft bolt from loosening. Valve clearance inspection and adjustment: Check & adjust valve clearance with thickness gauge. Valve clearance (IN) 0.10.02 mm. Valve clearance (EX) 0.150.02 mm. Loosen fixing nut and turn the adjustment nut for adjustment.
Caution
Re-check the valve clearance after tightened the fixing nut. Special tool: Tappet adjuster SYM-9001200-08 SYM-9001200-09 SYM-9001200-10 Special tool: Tappet adjuster wrench SYM-9001200
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Ignition System
Caution
Ignition system is set by the manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is normal or not. Remove right side cover. Remove ignition timing inspection cap located on the right cover of the engine. Connect the tachometer and the ignition timing light. Start the engine. Keep the engine at 2,500 rpm; check the F mark with the ignition timing light and see if it aligns with the timing mark. If so, it means that ignition timing is correct. Increase engine speed to 6,000 rpm to check ignition advance degree. If the timing is located within the ignition advance degrees, it means that the ignition advance degree is correct. If the ignition timing is incorrect, check ECU, flywheel and crankshaft position sensor. Replace it if the malfunction of these parts is found.
Spark plug
Spark Plug
Recommended spark plug: CR8E Remove the luggage box. Remove the central cover. Remove the spark plug cap. Clean dirt around the spark plug hole. Remove the spark plug. Measure the spark plug gap. Spark plug gap: 0.6~0.7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary. Screw in the spark plug by hand in order to avoid the damage of the spark plug. Then tighten it by a spark plug socket wrench. Tighten torque: 1.0~1.2kgf-m Install the spark plug cap.
Ground electrode Central electrode
0.6~0.7mm Insulator
2-7
Cylinder Compression Pressure
Warm up the engine. Turn off the engine. Remove the luggage box and the central cover. Remove the spark plug cap and the spark plug. Install the compression pressure gauge into the spark plug hole. Full open the throttle valve, and start the engine by the electric starter.
Caution
Run the engine until the reading on the gauge stops increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds. Compression pressure 122 Kg/cm Check following items if the pressure is too low: Incorrect valve clearance. Valve leaking. Cylinder head leaking, piston, piston ring and cylinder worn out. If the pressure is too high, it means too much carbon deposits in the combustion chamber or on the top of the piston.
Compression pressure gauge
CVT system
Drive Belt Remove the engine left side cover. Check if the belt is cracked or worn out. Replace the belt if necessary or in accordance with the periodical maintenance chart. Width limit: 22.5 mm or above
Teeth Width
Clutch Weight Run the motorcycle and increase throttle valve gradually to check the clutch operation. If the motorcycle vibrates during moving forward, inspect the wear condition of the clutch weight. Replace it if necessary.
Clutch weight
Clutch spring
2-8
Steering Mechanism
Caution
Check all the wires and cables if they are interfered during the rotation of the steering handlebar. Make the front wheel be spaced from the ground. Turn the handlebar from right to left and check if it is turned smoothly. If the handlebar turns unevenly, bent, or can be moved vertically, then adjust the top steering bearing.
Suspension System
Caution
Do not ride the motorcycle with poor cushion. Loose, worn or damaged cushion will make poor stability and steering.
Front suspension
Press the front suspension for several times to check its operational condition. Replace parts if damage is found. Tighten all nuts and bolts.
Rear Cushion
Press the rear cushion for several times to check its operational condition. Replace parts if damage is found. Park the motorcycle by main stand and make the rear wheel be spaced from the ground. Start the engine and speed up gradually. Replace the rubber bushing if looseness found. Tighten all nuts and bolts.
2-9
Disk Brake System
Brake System Hose Make sure the brake hoses for corrosion or leaking oil.
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 level found
Caution
In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle stop. Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. Do not mix non-compatible brake fluid together. Filling Out Brake Fluid Tighten the drain valve, and add brake fluid. Operate the brake lever so that brake fluid contents inside the brake system hoses.
Master cylinder cap
Added Brake Fluid

Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.
Diaphragm LOWER Brake Fluid
Caution
Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.
Air Bleed Operation

Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.
Air bubble
Drain valve
Caution
Before closing the air bleed valve, do not release the brake lever.
Transparent hose
2-10
Brake Lining Wear
The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc.
Lining
Caution
It is not necessary to remove brake hose when replacing the brake lining.
Brake caliper
Brake disk
Remove the brake clipper bolt, and take out the clipper.
2 bolts
Caution
Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.
Pry out the brake lining with a flat driver if lining is clipped. Remove 2 cotter pins
Cotter pins
Caution
In order to maintain brake power balance, the brake lining must be replaced with one set.
Remove the brake pad shafts and pads.
2-11
Brake Light Switch/Starting Inhibitor Switch
The brake lamp switch is to light up brake lamp as brake applied. Make sure that the engine can be started only when brake is applied.
Stop switch
Headlight Beam Distance

Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high.
Caution
To adjust the headlight beam follows related regulations. Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.
Headlight beam adjustment screws
Wheel / Tire
Caution
Tire pressure check should be done as cold engine. Appointed tire pressure Tire size Load for Tire pressure as under 90 Kg cold engine (Kg/cm) Full loaded Front tire Rear tire 1.75 1.75 2.25 2.50
Check if tire surface is ticked with nails, stones or other materials. Check if front and rear tires pressure is in normal. Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification Front tire 1.5 mm Rear tire 2.0 mm
2-12
Battery
Open the seat. Remove 3 screws and remove the battery cover
Battery cable remove 1. Disconnect the cable negative terminal (-), 2. then the cable positive terminal (+) 3. Remove the battery from the motorcycle. If there is some rust on battery posts, clean it with steel brush Install the battery in the reverse procedures of removal
3 screws
Caution
If there is rust on the posts very serious, spray some hot water on the posts. Then, clean it with steel brush so that can remove rust for more easily. Apply some grease on the posts after rust removed to prevent from rust again.
Nuts, Bolts Tightness

Perform periodical maintenance in accord with the Periodical Maintenance Schedule. Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose (pipe) clamps, and wire holders for security.
2-13
Special Tools List
NAME NO
Left crank bearing puller SYM-9100100
NAME NO
R/L. crank case disassemble tool SYM-1120000-HMA H9A
NAME NO
Valve cotter remove & assembly tool SYM-1471110/20
NAME NO
L. Crank shaft puller SYM-1130000-HMA H9A
NAME NO
Clutch special nut socket SYM-9020210-HMA
NAME NO
Tappet adjusting SYM-1472100
NAME NO
R. crank case bearing 6201 assembles tool SYM-9614000-HMA 6201
NAME NO
Left crankshaft & oil seal assembly socket. SYM-1332100-HMA RB1
NAME NO
Rocker arm shaft disassemble SYM-1445100
NAME NO
Bearing driver set SYM-6204024
NAME NO
Assembly directs puller

SYM-2341110
NAME NO
Drive shaft puller SYM-2341120- HMA RB1
2-14
NAME NO
Inner bearing puller SYM-6204025
NAME NO
Outer bearing puller SYM-6204010
NAME NO
Handle stand nut wrench
SYM-5321100
NAME NO
Clutch nut wrench SYM-9020200
NAME NO
Universal holder SYM-2210100
NAME NO
AC.G. Flywheel puller SYM-3110000-HMA
NAME NO
Steering head top thread wrench SYM-5320010
NAME NO
Bearing driver HK1516 SYM-9100200-HMA RB1 HK1516
NAME NO
Bearing puller 6205 SYM-9100400 HMA RAI 6205
NAME NO
Air operated bearing puller

SYM-9100410-400 A6205
NAME NO
Oil seal driver 34*52*5 SYM-9125500-HMA
NAME NO
Right crankcase cover bearing 6201 puller. SYM-9614000-HMA RB1 6201
2-15
NAME NO
Clutchspring compressor SYM-2301000-HMA
NAME NO
Drive shaft & oil seal (25*40*8) socket SYM-9120200-HMA RB1
NAME NO
Bearing puller 6303 SYM-6303000- A 6303
(30mm)
NAME NO
(22mm)
NAME NO
Bearing driver 6201 SYM-9614000-6201
NAME NO
Crankcase bush puller SYM-1120310
Crankcase bush puller SYM-1120320
NAME NO
Water pump mechanical seal driver SYM-1721700-H9A
NAME NO
Water pump bearing driver 6901 SYM-9100100
NAME NO
Water pump oil seal driver (inner) SYM-9120500-H9A
2-16
Note:
2-17
Home page
Contents
3. LUBRICATION SYSTEM
Precautions in Operation 3-2 Troubleshooting 3-2 Engine Oil 3-3 Engine Oil Strainer Clean 3-3 Oil Pump 3-4 Gear Oil 3-7
3
Valve Rocker Arm Press-In Lubrication
Cam Shaft Oil Route Spray Lubrication
Con-Rod
Spray Lubrication
Press-In Lubrication
Oil Route
Oil through
Rotate Direction
Oil Strainer
Oil Pump
3-1
General Information:
This chapter contains maintenance operation for the engine oil pump and gear oil replacement.
Specifications
Engine oil quantity Oil viscosity Gear oil Disassembly: 1400 c.c. Change: 1200 c.c. SAE 10W-30 (Recommended King serial oils) Disassembly: Change: 180 c.c. 160 c.c.
Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils)
Items Inner rotor clearance Oil pump Clearance between outer rotor and body Clearance between rotor side and body
Standard (mm) 0.15 0.15~0.20 0.04~0.09
Limit (mm) 0.20 0.25 0.12
Torque value
Torque value oil strainer cap Gear oil drain plug Gear oil inspection bolt Oil pump connection bolt 1.5~3.0kgf-m 1.0~1.5kgf-m 1.0~1.5kgf-m 0.8~1.2kgf-m
Troubleshooting
Low engine oil level
Oil leaking Valve guide or seat worn out Piston ring worn out
Dirty oil
No oil change in periodical Cylinder head gasket damage Piston ring worn out
Low oil pressure

Low engine oil level Clogged in oil strainer, circuits or pipes Oil pump damage
3-2
Engine Oil
Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Oil Change Caution

Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely. Place a oil pan under the motorcycle, and remove oil drain bolt. After drained, make sure washer can be re-used. Install oil drain bolt. Torque value 1.9~2.5kgf-m
Drain bolt
Engine Oil Strainer Clean

Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap. Torque value 1.9~2.5kgf-m Add oil to crankcase (oil viscosity SAE 10W-30) Recommended using King serial oil.
Oil strainer cap
Engine oil capacity: 1.2 L when replacing

Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks.
3-3
Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to chapter 10) Remove snap ring and take out oil pump driving chain and sprocket.
Clip
Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump.
2 screws
Oil Pump Disassembly

