SERVICE MANUAL

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 SYM FORWARD

This service manual contains the technical data of each component

inspection and repair for the SYM series motorcycle. The manual is shown
with illustrations and focused on 「Service Procedures」, 「Operation Key
Points」, and 「Inspection Adjustment」 so that provides technician with service
guidelines.

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

This manual that contains all data, illustration, indication and specifications
is based on current production information. SYM reserves the right to make
changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SYM.

SERVICE DEPARTMENT
SANYANG INDUSTRY CO., LTD.

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 HOW TO USE THIS MANUAL SYM

This service manual describes basic information of different system parts and
system inspection & service for SYM series motorcycles. In addition, please
refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance.
The third to the eleventh chapters cover engine and driving systems.
The twelfth to fifteenth chapters are contained the parts set of assembly
body.
The sixteenth chapter is electrical equipment.
The seventh chapter is for wiring diagram.
Please see index of content for quick having the special parts and system
information.

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 SYM CONTENTS

CONTENTS

GENERAL INFORMATION/TROUBLE DIAGNOSIS ...................................1

MAINTENANCE INFORMATION .................................................................2
LUBRICATION SYSTEM..............................................................................3
FUEL SYSTEM .............................................................................................4
ENGINE REMOVAL......................................................................................5
CYLINDER HEAD/VALVE............................................................................6
CYLINDER/PISTON......................................................................................7
"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/ STARTER CLUTCH .......8

FINAL DRIVING MECHANISM.....................................................................9

A.C. GENERATOR/STARTING CLUTCH ....................................................10
CRANKCASE/CRANKSHAFT .....................................................................11
BODY COVER ..............................................................................................12
BRAKE SYSTEM..........................................................................................13
STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER ........................14
REAR WHEEL/SUSPENSION......................................................................15
ELECTRICAL EQUIPMENT .........................................................................16
ELECTRICAL DIAGRAM .............................................................................17
SPECIAL TOOL............................................................................................18

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 MECHANISM ILLUSTRATIONS SYM
Meter
High&Low beam/Seat
open/turn signal/horn
Rear brake lever
Start magnetic switch
Horn/REG.REC Frame number
Front turn Fuel tank / Fuel unit
signal light Tail light

RR. turning
signal light
Air cleaner

Gear oil filling

bolt
Gear oil draining
bolt

Engine number/engine
oil draining bolt
Front brake lever

Front disk brake Ignition switch

Exhaust muffler

Light/starter switch
Engine control
Head light/
switch
Position light
Rear turn
Winker relay
signal light
Battery/Fuse/CDI

Ignition coil

A.C. Generator
Oil level

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

SYMBOLS AND MARKS ....................1-1 TORQUE VALUES (ENGINE) .............. 1-10

GENERAL SAFETY............................1-2 TORQUE VALUES (FRAME) ............... 1-11
SERVICE PRECAUTIONS .................1-3 TROUBLES DIAGNOSIS ..................... 1-12
SPECIFICATIONS..............................1-9 LUBRICATION POINTS ....................... 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 procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.

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

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

Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the
Engine oil damage that caused by not apply with the limited engine oil.

Limits to use SAE 85W-140 class oil. Warranty will not cover the damage
Gear oil that caused by not apply with the limited gear oil.

Grease King Mate G-3 is recommended.

Apply sealant, medium strength sealant should be used unless otherwise

specified.
Locking sealant

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

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

Special service tools.

Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions.

Components assembly directions each other.

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

1-1

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
GENERAL SAFETY
Carbon monoxide Battery
If you must run your engine, ensure the place is Caution
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if y Battery emits explosive gases; flame is
you have to run your engine in a closed area, be strictly prohibited. Keep the place well
sure to use an extractor. ventilated when charging the battery.
y Battery contains sulfuric acid (electrolyte)
Caution
which can cause serious burns so be careful
Exhaust contains toxic gas which may cause
do not be spray on your eyes or skin. If you
one to lose consciousness and even result in
get battery acid on your skin, flush it off
death.
immediately with water. If you get battery
acid in your eyes, flush it off immediately
with water, then go to hospital to see an
Gasoline
ophthalmologist.
Gasoline is a low ignition point and explosive y If you swallow it by mistake, drink a lot of
material. Work in a well-ventilated place, no water or milk, and take some laxative such
flame or spark should be allowed in the work as castor oil or vegetable oil, and then go to
place or where gasoline is being stored. see a doctor.
Caution y Keep electrolyte beyond reach of children.
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.

Brake shoe
Used engine oil Do not use an compressed air or a dry brush to
clean components of the brake system, use a
Caution
vacuum cleaner or the equivalent to avoid
Prolonged contact with used engine oil (or asbestos dust flying.
transmission oil) may cause skin cancer
Caution
although it might not be verdict.
Inhaling asbestos dust may cause disorders
and cancer of the breathing system.

Hot components
Caution
Brake fluid
Components of the engine and exhaust system
can become extremely hot after engine running. Caution
They remain very hot even after the engine has Spilling brake fluid on painted, plastic, or rubber
been stopped for some time. When performing parts may cause damage to the parts. Place a
service work on these parts, wear insulated clean towel on the above-mentioned parts for
gloves and wait until cooling off. protection when servicing the brake system.
Keep brake fluid beyond reach of children.

1-2

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
SERVICE PRECAUTIONS
y Always use with SANYANG genuine parts y Never bend or twist a control cable to prevent
and recommended oils. Using non-designed stiff control and premature worn out.
parts for SANYANG motorcycle may damage
the motorcycle.

y Rubber parts may become deteriorated when

y Special tools are designed for remove and old, and prone to be damaged by solvent and
install of components without damaging the oil. Check these parts before installation to
parts being worked on. Using wrong tools make sure that they are in good condition,
may result in parts damaged. replace if necessary.
y When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
y Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
y 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.
y 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.
y Wash and clean parts with high ignition point
solvent, and blow dry with compressed air.
y Note the reassemble position of the important
Pay special attention to O-rings or oil seals
components before disassembling them to
because most cleaning agents have an
ensure they will be reassembled in correct
adverse effect on them.
dimensions (depth, distance or position).
y Components not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.

1-3

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
y The length of bolts and screws for y Remove residues of the old gasket or sealant
assemblies, cover plates or boxes is different before reinstallation, grind with a grindstone if
from one another, be sure they are correctly the contact surface has any damage.
installed. In case of confusion, Insert the bolt
into the hole to compare its length with other
bolts, if its length out side the hole is the
same with other bolts, it is a correct bolt.
Bolts for the same assembly should have the
same length.

y The ends of rubber hoses (for fuel, vacuum,

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

Groove

y Tighten assemblies with different dimension

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

Boots
y The tool should be pressed against two (inner
and outer) bearing races when removing a
y When oil seal is installed, fill the groove with ball bearing. Damage may result if the tool is
grease, install the oil seal with the name of pressed against only one race (either inner
the manufacturer facing outside, check the race or outer race). In this case, the bearing
shaft on which the oil seal is to be installed should be replaced. To avoid damaging the
for smoothness and for burrs that may bearing, use equal force on both races.
damage the oil seal.

Manufacturer's
name

Both of these examples can result in bearing

damage.

1-4

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
y Lubricate the rotation face with specified y Before battery removal operation, it has to
lubricant on the lubrication points before remove the battery negative (-) cable firstly.
assembling. Notre tools like open-end wrench do not
contact with body to prevent from circuit short
and create spark.

y Check if positions and operation for installed

parts is in correct and properly.

y 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.

y Make sure service safety .

y Make sure that the battery post caps are

located in properly after the battery posts had
been serviced.

y Note that do not let parts fall down

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

capacity
verification

1-5

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
y When separating a connector, it locker has to y Before terminal connection, check if the boot
be unlocked firstly. Then, conduct the is crack or the terminal is loose.
service operation.

y Insert the terminal completely. Check if the

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

y Do not pull the wires as removing a

connector or wires. Hold the connector
body.

y Secure wires and wire harnesses to the

frame with respective wire bands at the
designated locations. Tighten the bands so
that only the insulated surfaces contact the
y Make sure if the connector pins are bent, wires or wire harnesses.
extruded or loosen.

y Insert the connector completely. If there are y Wire band and wire harness have to be
two lockers on two connector sides, make clamped secured properly.
sure the lockers are locked in properly.
Check if any wire loose.

y Check if the connector is covered by the twin y Do not squeeze wires against the weld or its
connector boot completely and secured clamp.
properly.

1-6

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
y Do not let the wire harness contact with y Protect wires or wire harnesses with electrical
rotating, moving or vibrating components as tape or tube if they contact a sharp edge or
routing the harness. corner. Thoroughly clean the surface where
tape is to be applied.

y Keep wire harnesses far away from the hot

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

Do not touch it.

y Never use wires or harnesses which

y Route wire harness to avoid sharp edges or insulation has been broken. Wrap electrical
corners and also avoid the projected ends of tape around the damaged parts or replace
bolts and screws. them.

y Route harnesses so that they neither pull too

tight nor have excessive slack.
y Never clamp or squeeze the wire harness as
installing other components.

Please do not clip or

squeeze the wire.

Do not extend
it too much.

1-7

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
y Do not let the wire harness been twisted as y With sand paper to clean rust on connector
installation. pins/terminals if found. And then conduct
connection operation later.

Clean rust.

y 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.

y Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.

Do you know how to set the

instrument to its measurement
position and the insert locations
of its two probes?

1-8

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
SPECIFICATIONS
MAKER SANYANG MODEL AY05W-6

Suspen

System
Overall Length 2000mm Front TELESCOPIC FORK

sion
DIMENSION

Overall Width 690mm Rear UNIT SWING ARM

cations
Specifi
Overall Height 1125mm Front 90/80-16 51N

Tire
Wheel Base 1330 mm Rear 90/80-16 51N
Curb Weight

Front 40 kg

System
Front DISK (ø 226 mm)

Brake
Rear 60 kg

Total 100 kg Rear DRUM (ø 130 mm)

WEIGHT

Passengers/

Performa
Two men/175 kg Max. Speed Less than 45 km/hr
Weight

nce
Total Weight

Front 85kg Climb Ability 22° Below

Rear 165 kg Primary Reduction C.V.T.

Deceleration
equipment

Secondary
Total 250kg GEAR
Reduction
Type 4-STROKE ENGINE Clutch Centrifugal, dry type
Installation and Vertical, below center,
Transmission V-belt
arrangement incline 80°
Fuel Used Unleaded (93/95) Speedometer 0 ~ 80 km/hr
4-stroke/forced air
Cycle/Cooling Horn 80~112 dB/A
cooled
Bore 37.0 mm Muffler Expansion & Pulse Type
Cylinder

Exhaust Pipe Position Right side, and

Stroke 46.0 mm
and Direction Backward
ENGINE

Number/Arran
Single Cylinder Lubrication System Separated-lubrication
gement
Displacement 49.6 cc CO <12.0 g/km
Exhaust
Compression Emission
12.6±0.2 : 1 HC <1.0 g/km
Ratio
Idle Speed 2100±100 Fuel tank capacity 4.80L
Max. HP 2.3KW/ 7500 rpm Air Filtration Paper filter
Max. Torque 3.1N.m /6500 rpm Noise Emission < 80dB(A)
Ignition C.D.I. Fuel tank capacity 4.8L
Starting System Electrical & Kick starter

1-9

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
TORQUE VALUES (ENGINE)
THREAD DIA TORQUE
ITEM Q'TY REMARKS
(mm) VALUE(Kg-m)
Cylinder head bolts 2 6 0.8~1.2
Cylinder head left side cover bolts 2 6 0.8~1.2
Cylinder head nuts 4 8 0.8~1.2 Apply oil to thread
Tappet adjust hole cap 2 30 1.0~2.0
Cylinder/cylinder head two-ends bolts 4 6 0.7~1.1 Tighten to crankcase
Camshaft sprocket bolt 1 8 2.0~2.4
Right crank case cover bolts 10 6 0.8~1.2
Pulse generator bolts 2 5 0.35~0.5
Valve adjustment fixing nuts 2 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.4
Engine oil filter screen cap 1 30 1.0~2.0
Engine oil drain plug bolt 1 12 3.5~4.5
Gear oil draining plug 1 8 1.0~1.5
Gear oil filling bolt 1 8 1.0~1.5
Oil pump flat screw 2 6 0.8~1.2
Left crankcase cover bolts 10 6 0.8~1.2
Camshaft chain tensioner pivot 1 6 0.8~1.2 Hex socket bolt
Camshaft chain adjuster bolts 2 6 1.0~1.4
Cooling fan bolts 4 6 0.8~1.2
Cooling fan cover bolt 2 6 0.7~1.1
RR. brake shoe anchor fixing nut 1 8 1.5~2.0
Shroud A/B 2 6 0.8~1.2
Start clutch lock nut 1 20 9.0~10
Flywheel nut 1 10 3.5~4.5
Transmission(Gear box) bolts 7 8 2.6~3.0
Movable drive face nut 1 12 5.0~6.0
Drive pulley nut 1 10 3.5~4.5
A.C. generator flange bolt 2 6 0.8~1.2
Start motor bolts 2 6 0.8~1.2
Crankcase bolts 1 6 0.8~1.2
Air/C connect bracket bolts 2 6 0.8~1.2
Kick starter arm bolt 1 6 0.8~1.2
Carburetor nut 2 6 0.8~1.2
Exhaust pipe bolts 2 8 3.0~3.6
Exhaust pipe connecting nuts 2 6 1.0~1.4

1-10

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
TORQUE VALUES (FRAME)
THREAD DIA TORQUE
ITEM Q'TY REMARKS
(mm) VALUE(Kg-m)
Mounting Hex socket bolt for steering
4 10 4.0~5.0
handlebar
Mounting nut for steering rod 1 25.4 1.0~2.0

Cone seat for steering rod 1 25.4 0.2~0.3

Front wheel shaft nut 1 12 5.0~7.0
Rear wheel shaft nut 1 16 11.0~13.0
Wheel hub/rim mounting nuts 8 8 2.8~3.2
Speedometer cable locking screw 1 5 0.15~0.3
Front shock absorber mounting bolts 4 8 2.4~3.0
Rear shock absorber upper connection
1 10 3.5~4.5
bolt
Rear shock absorber lower connection
1 8 2.4~3.0
bolt
Brake lever bolts 2 6 0.8~1.2
Front brake hose bolts 2 10 3.3~3.7
Front brake air-bleeding valve 1 6 0.8~1.0
Front brake disc mounting bolts 4 10 4.0~4.5
Front brake clipper mounting bolts 2 10 3.1~3.5
Drum brake arm bolts (front/rear) 2 6 0.8~1.2
Engine suspension bracket bolts 2 10 4.5~5.5 On frame side
Engine connection bolt 1 10 4.5~5.5 On engine side
Main standard nut 1 10 3.5~4.5
Foot-starting lever bolt 1 6 1.6~1.8
Air cleaner bolts 2 6 1.0~1.4
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference
TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE
5mm bolt、nut 0.45~0.60kgf-m 3mm screw 0.05~0.08kgf-m
6mm bolt、nut 0.80~1.20kgf-m 4mm screw 0.10~0.15kgf-m
8mm bolt、nut 1.80~2.50kgf-m 5mm screw 0.35~0.50kgf-m
10mm bolt、nut 3.00~4.00kgf-m 6mm screw、SH nut 0.70~1.10kgf-m
12mm bolt、nut 5.00~6.00kgf-m 6mm bolt、nut 1.00~1.40kgf-m
8mm bolt、nut 2.40~3.00kgf-m
10mm bolt、nut 3.50~4.50kgf-m

1-11

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
TROUBLES DIAGNOSIS
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes

1. No fuel in fuel tank

Loosen carburetor drain bolt 2. Check if the pipes, fuel tank to
to check if there is gasoline carburetor and intake vacuum,
inside the carburetor are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation
Fuel supplied tom No fuel is supplied to system clogged
carburetor sufficient carburetor 5. Malfunction of fuel pump
6. Loosen or damaged fuel pump
vacuum hose
7. Fuel filter clogged
Remove spark plug, install
it into spark plug cap, and
perform a spark test
against engine ground. 1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
Check if sparks Weak sparks, no spark 4. Malfunction of AC generator
at all 5. Ignition coil is in open or short
circuit
6. Ignition coil leads open or short
perform cylinder circuit
compression pressure test. 7. Malfunction of main switch

1. Piston ring seized

cylinder compression Low compression 2. Malfunction of cylinder valves
pressure normal pressure or no pressure 3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
Re-start by following the
starting procedures

1. Malfunction of throttle valve

No ignition There are some signs of operation
ignition, nut engine can 2. Air sucked into intake manifold
not be started 3. Incorrect ignition timing

Remove the spark plug

again and check it.

1. Fuel level in carburetor too high

Dry spark plug Wet spark plug 2. Malfunction of throttle valve
operation
3. Throttle valve opening too wide
Remove carburetor after 30 minutes
and connect a hose onto fuel rich
circuit. Then blow the hose with air

Blowing in normal Blowing clogged 1. Malfunction of automatic by-

starter

1-12

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
B. Engine run sluggish (Speed does not pick up, lack of power)

Check and adjustment Fault condition Probable causes

Try gradual acceleration

and check engine speed

1. Air cleaner clogged

Engine speed can be Engine speed can not be 2. Poor fuel supply
increased. increased. 3. Lines in fuel tank evaporation
system clogged
4. Exhaust pipe clogged
5. Fuel level too low in carburetor
Check ignition timing
6. Fuel nozzle clogged in
(Using ignition lamp)
carburetor.

Ignition timing correct Incorrect ignition timing 1. Malfunction of CDI

2. Malfunction of AC alternator

Check cylinder compression

pressure (using compression
pressure gauge)
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
Compression pressure correct No compression 3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
Check if carburetor jet is
clogged

No clogged Clogged 1. Remove foreign

Remove spark plug

No foul or discoloration Fouled and discoloration 1. Remove dirt

2. Incorrect spark plug heat range

Check if engine over heat

1. Piston and cylinder worn out
2. Lean mixture
Engine overheat 3. Poor fuel quality
Normal 4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling
Continually drive in system
acceleration or high speed

1. Too much carbon deposited in

Knock combustion chamber
No knock 2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced

1-13

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing

(using ignition lamp)

Normal Abnormal 1. Incorrect ignition timing (malfunction

of CDI or AC alternator)

Adjust the air screw of

carburetor

Good Poor 1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)

Air sucked through

carburetor gasket
1. Poor heat insulation gasket
2. Carburetor lock loose
No air sucked Air sucked 3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground 1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
Good spark Poor 4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes

Check ignition timing

Normal Abnormal 1. Malfunction of CDI

2. Malfunction of AC alternator

Check for fuel supplying

system in automatic fuel cup

1. Insufficient fuel in fuel tank

Good Poor 2. Fuel filter clogged
3. Restricted fuel tank vent

Check if carburetor clogged

No clogged Clogged 1. Cleaning

1-14

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 SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
E. CLUTCH, DRIVING AND DRIVING PULLEY

FAULT CONDITIONS PROBABLE CAUSES

1. Driving belt worn out or deformation

Engine can be started but 2. Driving disk damaged
motorcycle can not be moved. 3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damaged

Engine running and misfire as

motorcycle initial forward moving 1. Clutch ling spring broken
or jumping suddenly (rear wheel 2. Clutch outer stick with clutch balance weights
rotating as engine in running) 3. Connection parts in clutch and shaft worn out
or burned

1. Driving belt worn out or deformation

Poor initial driving ( Poor 2. Balance weight roller worn out
climbing performance) 3. Driving sliding gear shaft worn out
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.

