Sym AW12W, Service Manual

Page 1: ...SERVICE MANUAL Fiddle II 125 AW12W http www motorcycle in th...

Page 2: ...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 illustratio...

Page 3: ...stment 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...

Page 4: ...CYLINDER HEAD VALVE 6 CYLINDER PISTON 7 V TYPE BELT DRIVING SYSTEM KICK STARTER ARM 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 BODY COVER 12 BRAKE SYSTEM 13 S...

Page 5: ...bolt Oil level Tail light Front turn signal light Fuel tank Fuel unit High Low beam Seat open turn signal horn Head light Position light Rear turn signal light Engine number engine oil draining bolt...

Page 6: ...00 PURPOSE INSTALL CRANKCASE ITEM OUTER BEARING PULLER NO SYM 6204010 PURPOSE REMOVE THE BEARING ITEM ACG FLYWHEEL PULLER NO SYM 3110A00 PURPOSE REMOVE ACG FLYWHEEL ITEM LOCK NUT PULLER NO SYM 9020100...

Page 7: ...G COMPRESSOR NO SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH ITEM CLUTCH NUT WRENCH NO SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT ITEM GY6 STARTER GEAR PULLER NO SYM 2822100 GY6 PURPOSE REMOVE THE STARTER...

Page 8: ...may result if procedures are not followed Engine oil Limits to use SAE 10W 30 API SH CD class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Grease King Ma...

Page 9: ...ns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water...

Page 10: ...gs or oil seals because most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent stiff control and premature worn out Rubber parts may become deteriorated whe...

Page 11: ...ove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal...

Page 12: ...battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secur...

Page 13: ...ny wire loose Check if the connector is covered by the twin connector boot completely and secured properly Before terminal connection check if the boot is crack or the terminal is loose Insert the ter...

Page 14: ...tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied Secure the r...

Page 15: ...urrounding parts in all steering positions Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction With...

Page 16: ...ROKE ENGINE OHC Clutch Auto centrifugal clutch Installation and arrangement Vertical below center incline 80 Deceleration equipment Transmission C V T Fuel Required Unleaded gasoline Speedometer 0 140...

Page 17: ...2 Right crankcase cover bolts 10 6 0 8 1 2 Flywheel nut 1 12 5 0 6 0 Shroud A B tapping screws 3 5 0 8 1 2 Cooling fan bolts 4 6 0 8 1 2 Cooling fan cover 2 6 0 8 1 2 Transmission Gear box bolts 7 8...

Page 18: ...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 bolts 2 10 4 5 5 5 On frame side Engine connection bolt 1 10 4...

Page 19: ...h air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in...

Page 20: ...Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel level too low in carburetor 6 Fuel nozzle clogged in carburetor 1 Malfuncti...

Page 21: ...if carburetor clogged 1 Incorrect ignition timing malfunction of CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation gasket 2 Carburetor lock l...

Page 22: ...disk damaged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial forward moving or...

Page 23: ...LE DIAGNOSIS SYM 1 16 LUBRICATION POINTS Acceleration cable Front rear brake lever pivot Steering shaft bearing Speedometer gear Front wheel bearing Side stand shaft Main stand shaft Rear wheel bearin...

Page 24: ...15 PRECAUTIONS IN OPERATION Specification Main 5000 c c Fuel Tank Capacity auxiliary 1500 c c capacity 800 c c Engine Oil change 750 c c capacity 120 c c Transmission Gear oil change 110 c c Clearanc...

Page 25: ...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...

Page 26: ...cc Change 750cc 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 cove...

Page 27: ...lt Torque value 1 0 1 4 kgf m Quantity 100 c c Recommended King Mate HYPOID GEAR OIL 140 Fuel System Fuel Pipe Remove luggage box rear center cover body cover and rear fender as well as front inner bo...

Page 28: ...hrottle 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...

Page 29: ...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 a...

Page 30: ...ler 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 rele...

Page 31: ...omponents if malfunction of these parts are found SPARK PLUG Appointed spark plug A7RC Remove luggage box Remove center cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark p...

Page 32: ...head DRIVING SYSTEM DRIVING BELT 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...

Page 33: ...place 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 leaki...

Page 34: ...nts inside the brake system hoses AIR BLEED OPERATION Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no...

Page 35: ...rake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake perfor...