Remove the screws on oil pump cover and disassemble the pump as illustration shown.
Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm
3-4
Check clearance between inner and outer rotors. Limit: 0.20 mm
Check clearance between rotor side face and pump body Limit: 0.12 mm
Oil Pump Re-assembly

Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor. Install the driving shaft Install fixing pin
Pin
1 Screw
Install the oil pump cover and fixing pin properly
3-5
Oil Pump Installation
Install the oil pump, and then tighten bolts. Torque value 0.8~1.2kgf-m
Make sure that oil pump shaft can be rotated freely.
Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft.
Install starting gear and generator. (Refer to chapter 10)
3-6
Gear Oil
Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt.
Gear oil Inspection Bolt
Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil. Recommended using King series oils. Install oil inspection bolt.
Gear oil drain plug
Gear Oil Change

Remove oil level inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained. Torque value: 1.0~1.4kgf-m Make sure that the drain plug washer can be re-used. Add oil to specified quantity from the inspection hole. Gear Oil Quantity: 160 c.c. when replacing Make sure that the bolt washer can be re-used, and install the bolt. Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking.
3-7
Notes:
3-8
Home page
Contents
5. Removal & Installation of Engine

Operational Precautions 5-1 Engine Removal 5-2 Engine Hanger 5-7 Rear Fork 5-8 Removal of Engine Mount Bushing 5-10 Installation of Engine 5-11
Operational Precautions
General Information
Specification
Item LH30W
Torque Values
5-1

Engine Removal
Negative Positive
Remove fuel injection system of electrical couplers and fuel hoes

Idle speed control valve
MAP sensor coupler
Injector coupler
5-2

Thermo unit TW sensor
Throttle position sensor
Inlet temperature sensor
Secondary air pipe
5-3

AC generator and crankshaft position sensor coupler
Start motor wire O2 sensor coupler
Fuel tube
Caution
5-4
2 bolts
2 bolts
muffler band bolt
5-5

rear cushion lower bolt
2 bolts
wheel axle nut
Drain bolt
Inlet hose
5-6
1 bolt Frame side bolt
Engine Hanger
Removal
Engine side bolt
Installation
Engine hanger nut: Torque Value: 7.5~9.5kgf-m
5-7

Rear Fork
Bearing Inspection
Cir clip
Bearing removal
Bearing installation
Special Service Tools: Rear fork bearing puller SYM-6303000-6303
6303 bearing puller
6303 bearing puller washer
5-8

Special Service Tools: Assembly directs puller
SYM-2341110
Bearing puller
Cir clip
5-9

Removal of Engine Mount Bushing
28mm 20mm
Pressing out
Special Service Tools:
Pressing In
5-10

Installation of Engine
Caution
Engine hanger nut: Torque Value: 7.5~9.5kgf-m Rear cushion bolt: Torque Value: upper: 3.5~4.5kgf-m under: 2.4~3.0kgf-m Rear wheel axle nut: Torque Value: 11.0~13.0kgf-m
5-11
Home page
Contents
6. Cylinder Head / Valve

Mechanism Diagram 6-1 Precautions in Operation 6-2 Troubleshooting 6-3 Cylinder Head Removal 6-4 Cylinder Head Disassembly 6-6 Cylinder Head Inspection 6-8 Valve Stem Replacement 6-10 Valve Seat Inspection and Service 6-11 Cylinder Head Reassembly 6-13 Cylinder Head Installation 6-14 Valve Clearance Adjustment 6-16
Mechanism Diagram
1.0~1.4kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m
1.0~1.2kgf-m
0.7~1.1kgf-m
3.6~4.0kgf-m 2.4~3.0kgf-m 1.0~1.2kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
6-1

General Information
This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame.
Specification
Item Compression pressure Camshaft Height of cam lobe ID of valve rocker arm OD of valve rocker arm shaft OD of valve stem ID of valve guide Clearance between valve stem and guide Valve Free length of valve spring Valve seat width Valve clearance Tilt angle of cylinder head Intake Exhaust Intake Exhaust Inner outer Intake Exhaust Intake Exhaust Standard 122 kg/cm2 34.880 34.740 11.982~12.000 11.966~11.984 4.975~4.990 4.950~4.975 5.000~5.012 0.010~0.037 0.025~0.062 38.700 40.400 1.600 0.100.02mm 0.150.02mm --Limit --34.860 34.725 12.080 11.936 4.900 4.900 5.030 0.080 0.100 35.200 36.900 ------0.050
Rocker arm
Torque Value
Cylinder head cover bolt Exhaust pipe stud bolt Cylinder head bolt Cylinder head Nut Sealing bolt of cam chain auto-tensioner Bolt of cam chain auto-tensioner Cylinder side cover bolt Cam sprocket bolt Tappet adjustment screw nut Spark plug 1.0~1.4kgf-m 2.4~3.0kgf-m 1.0~1.4kgf-m 3.6~4.0kgf-m 0.8~1.2kgf-m 1.2~1.6kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m 0.7~1.1kgf-m 1.0~1.2kgf-m
Tools Special service tools

Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor
6-2

Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure

1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage Valve carbon deposit. 2. Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3. Piston Piston ring worn out.
High compression pressure

Too much carbon deposit on combustion chamber or piston head
Noise
Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto-tensioner wear out or damage Camshaft sprocket Rocker arm or rocker arm shaft wear out
6-3

Cylinder Head Removal
Remove engine. (Refer to chapter 5)
Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts).
Tensioner bolts
Thermostat bolts
Remove Air Injection system (AI) pipe mounting bolts. Remove spark plug.
4 bolts
Remove cylinder head cover (4 bolts).
4 bolts
6-4

Remove the side cover mounting blots of cylinder head, and then take out the side cover.
3 bolts
Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out.
Timing mark
2 bolts
Bolt 2
Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head.
4 nuts
Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.
2 dowel pins
Caution
Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.
Cam chain guide
6-5

Cylinder Head Disassembly
Remove cam shaft setting plate (1 bolt).
1 bolt Cam shaft setting plate
Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100
Rocker arm shaft and cam shaft puller
Remove cam shafts. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100
Cam shafts
Rocker arm shaft and cam shaft puller
Use a valve cotter remove & assembly tool to press the valve spring, and then remove valves.
Caution
In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Valve cotter remove & assembly tool SYM-1471110-SY125
Valve cotter remove and assembly tool
6-6

Remove valve cotters, spring retainers, springs and valves.
Inlet valve Inner spring Spring retainer
Exhaust valve
Outer spring
Cotter
Remove valve stem seals.
Valve stem seals
Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.
Caution
Do not damage the matching surface of cylinder head.
6-7

Cylinder Head Inspection
Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm Inspect the camshaft bearing for looseness or wear out. If any damage, replace whole set of camshaft and bearing.
Rocker Arm
Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm.
Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm shaft and cam rocker arm. Service Limit: Replace when it is less than 11.936 mm. Calculate the clearance between the rocker arm shaft and the rocker arm. Service Limit: Replace when it is less than 0.10 mm.
6-8

Valve spring free length
Measure the free length of intake and exhaust valve springs. Service limit: Inner spring 35.20 mm Outer spring 36.90 mm
Valve stem
Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter. Service Limit: IN: 4.90 mm EX: 4.90 mm
Valve guide Caution

Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide. Service Limit: IN 0.08 mm EX 0.10 mm
5.0 mm valve guide reamer
Caution
If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve guide.
6-9

Valve Stem Replacement
Heat up cylinder head to 100~150 plate or toaster. with heated
Valve guide driver 5.0mm
Caution
Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. Wear on a pair of glove to protect your hands when operating. Hold the cylinder head, and then press out old valve guide from combustion chamber side. Tool: Valve guide driver: 5.0 mm
Caution
Check if new valve guide is deformation after pressed it in. When pressing in the new valve guide, cylinder head still have to be kept in 100~150 . Adjust the valve guide driver and let valve guide height is in 13 mm. Press in new valve guide from rocker arm side. Tool: Valve guide driver: 5.0 mm Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.
Valve guide driver 5.0 mm
Caution
Using cutting oil when correcting valve guide with a reamer. Turn the reamer in same direction when it be inserted or rotated. Correct valve seat, and clean up all metal residues from cylinder head. Tool: Valve guide reamer: 5.0 mm
Valve guide reamer 5.0 mm
6-10

Valve Seat Inspection and Service
Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.
Caution
Do not let emery enter into between valve stem and valve guide. Clean up the emery after corrected, and apply with engine oil onto contact faces of valve and valve seat. Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is roughness, wear out, or incomplete contacted with valve seat.
Valve seat width
Valve seat inspection

If the valve seat is too width, narrow or rough, corrects it.
Valve seat width

Service limit: 1.6mm Check the contact condition of valve seat.
Valve seat grinding

The worn valve seat has to be ground with valve seat chamfer cutter. Refer to operation manual of the valve seat chamfer cutter. Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat.
Roughness
Caution
After valve guide had been replaced, it has to be ground with 45 valve seal chamfer cutter to correct its seat face. Use 32 cutter to cut a quarter upper parts out.
45
Old valve seat width
32
6-11

Use 60 cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat.
60
Use 45 cutter to grind the valve seat to specified width.
Caution
Make sure that all roughness and uneven faces had been ground. Grind valve seat again if necessary.
1.0mm
45
Coat the valve seat surface with red paint. Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a seal track will be created on contact surface.
Contact surface too high Old valve seat width
Caution
The contact surfaces of valve and valve seat are very important to the valve sealing capacity.
32
If the contact surface is too high, grind the valve seat with 32 cutter. Then, grind the valve seat to specified width. If the contact surface too low, grind the valve seat with 60 cutter. Then, grind the valve seat to specified width.
Contact surface too low
60
6-12

After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground.
Cylinder Head Reassembly

Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Install valve springs and retainers.
Valve spring retainer
Valve stem seal
Valve cotter
Inlet valve
Caution
The closed coils of valve spring should face down to combustion chamber.
Valve spring Exhaust valve
Put the valve cotters onto valve spring retainer. Use a valve cotter remove & assembly tool to press the valve springs, and then install valves.
Caution
In order to avoid damaging the valve stem and the cylinder head, in the combustion chamber place a rag between the valve spring remover/installer as compressing the valve spring directly. Special Service Tool: Valve cotter remove & assembly tool SYM-1471110-SY125 Tap the valve stems gently with a plastic hammer to make sure valve retainer and valve cotter is settled.
Valve cotter remove and assembly tool
Caution
Place and hold cylinder head on to working table so that can prevent from valve damaged.
6-13

Install camshaft into cylinder head. Install valve rocker arm, rocker arm shaft and cam shaft setting plate.
2 bolts Cam shaft setting plate
Cylinder Head Installation

Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder.
Gasket
Caution
Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.
Chain guide
Dowel pins
Install 4 washers and tighten 4 nuts on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head right side. Torque value: Nut 3.6~4.0kgf-m Bolt 1.0~1.4kgf-m
Bolt 2
4 nuts
Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts.
Timing mark
Caution
Make sure timing marks are matched.
2 bolts
6-14