1-15

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 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
LUBRICATION POINTS

Seat lock
Acceleration cable/ Front & rear brake lever pivot

Steering shaft bearing

Speedometer gear / Rear wheel bearing

Side stand shaft Main stand shaft
Front wheel bearing

1-16

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 SYM 2. MAINTENANCE INFORMATION

PRECAUTIONS IN OPERATION .......2-1 IGNITION SYSTEM/SPARK PLUG .. 2-8

PERIODICAL MAINTENANCE CYLINDER COMPRESSION
SCHEDULE ........................................2-2 PRESSURE........................................ 2-9
LUBRICATION SYSTEM ....................2-3 DRIVING SYSTEM............................. 2-9
FUEL SYSTEM...................................2-4 STEERING SYSTEM ......................... 2-10
AIR CLEANER....................................2-5 SUSPENSION SYSTEM .................... 2-10
THROTTLE VALVE OPERATION ......2-5 FRONT DISK BRAKE SYSTEM ......... 2-11
CRANKCASE BLOW-BY SYSTEM ....2-6 DRUM BRAKE SYSTEM .................... 2-13
VALVE CLEARANCE INSPECTION & WHEEL/TIRE...................................... 2-14
ADJUSTMENT....................................2-6 BATTERY ........................................... 2-15
CARBURETOR IDLING SPEED HEADLIGHT ADJUSTMENT .............. 2-15
ADJUSTMENT ..................................2-7 NUTS、BOLTS TIGHTEN.................. 2-15

PRECAUTIONS IN OPERATION
Specification
Fuel Tank Capacity 4.80L
capacity 800 c.c.
Engine Oil
change 650 c.c.
capacity 180 c.c.
Transmission Gear oil
change 170 c.c.
Clearance of throttle valve 2~6 mm
Spark plug A7RC Gap: 0.6~0.7 mm
“F” Mark in idling speed Before TDC 13º / 1700 rpm
Full timing advanced Before TDC 27º / 8000 rpm
Idling speed 2100±100 rpm
Cylinder compression pressure 12.6±0.2 kg/cm²
Valve clearance: IN/EX 0.05±0.02 mm
Tire dimension front / rear 90/80-16 51N / 90/80-16 51N
single Front: 2.00 kg/cm² rear: 2.00 kg/cm²
Tire pressure (cold)
Two persons Front: 2.00 kg/cm² rear: 2.25 kg/cm²
battery 12V6Ah (closed type, maintenance-free battery)
Play of drum brake lever 10~20 mm

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 2. MAINTENANCE INFORMATION SYM

PERIODICAL MAINTENANCE SCHEDULE

Mainte 1 year
1 Month 3 month 6 month
nance Item Initial 300KM Every12000K
Code Every1000KM Every3000KM Every6000KM
M
1 ☆Air cleaner I C C R
2 ☆Fuel filter I I R
3 ☆Oil filter C C C
4 ☆Engine oil change R Replacement for every 1000km
5 Tire pressure I I
6 Battery inspection I I
7 Brake & free play check I I
8 Steering handle check I I
9 Cushion operation check I I
10 Every screw tightening check I I
11 Gear oil check for leaking I I
12 ☆Spark plug check or change I I R
13 ☆Gear oil change R Replacement for every 5000km
14 Frame lubrication L
15 Exhaust pipe I I
16 ☆Ignition timing I I
17 ☆Emission check in Idling A I
18 ☆Throttle operation I I
19 ☆Engine bolt tightening I I
20 ☆CVT driving device (belt﹞ I R
21 ☆CVT driving device (roller) C
22 Lights/electrical equipment/mutli-meters I I
23 Main/side stands & springs I I
24 Fuel pipes I I
25 Cam chain I I
26 ☆Valve clearance I A
27 ☆Crankcase blow-by over-flow pipe I Replacement for every 2000km
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes
first.
Remarks:
1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items
must be perform 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.

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 SYM 2. MAINTENANCE INFORMATION

LUBRICATION SYSTEM
Engine Oil Capacity
Caution
y The vehicle must be parked on a level
ground when checking oil capacity.
y Run the engine for 2-3 minutes then
stop, wait about 2-3 more minutes
allowing engine oil to settle before
checking the oil level.
Dipstick
Remove dipstick to check the oil level. If oil
level is below the lower limit mark, add oil to
the specified upper limit mark.

Oil change
Shut off the engine and remove dipstick.
Remove the oil drain plug on the bottom-left
of crankcase to drain oil.
After draining out oil, clean oil plug and its
gasket and reinstall. Replace the gasket if it
is damaged.
Torque value: 3.5~4.5 kgf-m

Caution Oil drain plug

Warm up the engine. This will make the oil

flow out easily. strainer cover
Add oil to the specified capacity.
Oil Viscosity: SAE 10W-30, recommended
using King-Mate serial oil.
Engine oil capacity:
Disassembly: 800cc
Change: 650cc
When checking for oil leak, run the engine at
idle speed for a few minutes, then check oil
capacity with dipstick.
Cleaning the oil strainer
Drain oil from engine, remove the strainer oil strainer
cover, spring and strainer.
If there is an accumulation on the screen,
wash it off with suitable solvent
(recommended using compressed air).
Check O-ring for damage, replace if
necessary.
Reinstall strainer, spring, O-ring and strainer
cover.
Torque value: 1.3~1.7 kgf-m
spring

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 2. MAINTENANCE INFORMATION SYM

Gear Oil Gear oil refilling bolt

Inspection
Check gear oil if leaking.
Park the motorcycle with main stand on flat
level place.
Turn off engine and remove the gear oil
draining plug.
Place a measurement cup under the draining
hole.
Remove the oil drain plug and drain gear oil
into a measurement cup.
Check gear oil if enough.
Replacement
At first, remove the gear oil refilling bolt, and
then remove the draining plug.
Install the draining plug after drained oil out. Gear oil draining plug
Torque value: 0.8~1.2 kgf-m
Caution
Inspect if washer is in good condition.
Replace it with new one if it was deformed
or damaged.
Fill out gear oil to specified quantity from the
engine oil filling hole.
Install the oil filling bolt.
Torque value: 0.8~1.2 kgf-m
Transmission oil capacity: 180 c.c.(170
c.c. for change)
Recommended: genuine SYM HYPOID gear
oil (SAE 85W-140).

Fuel System
Fuel Pipe
Remove luggage box, side cover, center Fuel filter
cover, body frame cover, and pedal, as well
as front inner box.
Check all pipes, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any
kind of fire is strictly prohibited as dealing
it.

Fuel filter
Remove the side cover.
Remove fuel pipe from the fuel filter.
Replace the fuel filter with new one.
Install the fuel filter.
Caution
The arrow on the fuel filter means the flow
direction of fuel and check it if leaking after
installation.

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 SYM 2. MAINTENANCE INFORMATION

AIR CLEANER screws×7

Element
Remove left side cover.
Remove 7 screws from the air cleaner cover.
Remove element of air cleaner (2 screws).
Check the element if dirt or damaged.
Replace it with new one if dirt or damaged.

Caution screws×2 Air cleaner element

y Air cleaner element contains a paper

made filter so do not try to clean it.
y Make sure that the air cleaner cover
had been installed properly after
installation.

THROTTLE VALVE OPERATION

Have a wide open of throttle valve as handle
2~6 mm
bar in any position and release it to let back
original (full closed) position.
Check handle bar if its operation is smooth.
Check throttle valve cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not
smooth.
Measure handle bar free play in its flange
part.
Free play：2~6 mm

Adjustment can be done in either ends. Rubber boot

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

Fixing nut
Adjustment nut

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 2. MAINTENANCE INFORMATION SYM

Primary adjustment is conducted from button Fixing nut

side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check
acceleration operation condition.

Adjustment nut

Crankcase blow-by system

CRANKCASE VENTILATION
Pull out the plug from draining hose to clean
deposits

Caution
When always riding in rainy area or full
throttle position, maintenance period must
be shorted. The deposits can be seen in
the transparent section of draining hose.

VALVE CLEARANCE ADJUSTMENT TDC mark

Caution
Checks and adjustment must be performed
when engine is cold (below 35℃).

Remove luggage box and front center cover.

Remove the left body cover & left side cover.
Remove cylinder head cap.
Remove the ignition timing check hole on the
cooling fan cover.
With “T” type wrench, turn crankshaft in
clockwise motion so that mark (“T”) on the
generator flywheel aligns with the mark on
the crankshaft, and camshaft is at TDC
position also as same as level of cylinder
head top-end. A single hole on camshaft
sprocket is forward to up. (Piston is at TDC
position in the compression stroke.)
Caution Ignition timing mark
The crankshaft can not be rotated in
counter-clockwise to prevent from damage
so that valve clearance can not be
measured.

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 SYM 2. MAINTENANCE INFORMATION
VALVE CLEARANCE INSPECTION
AND ADJUSTMENT
Check & adjust valve clearance with feeler
gauge.
Valve clearance (IN/EX):
0.05±0.02 mm/0.10±0.02 mm
Loosen fixing nut and turn the adjustment
nut for adjustment.
Caution
It has to make sure that valve-rocker arm is Valve clearance adjustment
be adjusted to standard level when
adjusting it, and re-check the valve
clearance after tightened the fixing nut.

CARBURETOR IDLE SPEED

ADJUSTMENT
Caution
y Inspection & adjustment for idle speed
have to be performed after all other parts
in engine that needed adjustment have
been adjusted.
y Idle speed check and adjustment have to
be done after engine is being warm up Ignition coil cable
(around 10 minutes).
Park the motorcycle with main stand and
warn up engine.
Open the carburetor cover from the luggage
box.
Turn the throttle valve stopper screw to
specified idle speed.
Specified idle speed: 2100±100 rpm
Emission adjustment in Idle speed
Warm up the engine for around 10 minutes
and then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the idle speed adjustment screw and Throttle valve stopper screw
let engine runs in 2100±100 rpm.
3. Insert the exhaust sampling muffler of
exhaust analyzer into the front section of
exhaust pipe. Adjust the air adjustment
screw so that emission value in idle speed
is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for
2~3 times.
5. Read engine RPM and value on the
exhaust analyzer. Repeat step 2 to step 4
procedures until measured value within
standard.
Emission standard: CO: below 4.5%
HC: below 800ppm Air adjustment screw

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 2. MAINTENANCE INFORMATION SYM

IGNITION SYSTEM F mark

Ignition timing
Caution
C.D.I ignition system is set by manufacturer
so it can not be adjusted.
Ignition timing check procedure is for Ignition light
checking whether C.D.I. function is in normal
or not.

Remove right side cover.

Remove ignition timing hole cap located on
the cooling fan cap, or remove the cooling
fan cap.
Check ignition timing with ignition light.
Start engine and set engine idle speed in
1700 rpm, and if the mark aligns with the “F”,
then it means that ignition timing is correct.
Increase engine speed to 5000 rpm to check
ignition timing advance. If the detent aligns
with advance mark “‫”װ‬, then it means ignition
timing advance is in functional. If not,
check CDI set, pulse flywheel, and pulse
generator. Replace these components if
malfunction of these parts are found.

SPARK PLUG
Appointed spark plug: A7RC
Remove luggage box.
Remove body side cover.
Remove front center cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.6~0.7 mm Spark plug cap
Carefully bend ground electrode of the plug
to adjust the gap if necessary.
Screw the park plug into the plug hole with Side electrode Center electrode
hands, then tighten the plug with a wrench to
prevent from damaging the spark plug's
thread.
Torque value: 1.0~1.2 kgf-m
Connect spark plug cap.

0.6~0.7mm

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 SYM 2. MAINTENANCE INFORMATION

CYLINDER COPMRESSION PRESSURE

Warn up engine and then turnoff the engine.
Open the seat. Remove the luggage box.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the
engine by means of stepping the
kick-starting lever.
Caution
Rotate the engine until the reading in the
gauge no more increasing. Spark plug cap
Usually, the highest pressure reading will be
obtained in 4~7 seconds by electric start
engine.

Compression pressure: 12±2 Kg/cm²

Check following items if the pressure is too Cylinder
low: pressure gauge
z Incorrect valve clearance
z Valve leaking
z Cylinder head leaking, piston, piston ring
and cylinder worn out
If the pressure is too high, it means carbon
deposits in combustion chamber or piston
head.
Gear teeth
DRIVING SYSTEM
DRIVING BELT Width
Remove left side cover.
Remove mounting bolt located under air
cleaner.
Remove 9 bolts of the engine left crankcase.
Remove the left crankcase cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord
with the periodical maintenance schedule to
replace it.
Width limit: above 17.5 mm Clutch pad

Clutch pad
Start the motorcycle and gradually increase
throttle valve openness to check clutch pad Clutch
operation.
If the motorcycle moves with shaking, then
check its clutch pad for wearing. Replace it
if necessary.

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 2. MAINTENANCE INFORMATION SYM

STEERING SYSTEM
Caution
Check all wires and cables if they are
interfered with the rotation of steering
handle bar.
Lift the front wheel out of ground.
Turn handle from right to left and check if
turning is smoothly.
If handle turning is uneven and bending, or
the handle can be operated in vertical
direction, then adjust the handle top bearing.

SUSPENSION SYSTEM
Warning
y Do not ride the motorcycle with poor
shock absorber.
y Looseness, wear or damage shock
absorber will make poor stability and
drivability.
Front shock absorber
Hold front brake lever and press down the
front shock absorber for several times to
check its operation.
Hold front brake lever and push forward the
front shock absorber for several times to
check its locking status.
Check if it is scratched or leaking.
Replace damaged and non-repairable
components.
Tighten all nuts and bolts.

Rear Shock absorber

Press down the rear shock absorber for
several times to check its operation.
Check if it is scratched or leaking.
Replace damaged and non-repairable
components.
Park the motorcycle with main stand.
Start engine and let the rear wheel rotate
after increased engine rpm. Check engine
for any parts loose or shaking. Also check
the engine suspension bushing for wear out.
Replace the bushing if worn out.
Tighten all nuts and bolts.

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 SYM 2. MAINTENANCE INFORMATION

FRONT DISC BRAKE SYSTEM Brake hose

BRAKE SYSTEM HOSE

Make sure the brake hoses for corrosion or
leaking oil, and also check brake system for
leaking.

BRAKE FLUID
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the
LOWER limit, add brake fluid to UPPER limit.
Also check brake system for leaking if low
brake level found.
Lower limit
Caution
y In order to maintain brake fluid in the
reservoir in horizontal position, do not
remove the cap until handle bar stop.
y Do not operate the brake lever after the
cap had been removed. Otherwise, the
brake fluid will spread out if operated the
lever.
y Do not mix non-compatible brake fluid Brake fluid cap
together.
FILLING OUT BRAKE FLUID Low brake level
Tighten the drain valve, and add brake fluid.
Place the diaphragm in.
Operate the brake lever so that brake fluid
contents inside the brake system hoses.

AIR BLEED OPERATION Bubbles Draining valve

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.
Caution
Before closing the air bleed valve, do not
release the brake lever.
Transparent hose

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 2. MAINTENANCE INFORMATION SYM
Brake fluid cap
ADDED BRAKE FLUID
Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 Low limit
WELL RUN brake fluid.
Caution
Never mix or use dirty brake fluid to
prevent from damage brake system or
reducing brake performance.

BRAKE LINING WEAR

The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit Brake ling wear limit
mark closed to the edge of brake disc.
Caution
It is not necessary to remove brake hose
when replacing the brake lining.

Brake disc Brake clipper

Remove the brake clipper bolt, and take out

the clipper.
Caution
Brake clipper
Do not operate the brake lever after the bolt
clipper removed to avoid clipping the brake
lining.

Pry out the brake lining with a flat driver if

lining be clipped.

Remove brake lining bolt.

Take out the lining.
Brake lining

Caution
In order to maintain brake power balance,
the brake lining must be replaced with one
set.

Bolt

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 SYM 2. MAINTENANCE INFORMATION

DRUM BRAKE SYSTEM

Front Brake Free Play: (Drum brake) 10∼20mm
Measure free play of rear brake level at the
end of the lever.
Free play: 10-20 mm

Adjust the free play by turning the front brake

adjustment nut if necessary. “△” mark

Increasing free
play

Decreasing free play Adjustment nut

REAR BRAKE FREE PLAY: (DRUM
BRAKE TYPE)
Measure the free play of the front brake lever
at the end of the lever.
Free play: 10-20 mm
Adjust the free play by turning the front brake
adjustment nut if necessary.
Decreasing free play

Adjustment nut Increasing free play

BRAKE CONFIRAMTION
Caution
y After brake adjustment, it has to check
the brake operation to make sure the
front and rear wheel can be braked.
y Pull the brake lever, and make sure that
the wear limit marks of brake ling on the “△”marks
both front & rear brake arm are closer
and touch to the “△” marks. If so,
replace the brake ling with new one.

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 2. MAINTENANCE INFORMATION SYM

BRAKE LIGHT SWITCH Brake light switch

The brake light switch is to lit up brake light
as brake applied.
Make sure that electrical starter can be
operated only under brake applying.

WHEEL/TIRE
Check if both front and rear tire pressure are
within specification.
Caution
Tire pressure check should be done as cold
tire.

Appointed tire pressure

Tire size Front tire Rear tire
Tire Load for
1.75 2.0
pressure single
as cold Load for
tire two 1.75 2.25
(Kg/cm²) persons
Appointed Tire
Front/Rear wheel: 90/80-16 51J
Check if tire surface is ticked with nails,
stones or other materials.
Check if tire surface or wall for crack or
damaged, and replace it if necessary.
The tire tread depth can be checked by
visual inspection or depth gauge.
y Replace the tire if tire tread dent or
unusual wearing out.
y The tire should be replaced if the wear
limit mark (△) is in visible.
Measure tire thread depth from tire center
surface.
Replace the tire if the depth is not come with
following specification:
Front tire: 1.5 mm
Rear tire: 2.0 mm
Caution
The wear limit marks (△) are located
around the tire wall even for inspection.
Wear limit indictor 〝△〞mark

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 SYM 2. MAINTENANCE INFORMATION

BATTERY
Battery Removal
Remove the 2 screws on the floor panel.
Remove battery cap. (2 nuts)

Battery cables removal:

1. At first, remove the negative “-” cable.
2. Then, remove the positive “+” cable.
3. Remove the battery.

If there is some rust on battery posts, clean it

with steel brush.
Install the battery in the reverse procedures
of removal.
Caution
y 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.
y Apply some grease on the posts after
rust removed to prevent from rust again.

HEADLIGHT ADJUSTMENT
Park the motorcycle with the main stand.
Remove the front cover.
Turn on the main switch.
Turn the headlight adjustment screw. And
adjust the headlight beam height.
Then, tighten the adjustment screw after the
beam height in proper position.
Caution
y To adjust the headlight beam follows
related regulations. Headlight adjustment screw
y Improper headlight beam adjustment will
make in coming driver dazzled or
insufficient lighting.

NUTS, BOLTS TIGHTENESS

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.