Page 36: ...20 mm Adjust the free play by turning the front brake adjustment nut if necessary BRAKE CONFIRAMTION Caution After brake adjustment it has to check the brake operation to make sure the front and rear...

Page 37: ...f 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...

Page 38: ...proper position Caution 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 al...

Page 39: ...BLE DIAGNOSIS 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 7 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lubrication Inne...

Page 40: ...ems Standard Limit Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5kgf m...

Page 41: ...and tighten it 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 fo...

Page 42: ...nd then the oil pump driving gear nut and the gear and oil pump driver chain Remove oil pump body bolts 2 bolts Oil Pump Disassembly Remove the screw on oil pump cover Disassemble the oil pump as illu...

Page 43: ...r rotors Limit below 0 12 mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving...

Page 44: ...p 2 bolts Install oil pump driver chain and drive gear Install oil pump outer cover 2 bolts Install the starting gear and the alternator Refer to chapter 10 2 bolts 2 bolts oil pump driver chain drive...

Page 45: ...andard quantity 110cc Replacement 100 cc Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make su...

Page 46: ...S 4 3 CARBURETOR REMOVAL 4 4 VACUUM CHAMBER 4 4 AIR CUT OFF VALVE 4 6 AUTO BY STARTER 4 7 FLOAT CHAMBER 4 8 INSTALLATION OF CARBURETOR 4 9 IDLE SPEED ADJUSTMENT 4 9 FUEL TANK 4 10 AIR CLEANER 4 11 MEC...

Page 47: ...tools Vacuum air pressure pump General service tools Fuel level gauge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame whe...

Page 48: ...d Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insuffi...

Page 49: ...strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screw...

Page 50: ...ston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm Note direction as installing the piston...

Page 51: ...the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the vacuum diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Cautions...

Page 52: ...attery 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 Remove fixing plate screw and then r...

Page 53: ...ompressed air In case of worn out or dirt the float 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 valve must be rep...

Page 54: ...tment 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...

Page 55: ...der of removal Cautions FUEL TANK REMOVAL Open the seat Remove the luggage box assembly 6 bolts Disconnect the engine start control switch connector Disconnect the fuel unit connector Remove the fuel...

Page 56: ...e air cleaner Installation Install the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove the air cleaner cover 6 screws Remove the air cleaner element 2 screws With compr...

Page 57: ...PERATIONAL PRECAUTIONS 5 2 ENGINE REMOVAL 5 3 REMOVAL OF ENGINE SUSPENSION BUSHING 5 6 ENGINE SUSPENSION FRAME 5 7 INSTALLATION OF ENGINE 5 8 MECHANISM DIAGRAM 3 5 4 5kgf m 2 4 3 0kgf m 4 5 5 5kgf m 4...

Page 58: ...lutch and transporting disk 3 Final reduction gear mechanism Specification Specification Disassemble 850 c c Engine Oil Capacity Replacement 750 c c Disassemble 110 c c Gear Oil Capacity Replacement 1...

Page 59: ...er Remove the power connector of auto by start Remove the generator wire and pulse generator connector Remove the starter motor wire on the Starter magnetic switch Remove the spark plug Spark plug Sta...

Page 60: ...alve cable from the carburetor Loose the strap screw of the air cleaner guide and then the air cleaner guide Remove the exhaust muffler Bolts 2 Nuts 2 Remove the rear wheel Nut 1 Remove the air cleane...

Page 61: ...ngine suspension nut and bolt engine side and then remove the engine Caution Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so S...

Page 62: ...ng out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pr...

Page 63: ...side bolt of engine suspension frame 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...

Page 64: ...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 Torque Value 11 0 13 0kgf m Notice both feet and hands safety for squeezing...

Page 65: ...VAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD INSPECTION 6 8 VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLATION 6 13 VALVE...

Page 66: ...99 OD of valve stem Exhaust 5 00 4 97 4 98 OD of Guide 5 00 5 030 Intake 0 020 0 045 0 080 Clearance between valve stem and guide Exhaust 0 030 0 057 0 100 Outer 32 56 32 26 Free length of valve sprin...

Page 67: ...oor sealing on valve seat Improper spark plug installation 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder surface 3 Piston Piston ring worn out High compression pressure...

Page 68: ...to tighten the screw of camshaft chain adjuster in a clockwise motion for release adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with th...