Install cylinder head side cover (3 bolts).
3 bolts
Tensioner bolts
Install thermostat (2 bolts). Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt.
Thermostat bolts
Install cylinder cover (4 bolts).
4 bolts
Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder head. Install and tighten spark plug. Torque value: 1.0~2.0kgf-m
4 bolts
Caution
This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycles performance be effected. Install the engine onto frame (refer chapter 5).
6-15

Valve Clearance Adjustment
Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover.
4 bolts
Remove the cylinder head side cover.
3 bolts
Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position. Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut. Standard Value: IN 0.10 0.02 mm EX 0.15 0.02 mm Install the cylinder head side cover. Start the engine and make sure that engine oil flows onto the cylinder head. Stop the engine after confirmed, and then install the cylinder head cover and AI pipe.
Timing mark
2 bolts
Caution
If lubricant does not flow to cylinder head, engine components will be worn out seriously. Thus, it must be confirmed. When checking lubricant flowing condition, run the engine in idle speed. Do not accelerate engine speed.
6-16
Home page
Contents
7. Cylinder / Piston
Mechanism Diagram 7-1 Precautions in Operation 7-2 Trouble Diagnosis 7-2 Cylinder and Piston Removal 7-3 Piston Ring Installation 7-6 Piston Installation 7-7 Cylinder Installation 7-7
Mechanism Diagram
0.8~1.2kgf-m
1.0~1.4kgf-m
7-1
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification
Item Cylinder ID Bend Clearance between piston rings Piston/ Piston ring OD of piston (2 ) Clearance between piston and cylinder ID of piston pin boss OD of piston pin Clearance between piston and piston pin ID of connecting rod small-end
nd
Unit Standard 72.995~73.015 Top ring 2 ring Top ring Ring-end gap 2 ring Oil ring side rail
nd nd
mm
Limit 73.100 0.050 0.090 0.090 0.500 0.650 72.380 0.100 17.020 16.960 0.020 17.064
0.015~0.050 0.015~0.050 0.150~0.300 0.300~0.450 0.200~0.700 72.430~72.480 0.010~0.040 17.002~17.008 16.994~17.000 0.002~0.014 17.016~17.034
Trouble Diagnosis
Low or Unstable Compression Pressure
Cylinder or piston ring worn out
Smoking in Exhaust Pipe

Piston or piston ring worn out Piston ring installation improperly Cylinder or piston damage
Knock or Noise
Cylinder or piston ring worn out Carbon deposits on cylinder head top-side Piston pin hole and piston pin wear out
Engine Overheat
Carbon deposits on cylinder head top side Cooling pipe clogged or not enough in coolant flow
7-2
Cylinder and Piston Removal
Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder.
Coolant hose
Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
Remove cylinder gasket and dowel pin. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
Caution
Soap the residues into solvent so that the residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out or damaged. In the 3 positions, top, center and bottom, of cylinder, measure the X and Y values respective in the cylinder.
Top
Service limit: 71.100 mm
Center Bottom
7-3
Check cylinder if warp. Service limit: 0.05 mm
Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm 2nd ring: 0.09 mm
Remove piston rings

Check if the piston rings are damaged or its grooves are worn.
Caution
Pay attention to remove piston rings because they are fragile.
Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston. Service Limit: Top ring: 0.50 mm 2nd ring: 0.65 mm
7-4
Measure the outer diameter of piston pin. Service Limit: 16.96 mm
Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm
Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole. Service Limit: 0.02 mm
Measure piston outer diameter.
Caution
The measurement position is 10 mm distance from piston bottom side, and 90 to piston pin. Service limit 72.380 mm Compare measured value with service limit to calculate the clearance between piston and cylinder.
7-5
Piston Ring Installation
Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.
Caution
Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side. Make sure that all piston rings can be rotated freely after installed.
Top ring 2
nd
ring
Oil ring
Top groove 2
nd
groove
Oil groove
7-6
Piston Installation
Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve.
IN mark
Install new piston pin clip.
Caution
Do not let the opening of piston pin clip align with the piston cutout. Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation.
Clip end gap
Cutout
Cylinder Installation
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase.
Caution
Soap the residues into solvent so that the residues can be removed more easily.
Install dowel pins and new cylinder gasket.
Dowel pins
7-7
Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.
Caution
Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
Install coolant hose onto cylinder. Install cylinder head (refer to Chapter 6).
Coolant hose
7-8
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8. V-Belt Driving System

Mechanism Diagram 8-1 Maintenance Precaution 8-2 Trouble Diagnosis 8-2 Left Crankcase Cover 8-3 Drive Belt 8-5 Drive Face8-7 Clutch Outer / Driven Pulley8-10
Mechanism Diagram
5.0~6.0kgf-m
8.5~10.5kgf-m
5.0~6.0kgf-m
8-1

Maintenance Precaution
Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Drive belt and drive pulley must be free of grease.
Specification
Item Driving belt width OD of movable drive face boss ID of movable drive face OD of weight roller ID of clutch outer Thickness of clutch weight Free length of driven pulley spring OD of driven pulley boss ID of driven face Weight of weight roller Standard value 24.000 29.946~29.980 30.000~30.040 19.500~20.000 144.850~145.150 6.000 102.400 40.950~40.990 41.000~41.050 17.700~18.300 mm mm mm mm mm mm mm mm mm g Limit 22.500 29.926 30.060 19.000 3.000 97.400 40.930 41.070 17.200 mm mm mm mm mm mm mm mm g
145.450 mm
Torque value
Drive face nut: 8.5~10.5kgf-m Clutch outer nut: 5.0~6.0kgf-m Drive plate nut: 5.0~6.0kgf-m
Special Service Tools

Clutch spring compressor: SYM-2301000 Inner bearing puller: SYM-6204002 Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder: SYM-2210100 Bearing driver: SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can not be moved
1. Worn drive Belt 2. Worn drive face 3. Worn or damaged clutch weight 4. Broken driven pulley
Insufficient horsepower or poor high speed performance

1. Worn drive belt 2. Insufficient spring force of driven pulley 3. Worn roller 4. Driven pulley operation un-smoothly
Shudder or misfire when driving

1. Broken clutch weight 2. Worn clutch weight
8-2

Left Crankcase Cover
Left crankcase cover removal
Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket.
8 bolts
Left crankcase cover install

Install left crankcase cover in the reverse procedures of removal.
Bearing setting plate
Drive shaft holder bearing
Left cover plate
8-3

Left crankcase cover inspection
Remove 2 bolts to remove left crankcase cover bearing setting plate.
2 bolts
Check bearing on left crankcase cover. Rotate bearings inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
Bearing replacement
Remove bearing with special service tools Special tools: Inner bearing puller SYM-6204022
Install bearing with special service tools. Special tools: Right crank case bearing 6201 assembles tool SYM-9614000-HMA 6201
8-4

Drive Belt
Removal
Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool universal holder
Universal holder
Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
Universal holder
Bearing stay collar
Caution
Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage reduction gear system.
Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley. Do not remove drive belt. Remove the drive belt from the groove of driven pulley.
Inspection
Check the drive belt for crack or wear. Replace it if necessary. Measure the width of drive belt as diagram shown. Service Limit: 22.5 mm Replace the belt if exceeds the service limit.
Caution
Using the genuine parts for replacement. The surfaces of drive belt or pulley must be free of grease. Clean up all grease or dirt before installation.
Belt tooth Width
8-5

Installation Caution
Pull out driven face to avoid it closing. Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley.
Driven face
Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.
Install the clutch outer and bearing stay collar. Hold the clutch outer whit universal holder, and then tighten nut to specified torque value. Torque value: 5.0~6.0kgf-m
Universal holder Bearing stay collar
Install the drive face, washer and drive face nut. Hold drive face with universal holder, and then tighten nut to specified torque value. Torque value: 8.5~10.5kgf-m
Universal holder
8-6

Drive Face
Removal
Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt.
Universal holder
Remove movable drive face comp and drive face boss from crankshaft.
Movable drive face
Crankshaft
Drive face boss
Remove ramp plate.
Ramp plate
Remove weight rollers from movable drive face.
Movable drive face
Weight roller
8-7

Inspection
The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each rollers outer diameter. Replace it if exceed the service limit. Service limit: 19.0 mm Weight: 17.2g Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face boss, and replace it if it exceed service limit. Service limit: 29.962 mm Measure the inner diameter of movable drive face, and replace it if it exceed service limit. Service limit: 30.060 mm
Movable drive face Weight roller
Drive face boss
Reassembly/installation Install weight rollers.
Caution
The weight roller two end surfaces are not certainly same. In order to lengthen the roller life and prevented exceptionally wears the occurrence, Please end surface of the closure surface counter clockwise assembles onto movable drive face.
Weight roller
Install ramp plate.

Closure surface
Ramp plate
Guide collar
8-8

With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss.
Caution
The movable drive face surface has to be free of grease. Clean it with cleaning solvent.
Drive face boss
Install movable drive face comp. onto crankshaft.

Movable drive face Drive face boss
Driven pulley installation

Press drive belt into pulley groove, and then pull the belt onto drive shaft.
Crank shaft
Press down
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces have to be free of grease. Clean it with cleaning solvent. Hold drives face with universal holder. Tighten nut to specified torque. Torque value: 8.5~10.5kgf-m Install left crankcase cover.
Drive belt
8-9

Clutch Outer/Driven Pulley
Disassembly
Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily.
Clutch nut wrench
Caution
Do not press the compressor too much. Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool. Release the clutch spring compressor and remove friction plate, clutch weight and spring from driven pulley. Remove seal collar from driven pulley.
Clutch spring compressor
Remove guide pin, guide pin roller, and movable driven face, and then remove O-ring & oil seal seat from movable driven face.
Movable driven face Seal
Collar
Guide pin
Inspection Clutch outer

Measure the inner diameter of clutch outer. Replace the clutch outer if exceed service limit. Service limit: 145.450 mm
O-ring Guide pin Guide pin roller
Inner diameter
Clutch outer
8-10

Clutch lining
Measure each clutch weight thickness. it if exceeds service limit. Service limit: 3.0 mm Replace
Clutch lining
Clutch weight
Driven pulley spring

Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.400 mm
Free length
Driven pulley
Check following items: If both surfaces are damaged or worn. If guide pin groove is damaged or worn. Replace damaged or worn components. Measure the outer diameter of driven face and the inner diameter of movable driven face. Replace it if exceeds service limit. Service limit: Outer diameter 40.93 mm Inner diameter 41.07 mm
Driven face
Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage. Replace it if necessary. Check if needle bearing is damage or too big clearance. Replace it if necessary. Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary.
Movable driven face Guide pin groove
Needle bearing
Outer ball bearing
8-11

Clutch weight Replacement
Remove snap ring and washer, and then remove clutch weight and spring from driving plate.
Spring Driving plate
Caution
Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
Snap ring Clutch weight
Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins.
Shock absorption rubber Setting pin
Install new clutch weight onto setting pin and then push to the specified location. Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.
Shock absorption rubber
Caution
Grease or lubricant will damage the clutch weight and affect the blocks connection capacity.
Clutch weight
Install the spring into groove with pliers.