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 SYM 3. LUBRICATION SYSTEM

MECHANISM DIAGRAM ....................3-1 CLEANING ENGINE OIL STRAINER... 3-3

OPERATIONAL PRECAUTIONS .......3-2 OIL PUMP ............................................ 3-4
TROUBLE DIAGNOSIS......................3-2 GEAR OIL ............................................ 3-7
ENGINE OIL .......................................3-3

MECHANISM DIAGRAM

Valve rocker
arm Forcedly lubrication

Camshaft

Scoop lubrication

Inner passage
Connecting rod

Forcedly
lubrication

Crankshaft

Oil strainer
Oil pump

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 3. LUBRICATION SYSTEM SYM
OPERATIONAL PRECAUTIONS
General Information
z This chapter contains maintenance operations for the engine oil pump, engine oil and
gear oil.
Oil viscosity
Specifications
Engine oil quantity Disassembly 800 c.c.
Replacement 650 c.c.
Oil viscosity SAE 10W-30 or equivalent

Use SAE 5W-40 when

outside temperature is
below 0℃.
Gear Oil quantity Disassembly 180 c.c.
Replacement 170 c.c.
Oil viscosity of gear oil SAE 85W-140

unit : mm
Items Standard Limit
Inner rotor clearance - 0.12
Clearance between outer
Oil pump rotor and body - 0.12
Clearance between rotor
side and body 0.05~0.10 0.20

Torque value
Engine oil drain plug 3.5~4.5kgf-m
Engine oil filter screen cap 1.0~2.0kgf-m
Gear oil drain bolt 1.0~1.5kgf-m
Gear oil filling bolt 1.0~1.5kgf-m
Oil pump fixing screws 0.8~1.2kgf-m

TROUBLE DIAGNOSIS
Low engine oil level Dirty oil
z Oil leaking z No oil change in periodical
z Valve guide or seat worn out z Cylinder head gasket damage
z Piston ring worn out z Piston ring worn out
Low Oil Pressure
z Low engine oil level
z Clogged in oil strainer, circuits or pipes
z Oil pump damage

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 SYM 3. LUBRICATION SYSTEM
ENGINE OIL
Turn off engine, and park the motorcycle in
flat ground with main stand.
Check oil level with oil dipstick after 3-5
minutes.
Do not rotate the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.

Dipstick

Oil Replacement
Caution
Drain oil as engine warmed up so that
make sure oil can be drained smoothly and
completely.
Place an oil pan under the motorcycle, and
remove oil strainer cap.
Make sure if the aluminum washer of the
draining bolt is damaged. If so, replace it
with new one.
Install the drain plug and tighten it. Oil drain plug
Torque value: 3.5~4.5 kgf-m

CLEANING ENGINE OIL STRAINER

Remove the oil strainer cap.
Remove oil strainer and spring.
Clean oil strainer (recommended using
compressed air to clean dirty foreign).
Check if the strainer and O-ring of the oil
strainer are broken. Replace with new one if
found.
Install the oil strainer and spring.
Install the oil strainer cap and tighten it. Oil strainer cap
Torque value: 1.0~2.0 kgf-m
Fill out oil to the oil filler (Oil viscosity SAE
10W-30) oil strainer
Use SAE 5W-40 when outside temperature
is below 0℃.
Engine oil quantity: Replacement 650 c.c.

spring

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 3. LUBRICATION SYSTEM SYM
OIL PUMP
Oil Pump Removal
Remove the alternator (refer to chapter10).
Remove the engine right crankcase cover.
Make sure that the pump axle can be rotated
freely.
Remove the oil pump driving gear nut.
Remove the oil pump .

pump driving
gear nut

Oil Pump Inspection

Check the clearance between oil pump body
and outer rotor.
Limit: below 0.12 mm

Check clearance between inner and outer

rotors.
Limit: below 0.12 mm

Check clearance between rotor side face

and pump body.
Limit: below 2.0 mm

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 SYM 3. LUBRICATION SYSTEM

Oil Pump Re-assembly Oil pump body Drive shaft Fixing pin
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 the oil pump cover and fixing pin
properly and then tighten screw. (1 screw)

Oil pump
outer rotor inner rotor cover

Oil Pump Installation

Install according to the reverse procedure of
removal.

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 3. LUBRICATION SYSTEM SYM
Gear oil draining plug Filling bolt
GEAR OIL
Oil Level Inspection
Park the motorcycle on flat ground with main
stand.
Turn off engine and remove both gear oil
filling bolt and gear oil draining plug.

Remove gear oil filling bolt and place a

measurement cup under the draining plug.
Remove the oil draining plug and the pour
gear oil into the measurement cup.
Measure the gear oil quantity if within
standard value.
Add specified gear oil if the oil level too low.
Standard quantity: 180 cc.
Replacement: 170 cc.

Gear Oil Replacement

Remove the gear oil filling bolt and its
draining plug and then drain oil completely.
Install the draining plug and tighten it. (Make
sure if the plug washer is damaged. If so,
replace it with new one.)
Torque Value：1.0~1.5 kgf-m
Add new gear oil (170 c.c.) from the gear oil
filling hole and then install the gear oil filling
hole bolt after added oil. And then, tighten
the bolt.
Torque Value: 1.0~1.5 kgf-m
※Recommended to apply with SAE
85W-140.
Start engine and run it for 2~3 minutes.
Turn off engine and check if oil leaking.

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 SYM 4. FUEL SYSTEM

MECHANISM ILLUSTRATION ............. 4-1 AUTO BY-STARTER .......................... 4-7

PRECAUTIONS IN OPERATION ......... 4-2 FLOAT CHAMBER ............................. 4-8
TROUBLE DIAGNOSIS........................ 4-3 INSTALLATION OF CARBURETOR .. 4-9
CARBURETOR REMOVAL .................. 4-4 IDLE SPEED ADJUSTMENT ............. 4-9
VACUUM CHAMBER ........................... 4-4 FUEL TANK ........................................ 4-10
ACCELERATE PUMP ..........................4-6 AIR CLEANER.................................... 4-11

MECHANISM ILLUSTRATION

Carburetor

Fuel strainer

Fuel unit
Fuel tank cap

4-1
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 4. FUEL SYSTEM SYM
PRECAUTIONS IN OPERATION
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated
place and strictly prohibit flame when working with gasoline.

Cautions
z Do not bend or twist throttle valve cable. Damaged cable will make unstable driveability.
z When disassembling fuel system parts, pay attention to O-ring position, replace with new
one as re-assembly
z There is a drain screw in the float chamber for draining residual gasoline.
z Do not disassemble automatic by-starter and air cut-off valve arbitrarily.

Specification
Item Specification
Speed limited:45km/h 82#
Main jet Speed limited:25km/h 85#
Speed limited:30km/h 85#
Slow jet 35#
Idle speed 2100±100 rpm
Needle Jet ￠2.6 mm
Mass of float 7.2g±0.4 g
Float needle ￠2.0 mm
Fuel quantity adjustment screw 1 1/2±3/4 turns
Level in float chamber 7.0±0.5 mm
Jet needle DA8CD
Throttle handle free play 2~6 mm

Torque value
Fuel valve tightening nut: 1.5~2.0 Kgf-m

Tool
Special service tools
Vacuum/air pressure pump
General service tools
Fuel level gauge

4-2
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 SYM 4. FUEL SYSTEM
TROUBLE DIAGNOSIS
Power insufficiency and fuel consuming
Poor engine start z Fuel system clogged
z No fuel in fuel tank
z Clogged fuel tube
z Malfunction of ignition system
z Too much fuel in cylinder
z No spark from spark plug (malfunction of
ignition system)
z Clogged air cleaner
z Malfunction of automatic by-starter
z Malfunction of throttle valve operation

Stall after started Mixture too lean

z Malfunction of automatic by-starter z Clogged fuel injector
z Incorrect ignition timing z Vacuum piston stick and closed
z Malfunction of carburetor z Malfunction of float valve
z Dirty engine oil z Fuel level too low in float chamber
z Air existing in intake system z Clogged fuel tank cap vent
z Incorrect idle speed z Clogged fuel filter
z Obstructed fuel pipe
z Clogged air vent hose
z Air existing in intake system

Mixture too rich

Rough idle z Clogged air injector
z Malfunction of ignition system z Malfunction of float valve
z Incorrect idle speed z Fuel level too high in float chamber
z Malfunction of carburetor z Malfunction of automatic by-starter
z Dirty fuel z Dirty air cleaner

Intermittently misfire as acceleration

z Malfunction of ignition system

Late ignition timing

z Malfunction of ignition system
z Malfunction of carburetor

4-3
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 4. FUEL SYSTEM SYM

CARBURETOR REMOVAL throttle valve cable clamp strip of isolator

Remove the luggage box.
Loosen the adjustment nut and fixing nut of
throttle valve cable, and release the cable
from carburetor.
Remove fuel pipe, vacuum hose.
Disconnect auto by-starter connectors.
Release the clamp strip of air cleaner.
Release the clamp strip of carburetor isolator.
Take the carburetor out.
vacuum hose

vacuum hose auto by-starter

VACUUM CHAMBER Screws×2

Removal
Loosen drain screw, and drain out residual
fuel in float chamber.
Remove screws (2 screws) of vacuum
chamber cover and the cover.

Vacuum Chamber cover

Remove compress spring and vacuum Vacuum piston

piston.

compress
spring

4-4
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 SYM 4. FUEL SYSTEM

Remove fuel needle seat, spring, and

fuel needle
injector needle. seat
Check if the vacuum piston for wear out,
fuel needle
crack or other damage. spring
Check if the diaphragm for damage or crack.
Cautions injector
needle
Do not damage vacuum diaphragm.

piston Piston spring

Installation piston diaphragm lock position

Install injector needle, spring and fuel needle
seat to vacuum piston.

Cautions
z Note direction as installing the piston
set because wrong direction of the
piston cab not be installed.
z Align the indent of vacuum
diaphragm with the carburetor body.

Install vacuum piston to carburetor body.

Install compress spring.

Screws×2

Install vacuum chamber cover and tighten 2

screws.

Vacuum Chamber cover

4-5
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 4. FUEL SYSTEM SYM
ACCELERATE PUMP Screws ×2
Removal
Loosen the fixing screws from carburetor.

Remove the accelerate pump drive arm from Accelerate pump

the carburetor. drive arm

Remove 3 mounting screws and remove the

float chamber cover.
Remove 3 mounting screws and remove the
float chamber cover.

Installation
Install the valve as reverse order of removal.
Cautions
Do not damage the vacuum diaphragm or
in opposite installation direction.

4-6
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 SYM 4. FUEL SYSTEM
AUTO BY-STARTER
Inspection
Turn off engine and waiting for over 10
minutes for cooling.
Check resistance across the two terminals of
the auto by-starter
Resistance value: Max. 10Ω (Measured
after engine stopped for more than 10
minutes)
Replace the auto by-starter with a new one if
resistance value exceeds standard.
Remove the carburetor, allow it to cool off for
30 minutes.
Connect a hose to fuel richment circuit.
Pump compressed air to the circuit.
Replace the auto by-starter if the circuit
clogged.

Connect battery posts (12V) to starter’s

connectors. After 5 minutes, test the rich
circuit with compressed air. If air flow through
the circuit, then replace the starter.

Removal
auto by-starter
Remove fixing plate screw, and then remove
the plate and auto by-starter from carburetor.
round point

Screw
Valve inspection
Check if auto by-starter and valve needle for
damage or wear out.
fixing plate

Screw
Installation
Install auto by-starter to the carburetor body.
Install fixing plate to the upper groove of auto
by-starter, and install its flat surface to
carburetor. Install screw and tighten it.
Cautions
Align the round point of the starter with
the screw hole of air intake side.
fixing plate
valve needle

4-7
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 4. FUEL SYSTEM SYM
FLOAT CHAMBER screws× 3
float
Disassembly
Remove 3 mounting screws and remove the
float chamber cover.
Remove the float pin and float valve.

float pin

Checking
Check float needle valve and valve seat for float pin
drop difference damage, wear out, dirty or
clogged.

float needle
Cautions valve
In case of worn out or dirt, the float needle float pin
valve and valve seat will not tightly close
causing fuel level to increase and as a
result, fuel flooding. A worn out or dirty float float
needle valve must be replaced with a new
one.

Remove main jet,slow jet, fuel amount slow jet main jet
adjustment screw.

Cautions fuel amount

adjustment screw
z Take care not to damage jets and adjust
screw.
z Before removing adjustment screw, turn it
all the way down and note the number of
turns.
z Do not turn adjustment screw forcefully to
avoid damaging valve seat face.
main jet

Clean jets with cleaning fluid.

Then use compressed air to blow dirt off.
Blow carburetor body passages with
compressed air.

slow jet

4-8
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 SYM 4. FUEL SYSTEM
Installation
Install main jet, slow jet and fuel amount
adjustment screw.
Cautions fuel amount
Set the adjustment screw in according to number adjustment screw
of turns noted before it was removed.

Install the float needle valve, float and float pin.

Checking Fuel Level

Cautions
z Check again to ensure float valve, float for
proper installation.
z To ensure correct measurement, position
the float meter in such a way so that float
chamber face is vertical to the main jet.

Fuel level: 3.5±1 mm

INSTALLATION OF CARBURETOR
Install carburetor in the reverse order of removal.
Following adjustments must be made after float meter
installation.
z Throttle valve cable clearance adjustment
z Idle speed adjustment
throttle valve
IDLE SPEED ADJUSTMENT stopper screw
Caution
z Fuel amount adjust screw was set at factory,
so no adjustment is needed. Note the
number of turns it takes to screw it all the
way in for ease of installation.
z Never screw in forcedly to avoid damaging
the screw seat.
z The main stand must be used to support the
motorcycle to perform the adjustments.
Throttle valve cable
Use a tachometer when adjusting engine RPM. adjustment nut
Screw in adjustment screw gently, then back up to
standard turns.
Standard turns: 1 1/2±3/4 turns
Warm up engine, adjust throttle valve stopper
screw to standard RPM.
Idle speed rpm: 2100±100 rpm
Connect the sampling hose of exhaust analyzer to
exhaust front end. Press test key on the analyzer.
Adjust the air volume adjustment screw and read
CO reading on the analyzer.
CO standard value: 1.0~1.5 %
Accelerate in gradual increments, make sure both
rpm and CO value are in standard values after
engine running in stable. If rpm and CO value
air volume
fluctuated, repeat the procedures described above adjustment screw
for adjusting to standard value.

4-9
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 4. FUEL SYSTEM SYM
FUEL TANK fuel unit connector
Fuel unit removal
Remove the seat.
Remove the rear carrier. (3 bolts)
Remove the luggage box and the double
seat(4 bolts).
Disconnect fuel unit connector.
Remove fuel unit.
Cautions
z Do not bend the float arm of fuel unit.
z Do not fill out too much gasoline to
fuel tank.

Fuel unit inspection. (Refer to chapter 16 -

electrical equipment). fuel unit

Fuel unit installation

Install the gauge in the reverse order of
removal.
Cautions
Do not forget to install the gasket of fuel unit
or damage it.
gasket

FUEL TANK REMOVAL

Open the seat.
Remove the rear carrier. (3 bolts)
Remove the luggage box and the double
seat(4 bolts).
Remove the left & right body cover.
Disconnect the fuel unit connector.
Remove the fuel pipe, fuel filter.
Remove the fuel tank (2 bolts).

Fuel Tank Installation

Install the tank in the reverse order of
removal.

4-10
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 SYM 4. FUEL SYSTEM
AIR CLEANER air filter strap

Removal
Remove the seat .
Remove the luggage box assembly (4 bolts).
Loosen the clamp strip of air cleaner.
Remove evaporative return hose.
Remove the air cleaner body bolts (2 bolts).
Remove the air cleaner.

Installation
bolts×2
Install the air cleaner in the reverse order of
removal.

Air Cleaner Element Cleaning

Remove the air cleaner cover (7 screws).

screws×7

Remove the air cleaner element (2 screws).

With compressed air to clean dirty around
the element. Replace it if it is too dirty to
clean.
Cautions
The air cleaner element is made of paper
so do not soap it into water or wash it
with water.

Air cleaner element

4-11
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 SYM 5. REMOVAL OF ENGINE

MECHANISM DIAGRAM ...................... 5-1 REMOVAL OF ENGINE SUSPENSION

OPERATIONAL PRECAUTIONS ......... 5-2 BUSHING ............................................. 5-6
ENGINE REMOVAL ............................. 5-3 ENGINE SUSPENSION FRAME.......... 5-7
INSTALLATION OF ENGINE ............... 5-8
MECHANISM DIAGRAM

3.5~4.5kgf-m

4.5~5.5kgf-m

4.5~5.5kgf-m

2.4~3.0kgf-m

4.5~5.5 kgf-m

5-1

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 5. REMOVAL OF ENGINE SYM
OPERATIONAL PRECAUTIONS
General Information
y Engine must be supported by a bracket or adjustable tool in height.
y The following parts can be serviced with the engine installed on the frame.
1. Carburetor
2. Driving disk, driving belt, clutch, and transporting disk
3. Final reduction gear mechanism

Specification
Specification
Disassemble 800 c.c.
Engine Oil Capacity
Replacement 650 c.c.
Disassemble 180 c.c.
Gear Oil Capacity
Replacement 170 c.c.
Torque Values
Engine suspension bolt (frame side) 4.5~5.5kgf-m
Engine suspension nut (engine side) 4.5~5.5kgf-m
Bolt of rear shock absorber upper connection 3.5~4.5kgf-m
Bolt of rear shock absorber lower connection 2.4~3.0kgf-m

5-2

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 SYM 5. REMOVAL OF ENGINE
ENGINE REMOVAL Generator
connector
Open the seat.
Remove the luggage box assembly (4
bolts ).
Remove the body cover .
Remove the power connector of auto by-
start.
Remove the generator connector and pulse
generator connector.
pulse generator
Auto by-start connector
connector

Remove the starter motor wire on the Starter Starter magnetic switch
magnetic switch.

Remove the spark plug cap.

Spark plug cap

5-3

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 5. REMOVAL OF ENGINE SYM

Remove the fuel pipe, vacuum hose, and

throttle valve cable from the carburetor.
Loose the strap screw of the air cleaner
guide, and remove the air cleaner guide.

Bolts×2
Remove the exhaust muffler (Bolts ×
2, Nuts × 2).

Remove the rear wheel (Nut × 1).

Nut ×1

2 bolts
Remove the air cleaner connection bolts (2
bolts).

5-4

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 SYM 5. REMOVAL OF ENGINE

Remove the rear brake cable nut. Brake cable nut

Remove the rear brake cable.
Remove the rear shock absorber lower bolt.

Rear shock
absorber bolt

Loose the strap screw of engine left guide,

and then remove the engine left guide.

Strap screw of guide

Remove the engine suspension nut and bolt

(engine side), and then remove the engine.
Caution
y With a bracket to support the engine
to prevent from it damage by falling
down as removing the engine.

Engine suspension bolt/nut

Check if the engine suspension, rear shock Bushing

absorber bushing, and cushion rubber for
damage. Replace them with new ones if so.

5-5

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 5. REMOVAL OF ENGINE SYM
REMOVAL OF ENGINE
SUSPENSION BUSHING
If engine suspension frame and the cushion
rubber of rear shock absorber bushing
damaged. Then, with the bushing remover /
presser, Φ28mm &Φ20mm, to press the
bushing out, and replace it with new one.

Engine suspension bushing: Φ28mm

Rear shock absorber bushing: Φ20mm

Pressing out
Place the detent section of the bushing
remover toward the bushing, and drive both
the pressing ring and bolt in to press the
bushing out.

Pressing In
Place the flat section of the remover toward
the bushing, and then drive the bushing,
pressing ring, and bolt in to install the
bushing.

5-6

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 SYM 5. REMOVAL OF ENGINE
ENGINE SUSPENSION FRAME
Removal
Remove the right side bolt of engine
suspension frame.

Remove the left side bolt of engine

suspension frame.

Bolt of engine suspension

frame (left side)

Check if the engine suspension frame

bushing and cushion rubber for damage. If
so, replace with new ones.

Installation
Tighten the bolts and nuts of engine
suspension frame.

Engine suspension frame nut:

Torque Value: 4.5~5.5 kgf-m

5-7

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 5. REMOVAL OF ENGINE SYM
INSTALLATION OF ENGINE Engine suspension nut×1
Check if the bushings of engine suspension
frame and shock absorber for damaged. If so,
replace with new ones.
Install the engine according to the reversing
order of removal.