Spring
8-12

Install snap ring and mounting plate onto setting pin.
Snap ring
Replacement of Driven Pulley Bearing

Remove inner bearing.
Caution
If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. If the pulley equipped with ball bearing, it has to remove snap ring and then the bearing.
Outer bearing Clipper
Inner needle bearing Snap ring
Remove snap ring and then push bearing forward to other side of inner bearing. Place new bearing onto proper position and its sealing end should be forwarded to outside. Apply with specified oil.
Snap ring
Install new inner bearing.
Caution
Its sealing end should be forwarded to outside as bearing installation. Install needle bearing with hydraulic presser. Install ball bearing by means of hydraulic presser. Install snap ring into the groove of drive face. Align oil seal lip with bearing, and then install the new oil seal (if necessary).
Outer bearing
Bearing end
Inner bearing
8-13

Installation of Clutch Outer/Driven Pulley Assembly
Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face.
Oil seal
O-ring
Specified grease
Install the movable driven face onto driven face. Install the guide pin and guide pin roller.
Movable driven face Oil seal Guide pin
Install the collar.

O-ring Guide pin Guide pin roller
Collar
Install friction plate, spring and clutch weight into clutch spring compressor, and press down the assembly by turning manual lever until mounting nut that can be installed. Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench. Remove the clutch spring compressor. Torque value: 5.0~6.0kgf-m Install clutch outer/driven pulley and drive belt onto drive shaft.
Clutch nut wrench
Clutch spring compressor
8-14
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9. Final Drive Mechanism

Mechanism Diagram 9-1 Precautions in Operation 9-2 Trouble Diagnosis 9-2 Disassembly of Final Drive Mechanism 9-3 Inspection of Final Drive Mechanism 9-4 Bearing Replacement 9-5 Re-Assembly of Final Drive Mechanism 9-8
Mechanism Diagram
Final shaft
Counter gear
Final gear
Drive shaft Counter shaft
9-1

Specification
Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 180 c.c. (170 c.c. when replacing)
Torque value
Gear box cover 2.6~3.0kgf-m
Special tools
Bearing driver Bearing (6205) puller Drive shaft & oil seal (25*40*8) socket Bearing (HK1516) driver Oil seal drive 34*52*5 Inner bearing puller Outer bearing puller Drive shaft install puller Bearing install puller Clutch nut wrench SYM-6204024 SYM-9100400 HMA RA1 6205 SYM-9120200-HMA SYM-9100200-HMA HK1516 SYM-9125500-HMA SYM-6204022 SYM-6204010 SYM-2341110- HMA RB1 SYM-2341100 SYM-9020200
Trouble Diagnosis
Engine can be started but motorcycle can not be moved.
Damaged driving gear Burnt out driving gear Damaged driving belt.
Noise
Worn or burnt gear Worn gear
Gear oil leaks

Excessive gear oil. Worn or damage oil seal
9-2

Disassembly of Final Drive Mechanism
Remove the rear wheel. Remove the clutch. Drain out gear oil from gear box. Loosen 7 bolts and remove gear box cover bolts.
7 bolts
Remove the gear box cover. Remove the gasket & dowel pin.
Remove final gear. Remove counter shaft, gear and 2 washers. Remove final shaft.
Final shaft
Counter shaft
Remove the drive shaft. Special tool: Shaft protector
Caution
If non- essential do not remove the drive shaft from the cover upper side. If remove the drive shaft from the gear box cover, then its bearing has to be replaced.
Drive shaft
9-3

Inspection of Final Drive Mechanism
Check if the drive shaft is worn or damaged and replace it if necessary.
Caution
If remove the drive shaft from the gear box upper side, then its bearing has to be replaced.
Check if the countershaft is worn or damaged, replace it if necessary.
Check if the final shaft and gear are worn or damaged, replace it if necessary.
Check bearings on gear box cover. Rotate each bearings inner ring with fingers. Check if bearings can be rotated smoothly and silently, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Check oil seal for wear or damage, and replace it if necessary. Check gear box bearing as the same way above, and replace it if necessary.
Oil seal
Bearing
9-4

Bearing Replacement
Left crankcase side
If the drive shaft is pulled out with its bearing, then remove the bearing with bearing puller and shaft protector. Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010
Outer bearing puller
Remove final shaft bearing and counter shaft bearing from left crankcase using following tools. Special tool: Inner bearing puller SYM-620422
Inner bearing puller
Caution
Never install used bearings. Once bearing removed, it has to be replaced with new one. Install new final shaft bearing and counter shaft bearing into left crankcase. Special tool: Bearing driver SYM-6204024 Bearing driver HK1516 SYM-9100200-HK1516
Bearing driver
Install new drive shaft bearing and bearing puller onto left crankcase. Special tool: Bearing puller 6205 SYM-9100400-6205
Bearing puller 6205
9-5

Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Use screw driver hold bearing puller lower part, and turn the bearing puller upper part to install the drive shaft bearing.
Gear box cover side

Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021
Remove oil seal, and then remove final shaft bearing from gear box cover using following tools. Special tool: Inner bearing puller SYM-6204022
Install a new drive shaft bearing and counter shaft bearing into gear box cover.
9-6

Install new final shaft bearing and bearing puller onto left crankcase. Special tool: Bearing puller 6205 SYM-9100400-6205 Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110
Bearing puller 6205
Use screw driver holder bearing puller lower part, and turn the bearing puller upper part to install the final shaft bearing.
Apply with grease onto final shaft oil seal. Install the oil seal into gear box cover. Special tool: Oil seal driver 34*52*5 SYM-9125500-HMA
Oil seal driver
9-7

Re-Assembly of Final Drive Mechanism
Install drive shaft. Special tool: Drive shaft puller SYM-2341110- HMA RB1 Drive shaft socket & oil seal driver (25*40*8) SYM-9120200-HMA Clutch nut wrench SYM-9020200
Clutch nut wrench Drive shaft and seal install socket
Drive shaft puller
Apply with grease onto drive shaft oil seal. Install the oil seal to left crankcase. Special tool: Drive shaft socket & oil seal driver (25*40*8) SYM-9120200-HMA
Oil seal driver
Install 2 dowel pins & new gasket.
Dowel pins
Install counter shaft and final shaft into the gear box cover. Install the gear box and tighten the bolts (7 bolts). Torque value: 2.6~3.0kgf-m Install driven pulley / clutch outer / belt. Install movable drive face, drive face and left crankcase cover. Install rear wheel. Add gear oil. Gear oil quantity: 180c.c.
Final shaft
Drive shaft
Counter shaft
9-8
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10. AC Generator / Starting Clutch

Mechanism Diagram10-1 Precautions in Operation 10-2 Right Crankcase Cover Removal 10-3 AC Generator Removal10-4 Right Cover Bearing 10-4 Flywheel Removal 10-5 Starting Clutch 10-6 Flywheel Installation 10-8 AC Generator Installation 10-9 Right Crankcase Cover Installation 10-9
Mechanism Diagram
0.8~1.2kgf-m
10
1.0~1.4kgf-m
5.0~6.0kgf-m
10-1

General information
Refer to chapter 17: The troubleshooting and inspection of alternator. Refer to chapter 17: The service procedures and precaution items of starter motor.
Specification
Item ID of starting clutch gear OD of starting clutch gear Standard value (mm) 25.026~25.045 42.192~42.208 Limit (mm) 25.050 42.100
Torque value
Flywheel nut Starting clutch hexagon bolt 8 mm bolts 12 mm bolts 5.0~6.0kgf-m 1.0~1.4kgf-m with adhesive 0.8~1.2kgf-m 1.8~2.2kgf-m
Special tools
AC.G. flywheel puller Left crank case cover 6201 bearing puller Inner bearing puller
Universal holder
SYM-3110000-HMA SYM-9614000-HMA RB1 6201 SYM-6204025

SYM-2210100
10-2

Right Crankcase Cover Removal
Remove right side cover. Remove seat and luggage box.
(Refer chapter 13)
Remove the exhaust muffler (3 bolts, 2 nuts).
3 bolts
2 nuts
Drain out the engine oil and coolant (refer chapter 5). Remove coolant hoses.
Coolant hoses
Disconnect the couplers of the power source output line.
Generator couplers
Remove water pump cover (4 bolts). Remove 10 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket.
10 bolts
4 bolts
10-3

AC Generator Removal
Remove 2 mounting screws from CPS. Remove 3 screws from right crankcase cover and then remove generator coil set.
3 screws
CPS screws
Right Cover Bearing

Rotate the bearing by fingers to check if the bearing rotation is smooth and silent. Check if the bearing outer parts are closed and fixed, replace it if necessary.
Cir clip
Remove the bearing 6201 with inner bearing puller. Special tool: Inner bearing puller SYM-6204025
Install the bearing 6201 bearing with special tool. Special tool: Right crankcase cover bearing 6201 presser SYM-9614000-HMA RB1 6201
Inner bearing presser
10-4

Flywheel Removal
Remove right crankcase cover and generator coil. Remove flywheel nut.
Flywheel nut
Install shaft protector onto the crank shaft. Special tool: Shaft protector
Shaft protector
Reduction gear
Remove starter reduction gear and shaft. Pull out flywheel with AC generator flywheel puller. Special tool: Flywheel puller SYM-3110000-HMA
Flywheel puller
Remove flywheel and starting driven gear.
10-5

Starting Clutch
Starting Clutch Inspection
Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 25.050 mm OD: 42.100 mm
ID
OD
Check the starting reduction gear and shaft for wear or damage.
Check each roller for wear or damage.
Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in counterclockwise direction freely, but not clockwise direction.
10-6

Remove the starting gear Loosen 3 starting clutch socket bolts from one way clutch and remove one way clutch.
3 bolts
Push out the roller set and check each roller for wear or damage.
One way clutch Installation

Install the components in the reverse procedures of removal. Torque value: 1.0~1.4kgf-m
One way clutch
Caution
Cannot lock the thread of socket bolt.
Caution
The one way clutch must to with the generator flywheel and the starter gear, after one and loads the crank in, only then may lock the socket bolt, otherwise will create concentric the deviation, will cause the part to suffer injury.
Starting driven gear
10-7

Flywheel Installation
Install starting driven gear onto one way clutch.
Starting driven gear
Align the key on crankshaft with the flywheel groove, and then install the flywheel.
Groove
Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Torque value: 5.0~6.0kgf-m Special tool: Universal Holder SYM-2210100
10-8