Caution
y Notice both feet and hands safety for
squeezing as engine installation.
y Do not bent or squeeze each wires or
hose.
y Route all cables and wires in
Brake cable nut
accordance with the routine layout.
Engine suspension nut:
Torque Value: 4.5~5.5kgf-m

Rear shock absorber bolt:

Torque Value: Top: 3.5~4.5kgf-m
lower: 2.4~3.0kgf-m

Rear wheel axle nut: Rear shock

Torque Value: 11.0~13.0kgf-m absorber lower bolt

Nut ×1

5-8

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 SYM 6. CYLINDER HEAD/VALVE

MECHANISM DIAGRAM ....................6-1 CYLINDER HEAD INSPECTION.......... 6-8

PRECAUTIONS IN OPERATION .......6-2 VALVE SEAT INSPECTION AND SERVICE 6-10
TROUBLE SHOOTING.......................6-3 CYLINDER HEAD REASSEMBLY ....... 6-12
CAMSHAFT REMOVAL .....................6-4 CYLINDER HEAD INSTALLATION ...... 6-13
CYLINDER HEAD REMOVAL ............6-6 CAMSHAFT INSTALLATION ............... 6-13
CYLINDER HEAD DISASSEMBLY ....6-7 VALVE CLEARANCE ADJUSTMENT .. 6-14
MECHANISM DIAGRAM

0.7~1.1 kgf-m

1.0~1.4 kgf-m

0.8~1.2 kgf-m
0.8~1.2 kgf-m

0.8~1.2 kgf-m

6-1

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 6. CYLINDER HEAD/VALVE SYM
PRECAUTIONS IN OPERATION
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft
as well as valve rocker arm.
y Cylinder head service cannot be carried out when engine is in frame.

Specification unit: mm

Item Standard Limit

Compression pressure 12 kg/cm² -
Intake 25.686~25.786 25.29
Camshaft Height of cam lobe
Exhaust 25.50~25.60 25.12

Rocker ID of valve rocker arm 10.000~10.015 10.10

arm OD of valve rocker arm shaft 9.972~9.987 9.910
Intake 4.975~4.99 4.90
OD of valve stem
Exhaust 4.955~4.97 4.90
ID of Guide 5.000~5.015 5.030

Clearance between Intake 0.010~0.037 0.080

Valve
valve stem and guide Exhaust 0.030~0.057 0.100
Outer 35.25 -
Free length of valve
spring Inner 32.26~32.56 -

Torque Value
Cylinder head cover bolt 0.8~1.2kgf-m
Cylinder head bolt (LH) 0.8~1.2kgf-m
Bolt of timing chain auto-adjuster 0.8~1.2kgf-m
Spark plug 1.0~1.4kgf-m
Cylinder head nut 0.8~1.2kgf-m
Valve adjustment fixing nuts 0.7~1.1kgf-m

TOOLS
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor

6-2

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 SYM 6. CYLINDER HEAD/VALVE
TROUBLE SHOOTING
Engine performance will be effected by troubles on engine top end. The troubles usually can
be determinate or by performing cylinder compression test and judging the abnormal noise
generated.

Rough Idle
Low compression pressure.

Low compression pressure

1. Valve
y Improper valve adjustment.
y Burnt or bended valve.
y Improper valve timing.
y Valve spring damaged.
y Valve carbon.
y Poor sealing on valve seat.
y Improper spark plug installation.
2. Cylinder head
y Cylinder head gasket leaking or damage.
y Tilt or crack cylinder surface.
3. Piston
y Piston ring worn out.

High compression pressure

y Too much carbon deposit on combustion chamber or piston head.

Noise
y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Cam chain wear out or looseness
y Auto-adjuster wear out or damage of cam chain
y Camshaft sprocket wear out
y Rocker arm or rocker arm shaft wear out

White smoke
y Valve guide or valve stem wear out
y Valve stem seal wear out

6-3

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 6. CYLINDER HEAD/VALVE SYM
CYLINDER HEAD REMOVAL 4 bolts
Remove the engine from the vehicle (Refer
to chapter 5).
Remove the shroud of the engine.
Remove the crankcase blow-by system hose
from the cylinder head.
Remove the cylinder head cover 4 bolts and
then remove the cylinder head cover.

bolts
Loosen the bolt of camshaft chain adjuster in
a counter-clockwise motion for release
adjuster.
.

Removed cam chain adjustment bolt. And Chain adjuster

then removed the chain adjuster (bolts × 2)

Cylinder head side cover

Removed cylinder head side cover.

6-4

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 SYM 6. CYLINDER HEAD/VALVE

Turn the flywheel in counter-clockwise

motion with T type wrench until the “T” mark
on flywheel aligned with the mark on the
crankcase so that the hole on the camshaft
sprocket is forward up and piston is at TDC
position.

TDC mark

Bolts × 2
Remove camshaft sprocket bolt(bolt × 2).
Remove the cam sprocket and cam chain.

Bolts × 2
Removed the bolts of the left side of the
cylinder head between cylinder head and
cylinder(bolt × 2).

Removed cylinder head fixed nut (nuts × 4). Nuts × 4

6-5

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 6. CYLINDER HEAD/VALVE SYM

Remove cylinder head.

Caution
Loosen the nuts diagonally by 2-3
sequences.

DISASSEMBLY CYLINDER HEAD

Remove the fixed (bolt × 1), then remove the
camshaft.

Camshaft

Remove the valve rocker arm shaft.

Remove the valve rocker arm.

6-6

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 SYM 6. CYLINDER HEAD/VALVE

Use the special tool of compress valve

springs. Remove valve spring removed
location pin.

Caution
Do not over-compressed valve springs.
Avoiding weaken the spring flexibility.

Put out the spring stopper, spring and valve.

Remove the valve cotter,valve spring
retainer,valve oil seal .

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.

CAMSHAFT INSPECTION Camshaft

Inspect cam lobe height for damaged. bearing
Service Limit
IN: Replacement when less than 25.57 mm
EX: Replacement when less than 25.41 mm
Inspect the camshaft bearing for looseness
or wear out. If any, replace whole set of
camshaft and bearing.

6-7

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 6. CYLINDER HEAD/VALVE SYM

VALVE ROCKER ARM/ SHAFT

INSPECTION
Measure the valve rocker arm I.D.
Service Limit: Replace when it is above
10.100 mm

Measure the active O.D. of the valve rocker

arm shaft.
Service Limit: Replace when it is above
9.910 mm
Calculate the clearance between the rocker
arm shaft and the rocker arm.
Service Limit: Replace when it is above
0.10 mm

CYLINDER HEAD INSPECTION

Check if spark plug and valve holes are crack.
Measure cylinder head flat with a
straightedge and flat feeler gauge.
Service limit: below 0.05mm

Valve spring free length

Measure the free length of intake and
exhaust valve springs.
Standard:
35.250 mm

The narrow pitch of the spring shall face to the

combustion chamber.

6-8

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 SYM 6. CYLINDER HEAD/VALVE

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→ 4.900mm
EX→ 4.900mm

Valve guide

Caution
Before measuring the valve guide, clean
carbon deposits with reamer.
Special Service Tool: 5.0mm valve guide
reamer
Measure and record each valve guide inner 5.0mm valve guide reamer
diameters.
Service limit: 5.300mm
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→ 0.08mm
EX→ 0.10mm

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 must correct valve seat when replacing
valve guide.

Valve guide replacement Valve guide driver

Heat up cylinder head to 100~150 ℃ with 5.0mm

heated plate or toaster.

Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be
deformed as heating it.
y Wear on a pair of glove to protect your
hands when operating.

6-9

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 6. CYLINDER HEAD/VALVE SYM
Hold the cylinder head, and then press out old
Valve guide driver
valve guide from combustion chamber side. 13 mm 5.0mm
Tool: Valve guide driver 5 mm (0.15in)

Caution
y Check if new valve guide is deformation
after pressed it in.
y When pressing in the new valve guide,
cylinder head still must be kept in 100~150
℃.
Adjust the valve guide driver and let valve
guide height is in 13mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver 5 mm
Wait for the cylinder head cooling down to
room temperature, and then correct the new
valve guide with reamer.
Valve guide reamer 5.0mm
Caution
y Using cutting oil when correcting valve
guide with a reamer.
y Turn the reamer in same direction when it
be inserted or rotated.

Correct valve seat, and clean up all metal

residues from cylinder head.
Special tool: Valve guide reamer 5 mm
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
y Do not let emery enter into between valve
stem and valve guide.
y Clean up the emery after corrected, and
apply with red paint onto contact faces of
valve and valve seat.
Remove the valve and check its contact
face.
Valve seat
Caution valve seat
width
Replace the valve with new one if valve width
seat is roughness, wear out, or incomplete
contacted with valve seat.
If the valve and the valve seat still can not
be matched sealing after grinded, replace it
with new one.

6-10

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 SYM 6. CYLINDER HEAD/VALVE

Valve seat inspection Roughness

If the valve seat is too width, narrow or rough,
correct it.
Valve seat width
Service limit: 1.6mm
Check the contact condition of valve seat.
45°
Valve seat grinding
The worn valve seat has to be grinded with
valve seat chamfer cutter.
Use 45° valve seat chamfer cutter to cut any
rough or uneven surface from valve seat.

Caution Old valve seat width

After valve guide had been replaced, it has

to be grinded with 45° valve seal chamfer
32°
cutter to correct its seat face.

Use 32° cutter to cut a quarter upper part

out.

Use 60° cutter to cut a quarter lower part out.

Remove the cutter and check new valve
seat. Old valve seat width

60°

Use 45° cutter to grind the valve seat to

specified width.
1.0mm
Caution
Make sure that all roughness and uneven
faces had been grinded.

Grind valve seat again if necessary.

45°

6-11

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 6. CYLINDER HEAD/VALVE SYM

Coat the valve seat surface with red paint.

Install the valve through valve guide until the Contact surface too high
valve contacting with valve seat, slightly
press down the valve but do not rotate it so Old valve seat
that a seal track will be created on contact width
surface.

Caution 32°
The contact surfaces of valve and valve
seat are very important to the valve sealing
capacity.

Contact surface
If the contact surface too high, grind the too low
Old valve seat
width
valve seat with 32° cutter.
Then, grind the valve seat with 45° cutter to
specified width.

If the contact surface too low, grind the valve

seat with 60° cutter.
Then, grind the valve seat with 45° cutter to 60°
specified width.

After the valve seat grinded, coat valve seat

surface with emery and then slightly press
the grinded surface.
Clean up all emery coated onto cylinder and
valve after grinded.

Valve cotters
Valve stem
CYLINDER HEAD REASSEMBLY oil seal
Lubricate valve stem with engine oil, and Valve spring
retainer
then insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Valve spring
Caution Valve
The closed coils of valve spring should face
down to combustion chamber.

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 SYM 6. CYLINDER HEAD/VALVE

Use valve spring compressor to press valve

spring.
Install valve split locks and release the valve
compressor.

Caution
In order to avoid to loosing spring tension,
do not compress the spring too much. Its
length is based on the installation of latch.

Special tool: valve spring compressor

Tap valve stem to make valve retainer and

valve stem sealing properly.

Caution
Place and hold cylinder head on to working
table so that can prevent from valve
damaged.

CYLINDER HEAD INSTALLATION Lock pins Cylinder head gasket

Install the lock pins and new cylinder head

gasket onto the cylinder head.
Install the camshaft chain plate.

At first, tighten the 4 nuts on the cylinder top

and then tighten the 2 bolts on the left side of
cylinder head.
Nuts ×4 Bolts ×2
With T type wrench to turn crankshaft in a
clockwise motion so that the “T” mark on the
flywheel aligns with the mark on crankcase.
(piston is at TDC position).
Install the cylinder head nuts and tighten it.
Torque value: 2.0~2.4 kgf-m
Install the cylinder head left side bolt and
tighten it.
Torque value: 0.8~1.2 kgf-m
Install the spark plug and tighten it.
Torque value: 1.0~1.2 kgf-m

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 6. CYLINDER HEAD/VALVE SYM

y Apply with oil onto the thread of cylinder

head bolts and tighten the bolts in
diagonally for 2-3 sequences.
y Do not over tightening the bolts to avoid
the cylinder head deformation, noise
created or leaking so that effects
motorcycle’s performance.

Install the cam shaft. Place the TDC marks Bolts ×2

of the cam sprocket at same level of the
top-end of cylinder head. The other single
hole of the cam sprocket is in upward. Then,
install the cam chain onto the cam sprocket.
Tighten the 2 bolts of the cam sprocket.
Install the cylinder head side cover.

Turn the cam chain adjuster in clockwise

motion so that the adjuster is pushed out to
contact the cam chain plate tightly. Tighten “T” mark
the bolt cap of the adjuster adjustment hole.
Caution chain adjuster
The O-ring must be installed into glove.

VALVE CLEARANCE ADJUSTMENT

Loosen valve clearance adjustment nuts and
bolts located on valve rocker arm.
Measure and adjust valve clearance with Especial tool
feeler gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and
then tighten the adjustment nut.
Standard Value: IN/EX 0.12±0.02mm

6-14

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 PEUGEOT 7. CYLINDER/PISTON

MECHANISM DIAGRAM ....................7-1 PISTON REMOVAL............................7-5

PRECAUTIONS IN OPERATION .......7-2 PISTON RING INSTALLATION..........7-7
TROUBLE DIAGNOSIS......................7-2 PISTON INSTALLATION....................7-8
CYLINDER REMOVAL .......................7-3 CYLINDER INSTALLATION.............. 7-8
MECHANISM DIAGRAM

0.8~1.2kgf-m

7-1

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 7.CYLINDER/PISTON PEUGEOT
PRECAUTIONS IN OPERATION

General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.

Specification unit: mm
Item Standard Limit

ID 37.00 -

Bend/wrap age － 0.050

Cylinder
Roundness 0.005 0.050

Cylindrical 0.005 0.050

Clearance between Top ring 0.025~0.060 0.090

piston and rings 2nd ring 0.015~0.050 0.090

Top ring 0.200~0.400 0.500

Piston/ Ring-end gap 2nd ring 0.250~0.400 0.650

Piston ring Oil ring 0.200~0.700 -

OD of piston 37.005~36.985 -
Clearance between piston and
cylinder 0.025~0.040 0.100

ID of piston pin hole 13.002~13.008 13.040

OD of piston pin 12.994~13.000 12.980

Clearance between piston and piston pin 0.002~0.014 0.018

ID of connecting rod small-end 13.005~13.020 13.040

TROUBLE DIAGNOSIS
Low Or Unstable Compression Pressure Smoking in Exhaust Pipe
z Cylinder or piston ring worn out. z Piston or piston ring worn out.
z Compress pressure to high. z Piston ring installation improperly.
z Too much carbon deposited in z Cylinder or piston damage.
combustion chamber and piston.
Knock or Noise Engine Overheat
z Cylinder or piston ring worn out. z Carbon deposits on cylinder head top
z Carbon deposits on cylinder head side.
top-side.
z Piston pin hole and piston pin wear out.

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 PEUGEOT 7. CYLINDER/PISTON
CYLINDER REMOVAL Cylinder 2 bolts
Remove cylinder head. (refer to chapter 6)
Remove 2 bolts and then take out the cam
chain auto-adjuster.

camshaft chain adjuster

Remove cam chain plate.

Remove cylinder.

Remove cylinder gasket and lock pins

Clean the residues attached onto the

matching surfaces of cylinder and
crankcase.

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 7.CYLINDER/PISTON PEUGEOT

Cover the holes of crankcase and cam chain

with a piece of cleaning cloth.
Clean up all residues or foreign materials
from the two matching surfaces of cylinder
and crankcase.
Caution
To soap the residues into solvent so that
the residues can be removed more easily.

INSPECTION
Check if the inner diameter of cylinder is
worn out or damaged.
Exhaust side Intake side
In the 3 positions (top, center and bottom)
of cylinder, measure the X and Y direction
values respective in the cylinder.
Service limit:39.047mm
Calculate both the real roundness (the Top
difference between X and Y motion values) Center
and the cylindrical roundness (the Bottom
difference in the top, center or bottom
positions of X or Y motion values.). Then,
determinate by the max. value.
Service limit
Real roundness: correct or replace as
over 0.05 mm
Cylindrical roundness: correct or replace
as over 0.05 mm

Check Cylinder flat.

Service limit: correct or replace as over
0.05 mm

7-4

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 PEUGEOT 7. CYLINDER/PISTON
PISTON REMOVAL
Plug crankcase opening with a cleaning cloth
to prevent from piston pin snap ring or other
parts falling into crankcase when
disassembling.
Hold another snap ring with pliers.
Push out the piston pin from the side that not
removed the snap ring.

Remove piston rings.

Caution
Pay attention to remove piston rings
because they are fragile.

Disassemble the piston rings.

Check if the piston rings are damaged or its
grooves are worn.
Cleaning the carbon in piston ring grooves.

Piston ring
Install the piston rings and then measure
clearance between piston ring and its
grooves. Push in
Service Limit: Top ring: replace if over
0.09mm
2nd ring: replace if over Piston
0.09mm
Feeler gauge

Take out the piston rings and place them

respective into cylinder below 20mm of Feeler gauge
cylinder top. Measure each piston ring
gaps.
Caution
Push the piston rings into cylinder with
piston top-end in parallel motion.
piston ring
Service Limit: Top ring: replace if over
0.50mm
2nd ring: replace if over
0.650mm

7-5

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 7.CYLINDER/PISTON PEUGEOT
Measure the outer diameter of piston pin.
Service Limit: 12.980mm

Measure the inner diameter of connecting

rod small end.
Service Limit: 13.020mm

Measure the inner diameter of piston pin

hole.
Service Limit: 13.040mm

Calculate clearance between piston pin and

its hole.
Service Limit: 0.02mm

Measure piston outer diameter.

Caution
The measurement position is 10 mm
distance from piston bottom side, and 90°
to piston pin.

Service limit: 38.970mm

Compare measured value with service limit
to calculate the clearance between piston
and cylinder.

7-6

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 PEUGEOT 7. CYLINDER/PISTON
PISTON RING INSTALLATION
Clean up piston top, ring groove, and piston skirt.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.

Top ring

2nd ring
120°

Side ring

Spacer Oil ring

Side ring

Over 20 mm
Top groove

2nd groove

Oil groove

7-7

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 7.CYLINDER/PISTON PEUGEOT
PISTON INSTALLATION
Install piston and piston pin, and place the IN
mark on the piston top side forward to intake IN mark
valve.
Install new piston pin snap ring. Piston pin
Caution
y Do not let the opening of piston pin snap
ring align with the opening piston ring.
y Place a piece of cleaning cloth between
Piston
piston skirt section and crankcase in
order to prevent snap ring from falling
into crankcase as operation.

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
To soap the residues into solvent so that
the residues can be removed more
easily.
Install 2 lock pins and new cylinder gasket.

Coat 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 this will cause the piston and the
piston rings to be damaged.

Install the cam chain plate, the cylinder head

gasket and lock pins.
Install cylinder head. (refer to Chapter 6)
Install the cam chain auto-adjuster. (2 bolts)

7-8

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

MECHANISM DIAGRAM ....................8-1 KICK STARTER ARM ........................ 8-3

MAINTENANCE DESCRIPTION ........8-2 DRIVING BELT................................... 8-4
TROUBLE DIAGNOSIS......................8-2 SLIDING PULLEY .............................. 8-6
LEFT CRANKCASE COVER ..............8-3 CLUTCH/DRIVEN PULLEY............... 8-9

MECHANISM DIAGRAM

5.0~6.0kgf-m

3.5~4.5kgf-m

0.8~1.2kgf-m
5.0~6.0kgf-m

8-1

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

MAINTENANCE DESCRIPTION
Precautions in operation
General information
• Driving pulley, clutch, and driven pulley can be serviced on the motorcycle.
• Driving belt and driving pulley surface must be free of grease.