AC Generator Installation
Install the AC Generator coil onto right crankcase cover (3 screws). Install the CPS (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator.
Pulse generator screws 3 screws
Right Crankcase Cover Installation

Install dowel pins and new gasket. Remove water pump cover. Install right crankcase cover onto the crankcase. Note: Align the water pump shaft indent with the oil pump shaft.
Dowel pins
10 bolts
Install right crankcase cover (10 screws). Install the dowel pin, new gasket and water pump cover onto crankcase cover.
4 bolts
Connect coolant hoses onto the right crankcase cover. Add engine oil and coolant.
10-9

Notes:
10-10
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11. Crankcase / Crank

Mechanism Diagram 11-1 General Information 11-2 Trouble Diagnosis 11-2 Crankcase Disassembly 11-3 Crankshaft Inspection 11-4 Crankcase Reassembly 11-6
Mechanism Diagram
0.8~1.2kgf-m
1.0~1.4kgf-m
11
0.8~1.2kgf-m
11-1

General Information
Operational precautions
This Section concerns disassembly of the crankcase for repair purpose. Remove following components before disassembling crankcase. Engine remove Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 Drive face and driven pulley Chapter 8 AC generator/Start one way clutch Chapter 10 In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing chain, it is preferably to replace crankshaft as a unit.
Specification
Item Connecting rod side clearance of the big end Vertical clearance of the big end of the connecting rod Run-out Standard 0.100~0.400 0~0.008 -
Unit: mm
Limit 0.600 0.050 0.100
Torque value
Bolts for crankcase Cylinder stud bolts Bolt for cam chain adjuster 0.8~1.2kgf-m 1.0~1.4kgf-m 1.2~1.6kgf-m
Special tools
R/L. crank disassemble tool L. crank shaft bearing puller Crank shaft install socket & oil seal driver Crank shaft puller Outer bearing puller Inner bearing puller
Clutch nut wrench SYM-1120000-HMA H9A SYM-9100100 SYM-2341110- HMA RB1 SYM-1130000-HMA H9A SYM-6204010 SYM-6204025 SYM-9020200
Trouble Diagnosis
Engine noise
Loose crankshaft bearing Loose crankshaft pin bearing Worn out piston pin and pin hole
11-2

Crankcase Disassembly
Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the cam chain tensioner. Loosen 2 bolts on the right crankcase.
Setting plate Tensioner
2 bolts
Loosen 8 bolts on the left crankcase.
8 bolts
Place right crankcase downward and left crankcase upward. Install crankshaft disassemble tool onto left crankcase. Caution Care should be taken not to damage the contact surfaces.
Crank case disassemble tool
Crank shaft puller
Install left crank shaft puller into crank case disassemble. Hold left crank shaft puller nut by clutch nut wrench, and turn the shaft puller to press out crank shaft from left crankcase. Special tool: Crank case disassemble SYM-1120000-HMA H9A L. Crank shaft puller SYM-1130000-HMA H9A
11-3

Remove crankshaft and wave washer from right crankcase.
Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping.
Drive out left crankcase oil seal.
Crankshaft Inspection
Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm
Measure point for the crank big end of the connecting rod.
11-4

Measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm
Place the crankshaft on a V-block, measure run-out of the crankshaft. Service limit: 0.10 mm
50 mm
50 mm
Check crankshaft bearing Use hand to crank the bearing to see it moves freely, smoothly and noiseless. Check the inner ring to see it links firmly on the bearing.
Crank bearing
If any roughness, noise and loose linkage are detected, replace the bearing with new one. Caution The bearing shall be replaced in pair. Special tool: Outer bearing puller SYM-6204010
Out bearing puller
11-5

Crankcase Reassembly
Install new bearing and bearing puller onto left crankcase bearing hole. Special tool: L. crank shaft bearing puller SYM-9100100
Crank shaft bearing puller
Install crank disassemble tool onto left crankcase. Install left crank shaft puller into crank case disassemble. Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft bearing into left crankcase. Special tool: Crank case disassemble SYM-1120000-HMA H9A L. Crank shaft puller SYM-2341110-HMA
Crank shaft puller
Install crank shaft onto the left crankcase and install crank shaft install socket. Special tool: Crank shaft install socket & oil seal driver
SYM-2341110- HMA RB1
Crank shaft install socket
Turn in the crank shaft puller spiral tooth to the left crank shaft. Special tool: L. Crank shaft puller SYM-1130000-HMA H9A
Crank shaft puller
11-6

Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft into left crankcase.
Crank shaft puller
Put wave washer onto right crank bearing. Caution Right flank the wave washer piece certainly must install. Cannot install the wrong position or leak the attire. Otherwise can cause the motorcycle to have the fierce vibration
Install 2 dowel pins and new gasket. Install the right crankcase onto the left crankcase
Tighten 8 bolts on the left crankcase. Tighten 2 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m
R. crankcase
L. crankcase
2 bolts
8 bolts
11-7

Apply a layer of grease on the lip of oil seal Clean the crankshaft with clean solvent.
Install the oil seal in the left crankcase with special tool. Special tool: Crank shaft install socket & oil seal driver
SYM-2341110- HMA RB1
Oil seal driver
Setting plate
Tensioner
Install the cam chain tensioner & and tighten the bolts. Torque value: 1.2~1.6kgf-m Install the cam chain. Install the cam chain setting plate.
2 bolts
11-8
Home page
Contents
12. Cooling System

Mechanism Diagram 12-1 General Information 12-2 Trouble Diagnosis 12-2 Cooling System Fault Elimination 12-3 Coolant Replacement 12-5 Radiator 12-6 Water Pump 12-8 Thermostat 12-12
Mechanism Diagram
Reserve tank filler cap
Reserve tank
Reserve tank inlet pipe Thermo switch (fan) Cooling fan Radiator Engine coolant outlet pipe
12
Engine coolant inlet pipe
Reserve tank outlet pipe
Thermo unit (temp meter)
Thermostat
Water pump
12-1
12. Cooling System

General Information
General Warning
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. Refill the radiator with distilled water or specified additives. Add coolant to the reserve tank. The cooling system can be serviced on the motorcycle. Never spill the coolant to the painted surface. Test the cooling system for any leakage after repair. Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the water thermometer.
Technical Specification
Item Pressure to open filler cap Capacity of coolant: Engine + radiator Reserve tank Thermostat Boiling point Specification 0.9 0.15 Kg/cm 1400c.c. 420c.c. Begins to activate at : 82~92C Stroke : 0.05~3.0mm/80C Not-pressure : 107.7C Pressurized: 125.6C
Torque Value
For water pump rotor 1.0~1.4kgf-m
Tools Requirement Special tools

Water pump bearing driver (6901): SYM-9100100 Water pump oil seal driver (Inner): SYM-9120500-H9A Water pump mechanical seal driver: SYM-1721700-H9A Inner bearing puller: SYM-6204020
Trouble Diagnosis
The engine temperature is too high
The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to closed. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The filler cap of the radiator malfunction. The engine temperature is too low The water thermometer and the temperature sensor malfunction. The thermostat is stuck to open. Coolant is leaking The water pump mechanical seal does not function properly. The O ring is deteriorated. The water hose is broken or aged
12-2
12. Cooling System

Cooling System Fault Elimination
The temperature indicated is too high
Y
A. Stop and waiting for the engine is completely cooled down, open cap to check the capacity of coolant in radiator. A1.Refill the radiator with coolant then check for any leakage?
Water leaking problem
Y
B. Turn on main switch and check the water temperature indicator back to zero?
B-1. Measure thermo unit to confirm voltage 6V ?
Replace thermo unit
Y Y
B-2. Inspect the circuits of water temperature have short or earth?
Short or earth handle
N
Meter problem
C. Open radiator cap and softly throttle, inspect coolant have circulated?
C-1. Eng. stop and remove water pump cover, start the motor to inspect pump its rotation?
Water pump repair
N
Water hose clogged
Y
D. Close radiator cap, measure thermo unit to confirm voltage reduced comply with temperature rise?
Replace thermo unit
Y
Next page
12-3
12. Cooling System

Preceding page
E. Keep eng. 3000~4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks?
E-1. Measure thermal switch to confirm voltage be changed (12 0V)?
Replace thermal switch
Y Y
F. Confirm the cooling fan was convulsion? E-2. Connect cooling fan terminals with battery (12V) directly to inspect its operation?
Replace cooling fan
Y
Meter unusual
Y
E-3. Keep eng. 3000~4000 rpm and inspect coolant flow into reserve tank after the temperature gauge over 3 checks?
If circuit connects reverse cooling fan will forward, correct and check again.
Y
E-4. Remove thermostat from holder then heats it by water directly to check its operation?
Replace thermostat
Refill with coolant then check again
For bleed the air bubbles completely, open radiator cap and start engine while engine is cool then press water hose softly by hand to bleeding. Turn the throttle repeatedly until the coolant surface becomes stable.
Notice the water hose cant any unsuitable bend or twist and bleed the air bubbles completely.
12-4
12. Cooling System

Coolant Replacement
Warning
Never attempt to carry out service work on the cooling system unless the engine is completely cooled down, otherwise, you may get scalded. Remove the reserve tank cap cover, and then remove tank cap.
Reserve tank cap
Place a water pan under the water pump; loosen the drain bolt to drain out the coolant. Reinstall the drain bolt.
Drain bolt
Refill system with the coolant and bleed out the air bubbles. Run the engine, and remove by-pass pipe. Check the by-pass hole and see if the air bubble emit or not. If there is no air bubble emit with only the coolant flow out, then reinstall the pipe and shut down the engine. Remove the radiator filler cap. Start the engine; make sure the coolant level is stable without any air bubble emitting. Shut down the engine; add the coolant to the proper level if necessary. Reinstall the radiator filler cap.
By-pass pipe
Caution
To avoid the water tank rusting, do not use the uncertified coolant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50%
12-5
12. Cooling System

Check reserve tank
Open the inner box lid. Check the coolant level in the reserve tank. Add coolant to proper level if too low.
Caution
Do not make the coolant level in the reserve tank too high, whick
Viewing window
Radiator
Check
Check for any leakage from weld seam. Blow radiator clean using compressed air. If the radiator is blocked by dirt, use low pressure water jet to clean it. Care shall be taken when straightening the sink fan.
Remove
Place a water pan under the water pump; loosen the drain bolt to drain out the coolant.
Drain bolt
Remove the front cover and under spoiler (refer chapter 12). Loosen the radiator mounting bolts (4 bolts).
Each side 2 bolts
12-6
12. Cooling System