Specification Unit: mm
Item Standard value Limit
Driving belt width 17.50 16.8
ID of sliding pulley bush 20.035~20.085 20.150
OD of roller 15.920~16.080 15.570
ID of clutch outer 107.00~107.20 107.50
Thickness of clutch pad 4.000 2.0
Free length of drive pulley spring 97.20 96.5
OD of driven pulley 33.965~33.985 33.940
ID of sliding pulley 34.000~34.025 34.060
ID: Inner Diameter
OD: Outer diameter

Torque value Special Service Tools

Sliding pulley nut: 5.0~6.0kgf-m Clutch spring compressor
Clutch outer nut: 5.0~6.0kgf-m Bearing puller (inner type)
driving pulley nut: 3.5~4.5kgf-m Clutch mounting nut wrench
Universal fixture

TROUBLE DIAGNOSIS
Engine can be started but motorcycle
can not be moved
z Worn driving Belt Insufficient horsepower or poor high
z Worn tilt plate speed performance
z Worn or damaged clutch pad z Worn driving belt
z Broken driven pulley z Insufficient spring capacity of driven
pulley
Shudder or misfire when driving z Worn roller
z Broken clutch pad z Driven pulley operation un-smoothly
z Worn clutch pad

8-2

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

LEFT CRANKCASE COVER air cleaner lock bolts

Left crankcase cover removal
Remove air cleaner. (2 bolts)
Remove kick starter arm. (1 bolt)
Loosen vent strap on the front-left side of
cover, and then remove the vent.
Remove engine left-side cover (8 bolts).

Screws×6
KICK STARTER ARM
Disassembly
Remove left side cover plate on the left
crankcase cover(screws×6).
Remove left side cover plate gasket.

First put kick starter pedal into the starter

shaft. After a little rotation, remove the drive
gear and washer.
Removed kick starter pedal, starter shaft,
return spring and the thrust washer.

Friction spring Starter shaft

Check if starter shaft, drive gear, bushing, for
wear or damage. Replace it with new one if
return spring
necessary.
Check the return spring for spring force or
damaged. Replace it with new one if poor
parts found.

drive gear

8-3

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

Reassembly starter shaft gear driving gear

Apply with some specified grease on the
gear, shaft.
Install the friction spring of driving gear onto
convex part of the case cover.
Install, return spring and starter shaft as
diagram shown.
Install kick starter arm temporary.
Rotate the lever and then align driving gear
with width-tooth on the starter shaft.
Install thrust washer and socket onto starter
shaft.

Strap Bolts
Installation of the left crankcase
cover
Install the left crankcase cover. (8 bolts)
Install front vent tube of left cover and tighten
the strap.
Install kick starter arm. (1 bolt)
Tighten the air cleaner. (2 bolts)

8-4

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

DRIVING BELT sliding pulley

Removal
Remove left crankcase cover.
Hold the sliding pulley with a universal fixture,
and then remove the nut and sliding pulley.

Universal fixer

Hold driving pulley with universal fixture, and

driving pulley
remove nut and clutch outer.
Caution
Using special service tools for tightening or
loosening the nut. Fixed rear wheel or rear
brake only will damage reduction gear
system.
Nut

Universal fixer
Push the driving belt into belt groove as
diagram shown so that the belt can be
loosened, and then remove driven belt and
Driving belt
clutch at same time.

Inspection
Check the driving belt for crack or wear.
Replace it if necessary.
Measure the width of driving belt as diagram
shown. Replace the driving belt if it exceed
maintenance limited specification.
Service Limit: 16.80mm
Caution Tooth
Width
y Using the genuine parts for replacement.
y The surfaces of driving belt or pulley must
be free of grease.
y Clean up all grease or dirt before
installation.

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

Installation
Pull out driving pulley and then insert the
driving belt into the driven belt.
Driven
pulley
Caution
Pull out driving pulley and then insert the
driving belt into the driving pulley so that the
driving belt set can be installed onto sliding
pulley more easily.

Install the starter clutch.

Install the clutch set with driving belt onto the
driving shaft.
Install the sliding pulley on the other end of
belt.
Install clutch outer.

sliding pulley clutch outer

Clutch outer
Install the clutch with universal fixture, and
then tighten nut to specified torque value.
Torque value: 3.5~4.5 kgf-m
Nut

Universal fixer

Caution
When install the driving belt, if there is a
arrow mark, then the arrow mark must
point to rotation motion. If not, the letters
on the belt must be forwarded to
assembly direction.

8-6

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

SLIDING PULLEY
REMOVAL
Remove left crankcase cover.
Hold driving pulley with universal fixture, and
then remove driving pulley nut.
Remove driving pulley.

Special tool

Remove the sliding pulley fixing nut and Crankshaft

Sliding pulley
remove the driving belt from the sliding
pulley.
Remove the driving belt from the sliding
pulley. Bush
Remove the limited speed bush.
Remove the bush and remove the sliding
pulley from the crankshaft.

Limited speed
bush

Tilt plate
Remove tilt plate.

Sliding pulley
Remove weight rollers from sliding pulley.

Roller

8-7

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

Inspection
The operation of sliding pulley is means of Weight roller
the weight roller to pressing on it with
centrifuge force. And then the speed is
changed by the title plate rotation. Thus, if
weight rollers are wear out or damage, the
centrifuge force will be effected.
Check if rollers are wear out or damage.
Replace it if necessary.
Measure each rollers’ outer diameter.
Replace it if exceed the service limit.
Service limit: 15.57 mm

Measure the inner diameter of the sliding

Sliding pulley
pulley.
Service limit: 34.06 mm

Pulley bush
Measure the inner diameter of the pulley
bush.
Replace it if exceed the service limit.
Service limit: 20.15 mm

Assembly/Installation Weight roller

Install the weight rollers.

Install the title plate guide boot onto the title Guide boot
plate.
Install the title plate.

Tilt plate

8-8

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

Apply with grease 4~5 g to inside of driving

Pulley bush
shaft hole, and install driving pulley hub.

Caution
The pulley surface has to be free of
grease. Clean it with cleaning solvent.

Pulley surface

Install siding pulley assembly onto crankshaft. Crankshaft

Sliding pulley

Pulley bush

Limited speed
bush

Press down
Driving pulley install
Press driving belt into pulley groove, and
then press down the up & down sides of the
driving belt to separate it away from the
driving pulley hub.
Caution
To press down the up & down sides of the
driving belt can avoid to pressing and
damaging the belt when installing the Driving belt
driving pulley, and also can make sure that
the driving pulley can be tighten.

Install driving pulley, washer and nut.

Caution
Make sure that two sides of pulley
surfaces have to be free of grease.
Clean it with cleaning solvent.
Hold driving pulley with universal fixture.
Tighten nut to specified torque.
Torque value: 5.0~6.0 kgf-m
Install left crankcase cover.

8-9

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

CLUTCH/DRIVEN PULLEY Special nut wrench

Disassembly
Remove driving belt and clutch/driven pulley.
Install clutch spring compressor onto the
pulley assembly, and operate the
compressor to let nut be installed more
easily.

Caution
Do not press the compressor too much.
Clutch spring compressor

Hold the clutch spring compressor onto

bench vise, and then remove mounting nut
with special nut wrench.
Release the clutch spring compressor and
remove clutch and spring from driven pulley.
Remove socket from driven pulley.

Socket

Remove oil seal from driven pulley. Sliding pulley

Oil seal Guide pin
Remove guide pin, guide pin roller, and
sliding pulley, and then remove O-ring & oil
seal seat from sliding pulley.

Guide pin
O-ring Guide pin roller

Inspection
Clutch outer
Measure the inner diameter of clutch outer
friction face. Replace the clutch outer if
exceed service limit.
Service limit: 107.5 mm
Inner
diameter Clutch outer

8-10

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

Clutch pad Clutch pad

Measure each clutch pad thickness.
Replace it if exceeds service limit.
Service limit: 2.0mm

Clutch

Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 93.2mm

Free length

Driven pulley Outer diameter

Check following items;
Inner diameter
• If both surfaces are damage or wear.
• If guide pin groove is damage or wear. Driven face
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 33.94mm
Inner diameter 34.06mm Movable
Driven surface Guide pin groove
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 Needle bearing
and silent.

Outer ball bearing

8-11

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

Clutch Block Replacement Driving plate

Remove snap and washer, and the remove Spring
clutch block and spring from driving plate.
Check if spring is damage or insufficient
elasticity.

Snap ring

Clutch block

Shock absorption rubber

Check if shock absorption rubber is damage
or deformation. Replace it if necessary.
Apply with grease onto setting pins.

Setting pin

Apply with grease onto setting pins. But,

Shock absorption rubber
the clutch block should not be greased. If so,
replace it.
Install new clutch block onto setting pin and
then push to specified location.
Caution
y Grease or lubricant will damage the
clutch block and effect the block’s
connection capacity.
Clutch block

Install the spring snap into groove with pliers.

Spring

8-12

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 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH

Install snap ring and mounting plate onto

setting pin.

Snap ring

Replacement of driven pulley bearing

Remove inner bearing. Oil seal
Outer bearing
Caution
y If the inner bearing equipped with oil
seal on one side in the driven pulley,
then remove the oil seal firstly.
y If the pulley equipped with ball bearing,
it has to remove snap ring and then the
bearing.
Snap ring Inner needle
bearing

Remove snap ring and then push bearing

forward to other side of inner bearing.
Place new bearing onto proper position and Specified grease
its sealing end should be forwarded to
outside.
Apply with specified grease. Snap ring
Recommended to use G-3.
Install the snap ring and hold the bearing.

Outer bearing

Sealing end

Install a new inner bearing.

Caution Sealing end
y Its sealing end should be forwarded to
outside as bearing installation.
y Install needle bearing with hydraulic
presser. Install ball bearing by means of
hydraulic presser.

Align oil seal lip with bearing, and then install Inner bearing
the new oil seal (if necessary).

8-13

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 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM/STARTER CLUTCH SYM

Installation of clutch/driven pulley Oil seal

Install new oil seal and O-ring onto sliding
pulley. Apply with specified grease to
lubricate the inside of sliding pulley.

Specified
O-ring grease

Install sliding pulley onto driven pulley. Sliding pulley Guide pin
Oil seal
Install guide pin and guide pin roller.

Guide pin
O-ring Guide pin roller

Install oil socket. Oil socket

Install driven pulley, spring and clutch into

clutch spring compressor, and press down
the assembly by turning manual lever until Special nut wrench
mounting nut that can be installed.
Hold the compressor by bench vise and
tighten the mounting nut to specified torque
with special nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0 kg-m
Install clutch/driven pulley and driving belt
onto driving shaft.

Clutch spring compressor

8-14

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 SYM 9. FINAL DRIVING MECHANISM

MECHANISM DIAGRAM ....................9-1 INSPECTION OF FINAL DRIVING

OPERATIONAL PRECAUTIONS .......9-2 MECHANISM ..................................... 9-3
TROUBLE DIAGNOSIS......................9-2 BEARING REPLACEMENT ............... 9-4
DISASSEMBLY OF FINAL DRIVING RE-ASSEMBLY OF FINAL DRIVING
MECHANISM......................................9-3 MECHANISM .....................................9-6

MECHANISM DIAGRAM

2.6~3.0 kgf-m

9-1
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 9. FINAL DRIVING MECHANISM SYM
OPERATIONAL PRECAUTIONS
Specification Torque value
Application gear oil: 4-stroke lubricant Gear box cover 2.6~3.0 kgf-m
Recommended gear oil: 85W-140 Gear oil drain plug 1.0~1.5 kgf-m
Oil quantity: 180 c.c. (170 c.c. when Gear oil filling bolt 1.0~1.5 kgf-m
replacing)

Tools
Special service tools
Inner type bearing puller
Outer type bearing puller
Gear box oil seal installer
Gear box bearing installer

TROUBLE DIAGNOSIS
Engine can be started but motorcycle Gear oil leaks
can not be moved • Excessive gear oil
• Damaged driving gear • Worn or damage oil seal
• Burnt out driving gear
• Broken driving belt

Noise
• Worn or burnt gear
• Worn gear

9-2
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 SYM 9. FINAL DRIVING MECHANISM
DISASSEMBLY OF FINAL DRIVING 7 bolts
MECHANISM
Remove the rear wheel. (refer to chapter 15)
Remove the clutch.
Drain gear oil out from gear box.
Remove gear box cover bolts (7bolts) and
then remove the gear box cover and the final
driving shaft.
Remove gasket and setting pin.

final driving shaft

Remove countershaft and gear. countershaft gear
Remove final driving gear and shaft.

countershaft final driving gear

driving shaft

INSPECTION OF FINAL DRIVING

MECHANISM
Check if the countershaft and the gear are
wear or damage.

final driving shaft

Check if the final driving shaft and gear are
burn, wear or damage.

final driving gear

9-3
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 9. FINAL DRIVING MECHANISM SYM

Check bearings on the gear box cover. bearing

Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth
and silent, and also check if bearing outer
ring is mounted on gear box & cover 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 driving shaft and gear for wear or final driving shaft
damage. countershaft gear

countershaft final driving gear

BEARING REPLACEMENT
Caution driving shaft
Never install used bearings. Once bearing
removed, it has to be replaced with new
one.

Remove driving shaft bearing from left

crankcase using following tools;
Inner type bearing puller

Install new driving shaft bearing into left

crankcase.
Tool:
Press the bearing into cover with C type
hydraulic presser or bearing installer.

Special tool

9-4
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 SYM 9. FINAL DRIVING MECHANISM
Press out the driving shaft from the Driving shaft
crankcase.
Remove oil seal from the crankcase.
Remove the driving shaft bearing from the
gear box cover with the inner type bearing
puller.
Caution
Using the bearing protector as pressing out
the driving shaft from the left crankcase.

Specified tool:
Inner type bearing puller.
Bearing protector

If the driving shaft is pulled out with its

bearing, then remove the bearing with bearing
puller and bearing protector.
Tool:
Multi-functional bearing puller
Bearing protector

Multi-functional bearing puller

driving shaft

Install a new driving shaft bearing onto

crankcase.
Then, install the driving shaft.
Specified tool:
Press the bearing in with C type hydraulic
presser or bearing installer.

final driving shaft

bearing
Install a new final driving shaft bearing onto
crankcase.
Specified tool:
Press the bearing in with C type hydraulic
presser or the bearing installer.
Apply with some grease onto the lip section
of oil seal and then install the seal.

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 9. FINAL DRIVING MECHANISM SYM
RE-ASSEMBLY OF FINAL DRIVING
MECHANISM countershaft final driving shaft
Install final driving shaft and final driving gear,
countershaft, and countershaft gear.

final shaft gear

Install the setting pins(2 pins) and new gasket.

dowel pins

Apply with grease onto the oil seal lip of final

driving shaft. 7 bolts
Install the gear box cover and 7 bolts.
(tighten the bolts)
Torque: 2.6~3.0 kgf-m
Install the clutch/sliding driving pulley.
Install the driving pulley, belt and left
crankshaft cover.
Install the rear wheel.

Filling bolt

Add gear oil.

Recommended usage gear oil :SAE
85W-140
(180 cc: standard capacity)
(170 cc: when replacement)

Draining bolt

9-6
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 SYM 10. A.C. GENERATOR

PRECAUTIONS IN OPERATION .......10-1 RIGHT CRANKCASE COVER

A.C.GENERATOR REMOVAL ...........10-2 INSTALLATION .................................. 10-4
RIGHT CRANKCASE COVER MOUNTED COIL SET
REMOVAL .......................................... 10-3 INSTALLATION .................................. 10-4
FLY WHEEL INSTALLATION............. 10-4

PRECAUTIONS IN OPERATION
General information
y Refer to chapter 5: Engine removal and installation
y Refer to chapter 1: The troubleshooting and inspection of A.C. generator

Torque value:
Flywheel nut 3.5~4.5kgf-m
Exhaust muffler bolt 8 mm 3.0~3.6kgf-m
Oil screen cover 1.0~2.0kgf-m

Special service tools

Flywheel puller
Universal fixture

10-1

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 10. A.C. GENERATOR/STARTING CLUTCH SYM

A.C. GENERATOR REMOVAL

Pulse generator Flywheel
Cooling fan

Cooling fan
shroud

Coil Cable guide

Cooling fan shroud

Drain out the engine oil.
Remove the exhaust muffler. (2 bolts, 2 nuts)
Remove the fan shroud. (4 bolts)

Exhaust muffler

Remove the fan. (4 bolts)

Cooling fan

Hold the flywheel with the universal fixture.

Remove the 10mm nut on the flywheel. Universal fixture
Special Service Tools:
Universal Fixture

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 SYM 10. A.C. GENERATOR
Remove the flywheel with the flywheel puller.
Special service tools:
Flywheel puller
Shaft protector
Caution
Install a shaft protector on the right end of
crankshaft to avoid damaging the
crankshaft before installing the flywheel
puller.
Flywheel puller

Pulse generator connector

Remove the connectors of the A.C.
generator and pulse generator.

generator connector

Pulse generator Cable guide

Remove the 6 bolts for the pulse generator,
the A.C. generator coil and cable guide.
Then, remove the A.C. generator assembly.
Caution
Do not damage the alternator coil.

Coil

RIGHT CRANKCASE COVER

REMOVAL
Remove the right crankcase cover. (8 bolts)
Remove setting pin and gasket.
Remove the gasket or foreign materials on
the connection surfaces of both the cover
and crankcase.
Caution
Do not damage the connection surfaces.
8 bolts

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 10. A.C. GENERATOR/STARTING CLUTCH SYM
RIGHT CRANKCASE COVER
INSTALLATION
Install setting pin and new gasket on the
crankcase.
Replace the right crankshaft oil seal of the
crankcase and apply some oil onto the oil
seal lip.
Install right crankcase cover onto the right
crankcase. (8 bolts)
Torque value: 1.5~2.0kgf-m
8 bolts

Pulse generator
MOUNTED COIL SET
INSTALLATION
Install the coil set onto right crankcase
cover. (2 bolts)
Install pulse generator. (2 bolts)
Torque: 0.8~1.2kgf-m
Tie the wire harness hose onto the indent of
crankcase.

Coil

generator connector

Install A.C. generator connector and pulse

generator connector.

Pulse generator Auto by-start

connector connector

FLYWHEEL INSTALLATION
Make sure that there is no magnetic powder.
If so, clean up it. Universal fixture
Align insert on crankshaft with the flywheel
groove, and then install the flywheel.
Hold the flywheel with flywheel holder, and
tighten its nut.
Torque value: 3.5~4.5kgf-m
Special service tool:
Universal fixture

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 SYM 10. A.C. GENERATOR

Install the cooling fan. (4 bolts) 4 bolts

Cooling fan

Cooling fan shroud

Install the cooling fan shroud. (4 bolts)
Install the exhaust muffler. (2 bolts, 2 nuts)
Add some engine oil according the
specified quantity.

Exhaust muffler

10-5

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 SYM 11. CRANKCASE/CRANKSHAFT

MECHANISM DIAGRAM .............. 11-1 DISASSEMBLY OF CRANKCASE 11-3

OPERATIONAL PRECAUTIONS ... 11-2 CRANKSHAFT INSPECTION ....... 11-5
TROUBLE DIAGNOSIS................ 11-2 ASSEMBLY OF CRANKCASE ..... 11-6
MECHANISM DIAGRAM

0.7~1.1 kgf-m

0.8~1.2 kgf-m

11-1
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 11. CRANKCASE/CRANKSHAFT SYM
OPERATIONAL PRECAUTIONS
General Information
z This Section contains descriptions concerning disassembly of the crankcase so that the
crankshaft can be serviced.
z Complete following operations before disassembling crankcase.
Engine Chapter 5
Cylinder head Chapter 6
Cylinder and piston Chapter 7
V-belt Drive pulley Chapter 8
AC generator/ Starting Clutch Chapter 10
If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have to
replaced.

Specification Unit: mm
Item Standard Limit

Left, right clearance of the big end of the connecting rod 0.100~0.350 0.550

Radial clearance of the big end of the connecting rod 0.000~0.008 0.050

Run-out Below 0.030 0.10

Torque value
Bolts for crankcase 0.8~1.2 kgf-m
Bolts for cylinder/cylinder head 0.7~1.1 kgf-m
Engine oil draining plug 3.5~4.5 kgf-m
Bolts for cam chain tensioner 0.8~1.2 kgf-m

Special Service Tools

Crankcase remover/set
Crankshaft installation puller
Inner type bearing puller
Outer type bearing puller
Bearing pressing tools
Oil seal pressing tools

TROUBLE DIAGNOSIS
Engine noise
• Loose crankshaft bearing
• Loose crankshaft pin bearing
• Wear piston pin or piston pin hole

11-2
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 SYM 11. CRANKCASE/CRANKSHAFT
DISASSEMBLY OF CRANKCASE 2 bolt
Remove the 2 bolt from the right crankcase.

Remove the cam chain tensioner (hex socket 1 hex socket bolt
bolt) from the left side of crankcase.

Place the left side of crankcase upward,

and then install the crankcase remover/set
onto the crankcase.
Drive the screw of the crankcase
remover/set into the crankcase, and then
separate the left and the right crankcases.
Remove the cam chain.
Caution
z Never pry out the connection surfaces of
crankcases as separating. Otherwise,
the connection surfaces could be
damaged and cause oil leaking.
z It have to separate the cam chain and the
drive gear before pressing out the both
left and right crankcases.

Special Service Tools:

Crankcase remover/set

11-3
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 11. CRANKCASE/CRANKSHAFT SYM
Remove the crankshaft from the right
crankcase.
Caution
z The left and right bearings of crankshaft is
to press-fit onto the crankshaft.

Remove gasket and dowel pins (2).

Scrape gasket residues off the crankcase
contact surface.
Caution
z Do not damage contact surface of the
crankcase.
z Soap the gasket residues into solvent and
the residues will be removed easily.

Remove oil seal from the left crankcase.

11-4
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 SYM 11. CRANKCASE/CRANKSHAFT
CRANKSHAFT INSPECTION
Measure left and right clearance of connecting
rod big end.
Service limit: Replace when it is more
than 0.55 mm

Measure the radical clearance of the big

end at the vertical directions.
Service limit : 0.05 mm

Place the crankshaft onto a V-block and

measure run-out of the crankshaft with dial
gauge.
Service limit: 0.10 mm

60 mm 90 mm

Bearing Inspection clearance

Rotate the bearing with fingers and make
sure the bearing can be rotated smoothly clearance
and quietly.
Check if the inner ring is connected onto the
crankshaft tightly.
Replace crankshaft as a set when noise or
looseness is detected.

11-5
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 11. CRANKCASE/CRANKSHAFT SYM
ASSEMBLY OF CRANKCASE
Install cam chain into the chain hole of the
left crankcase, and then split out the cam
chain.
Caution
z Do not damage the cam chain as
installing the crankshaft.

Install crankshaft into the left crankcase and dowel pins

then install two dowel pins and new
crankcase gasket.

Install the right crankcase and tighten the 2 bolt

crankcase bolts (1 bolts).
Torque value: 0.8~1.2 kgf-m

Install the cam chain tensioner. 1hex

hexsocket
socketbolt
bolt
Install a new O-ring onto the mounting bolt
of the chain tensioner.
Apply some oil on the O-ring and tighten the
bolt.
Torque value: 0.8~1.2 kgf-m
Caution
z The O-ring must be installed into the
bolt’s groove.

11-6
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 SYM 11. CRANKCASE/CRANKSHAFT
Apply with some grease onto the oil seal lip
and then install it onto the left crankcase.

Press-fit the oil seal to specified position

with the oil seal installer (25x37x6).
Special service tools: the oil seal
installer (25x37x6)

11-7
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 SYM 12. BODY COVER

MAINTENANCE INFORMATION........12-2 FRONT CENTER COVER.................. 12-8

HANDLE COVER ...............................12-3 LUGGAGE BOX ................................. 12-8
FRONT COVER..................................12-4 FLOOR PANEL .................................. 12-8
FRONT INNER BOX...........................12-5 SIDE COVER ..................................... 12-9
BODY COVER/REAR CENTER UNDER COVER ................................. 12-10
COVER/REAR FENDER .................... 12-6

Rear handle cover

Double Seat

Luggage box
FR.Inner lid
Front handle cover
Rear carrier

Top cover FR.Inner

Front cover box

Right body
cover

RR. fender
RR. mudguard

FR. center Left body

cover cover

Right side cover

Front under
cover Floor panel Left side cover

Under cover
Front center
cover

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 12. BODY COVER SYM
MAINTENANCE INFORMATION
Body covers disassemble sequence:

Front Handle cover Front wheel Luggage box & Seat

Rear handle cover Front cover Rear carrier

Front fender Left/right side cover

Under cover

Front center cover

Floor panel

Rear fender

Front inner box

Tail light

y Be careful not to damage various covers in disassembly or re-assembly operation.

y Never injure hooks molded on the body covers in disassembly or re-assembly operation.
y Align the buckles on the guards with slot on the covers.
y Make sure that each hook is properly installed during the assembly.
y Never compact forcefully or hammer the guard and the covers during assembly.

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 SYM 12. BODY COVER
HANDLE COVER
Removal:
Remove 1 lower mounting screw of the
handle front cover.

screw×1

Remove the mounting screws (4 screws)

between the front handle cover and the rear
handle cover.

screws×4

Removed the head light wire connectors. turn signal light

Removed the left/right turn signal light connectors
connectors.

Remove the front handle cover.

Remove the speedometer cable.
Remove the rear handlebar cover. (3 screws)
Removed the rear handle cover.
Installation:
Install according to the reverse procedure
of removal.
Caution
With the clipper to fix the end-section of the
handlebar cover. Do not pull it forcedly to
avoid to breaking the hooks. screws×3

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 12. BODY COVER SYM
FRONT COVER Top cover
Removal
Remove the top cover.

bolt×1
Remove the 1 mounting bolt of front cover
from the frame.

Remove the front under cover 4 mounting

screws between the front under cover and
the frame .

screws2×2

Remove the 2 mounting screws between the

front cover and the left/right side cover.

Screws1×2

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 SYM 12. BODY COVER

Remove the 8 mounting screws between the

front cover and the front inner box.

screws 4×2

Front cover
Remove the front cover from the frame.

Installation
Install according to the reverse procedure
of removal.

FRONT INNER BOX

Removal
Remove the 8 mounting screws of front
cover from the inner box A.
screws 4×2

1 bolt
Remove the hook screw bolt from the front
inner box.

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 12. BODY COVER SYM

Remove the main switch cover. Main switch cover

Remove the front cover and front under 2 screws

cover.
Remove the 2 screws between the inner box
and the floor panel.

Remove the front inner box

Installation
Install the inner box A and the front inner box
B according to the reverse procedure of
removal.

2 bolts
BODY COVER/REAR CENTER
COVER/REAR FENDER
Removal
Open the seat.
Remove 2 bolts in front of the luggage box.

Remove 2 bolts in rear of the luggage box.

Remove the luggage box.
Remove the rear carrier. (3 bolts)
3 bolts
2 bolts

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 SYM 12. BODY COVER

1 bolt

Remove the 2 mounting bolts of the rear

fender.

4 screws
Remove the 4 mounting screws between the
body cover and the frame.

Remove the left/right side 2 mounting bolts Bolts1×2

under rear of the body cover between the
body cover and the frame.

Remove the rear fender.

Remove the left/right body cover.

Installation
Install the body cover and rear fender
according to the reverse procedure of
removal.

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 12. BODY COVER SYM
Front center cover screws×5
FRONT CENTER COVER
Removal
Remove the 5 screws bolt.

Remove the front center cover.

Installation
Install the front center cover according to the
reverse procedure of removal.

4 bolts

LUGGAGE BOX
Removal
Open the seat.
Remove the 4 bolts from the luggage box.
Remove the luggage box and the double
seat.
Installation
Install the luggage box according to the
reverse procedure of removal.

4 bolts
FLOOR PANEL
Removal
Remove the 4 bolts from the luggage box.
Remove the luggage box and the double
seat.
Remove the front center cover.

Bolts1×2
Remove the 2 bolts between the floor panel
and the frame.

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 SYM 12. BODY COVER
Remove the front cover and front under
2 screws
cover.
Remove the 2 mounting screws between
the floor panel and the front inner box.
Remove the floor panel.

Installation
Install the floor panel according to the
reverse procedure of removal.

SIDE COVER
Removal
Remove the left/right side 2 mounting
screws in the front of the side cover.

Screws1×2

Remove the left/right side 2 mounting bolts Screws1×2

in the rear of the side cover.

Remove the left/right side cover.

Installation
Install the side cover according to the
reverse procedure of removal.

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 12. BODY COVER SYM

UNDER COVER Bolts2×2

Removal
Remove the floor panel.
Remove the left/right side cover.
Remove the left/right side 4 mounting bolts
between the under cover and frame.

Remove the under cover.

Installation
Install the under cover according to the
reverse procedure of removal.

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 SYM 13. BRAKE
MECHANISM DIAGRAM-FRONT BRAKE FLUID
DISC BRAKE SYSTEM...................... 13-1 REPLACEMENT/AIR-BLEED............ 13-6
MECHANISM DIAGRAM-REAR BRAKE CALIPER .............................. 13-7
DRUM BRAKE SYSTEM.................... 13-2 BRAKE DISC ..................................... 13-8
MAINTENANCE INFORMATION ....... 13-3 BRAKE MASTER CYLINDER ........... 13-8
TROUBLE DIAGNOSIS ..................... 13-4 DRUM BRAKE-DRUM ....................... 13-11
HYDRAULIC BRAKE SYSTEM BRAKE LING ..................................... 13-11
INSPECTION...................................... 13-5 BRAKE PANEL.................................. 13-12
MECHANISM DIAGRAM
Front Disc Brake System

3.3~3.7 kgf-m
0.8~1.0 kgf-m

2.8~3.2 kgf-m

4.0~4.5 kgf-m

5.0~7.0 kgf-m

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 13. BRAKE SYM

MECHANISM DIAGRAM
Rear Drum Brake System

0.8~1.2 kgf-m

0.8~1.2 kgf-m

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 SYM 13. BRAKE

MAINTENANCE INFORMATION
Precautions in Operation
Caution
Installing lining dusts 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.

z The brake caliper can be removed without removing the hydraulic system.
z After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the
hydraulic system.
z While refilling brake fluid, care should be taken not to let the foreign material entering into
the brake system.
z Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
z Check the operation of the brake system before you go.

Specifications Unit: mm
Item Standard Limit
The thickness of front brake 3.50 2.00
Front brake disc eccentricity 0.15 0.30
Master cylinder inner diameter 25.40 ─

IID of front & rear brake drums 130.00 131.00

OD of front brake disc 226.00 ─

Thickness of front disc brake ─ As brake ling mark

Thickness of front drum brake ─ 2mm or As brake ling mark

Thickness of rear brake lining ─ 2mm or As brake ling mark

Torque values
Bolt for front brake arm 0.8~1.2kgf-m
Bolt for rear brake arm 0.8~1.2kgf-m
Brake hose bolt 3.3~3.7kgf-m
Bolt for brake caliper 3.1~3.5kgf-m
Air-bleed valve 0.8~1.0kgf-m

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 13. BRAKE SYM

TROUBLE DIOGNOSIS
DISC BRAKE
Soft brake lever Uneven brake
z Air inside the hydraulic system z Dirty brake lining/disc
z Hydraulic system leaking z Poor wheel alignment
z Worn master piston z Clogged brake hose
z Worn brake pad z Deformed or warped brake disc
z Poor brake caliper z Restricted brake hose and fittings
z Worn brake lining/disc
z Low brake fluid Tight brake
z Blocked brake pipe z Dirty brake lining/disc
z Warp/bent brake disc z Poor wheel alignment
z Bent brake lever z Deformed or warped brake disc

Hard operation of brake lever Brake noise

z Blocked brake system z Dirty lining
z Poor brake caliper z Deformed brake disc
z Blocked brake pipe z Poor brake caliper installation
z Seized/worn master cylinder piston z Imbalance brake disc or wheel
z Bent brake lever

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 SYM 13. BRAKE

HYDRAULIC BRAKE SYSTEM Hose connection

INSPECTION
Inspection
Visual inspect for brake fluid leaking or
damage. Check if brake hose connection
loosen with wrench and turn the handlebar
from right to left motion or press down the
shock absorber to check if there is something
is interfered with the brake system or brake
components.

Brake disc
Operate the brake system and check the
brake lining. Check the front brake from front
side, and replace the brake lining with new
one when the brake lining wear limitation
groove reaches to the brake disc.

brake lining
wear limitation
brake caliper groove

Park the motorcycle on a flat ground and

check its brake fluid level.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
CAUTION
lower level
z The fluid level will not be correct if
parking the motorcycle in title or just
parking. It has to waiting for around 3~5
minutes.
z Never use faked brake fluid to prevent
from chemical reaction.
z It has to apply with same brand brake
fluid to sure the brake performance.
Brake Fluid Add Master
Turn the handlebar to let the master cylinder cylinder cap
in horizontal position before removed the
master cylinder cap.
Place a rag onto painting, plastic or rubber
components when conduct brake system
maintenance.
CAUTION
z Do not over the upper level when adding
brake fluid and avoid to spilling brake fluid
on painted surfaces, plastic or rubber
components to result in their damages.

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 13. BRAKE SYM
Remove the master cylinder cap and
diaphragm. master
Add good quality brake fluid and it has to add cylinder
same brand brake fluid into the master cylinder.
Clean dirty brake disc. diaphragm
CAUTION
The dirty brake lining or disc will reduce the
brake performance. The mixed
non-compatible brake fluid will reduce brake
performance. Foreign materials will block
the system causing brake performance to
be reduced or totally lost.
BRAKE FLUID REPLACEMENT/
AIR-BLEED drain valve
Connect drain hose to drain valve.
Open the drain valve on the caliper and hold
and release the brake lever alternatively until
the old brake fluid is entirely drained out.
Close the drain valve and add specified brake
fluid into the brake master cylinder.
CAUTION
To reuse the spent brake fluid will effect
brake performance.
Connect one end of transparent hose to the
drain valve, and put the other end into a
container.
Open the drain 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 Bubbles Draining valve
also feeling resistance on the brake lever.
Close the drain 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
drain valve around 1/4 turns, and then close
the valve.
CAUTION
z Do not release the brake lever before the Transparent hose
drain valve is closed.
z Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air entering 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. Tightly close
the drain valve.
4. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the
fluid if necessary.
5. Cover the cap.

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 SYM 13. BRAKE

BRAKE CALIPER hose bolt

Removal
Place a container under the brake caliper,
and loosen the brake hose bolt and finally
remove the brake hoses.
CAUTION
z Do not spill brake fluid on painted
surfaces.
Remove two caliper bolts and the caliper.

Make sure the brake lining condition. Replace

the lining if the brake lining wear limitation brake pad wear
groove close to the brake disc. limitation groove
Brake Lining Replacement
Compress the caliper and let the brake lining
out of the caliper mounting plate. Compress the
brake lining locking spring. Remove the inner
brake lining firstly and then remove the outer
brake lining.
Compress the brake caliper at first as
installation. Install the inner brake lining firstly,
and then install the outer brake lining.
brake pad

brake mounting
INSTALLATION brake lining plate
Install the brake caliper and tighten the
attaching bolts securely.
Torque: 3.3 kgf-m
CAUTION
piston
z Use M8 x 35 mm flange bolt only.
z Long bolt will impair the operation of
brake disc. brake
caliper
Tighten the lining guide bolt. locking spring
Torque: 1.8 kgf-m

Use two seal washers and hose bolts to lock

the hose and brake caliper in place.
Torque: 3.5 kgf-m

Refill up the brake fluid to the reservoir and

make necessary air bleeding.

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 13. BRAKE SYM

BRAKE DISC
Inspection
Visually check the brake disc for wear or
break.
Measure the thickness of the disc at several
places. Replace the disc if it has
exceeded the service limit.
Allowable limit: 2.0 mm brake disc
micrometer

Remove the brake disc from wheel.

Check the disc for deformation and bend.
Allowable limit: 0.30 mm
CAUTION
z Do not let grease touch to the brake disc
that will cause brake performance.
z Do not clean the brake lining with air gun.
Operator should wear mask & glove and
use vacuum cleaner to clean the brake
lining.

BRAKE MASTER CYLINDER

Removal
brake hose
CAUTION
Do not let foreign materials enter into the
cylinder.

CAUTION bolts x2
The whole set of master cylinder, piston,
spring, diaphragm and circlip should be
replaced after removal.
Remove the front and rear handlebar
guards. circlip
rubber boot
Remove the leads of brake lamp switch.
Drain out the brake fluid. brake lamp
piston switch
Remove the brake lever from the brake
master cylinder. rubber spring
Remove the brake hose. washer
Remove the master cylinder seat and the
master cylinder. master
Remove the rubber pad. cylinder
Remove the circlip.
Remove the piston and the spring.
Clean the master cylinder with
recommended brake fluid.

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 SYM 13. BRAKE

Inspection
Check the master cylinder for damage or master cylinder
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: 11.055 mm
Dial gauge

Measure the outer diameter of the piston.

Replace the piston if its measured value
exceeds allowable limit. Piston
Allowable limit: 10.945 mm

Micrometer

Assembly
circlip
CAUTION rubber boot
z It is necessary to replace the whole set piston brake lamp
comprising piston, spring, piston cup, switch
and circlip. rubber spring
z Make sure there is no dust on all washer
components before assembling.
master
cylinder
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 cup’s cavity should be face inside
of master cylinder when installing the master
cup.
Install the circlip.
CAUTION
z Never install cup lip in the opposite
direction.
z Make sure the circlip is seated securely
in the groove.

Install the rubber pad into groove properly.

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 13. BRAKE SYM

INSTALLATION master cylinder mounting seat

Place the master cylinder onto handlebar,
and install the split ring and bolts. The
“UP” mark on the split ring should face bolts x 2
upward.
Align the split ring on the master cylinder
seat with the alignment point on the split ring
handlebar.
Tighten the upper bolt of the seat to
specified torque value, and then tighten
lower bolt to the same specified torque
value. “UP” mark

sealing washer

Install the brake lever, and connect leads to

hose bolt
brake lamp switch.
Connect brake hoses with 2 new washes.
Tighten the brake hose bolt to the specified
torque value.
Torque value: 3.5 kgf-m
Make sure the hose is installed correctly.
CAUTION brake hose
Improper routing may damage leads,
hoses or pipes.

CAUTION
Kink of brake leads, hose or pipe may
reduce brake performance.

Add specified brake fluid and bleed the

system and conduct the air-bleeding job for
the system.

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 SYM 13. BRAKE

DRUM BRAKE-DRUM
Brake Drum
Removal
Use a vacuum cleaner and other suitable
tools to clean the brake parts to minimize
the hazard caused by the dust.
Caution
•Inhaling dust may cause respiration
system disorder even cancer. Never
use an air hose or a dry brush as to
clean the brake parts.
•Grease on brake lining will reduce
braking efficiency.
Remove wheel. Remove brake drum from
wheel hub.
Inspection
Check the brake drum for wear and damage,
replace wheel hub if necessary
Measure the ID of hub at several points and
record the largest value.
Service limit : 131.0 mm
Caution
Rear brake drum
•Remove the rust by using #120 sand
paper.
•An inside micrometer must be used Brake lining
when measuring ID of brake drum
because the brake drum has a friction
back plate.

BRAKE LINING
Inspection
Measure the thickness of the brake lining at
three points (both ends and center).
If the thickness is less than specified, or if it is
contaminated by oil or grease, replace as a
set.
Service limit : Front 2.0 mm
Rear 2.0mm

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 13. BRAKE SYM
Removal
front brake cam
Caution
Brake linings must be replaced as a set.
brake spring
Remove brake shoes from the brake panel by
pulling out the brake linings with two hands.