Disconnect the couplers for the thermo switch and fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe.
Thermo switch coupler
Cooling fan coupler
Engine coolant inlet pipe
Remove reserve tank coolant inlet pipe. Remove the radiator and the cooling fun.
Coolant inlet pipe
Loosen the cooling fun mounting bolts (3 bolts). Remove thermo switch.
Cooling fun
3 bolts
Thermo switch
Installation
Install the removed parts in the reverse order of removal. Install radiator in the reverse order of removal. Upon completion, check for any leakage.
Caution
Liquid packing must be applied to the thermo switch before installing to avoid damaging the radiator.
12-7
12. Cooling System

Water Pump
Check water pump seal / cooling system divulges inspection
Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified. If has the above two kind of interior to divulge the phenomenon, possibly for the water pump inner two seal damages, the engine cooling system damages or the cylinder and the cylinder head gasket damages, please first dismantles the right crank case to say A confirms the replacement water pump seal, if does not have the question to take apart for overhaul cooling system of system again the cylinder head, the cylinder.
Drain bolt
Removal of water pump

Loosen the drain bolt to drain out the coolant. Remove the water hose. Loosen 4 bolts and remove the pump cover. Loosen 10 bolts and remove the engine right cover. Take off the gasket and dowel pins. Turn pump rotor clockwise and remove.
Caution
The rotor is provided with left turn thread.
Remove the cir clip from the right crankcase cover. Remove the water pump shaft and the inner bearing. Remove the outside bearing by inner bearing puller. Rotate the inner ring of bearing, the bearing shall move smoothly and quietly. If the bearing does not rotate smoothly or produces a noise, replace it with new one.
12-8
12. Cooling System

Check any wear and damage of the mechanical seal and inside seal.
Mechanical seal
Caution
The mechanical seal and inside seal must be replaced as a unit.
Replacement of Mechanical Seal

Remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase. Special tools: Inner bearing puller Water pump bearing drive SYM-9100100
Water pump mechanical seal driver
Caution
Replace a new mechanical seal after removing it.
Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new mechanical seal.
Mechanical seal
Install the mechanical seal onto the right crankcase. Special tools: Water pump mechanical seal driver SYM-1721700-H9A
Water pump mechanical seal driver
12-9
12. Cooling System

Install the new inner seal onto the right crankcase. Special tools: Water pump oil seal driver (inner) SYM-9120500-H9A
Water pump oil seal driver (inner)
Install a new outside bearing to the right crankcase cover. Special tools: Water pump bearing driver (6901) SYM-9100100
Water pump bearing driver (6901)
Caution
Do not reuse old bearing. It must be replaced with a new one once it has been removed.
Mount the water pump shaft and the inner bearing to the right crankcase cover.
Inner bearing
Water pump shaft
Install the cir clip to hold the inner bearing.
12-10
12. Cooling System

Install the seal washer into the rotor.
Caution
Washer must be replaced together with the mechanical seal.
Install the rotor onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m
Water pump rotor
Caution
The rotor is left thread.
Install the dowel pin and right cover gasket. The rotation water pump rotor, causes the water pump drive shaft scoop channel, aligns the oil pump drive shaft flange, install the right crank case. (10 bolts)
Install the dowel pin and new gasket. Install the water pump cover with 4 bolts.
12-11
12. Cooling System

Thermostat
Please refer to chapter 17 for inspection of thermo unit.
Thermo unit
Removal
Remove the luggage box and body cover. Drain out the coolant.
Remove the thermostat cover. (2 bolts)
2 bolts
Remove the thermostat.
Inspection
Visually inspect thermostat for any damage.
12-12
12. Cooling System

Place the thermostat into heated water to check its operation.
Caution
Whenever the thermostat and the thermometer are in contact to the wall of heated water container, the reading displayed is incorrect. If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change, then it must be replaced.
Technical Data
Valve begins to open Valve stroke 82~95 0.05 ~ 3mm
Installation
Install the thermostat. Install the thermostat cover. (2 bolts) Refill the coolant and bleed out the air bubble (Page 12-5).
2 bolts
12-13
12. Cooling System

Notes:
12-14
Home page
Contents
13. Body Cover

Mechanism Diagram13-1 Maintenance 13-2 Handle Front Cover 13-3 Wind Screen 13-4 Front Cover 13-4 Handle upper cover 13-5 Handle lower cover13-6 Inner Box 13-7 Side Cover 13-9 Front Under Spoiler 13-10 Side Garnish 13-10 Front Fender 13-11 Luggage Box 13-12 Rear Carrier 13-13 Rear Body Cover 13-14 Floor Panel 13-15 Under Cover 13-16
Mechanism Diagram
13
13-1
13. Body Cover

Maintenance
Body covers disassemble sequence:
Wind screen garnish
Front cover lid
Luggage box & seat
Wind screen
Front cover
Rear carrier
Handle lower covers
Inner box
Rear fender
Handle upper cover
Handle under cover
Rear body cover
R/L. side cover
R/L. side cover
Rear mudguard
Under cover
Front under spoiler
Floor panel
R/L. side garnish
Be careful not to damage various covers in assembly or disassembly operation. Never injure hooks molded on the body covers. Align the buckles on the guards with slot on the covers. Make sure that each hook is properly installed during the assembly. Never compact forcefully or hammer the guard and the covers during assembly.
13-2
13. Body Cover

Handle Front Cover
Remove Loosen 2 screw bottom of front handle cover
2 Loosen 2 screws from left and right side for handle front cover after side
Wind Screen
Remove the 5 screws from to meter visor.
Lift and right 2
5 screws
Remove handle meter visor. Installation Install in reverse order of removal procedures.
13-3
13. Body Cover

Front Cover
Remove Loosen 2 screws from the front cover emblem.
2 screws Loosen 3 bolts from the front cover front end.
Loosen 8 screws from each side 4 screws for front cover after side
3 bolts
Installation Install in reverse order of removal procedures.
13-4
13. Body Cover

Handle upper cover
speedometer set
Loosen 2 screws from the handle front cover upper side.
2 screw
winker relay coupler
Remove the 4 screw from the handle lower cover rear side.
Winker & foggy light the winker relay and brake light couplers Remove the handle upper cover. brake light
Installation Install in reverse order of removal procedures. Winker relay
13-5
13. Body Cover

Handle lower cover
Loosen the 2 screws from handle lower cover.
2 Remove the handle stand nut and bolt.
Remove the handle lower cover.
Stand nut and
13-6
13. Body Cover

Inner Box
Remove Remove 1 screw on the fuse box stay and . 1 screw on the reserve tank stay. Remove the dc power outlet connect.
power outlet
Remove main switch cap bolt then remove main switch cap.
bolt Loosen 2 screws from the front spoiler.
2 screws luggage reserve tank
Open inner box lid. Remove 1 screw from the inner box in side. Remove 1 screw from reserve tank lid. Remove 1 bolt from luggage hook then remove luggage hook.
inner box
13-7
13. Body Cover

Remove fuel tank cap and rubber. Reserve
1 1
Loosen 1 screw and 1 bolt from left and right side for inner box down side
1 bolt Remove reserve tank cap then separate the reserve
Reserve tank cap
Remove the inner box.
13-8
13. Body Cover

Side Cover
Remove: Loosen 1 screw from left and right side for side covers font side.
1 Loosen 1 screw from left and right side for side covers rear upper side.
Remove side cover.
13-9
13. Body Cover

Front Under Spoiler
Remove Remove the side cover. Loosen 1 screws and 1 bolt from the front spoiler front side. 1 screw
1 screw Remove the front spoiler.
Side Garnish
Loosen 1 screw from left and right side for side garnish. 1 screw
Remove the left and right side garnish.
13-10
13. Body Cover

Front Fender
Remove front fender B Loosen each side 2 bolts from front fender B. . Remove the front fender B. Installation Install in reverse order of removal procedures. Each side 2
Remove front fender A Loosen 3 bolts from the front fender above the inside
Loosen 2 screws from the front fender above the inside
Remove the front fender A.
13-11
13. Body Cover

Luggage Box
Remove Open the seat. Loosen 3 screws from the battery cover. Remove the battery cover. 2
Loosen 6 bolts from luggage box.
6 bolts
Disconnect the luggage box light and switch coupler.
Remove the luggage box.
13-12
13. Body Cover

Rear Carrier
Loosen 1 screw front the rear center cover. 2
Loosen 2 bolts front tail light upper side.
2 bolts
Tail
Loosen each side 2 bolts from body inside.
each side 2 bolts
Remove the rear carrier.
To this chapter co
13-13
13. Body Cover

Rear Body Cover
Remove Loosen Each side 2 screws from rear end of floor panel. floor panel
Each side 2 screws Loosen 2 bolts from rear fender.
2 bolts Disconnect the tail light coupler.
Tail light coupler
Remove the body cover.
13-14
13. Body Cover

Floor Panel
Remove Remove side garnish, front cover, front spoiler, R/L side cover, inner box, luggage box and body cover. Remove each side 2 caps from floor panel.
Each side 2 caps Loosen 4 bolts from floor panel 4 bolts
Loosen each side 1 screws from floor panel rear side.
Each side 1 screws Remove floor panel.
13-15
13. Body Cover

Under Cover
Each side 2 bolts from under cover.
Each side 2 bolts
Remove the under cover.
13-16
Home page
Contents
14. Brake System

Mechanism Diagram 14-1 Maintenance Description 14-2 Trouble Diagnosis 14-3 Disk Brake System Inspection 14-4 Adding Brake Fluid 14-5 Brake Fluid Replacement 14-6 Front Brake Caliper 14-7 Rear Brake Caliper 14-8 Brake Disk 14-9 Master Cylinder 14-9
Mechanism Diagram
14
14-1
14. Brake System

Maintenance Description
Operational precautions Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system. While refilling brake fluid, care should be taken not to let the foreign material entering into the brake system. Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage. Check the operation of the brake system before riding.
Specifications
Item The thickness of front brake disk The thickness of rear brake disk Front and rear brake disk eccentricity Front brake master cylinder inner diameter Front brake master cylinder piston outer diameter Rear brake master cylinder inner diameter Rear brake master cylinder piston outer diameter Diameter of front disk Diameter of rear disk Thickness of front brake lining Thickness of rear brake lining Standard 4.000 5.000 < 0.100 11.000~11.043 10.957~10.984 14.000~14.043 13.957~13.984 240.000 220.000 5.000 6.000 2.000 2.000 Limit 2.500 3.500 0.300 11.055 10.945 14.055 13.945
unit: mm
Torque values:
Brake hose bolts Bolt for front brake caliper Brake lever nut Air-bleed valve 3.0~4.0kgf-m 2.9~3.5kgf-m 0.8~1.0kgf-m 0.8~1.0kgf-m
14-2
14. Brake System

Trouble Diagnosis
Soft brake lever
1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8. Blocked brake hose 9. Warp/bent brake disk 10. Bent brake lever
Hard operation of brake lever