Installation
Apply a thin coat of grease to the brake cam 後 anchor pin
and the anchor pin. brake shoes
Hook the brake spring onto the brake cam.
Pull out the brake linings and install them onto
the brake panel. Wipe off the excessive rear brake cam
grease from the brake cam and the anchor pin
after installation.
Slightly grind the brake lining surfaces with
sand-paper to clean the surfaces. anchor
pin
Caution
Braking efficiency will be reduced if
brake lining is contaminated by oil or
grease. brake spring brake shoes

BRAKE PANEL
Removal Front Brake cam Brake arm
Remove the brake arm bolt and then
remove the brake arm, wear indicator,
brake return spring and brake cam as well
as the oil seal from the brake panel.

Return
spring
Wear indicator
Bolt

Rear Wear indicator

Return spring

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 SYM 13. BRAKE

Installation Front Return spring

FRONT BRAKE PANEL Wear
Apply a thin cost of grease onto the brake indicator
cam shaft. Oil seal
Install the brake cam.
Apply a thin cost of grease onto the oil seal Brake cam
lip and then install the oil seal onto the
brake cam shaft. Finally, install it on the
brake panel.
Align the end-part of the brake return spring
with the hole of brake panel. Brake arm
Align both the inner gear of wear indicator
and the mark on the brake arm with the
indent gear of brake cam, and then install it. Rear Wear indicator
Tighten the bolts and nuts to specified
torque.
Torque: 0.8~1.2 kgf-m

REAR BRAKE PANEL

Apply a thin cost of grease between the oil
seals on the brake cam shaft.
Install the brake cam.
Align the mark on the brake arm with the
inner gear of the brake cam. Brake arm
Return spring
Tighten the bolts and nuts to specified
torque.
Hook on the return spring.
Torque: 0.8~1.2 kgf-m

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 SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

MECHANISM DIAGRAM ....................14-1 FRONT WHEEL ................................. 14-4

PRECAUTIONS IN OPERATION .......14-2 FRONT SHOCK ABSORBER ............ 14-9
TROUBLE DIAGNOSIS......................14-2 FRONT FORK/STEERING COLUMN 14-9
STEERING HANDLE.......................... 14-3
MECHANISM DIAGRAM

4.0~5.0kgf-m

1.0~2.0kgf-m

0.2~0.3kgf-m

3.1~3.5kgf-m
2.4~3.0kgf-m

5.0~7.0kgf-m

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 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

PRECAUTIONS IN OPERATION
General Information
y Before remove front wheel, use a jack to lift the body until front wheel free of ground, and
take care not to rotate body in reverse.
y Be careful not to allow oil or grease get on brake drum or linings.

Torque values
Front wheel axle 5.0~7.0kgf-m
Steering handlebar nut 4.0~5.0kgf-m
Steering column top cone sliding ring 0.2~0.3kgf-m
Steering column lock nut 1.0~2.0kgf-m
Speedometer cable nut 0.15~0.3kgf-m
Front shock absorber: Upper nut 2.4~3.0kgf-m

Tools
Special service tools
Steering column wrench
Bearing remover
Inner type bearing remover
Attachment, 32×35 mm
Attachment, 42×47 mm
Steering column nut wrench
Steering column top cone ring nut wrench

TROUBLE DIAGNOSIS Front wheel wobbling

Hard steering stem y Deformed rim
y Over tightening of steering stem lock nut y Front wheel bearing loose
y Broken steering stem steel ball and cone y Faulty tire
bearing seat y Wheel axle nut tightened improperly
y Insufficient tire pressure
Soft front suspension
Steering stem off center y Weak fork springs
y Uneven left/right cushion y Oil leakage of the shock absorber seal
y Bend fork
y Bent front wheel/tire offset Front suspension noise
y Cushion cover friction noise
y Cushion bolts loose

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 SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

STEERING HANDLE
REMOVAL
Remove handle front & rear covers and the
front cover (refer to chapter 12).

Master cylinder
Disc Brake Seat
Remove the 2 bolts of the brake master
cylinder, and then take out the master Split
cylinder and the split ring. ring
Caution
Do not operate the front brake lever to avoid
to pressing out the brake lining when Bolts x 2
removing the master cylinder.

Remove acceleration handlebar screw and

then remove the handlebar, acceleration
cable, and handlebar cover & seat.

Screw

Brake lever seat bolt

Remove the rear brake lever nut and screw,
then take out the rear brake cable.
Remove the brake lever seat bolt, and then
remove the seat.

Brake lever nut

Brake lever screw

Brake cable

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 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

With a wrench to hold the handlebar bolt and

Bolt
then remove the nut.
Take out the handlebar after removed the
bolt.

Nut

Installation
Install the handlebar according to the
reverse procedure of removal.
Apply with some grease onto the handlebar
moving parts when installing the acceleration
handlebar seat, acceleration handlebar, and
acceleration cable.

FRONT WHEEL
Removal Speedometer cable
Disc Brake type
Support body bottom and lift front wheel free
of ground.
Remove the bolts, and disconnect
speedometer cable from the gear box.

Remove the wheel axle nut and pull out the

axle. Then, remove the front wheel.
Caution
Do not operate the front brake lever to
avoid to pressing out the brake lining
when removing the master cylinder.

Wheel axle nut

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 SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

Inspection
Wheel axle
Set the axle in V-blocks and measure the
run-out.
Service limit: 0.2 mm.

Wheel axle

Wheel Rim
Place the wheel onto a rotated bracket.
Turn the wheel with hand and measure its
wobble value with a dial gauge.

Service limit:
Radial : 2.0 mm
Axial : 2.0 mm

Disassembly (Disc type)

Remove 3 hex socket bolts and brake disc.

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 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

Remove the left axle ring and dust seal. Speedometer gear dust seal
DISC BRAKE
Remove the dust seal on the right side of
speedometer gear.
Remove the bearing with the inner type Bearing spacer
bearing remover.
Take out the bearing spacer and then Bearing
remove the other bearing.
Bearing
Tool:
Inner type bearing remover
Dust seal

Wheel side collar

Bearing Inspection Clearance

Turn the inner race of bearing with fingers.
Clearance
The bearing should be turn smoothly. Also
check if the outer collar is tightly connected
to the wheel hub.
If the bearing do not turn smoothly, or if they
are too loose in the races, or damaged, then,
remove and replace the bearings with new
ones.
Caution
The bearing must be replaced in pair.

Installation
Install the bearing according to the reverse
procedure of removal.
Apply some grease into the bearing seat of
the wheel hub.
Install the left bearing onto the seat.
Install the bearing spacer and then install
the right bearing onto the seat.

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 SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

Caution
y Do not install used bearing and replace
the bearing once it has been removed.
y Do not the bearing in tile motion when
installing.

Tool:
C-type compressor or bearing compressor.
This two example will to louse the bearing.

Speedometer gear dust seal

DISC BRAKE
Disc Brake
Apply with some grease inside of the dust
bearing. Bearing spacer
Install the dust seal and the front wheel side
Bearing
collar.
Apply with some grease on both side of the Bearing
speedometer gear oil seal, and then install
the seal.
Dust seal

Wheel side collar

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 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

Align the flange part on the speedometer

gear with the slot of wheel hub, and then
install the brake disc (drum brake) or
speedometer gear box.
Caution
Contaminated brake lining will reduce
brake performance so the brake lining,
brake drum and disc must be free of
grease.

Stopper
Place the front wheel between the front
shock absorbers.

Disc Brake
Align the flange part on the speedometer
gear with the slot of shock absorber stopper.

Disc Brake Gear box flange part Brake panel slot

Install the front wheel axle from right shock
absorber side.
Install the wheel axle nut, and tighten it to
specified torque value.
Torque value: 11.0~13.0kgf-m
Connect the speedometer cable to the
speedometer gear box.

Wheel axle nut Speedometer cable

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 SYM 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER

FRONT SHOCK ABSORBER

Removal
Remove the front fender, front lower spoiler,
front guard, and front wheel as well as front
brake components.
Remove the brake fluid hose clipper or cable
guide on the left shock absorber. (bolt x 1)
As for disc brake, remove the cable guide on
the right shock absorber. (bolt x 1)
Brake fluid
hose clipper

Remove the top connection bolt of the right Bolts

shock absorber. (bolt x 4)
Remove the shock absorber from the front
fork.

Shock absorbers

Installation
Install the shock absorbers according to the
reverse procedure of removal.
Align the shock absorber top-edge with the
top-end level of the front fork when installing
the front shock absorber onto the front fork.
Then, tighten the nut.
Torque value: 2.4~3.0kgf-m

FRONT FORK/STEERING COLUMN

Removal
Steering column nut
Firstly, remove the handlebar, front wheel,
front brake set, and front shock absorbers.
Remove the steering column nut.
Remove the top cone ring, and then remove
the steering column.
Caution
Place the steering column bearing balls
into a parts container to avoid to
missing or shortage. Top cone race

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 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER SYM

With a plastic hammer to tap the steering

column slightly, and then remove the top ball
bearing seat.
Remove the lower-end cone bearing seat on
the frame with a punch.
Caution
Do not damage the frame and the steering
column.

Installation
Install a new top-cone bearing seat onto the
top of steering column.
Lower all bearing seat Steering column nut
And then, push the lower-cone bearing seat
from bottom until to locking position. Balls

Caution Lower cone-race

Do not let the ball bearing in title motion as Top cone-race

installation.
Balls

Apply with some grease onto the top &

bottom bearing balls, and then install the Top ball bearing seat.
balls into bearing seat.
Press in a new lower cone-race onto the
steering column, and lubricate it with grease.
Install the steering column.
Steering column nut
Lubricate the top-cone race with grease.
Drive the cone-race into the steering column
Return 1/2 turn
until contact with the top bearing seat no
clearance. Note, return 1/2 turn and then
tighten the top cone race to specified torque.
(tighten the race around 1/4~3/8 turn more.)
Torque value: 0.2~0.3kgf-m Locking to
1/4~3/8 turn
Caution
Do not tighten the top cone race too tight
to prevent from damage the ball bearing Top cone-race
seat when tightening the top cone race.

Install the steering column nut and lock the Steering column nut
top cone race. Then, tighten the nut.
Torque value: 1.0~2.0kgf-m
Install the bearing seat according to the
reverse procedure of removal.
Caution
Check the steering column if it can be
turned freely and no clearance in vertical
motion. Top cone-race

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 SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

MECHANISM DIAGRAM.................... 15-1 EXHAUST MUFFLER......................... 15-3

PRECAUTIONS IN OPERATION....... 15-2 REAR WHEEL.................................... 15-3
TROUBLE DIAGNOSIS ..................... 15-2 REAR SHOCK ABSORBER ............... 15-4

MECHANISM DIAGRAM

3.5~4.5kgf-m

2.4~3.0kgf-m

0.8~1.2kgf-m

1.0~1.4kgf-m

3.0~3.6kgf-m 11.0~13.0kgf-m

15-1
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 15. REAR WHEEL/REAR SHOCK ABSORBER SYM

PRECAUTIONS IN OPERATION
General Information
As for the wheel removal, service, and installation procedures, please refer to the service
manual of high speed tire.

Specification Unit: mm
Items Standard Limit
Radial - 2.0
Wheel wobbling
Axial - 2.0
Thickness of rear brake lining 4.0 2.0

Torque values:
Rear axle nut 11.0~13.0kgf-m
Rear shock absorber upper mount bolt 3.5~4.5kgf-m
Rear shock absorber lower mount bolt 2.4~3.0kgf-m
Exhaust muffler connection nut 1.0~1.4kgf-m
Exhaust muffler connection bolt 3.0~3.6kgf-m

TROUBLE DIAGNOSIS
Rear wheel wobbling Braking Noise Poor brake performance
z bend wheel rim z worn brake lining z Poor brake adjustment
z poor tire z brake drum deformation z contaminated brake
z loosen wheel shaft z improperly brake panel lining
installation z worn brake lining
Shock absorber too soft z unparalleled brake drum z greased brake drum
z insufficient shock or wheel unparallel. z contaminated and
absorber spring force seized brake cable
z improperly installation of
brake cable

15-2
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 SYM 15. REAR WHEEL/REAR SHOCK ABSORBER

EXHAUST MUFFLER Exhaust muffler

Removal
Remove the front-end nut of the exhaust
muffler. (nuts x 2)
Remove the bolts. (bolts x 2)
Remove the exhaust muffler.

Installation
Install the exhaust muffler according to the
reverse procedure of removal.
Caution Nuts x 2
Replace the exhaust muffler gasket if it is
broken or deformed.

Torque value:
Exhaust muffler connection bolt:
3.0~3.6kgf-m
Exhaust muffler connection nut:
1.0~1.4kgf-m

Bolts x 2

REAR WHEEL
Inspection
Measure wheel rim wobbling.
Service limit:
Radial: 2.0mm
Axial: 2.0mm
If the wheel rim wobbling out of the
specification, except resulted from the
wheel rim deformation, it might be loosen or
worn final driving shaft bearing or bend,
deformed driving shaft.

Removal
Remove the rear inner mudguard. (Bolt x 1)
Remove the exhaust muffler bracket. (bolts
x 3)
Remove the rear disk brake caliper. (bolts
x2)
Remove the rear wheel. (wheel axle nut x1)

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 15. REAR WHEEL/REAR SHOCK ABSORBER SYM

REAR SHOCK ABSORBER

Removal
Remove the luggage box. (bolts x 4)
Remove the rear carrier. (bolts x 3)
Remove the left & right body covers. (screws
x 4, bolts x 3)
Remove the air cleaner bolts (bolts x2)
Remove the lower nut of the rear shock
absorber (bolt x 1)
Remove the upper nut of the rear shock
absorber (bolt x 1)
Remove the rear shock absorber.
lower mount bolt

Installation upper mount bolt

Install the rear shock absorber according to
the reverse procedure of removal.
Caution
The rear shock absorber has to be replaced
with one set and can not be replaced by
unauthorized persons. Otherwise, it might
damage the rubber bushing and
construction.

Torque values
Rear shock absorber lower mount bolt:
2.4~3.0 kgf-m
Rear shock absorber upper mount bolt:
3.5~4.5 kgf-m

15-4
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 SYM 16. ELECTRICAL EQUIPMENT

MECHANISM DIAGRAM ....................16-1 STARTING SYSTEM ..........................16-14

PRECAUTIONS IN OPERATION .......16-2 METER ...............................................16-15
TROUBLE DIAGNOSIS......................16-4 LIGHTS/BULBS ..................................16-17
CHARGING SYSTEM.........................16-5 SWITCH .............................................16-19
IGNITION SYSTEM ............................16-11 FUEL UNIT .........................................16-22
MECHANISM DIAGRAM

Horn/turn signal
light/high & low
Rear stop switch beam
Winker relay
REG.REC

Horn

Light/starter switch

Starter magnetic switch

Front stop switch
Fuel unit

Main switch

C.D.I/ Battery/
fuse box

Auto by-star

Spark plug

Ignition coil

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 16. ELECTRICAL EQUIPMENT SYM
PRECAUTIONS IN OPERATION
Charging System
z When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
z MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water.
z Battery must be taken out from scooter when charging the battery. But do not open the battery caps.
z Do not quick charge the battery unless in emergency.
z A voltmeter must be used when checking battery charging condition.
z Battery can be charged or discharged alternately. To set a discharged battery idle for a prolonged
period will shorten its service life and reduce its capacity. Usually, battery’s capacity will reduce after
1~2 years. After low capacity battery was charged, its voltage will increase. If it connects to an
additional load, the voltage will reduce suddenly, and then go up again.
z Over-charged battery. Usually, the over-charged battery can be seen externally. If a short circuit
occurred inside the battery, there will be no voltage on the terminals of battery if voltage regulator does
not operate. Then, the battery’s voltage will be too high that may reduce battery’s life.
z The battery will be self-discharged if it was set idle for a long time. An idle battery must be charged
about every 2months.
z A new battery filled with electrolyte will generate a voltage after filled out electrolyte. The voltage
should be in 12.5V or more after 10 minutes. When electrolyte is not enough, the battery must be filled
with electrolyte and then charged to prolong the battery’s life-span.
z Please check electrical device according to the procedure of diagnosis chart.
z Do not disconnect and connect the connector of electrical devices when current is passing these
devices because this will generate high voltage and the electrical components in the voltage-current
regulator will be damaged. The ignition switch must be turned OFF before performing any work.
z Please do not replace with traditional type battery as replacement.
z Please refer to the removal instruction when removing the alternator and the pulse generator.

Ignition System
z Please follow the procedure of trouble diagnosis chart to check ignition system.
z The ignition system equipped with a auto-advanced timing device in CDI unit. Thus, ignition timing
need not to be adjusted. In case of incorrect ignition timing occurred, check the CDI unit or alternator
system. It has to check the ignition timing with the ignition timing light if replaced these components.
z Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by
impact. Therefore, take care when disassembling.
z Most of ignition system problems were resulted from poor connecting connector. Please check the
connectors first when servicing.
z Make sure that the heat range of spark plug is suitable. Improper spark plug is the main cause of poor
engine operation or combustion.
z Inspection procedures in this manual are based on Max. voltage. This manual also contains methods
of how to check ignition coil resistance and component operation.
z Please follow the continuity chart to check ignition switch.

Starting System
z Starting motor can be removed directly from engine.
z Please refer to chapter 10 for starting clutch removal procedures.

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 SYM 16. ELECTRICAL EQUIPMENT
Specification
Charging System
Items Specification
Capacity/type 12V 6Ah
STD:0.6A/5~10hrs, emergency charging:
Charging rate
Battery 6A/0.5hrs
Voltage Full charged 13.1V
(20℃) Under charged 12.3V
Capacity 12V / 6.2A
Alternator Lighting coil resistance (20℃) Between yellow-green: 0.8±0.1Ω
Charging coil resistance (20℃) Between white-green: 0.6±0.1Ω
Leaking current Less 1mA
RPM for starting charging 2000rpm(headlight ON)
Voltage controlled by regulator 14.5±0.5 V
Resistance (20℃) 5W5Ω 4.5~5.5Ω
Resistor
Resistance (20℃) 30W7.5Ω 7.0~8.0Ω

Ignition System
Item Specification
Standard A7RC (Recommended usage)
Hot type A8RC
Spark plug
Cold type A6RC
Spark plug gap 0.6~0.7 mm
Primary 0.21±10%Ω
Ignition coil resistance
With plug cap : 7.6±10%KΩ
(20℃) Secondary
Without plug cap : 3.1±10%KΩ
“F” Mark Before TDC 13° / 1700 rpm
Ignition timing Timing advanced Before TDC 28° / 4000 rpm
character Before TDC 27° / 8000 rpm
Pulse generator resistance (20℃) 50~200Ω
Exciting coil resistance (20℃) 400~800Ω
Ignition coil-primary max. voltage 95~400 V
Pulse generator voltage 1.7 V above
Exciting coil voltage 95~400 V

Starting System
Item Specification
type DC TYPE
Starting motor
capacity 0.5 KW

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 16. ELECTRICAL EQUIPMENT SYM
TROUBLE DIAGNOSIS
Charging System Ignition System
No power supply No spark produced by spark plug
z Dead battery z The spark plug is out of work
z Disconnect battery cable z The cable is poorly connected, open or
z Fuse burned out short-circuited
z Faulty ignition switch - Between alternator and C.D.I.
- Between CDI and ignition coil.
Low voltage - Between CDI and main switch
z Weak battery z Poor main switch
z Loose battery connection z Poor C.D.I.
z Charging system failure z alternator is out of work
z Voltage-current regulator failure
Engine does not crank smoothly
Intermittent power supply z Primary coil circuit
z Loosen wire connector in charging system - Poor ignition coil
z Loose battery cables - Poor connection of cable and connectors
z Loose charging system connection - Poor main switch
z Loose connection in lighting system z Secondary coil circuit
- Poor ignition coil
- Poor spark plug
Charging system failure
- Poor high-tension cable
z burn Fuse
- Current leakage in the spark plug cap
z Loose, broken or shorted wire or wire
connection z Incorrect ignition timing
- Poor alternator
z Faulty voltage-current regulator
- Improper installation of the pulse sensor
z Faulty alternator - Poor C.D.I.

Starting System Weak starter motor

Starter motor does not work z Poor charging system
z The fuse is blown z The battery is not fully charged
z The battery is not fully charge z Poor connection in the windings
z Poor main switch z The motor gear is jammed by foreign material
z Poor starter switch
z The front and rear brake switches do not Starter motor is working, but engine does
operate correctly not crank
z Starter magnetic switch is out of work z Poor starter motor pinion
z The ignition coil is poorly connected, open or z Poor starter clutch
short-circuited z The starter motor run in reverse direction
z The starter motor is out of work z Poor battery

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 SYM 16. ELECTRICAL EQUIPMENT
CHARGING SYSTEM
Charging wire diagram
white green
fuse(10A) green

red green
red
yellow

alternator
REG.REC. battery

green/black

Auto 5W
by-starter 5Ω

Current Leakage Inspection

Turn the main switch to OFF position, and
remove the negative cable terminal (-) from
the battery.
Battery(-) terminal
Connect an ammeter between the negative
cable terminal and the battery negative
terminal (as shown on left diagram).
Caution
z In the current leakage test, set the current
range at larger scale, then gradually ground
decrease to the lower scale as the test wire
process goes to avoid possible damage to
the ammeter and the fuse.
z Do not turn the main switch to “ON”
position during test.

If the leaked current exceeds the specified

value, it may indicate a short circuit.
Allowable current leakage: Less than 1
mA.
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.

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 16. ELECTRICAL EQUIPMENT SYM
Battery Battery cover
Removal
Remove the battery cover.

CAUTION
z Electrolyte (diluted sulfuric acid) is very
toxic. Once it spreading on clothes,
skin, or eyes, it will cause burned or
blind. In case of being spread, flush
with great quantity of water immediately,
and then send to hospital.
z When clothes is spread by electrolyte, it
will contact with skin. So, it must flush
with great quantity water to take off the
clothes.

Negative cable (-)

Remove the battery cover.

Fuse box Positive cable (+)

Disconnect the negative (-) cable from the

battery first, then the positive (+) cable.
Remove the battery.

positive (+) negative (-)

Install the battery in reverse order of

removal.
CAUTION
z To prevent form circuit short, connect
positive(+) terminal at first, and next
negative (-) terminal.

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 SYM 16. ELECTRICAL EQUIPMENT
Voltage Check
With a digital voltage meter or multi-meter to
measure battery voltage.
Voltage:
Fully charged: 13.0 – 13.2V (at 20℃)
Undercharged: Below 12.3 V (at 20℃)

CHARGING
Connect the Charger positive (+) to the
battery positive (+) terminal.
Connect the Charger negative (-) to the
battery negative (-) terminal.

Standard Max.
Charging
current 0.6A 6.0A

Charging time 5~10H 1H

Warning
z Strictly keep flames away from a charging
battery.
z The charging “ON”/ “OFF” is controlled by
the charger’s switch. Do not control the
charging by battery jump wires.
z Turn the charger’s switch “OFF” at first
before or after charging to prevent from
sparks created on the connectors and
explosion.
z To charge a battery must be based on the
battery’s ampere-hour showed on label.

CAUTION
z Quick charge a battery should be used
only in an emergency.
z Make sure the current and charging time
of above description.
z The battery will be damaged by too much
current or too rush charging.
z When finishing charge, it is necessary to
measure voltage after 30 minutes.

After installing the battery, coat the terminals

with clean grease.

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 16. ELECTRICAL EQUIPMENT SYM
digital voltmeter
Charging Voltage/Current
ammeter
Inspection
Caution
z Before conducting the inspection, be
sure that the battery is fully charged. Use
a fully charged battery having a voltage
larger than 13.1 V. If undercharged, the
current changes dramatically.
z While starting the engine, the starter
motor draws large amount of current Fuse ends
from the battery. Thus, do not start the
engine with battery.
Connect a tachometer.
Turn on the headlight to high beam and start the
After the engine is warmed up, replace engine.
original battery with a fully charged battery. Accelerate the engine gradually to the specified
Connect a digital voltmeter to the battery revolution per minute and measure the charging
terminals. voltage/current.
Connect an ammeter between both ends of Specified Charging Current:
the main fuse. (headlight OFF) 0.6 A or more/2500rpm
1.2 A or more / 6000 rpm
(headlight ON) 0.4 A or more/2500rpm
Caution 1.0 A or more / 6000 rpm
When the probe is reversibly connected, use Control Charging Voltage:
a voltmeter having an indication that the 14.0+/0.5 V / 2000 rpm
current flows from the positive or the Caution
negative direction and the measurement To replace the old battery, use a new battery
should be at zero, ammeter at one direction with the same current and voltage.
only.
The following problems are related to the
charging system, follow the instructions provided
Caution in the checking list to correct it if any one of the
z Do not use short-circuit cable. problems takes place.
z It is possible to measure the current by (1) The charging voltage can not exceed the
voltage between two battery terminals and
connecting an ammeter between the the charging current is in the discharging
battery positive terminal and the cable direction.
position terminal, however, while the (2) The charging voltage and current are too
starter motor is activated, the surge much higher than the standard values.
current of the motor draws from the The following problems are not related to the
battery may damage the ammeter. Use charging system; correct it if any by following
the kick lever to start the engine. steps indicate in the checking list.
z The main switch shall be turned to OFF (1) The standard charging voltage and current
position during the process of inspection. can only reach when the revolution of the
Never tamper with the ammeter and the engine exceeds the specified rpm.
cable while there is current flowing z Bulbs used exceed their rate and
consume too much power.
through. It may damage the ammeter. z The replacement battery is aged and
does not have enough capacity.
(2) The charging voltage is normal, but the
current is not.
z The replacement battery is aged and
does not have enough capacity.
z Battery used do not have enough
electricity or is over charged.
z The fuse of the ammeter is blown.
z The ammeter is improperly connected.
(3) The charging current is normal, but the
voltage is not.
z The fuse of the voltmeter is blown.

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 SYM 16. ELECTRICAL EQUIPMENT
VOLTAGE REGULATOR INSPECTION
Remove the front cover. (screws 4 x 2). REG.REC
Remove the front cover mounting bolt(bolt x
1)and remove the left/right turnlight wiring
connector.
Disconnect the 4P connector on the diode,
and check the continuity between main wire
terminals according to following method.
Main wire circuit inspection
Item (wire color) Judgment
Check voltage between
battery terminal (red) and Battery voltage Horn Winker relay
ground (green).
Check continuity between Headlight wiring connector
Continuity
ground(green) and frame.
Check illumination wire
(yellow) to ground.
(disconnect the connector of Continuity &
the resistor’s pin and resistance
automatic by-starter pin.
Illumination switch is in OFF)
Check charging coil (white) to Continuity &
ground) resistance
If the measured value is abnormal, check the
abnormal wire circuit. If components are
good, it could be a poor wire circuit.
If all items are in good condition, then
replace the voltage regulator.
If main wire circuit check is in normal and
there is no loose in the pins of voltage
regulator connector, then measure the
resistance between the connector of voltage
regulator.
Voltage Regulator Check Unit: Ω
Multi-meter(+)
Red White Yellow Green
Multi-meter (R) (W) (Y) (G)
Red (R) ∞ ∞ ∞

White (W) ∞ 0.04~0.06 160~180

Yellow (Y) ∞ 0.04~0.06 160~180

Green (G) ∞ 160~180 160~180 REG.REC

If the resistance values are abnormal among
the pins, replace the voltage regulator.
Caution
z Do not touch the probe of multi-meter by
fingers, then the resistance values will be
incorrect because there is some resistance White RED
existence in human body.
z To use the multi-meter recommended by
SYM. Otherwise, the measured resistance Yellow
might be different. Green

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 16. ELECTRICAL EQUIPMENT SYM
Alternator charging coil Charging coil Auto light coil
connector by-star connector
Caution
The check of alternator charging coil and
illumination coil can be done when the
alternator is mounted on engine.
Check
Remove the 3P connector of the alternator.
Measure the resistance between the white
wire on the alternator and frame ground with
a multi-meter. Pulse generator
connector
Standard: 0.6±0.1Ω (20℃)
Replace the alternator charging coil if the
measured value exceeds standard.

Alternator lighting coil

Check
Remove the 3P connector of the alternator.
Measure the resistance between the yellow
wire on the alternator and frame ground by
multi-meter.
Standard: 0.8±0.1Ω (20℃)
Replace the alternator lighting coil if the
measured value exceeds standard.

Resistor check resistors

Remove the front cover.

Measure the resistance between the resistor

wire (green/black) and frame ground.
Standard: 5Ω/5W: 4.5~5.5(green/black)
Standard: 7.5Ω/30W: 7.0~8.0(pink)

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 SYM 16. ELECTRICAL EQUIPMENT

IGNITION SYSTEM
Ignition System Circuit

green Blue /yellow

green Black/ yellow
Black/red Black/ white

Pulse spark plug

Blue/yellow green
Black/red black/yellow green
Black/white

C.D.I. unit
green

main switch Ignition coil

CDI UNIT
Removal
Remove the right body cover, then the C.D.I.
unit can be removed from the frame.

CDI UNIT

Check
Disconnect the connector from the CDI unit.
Make the following inspection at each terminal of the harness side connector.
ITEM Measure at: Standard (at 20C)
Pulse Generator Blue/Yellow-green 50 ~200Ω
Primary Black/yellow-green 0.21Ω±10%

Ignition Green-high voltage cable -w/o cap 3~5KΩ

Coil Secondary
Green-high voltage cable - w/ cap 7~12KΩ

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 16. ELECTRICAL EQUIPMENT SYM
Ignition coil Ignition coil
Removal
Remove the luggage box, center cover.
Remove spark plug cap.
Remove the primary coil wire of ignition coil.
Remove the fix bolts for the ignition coil, and
remove the ignition coil.
Install the ignition coil in reverse order of
removal.
Caution
Install primary coil with black/yellow lead
connected to black connector and green lead
connected to green connector.

Spark plug confirmation

Remove the spark plug and install a good
plug into plug cap, and then ground it to
engine ground.
Make sure its spark condition. If it is in not
good or burnt spark plug, replace the spark
plug with new one.
Caution
z Make sure each wire connection is correct,
and test as required. Even the wire
connection is in correct, sometimes, it
might not be tested occurred.
black/yellow
Connect the high voltage shunt with a
multi-meter or input a resistor in the 10MΩ
100V of voltage meter.
Connect ignition coil wires, and connect a
shunt between primary terminal (black/yellow
and green) and frame ground. green
Press the starting motor button, or starting
lever to test the max. primary voltage of
ignition coil.
Connection: connect (+) terminal to green
side, and (-) to black/yellow side. high voltage shunt
Min. voltage: Above 95 V.
Caution
Do not touch metal parts on the test probe
with fingers to avoid electric shock.
Primary coil check
Disconnect the primary coil connector and
check the resistance between primary coil
terminals.
Standard: 0.21Ω±10%Ω(at 20℃)
Primary coil is good if resistance within
standard.
Primary coil is broken if resistance is infinite.
Replace the coil.

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 SYM 16. ELECTRICAL EQUIPMENT
Secondary coil
Attached the spark plug cap, measure the
resistance between plug cap side and green
terminal.
Standard value: 7-12 kΩ(20℃)
Remove the spark plug cap, measure the
resistance between plug cap side and green
terminal.
Standard value: 3-5 kΩ(20℃)
Secondary coil is good if resistance within
standard.
Secondary coil is broken if resistance is
infinite. If the spark plug cap attached and
the measured value is exceed standard value,
it means the spark plug cap is in not good.
Ignition coil
Replacement
Remove the ignition coil bolt to replace the
ignition coil if necessary.

Pulse generator
Caution
Checking pulse generator can be done on
engine. But, the spark plug must be
installed onto the cylinder head, and
cylinder compression pressure must be in
normal condition.

Check
Remove body cover.
Remove the pulse generator connector.
Measure the resistance between blue/yellow
terminal on engine side and frame ground.
Standard: 140±20Ω(20℃)
Replace the alternator if the measured value
exceeds standard value.

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 16. ELECTRICAL EQUIPMENT SYM

STARTING SYSTEM
Starting Circuit

Starter magnetic switch inspection Starter magnetic switch

Turn main switch to "on", and operate the
brake lever. Then press starting button to
check if there a click sound. It is normal if
there is a click sound.

Remove the luggage box.

Disconnect the battery negative (-) terminal.
Remove the battery positive (+) connection Starter magnetic switch
and starting motor wires from the starter
magnetic switch large pin.
Remove the power control connector of the
Starter magnetic switch.
Connect a Ohmmeter between the Starter
magnetic switch large pins.
Connect the green/yellow wire to battery
positive (+) terminal, and yellow/red to
battery negative (-) terminal.
Check the continuity between the Starter
magnetic switch large pins. If it is not
continuity, then replace the starter magnetic
switch.

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 SYM 16. ELECTRICAL EQUIPMENT
Starting Motor Removal Bolts x2
Remove the battery cover.
Firstly, remove the battery negative (-)
terminal, and then remove the positive (+)
terminal.
Remove the luggage box.
Remove the starting motor power wire.
Remove the starting motor mounting bolts
and motor.

Starting Motor Installation

Install the motor in reverse order of removal.

METER
Removal
Remove the front handle cover.

Meter

Remove the speedometer cable.

speedometer cable

Meter connector
Remove the front cover.
Remove the power connector of the meter.

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 16. ELECTRICAL EQUIPMENT SYM
Remove the rear handle cover.
Remove the meter mounting screws.
Take out the meter.

Speedometer High Beam Indicator

Odometer

Turn Left Signal Turn Right Signal

Indicator Indicator

Fuel meter

Speedometer High Beam Indicator

Time meter

Turn Left Signal Turn Right

Indicator Signal

Fuel meter Odometer/Trip

kilometer

Caution
Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from
damage these components.
Installation
Install the meter in reverse order of removal.

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 SYM 16. ELECTRICAL EQUIPMENT
LIGHT/BULBS
Headlight Bulb Replacement
Rear the front handle cover.
Disconnect the headlight wire connector.
Press down the bulb spring locker and then
remove the locker with turning it left motion.
Remove the bulb.
Replace the bulb with new one if necessary.
(12V 35W/35W)

Caution
z Do not touch the bulb surface with fingers
because the bulb will create hot-spot so
that let it be burnt. It has to be package
with cloth or wear glove as installing.
z Wipe the bulb with cloth to prevent from
damaged if the bulb be touched by hands.

Install the bulb in reverse order of removal.

Turn the main switch ON/OFF to check if the
bulb has been installed properly after
installation.

Please conduct the headlight beam

adjustment job if replace the headlight bulb.

headlight beam
The headlight beam adjustment adjustment screw
Loosen the adjustment bolt located under the
headlight.
Caution
z This outer cover of headlight is a fixed type
so that the light seat will be moved only
when adjusting.

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 16. ELECTRICAL EQUIPMENT SYM
Front Turn Signal Lamp Bulb Front turn signal light
Replacement
Remove the front handle cover.
Remove the wire connector of the turn signal
light.

the wire connector of

the turn signal light
Pull out the bulb and replace it with new one.
(12V 10W)

Installation
Install the bulb in reverse order of removal.

Bulbs Replacement of tail light/brake

light/rear turn signal light.
Remove the 2 screws of the taillight
&left/right turn light lens.

Remove the tail light assembly.

Screw x 2 turn signal light

Replace the bulbs of the tail light, brake light

(12V 5W/21W) tail light & brake light
Replace the bulbs of the turn signal light
(12V/10W).

Installation
Install the bulb in reverse order of removal.

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 SYM 16. ELECTRICAL EQUIPMENT

MAIN SWITCH/HORN main switch connector terminals

Main Switch
Check
Remove the headlight connector and the front
cover.
Disconnect main switch leads connector.
Check connector terminals for continuity.
color
Black Red green green
Location
OFF ● ●

ON ● ● main switch bolts x 2

LOCK ● ●

Replacement
Remove the main switch connector and
fixing bolts (bolts x 2)
Remove the main switch.
Install a new main switch and tighten the
bolts. (bolts x2)

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 16. ELECTRICAL EQUIPMENT SYM
Handle switch headlight switch
Remove the front handle cover.
Disconnect the connector of the handle switch.
Check the continuity of follow pins listed below
columns.
Headlight switch
color Brown
Brown Yellow Pink Yellow
Location /White

● ● ●

● starting switch
●
yellow headlight
● ● ● ● brown /white switch
Starting switch
color brown pink
Yellow/red green
Location yellow

FREE Starting
switch
● ●
yellow/red green

High/Low beam switch/ passing High/Low beam

color switch/ passing
brown/ White/
blue white
Location white green

● ●

● ●
turn signal
switch
passing ● ●
horn switch

High/Low beam
switch/ seat open
Horn switch Black
color Blue white
Black Light green
Location brown/white
orange
turn signal
FREE switch
gray
● ● Sky blue
Light green
Black
Horn switch

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 SYM 16. ELECTRICAL EQUIPMENT
Turn signal light switch
color Sky
Gray orange
Location blue
● ●
turn signal
FROM R ● ● orange light switch
N PUSH OFF
FROM L ● ●
Sky blue gray
● ●

Brake light switch

The circuit of black wire and the
green/yellow wire on the brake light switch
should be in continuity when operating the
brake lever.
If the switch damaged, replace it with new
one.

Horn
Remove the front cover.
Connect the light blue wire on the horn to the
battery positive (+) terminal, and the green
wire to the battery negative (-) terminal.
Then, the horn should sound.
Replace it if necessary.

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 16. ELECTRICAL EQUIPMENT SYM

FUEL UNIT
Fuel unit
Open the seat.
Remove the luggage box(bolts x 4) .
Remove the R.R. carrier(bolts x 3) .
Remove the body cover.
Disconnect the fuel unit wire connector.

Caution
Do not damage or bend the float arm as
removing.

The resistance values are listed below when

the float arm in “F” and “E” positions.
Float arm position Resistance value

E(empty) 97.5~107.5Ω

F(full) 4~10Ω

DOWN(empty)Connect the fuel unit to the UP

main harness. (full)
Turn the main switch “ON” position.
Move the float arm in “UP” & “DOWN”, and
then check if the fuel unit indication needle is
in correct position.
Caution
Turn on the turn signal light to make sure DOWN
battery is in good condition before this test. (empty)

Float arm position Indicator needle

UP(full) E(empty)

DOWN(empty) F(full)

Installation
Install the fuel unit in reverse order of removal.

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 SPECIAL TOOL SYM
ITEM: ACG FLYWHEEL PULLER ITEM: ONE-WAY CLUTCH & STARTING GEAR
NO：SYM-3111000 LOCK NUT PULLER
PURPOSE: REMOVE ACG FLY WHEEL NO：SYM-9020100
PURPOSE: REMOVE ONE-WAY CLUTCH FIX NUT

ITEM: BEARING DISASSEMBLER ITEM: UNIVERSAL HOLDER

NO：SYM- 6202Z / 6204 NO：SYM-2210100
PURPOSE: REMOVE THE BEARING PURPOSE:HOLD THE MDF/CLUTCH OUTER

ITEM: CLUTCHSPRING COMPRESSOR ITEM: CLUTCH NUT WRENCH

NO：SYM-2301000 NO：SYM-9020200
PURPOSE:DISASSEMBLE THE CLUTCH PURPOSE:LOOSE THE CLUTCH NUT

1
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