1. 2. 3. 4. 5. Blocked brake system Poor brake caliper Blocked brake pipe Seized/worn master cylinder piston Bent brake lever
Uneven brake
1. 2. 3. 4. 5. Dirty brake lining/disk Poor wheel alignment Clogged brake hose Deformed or warped brake disk Restricted brake hose and fittings
Tight brake
1. Dirty brake lining/disk 2. Poor wheel alignment 3. Deformed or warped brake disk
Brake noise
1. 2. 3. 4. Dirty lining Deformed brake disk Poor brake caliper installation Imbalance brake disk or wheel
14-3
14. Brake System

Disk Brake System Inspection
Inspection
By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Remove the front brake pad cap. Check the brake from behind the brake caliper.
Brake linings wear limit grooves
The brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk.
Brake linings wear limit grooves
Park the motorcycle on a level ground, and check if fluid level is under the LOWER mark. Recommended Brake Fluid: WELL RUN BRAKE OIL (DOT 3).
Brake caliper
Brake disk
Caution
The vehicles inclined or just stop, the survey oil level could not be accurate, had to settle the 3~5 minute. In order to prevent has the chemical change, please do not use counterfeiting or other unclear trade marks brake fluid. Uses by all means must with the trade mark brake fluid, guarantees the ghost vehicle efficiency.
14-4
14. Brake System

Adding Brake Fluid
Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
Front brake master cylinder
Caution
Supplement brake fluid please do not surpass the upper limit, spilled brake fluid on painted surfaces, plastic or rubber components may result in their damages.
Rear brake master cylinder
Remove the master cylinder cap and diaphragm. Increases the high quality brake fluid, uses by all means must with the trade mark brake fluid joins in the master cylinder. Clean the dirty brake disk.
Master cylinder cap
Diaphragm Upper level Brake Fluid
Caution
The dirty brake lining or disk will reduce the brake performance. To mixed non-compatible brake fluid will reduce brake performance. Foreign materials will block the system causing brake performance to be reduced or totally lost.
14-5
14. Brake System

Brake fluid replacement
Connect drain hose to brake bleeder valve. Open the valve on the calipers and delay valve the brake lever until the old brake fluid is entirely drained out. Close the valve and add specified brake fluid into the brake master cylinder. Recommended brake fluid: WELLRUN DOT 3 brake fluid Connect one end of transparent hose to the drain valve, and put the other end into a container. Open the valve around 1/4 turns, and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever. Close the valve when finishing the brake system refilling fluid procedure, and operate the brake lever to check whether air bubble is in brake system or not. If brake is still soft, please bleed the system as described below: 1. Tightly hold the brake lever and open the valve around 1/4 turns, and then close the valve.
Brake bleeder valve
Delay valve Brake bleeder valve
Front brake caliper
Caution
Do not release the brake lever before the drain valve is closed. Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system. 2. Slowly release the brake lever, and wait for a few seconds until it reaches its top position. 3. Repeat the steps 1 and 2 until there is no air bubble at the end of the hose. 4. Tightly close the drain valve. 5. Make sure the brake fluid is in the UPPER level of the master cylinder, and refill the fluid if necessary. 6. Cover the cap Caution Divulges the air to have to pump by the minute first divulges, then to caliper. May use fluid the replacement machine, the replacement fluid, the time is quicker, the air bubble also Compared with cannot remain
Brake bleeder valve
Rear brake caliper
Bubble
Brake bleeder valve
Transparent hose
14-6
14. Brake System

Front Brake Caliper
Removal
Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the brake hoses.
Brake hose bolts
Caution
Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.
Installation
Install the brake caliper and tighten the mounting bolts. Torque: 2.9~3.5kgf-m
Caliper mounting bolts
Pad caps
Caution
Use M8 x 35 mm flange bolt only. Long bolt will impair the operation of brake disk. Use two seal washers and hose bolts to lock the hoses and brake caliper in place. Torque: 3.0~4.0kgf-m Refill up the brake fluid to the reservoir and make necessary air bleeding.
Cotter pins
Brake pad replacement

Remove brake caliper. Remove brake pad caps. Remove the brake pad guidance shafts cotter pins.
Guidance shaft
Remove the brake pad guidance shafts and locking spring, and then remove brake pads.
Locking spring
Install the new brake pads onto brake caliper. Install the brake pad guidance shafts and locking springs. Install the brake pad guidance shafts cotter pins. Install the brake caliper and tighten the mounting bolts.
14-7
14. Brake System

Rear Brake Caliper
Removal
Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose.
Brake hose bolts
Caution
Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.
Installation
Install the brake caliper and tighten the mounting bolts. Torque: 2.9~3.5kgf-m
Caliper mounting bolts
Caution
Use M8 x 35 mm flange bolt only. Long bolt will impair the operation of brake disk. Use two seal washers and hose bolts to lock the hoses and brake caliper in place. Torque: 3.0~4.0kgf-m Refill up the brake fluid to the reservoir and make necessary air bleeding.
Socket bolts
Brake pad replacement

Remove the brake caliper upper parts (2 socket bolts).
Take out the brake pads.
Install the new brake pads onto brake caliper bracket. Install the brake caliper upper parts and tighten the socket bolts.
14-8
14. Brake System

Brake Disk
Inspection
Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: Front brake disk 2.5 mm Rear brake disk 3.5 mm
Brake disk
Micrometer
Remove the brake disk from wheel. Check the disk for deformation and bend. Allowable limit: 0.30 mm
Caution
The dirty brake lining or disk will reduce the brake performance. Brake lining includes the asbestos ingredient, cannot use the air-gun to be clean, the operator should dress the mouthpiece and the glove, use vacuum cleaner clean it.
Master Cylinder
Master Cylinder Removal Caution
Do not let foreign materials enter into the cylinder.
Brake hose
Caution
The whole set of master cylinder, piston, spring, diaphragm and cir clip should be replaced as a set. Remove the handlebar covers. Remove the leads of brake light switch. Drain out the brake fluid. Remove the brake lever from the brake master cylinder. Remove the brake hose. Remove the master cylinder bolts and the master cylinder.
Brake switch
2 bolts
14-9
14. Brake System

Remove the rubber pad. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid.
Rubber boot Piston Piston Spring Cir clip
Master cylinder
Master Cylinder Inspection

Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Allowable limit: Front brake: 11.055 mm Rear brake: 14.055 mm Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Front brake: 10.945 mm Rear brake: 13.945 mm
Master cylinder
Master cylinder piston
Master Cylinder Assembly Caution

It is necessary to replace the whole set comprising piston, spring, piston cup, and cir clip. Make sure there is no dust on all components before assembling. Apply clean brake fluid to the piston cup, and then install the cup onto the piston. Install the larger end of the spring onto the master cylinder. The master cups cavity should be face inside of master cylinder when installing the master cup. Install the cir clip.
Rubber boot Piston Piston
Cir clip
Caution
Never install cup lip in the opposite direction. Make sure the cir clip is seated securely in the groove. Install the rubber pad into groove properly.
Master cylinder Spring
14-10
14. Brake System

Master Cylinder Install
Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch.
2 bolts
Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified torque value. Make sure the hose is installed correctly. Install all wires, hoses, and components carefully so avoid to twisting them together.
Washers
Caution
Improper routing may damage leads, hoses or pipes.
Brake light switch Brake hose
Caution
Kink of brake leads, hose or pipe may reduce brake performance. Add specified brake fluid and bleed the system.
14-11
14. Brake System

Note:
14-12
Home page
Contents
15. Steering / Front Wheel / Front Cushion

Mechanism Diagram 15-1 Operational Precautions 15-2 Trouble Diagnosis 15-2 Steering Handle 15-3 Front Wheel 15-5 Front Cushion 15-8 Steering Stem 15-9
Mechanism Diagram
4.0~5.0kgf-m
1.0~2.0kgf-m
2.4~3.0kgf-m
0.2~0.3kgf-m
5.0~7.0kgf-m
15
4.0~4.5kgf-m
15-1

Operational Precautions
General
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of the tire.
Torque Values
Nut for the front wheel axle Nut for the steering handle Lock nut for the steering handle stem Top crown for the steering handle stem Locating screw for the speedometer cable Front cushion upper lock bolt Front brake disk 5.0 ~ 7.0kgf-m 4.0 ~ 5.0kgf-m 1.0 ~ 2.0kgf-m 0.2 ~ 0.3kgf-m 0.15 ~0.3kgf-m 2.4 ~ 3.0kgf-m 4.0~4.5kgf-m
Special Tools
Steering handle top thread wrench Inner bearing puller Steering nut wrench Driver 32*35mm Driver 42*47mm SYM-5320000 SYM-6204020 SYM-6204010 SYM-5321100
Trouble Diagnosis
Hard to steer
The steering handle stem nut is too tight. The ball and the top crown of the steering handle stem are damaged. Insufficient tire pressure.
The front wheel rim run-out

The rim is bent. The wheel axle nut is not tightened enough. Side-worn or poor tire. The bearing clearance of the wheel axle is too large.
The steering handlebar is tilted

Uneven arrangement of the front cushion. The front fork is bent. The front wheel axle is bent
Soft front cushion

The front cushion spring is worn out. The oil seal of the front cushion is leaking.
Noise in front cushion

Front cushion is warped. The joint of the front cushion gets loose.
15-2

Steering Handle
Remove
Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake.
Master cylinder
Holder
2 bolts
Loosen the deceleration throttle cable fixing nut. Loosen 1 screw from the acceleration throttle fixing plate.
Fixing nut
1 screw
Loosen 2 screws from the throttle holder.
2 screws
Remove throttle holder, handle switch, cables and grip.
Throttle cables
15-3

Loosen 2 bolts from the master cylinder of the rear brake. Remove holder and master cylinder.
Master cylinder
Holder
2 bolts
Loosen left handle switch connecter. Loosen 2 screws from left side handle switch holder. Remove the right handle switch.
2 screws
Switch connecter
Loosen handle mounting nut. Remove handle mounting bolt, and then remove the handle.
Installation
Install handle and align with bolt hole. Install bolt and nut and then tighten it. Torque value: 4.0~5.0kgf-m
Handle mounting BOLT
Apply with grease onto throttle cable and the sliding surface of handle. Align the lock pin with the hole on the handle. After the installment completes, carries on the following inspection and the adjustment: Throttle grip operation. All electric appliances, the meter function
15-4

Front Wheel
Loosen 2 bolts from the front brake caliper and remove it
2 screws
Caution
Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out. In case that the brake pad is accidentally squeezed out, use a screwdriver to force it back to the place. Loosen screw & remove speedometer cable. Turn loose the axle nut.
Speedometer cable
Loosen the socket bolt and front axle from light side front cushion.
Front Axle
socket bolt
Pull out the front wheel axle. Remove the front wheel and both side collar.
15-5

Inspection
Wheel axle Place the wheel axle on a V block, measure its run out. Service limit: 0.2 mm
Bearing Use finger to move the inner ring of each bearing, it shall move smoothly and quietly. Check the outer ring is securely attached on the wheel hub. If the motion of the inner ring of the bearing is not smooth, or noisy and loose when being moved, remove and discard it.
Free play
Free play
Caution
The bearing shall be replaced in pair.
Wheel Place the wheel on to a rotation seat to check its rim wobbling. Turn the wheel with hand and measure its rim wobbling value with a dial gauge. Service limit: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
Disassembly
Remove brake disk (5 bolts). Remove dust seal, bearing and dist collar from left side. Remove dust seal and bearing from right side. Special tools: Inner bearing puller SYM-6204020
15-6

Assembly
Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist. collar. Install the right side bearing.
Dist collar
Bearing 6202U
Caution
Carefully install the bearing in correct and evenly. Bearing outer face should be faced up as bearing installation.
Bearing 6202U
Install the brake disk and then tighten the bolts. Torque value: 4.0~4.5kgf-m
15-7

Front Cushion
Remove
Remove front cover, front under spoiler and front fender. Remove front wheel. Remove front brake caliper. Remove speedometer cable.
2 bolts
Speedometer cable
Loosen 4 bolts from steering stem. Remove the front cushions.
4 bolts
Installation
Align the cover flange with upper level of the cushion clamp, and then tighten bolts. Torque value: 2.4~3.0kgf-m Install the removed components in reverse order of removal procedures.
15-8

Steering Stem
Remove
Remove handle, front wheel and front cushion. Remove the steering stem mounting nut.
Stem mounting nut Steering stem top thread wrench
Top cone race
Remove top cone race and steering stem.
Top cone race
Caution
Place the steel ball onto a parts container to prevent from missing. Special tools: Steering stem top thread wrench SYM-5320010 Handle stand nut wrench SYM-5321100
Handle stand nut wrench
Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats. Remove bottom cone race body with a punch.
Caution
Do not damage the steering stem.
Installation
Install a new bottom cone race onto the steering stem. Push the cone race until to mounted position.
Steering stem mounting nut Top cone race Top ball bearing seat Bottom ball bearing seat
Caution
Do not tilt the ball bearing seats as installation. Apply with grease onto the ball bearing seats, and install steel balls onto the seats.(Top: 26 balls, bottom: 29 balls)
Steel balls Bottom cone race
15-9

Lubricate the top cone race seat with grease. Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turns. Torque value: 0.25kgf-m
Steering lock nut
Return 1/2 turns
Caution
Check the steering stem that should be rotated freely and no clearance in vertical direction.
Top cone-race Locking to 1/4~3/8 turns
Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.0~2.0kgf-m
Install in reverse order of removal procedures.
15-10
Home page
Contents
16. Rear Wheel / Rear Fork / Rear Cushion

Mechanism Diagram16-1 Operational Precaution 16-2 Trouble Diagnosis 16-2 Muffler16-3 Rear Wheel 16-3 Rear Fork 16-5 Rear Cushion 16-6
Mechanism Diagram
11.0~13.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
16
4.0~5.0kgf-m 4.0~5.0kgf-m
16-1

Operational Precaution
General
Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires.
Service data
Item Run-out of rear rim Radial Axial Standard -
Unit: mm
Allowable Limit 2.0 2.0
Torque Value
Rear wheel axle nut Rear cushion upper bolt Rear cushion under bolt Rear fork mounting bolt Exhaust muffler mounting nut Exhaust muffler mounting bolt Brake clipper mounting bolts Brake disc mounting bolt 11.0~13.0kgf-m 3.5~4.5kgf-m 2.4~3.0kgf-m 4.0~5.0kgf-m 1.0~1.2kgf-m 3.2~3.8kgf-m 2.9~3.5kgf-m 4.0~5.0kgf-m
Trouble Diagnosis
Run-out of rear wheel
Deformed or bent wheel hub. Improper tires. Loose wheel shaft.
Poor Performance of Brake

Improperly adjusted brake. Contaminated brake disc. Worn brake lining. Air inside brake fluid pipe. Grease on brake disc. The brake fluid piping is clogged. The brake fluid pipe is deformed or bent. The brake fluid pipe is deformed or bent. Insufficient amount of brake fluid in the reservoir
Soft Cushion
The spring is too weak.
Noisy Brake
Worn brake lining. Offset brake disc. Improper assembly of brake caliper. Brake disc or wheel imbalance.
16-2

Muffler
Removal
Loosen the 1 mounting bolt by exhaust muffler front side. Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler.
Installation
Caution
Replace the front side muffler pipe gasket if worn or deformed. Torque Value: Muffler mounting bolt Muffler mounting nut 3.2 ~ 3.8kgf-m 1.0 ~ 1.2kgf-m
3 bolts
1 bolt
bolt
2 bolts
Rear Wheel
Removal
Remove the exhaust muffler. Remove the lower bolt of the right side rear cushion. Remove 2 bolts and rear axle nut of the rear fork. Remove the rear brake caliper (2 bolts) and brake hose clamp (1 bolt).
Rear axle nut
Caution
Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out. In case that the brake pad is accidentally squeezed out, use a screwdriver to force it back to the place.
rear brake caliper
2 bolts
Remove the rear wheel.
16-3

Inspection rear wheel rim
Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm
Installation
Install in reverse order of removal procedures. Torque Value: Rear wheel axle nut 11.0~13.0kgf-m Rear cushion under bolt 2.4~3.0kgf-m Rear fork mounting bolt 4.0~5.0kgf-m Brake clipper mounting bolts 2.9~3.5kgf-m
16-4

Rear Fork
Inspection rear fork bearing
Rotate the inner ring of the bearing with a finger. The bearing should move smoothly and quietly. Check the fit of the bearing and rim. Replace the bearing if its motion is not smooth or noisy.
Free play Free play
Replacement of rear fork bearing

Remove the bearing lock cir clip.
Cir clip
Uses the bearing driver; drive out the bearing. Special tool: Bearing driver
Install new rear fork bearing and bearing puller (6303) onto rear fork. Install assembly directs puller bearing puller. Special Service Tools: Rear fork bearing 6303 bearing puller SYM-6303000-HMA H9A 6303 Assembly directs puller SYM-2341110 Use screw driver hold bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing.
16-5

Install the bearing lock cir clip.
Outside collar Cir clip Bearing (6303UU)
Inside collar
Rear Cushion
Removal
Remove the luggage box, rear carrier and body covers. Loosen the mounting bolts of the air cleaner (2 bolts). Remove the exhaust muffler (3 bolts, 2 nuts). Remove the under bolts by left and right rear cushions. Remove the upper bolts by left and right rear cushions, and then remove the cushion.
Under bolt
Left
Upper bolt
Installation
Right
Upper bolt
Caution
The rear cushion must be replaced as a unit. Never disassemble the rear cushion as that would damage the structure. Torque Value Rear cushion upper bolt: 3.5~4.5kgf-m Rear cushion under bolt: 2.4~3.0kgf-m
Under bolt
16-6
Home page
Contents
18. Emission Control System

Emission Control System Classification 18-1 Emission Control System Description 18-1 Evaporative Emission Control System (E.E.C.) 18-2 Catalytic Converter (CATA) 18-4 Positive Crankcase Ventilation System (P.C.V.) 18-5 Inspection Items18-6 Countermeasure for Abnormal Emission Pollutants18-7
Emission Control System Classification
Emission Control System Description
18
18-1

Evaporative Emission Control System (E.E.C.)
1. Construction:
Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Automatic control fuel cup Vapor purge control solenoid Vapor hose Carburetor
Blow-by hose
Air cleaner Activated- carbon canister Flesh air Fuel Fuel vapor Vacuum Flesh air inlet Engine
2. Principle of operation
3. Trouble Diagnosis:
4. Cautions:
18-2

Evaporative Emission Control System (E.E.C.) Inspection 1. Visual check:
2. Leakage test:
Fuel tank
Pressure gauge
Pressure source Activated-carbon canister
Plugged
3. PCV Function Test
Pressure gauge Engine vacuum
To air filter
Pressure source
Purge Control Valve
18-3

Catalytic Converter (CATA)
1. Construction:
Catalytic converter
Engine
Exhaust muffler
2. Description:
18-4
Positive Crankcase Ventilation System (P.C.V.)

1. Construction
Flesh air Fuel vapor separator Blow-by pipe
Drain pipe
Air filter
Carburetor
Crankcase
Flesh air Mixture gas Blow-by Engine oil Piston
Cylinder head
2. Principle of operation:
3. Service Methods
Visual check:
18-5

Inspection Items
Fuel Evaporation Control System
Catalytic converter
Fuel Supply System
Ignition system
18-6

Countermeasure for Abnormal Emission Pollutants
18-7
Home page
Contents
19. Electrical Diagram

LH30W EFi Electrical Diagram
19
19-1

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FOREWORD

HOW TO USE THIS MANUAL

Service Department SANYANG INDUSTRY CO., LTD.

How To Use This Manual

Symbols and Marks

To this chapter contents

Used engine oil Caution

Brake fluid Caution

Hot components Caution

To this chapter contents

Never bend or twist a control cable to prevent

To this chapter contents

Both of these examples can result in bearing damage.

To this chapter contents

To this chapter contents

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

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

To this chapter contents

Keep wire harnesses far away from the hot parts.

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

Never clamp or squeeze the wire harness as installing other components.

Never too tight

To this chapter contents

To this chapter contents

Max. Speed Climb Ability Primary Reduction

Secondary Reduction Clutch Transmission

Stroke Number/Arrange ment Displacement

Solid Particulate CO HC EEC PCV

Compression Ratio Max. HP Max. Torque Ignition Starting System

To this chapter contents

Standard Torque Values for Reference

8 mm bolt nut 10 mm bolt nut

Engine Torque Values

Apply oil to thread

To this chapter contents

To this chapter contents

3. Malfunction of ECU. 4. Malfunction generator

7. Malfunction of main switch

cylinder compression pressure normal

Re-start by following the starting procedures

Remove the spark plug again and check it.

To this chapter contents

Engine speed can be increased.

Engine speed can not be increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct

Incorrect ignition timing

Malfunction of ECU Malfunction of AC generator

Compression pressure correct

Check fuel injector clogged or not

Fouled and discoloration

1. change the fuel injector

Remove spark plug

foul and discoloration

Remove dirt Incorrect spark plug heat range

To this chapter contents

Check ignition timing (using ignition lamp)

Incorrect ignition timing (malfunction of ECU or AC generator)

throttle body or not

Oil seal driver 34525 SYM-9125500-HMA

Drive shaft & oil seal (25408) socket SYM-9120200-HMA RB1