Page 69: ...ssembly Of Camshaft Holder With a 5 mm bolt to screw in the cam rocker arm shaft so that take it out Remove cam rocker arm Inspection Of Camshaft Holder Check if the camshaft holder cam rocker arm and...

Page 70: ...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 REMOVAL Remove double seat luggage box an...

Page 71: ...and valves Caution Special Service Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching...

Page 72: ...m in valve guide and measure record the valve stem outer diameter Service Limit IN 4 900mm EX 4 900mm Valve guide Caution Special Service Tool 5 0mm valve guide reamer Measure and record each valve gu...

Page 73: ...clean up all metal residues from cylinder head Special tool Valve guide reamer 5 mm If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only re...

Page 74: ...fer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat Caution Use 32 cutter to cut a quarter upper part out Do not let emery enter into between valve stem and...

Page 75: ...ck will be created on contact surface Caution If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the contact surface too...

Page 76: ...mpressor to press valve spring Install valve split locks and release the valve compressor Caution Special tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing prop...

Page 77: ...aution 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 Place the TDC marks of the cam sprocke...

Page 78: ...ver turn the cam sprocket adjuster in counter clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the a...

Page 79: ...IAGRAM 7 1 PRECAUTIONS IN OPERATION 7 2 TROUBLE DIAGNOSIS 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 MECHANISM DIAGRAM 0...

Page 80: ...rance between piston and cylinder 0 010 0 040 0 100 Piston Piston ring ID of piston pin hole 15 002 15 008 15 040 OD of piston pin 14 994 15 000 14 980 Clearance between piston and piston pin 0 002 0...

Page 81: ...bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and c...

Page 82: ...ylinder Service limit 58 00mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or...

Page 83: ...piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Take out the...

Page 84: ...eter of piston pin hole Service Limit 15 04mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 52 30mm Compare measured valu...

Page 85: ...enings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rings can be r...

Page 86: ...piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam cha...

Page 87: ...GRAM 8 1 MAINTENANCE DESCRIPTION 8 2 TROUBLE DIAGNOSIS 8 2 LEFT CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 MECHANISM DIAGRAM 5 0 6 0kgf m 5 0...

Page 88: ...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 Sliding pulley nut 5 0 6 0kgf m Clutch outer nut 5 0 6 0kgf m Driving pulley nut...

Page 89: ...t with one if poor parts found Reassembly Apply with some specified grease on the gear socket shaft Install the friction spring of driving gear onto convex part of the case Install socket return sprin...

Page 90: ...me 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 specifi...

Page 91: ...ixture and then tighten nut to specified torque value Torque value 5 0 6 0 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set c...

Page 92: ...and then remove driving pulley nut Remove driving pulley Remove the driving belt from the pulley Remove sliding pulley set and driving pulley hub from crankshaft Remove tilt plate Remove weight roller...

Page 93: ...lers outer diameter Replace it if exceed the service limit Service limit 19 50 mm Check the pulley hub if damaged or wear out Replace it if necessary Measure the pulley hub s outer diameter Replace it...

Page 94: ...old driving pulley with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover The pulley surface has to be free of grease Clean it with cleaning sol...

Page 95: ...sor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring oil...

Page 96: ...omponents Measure the outer diameter of driven surface and the inner diameter of driven pulley Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pu...

Page 97: ...th grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified locatio...

Page 98: ...stall a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary Its sealing end should be forwarded to outside as bearing installation Install needle b...

Page 99: ...d clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to sp...

Page 100: ...MBLY OF FINAL DRIVING MECHANISM 9 3 INSPECTION OF FINAL DRIVING MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANISM 9 6 MECHANISM DIAGRAM driving gear countershaft gear final...

Page 101: ...uter type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover bolts 1 8 2 2 kgf m Gear oil drain plug bolt 3 5 4 5 kgf m Gear oil filling bolt 1 0 1 4 kgf...

Page 102: ...ve the cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft...

Page 103: ...for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase T...

Page 104: ...ring protector Install a new driving shaft bearing onto gear box cover Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a n...

Page 105: ...eal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 1 8 2 2 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left cranksha...

Page 106: ...A C GENERATOR REMOVAL 10 3 RIGHT CRANKCASE COVER REMOVAL 10 4 STARTING CLUTCH 10 5 RIGHT CRANKCASE COVER INSTALLATION 10 8 MOUNTED COIL SET INSTALLATION 10 8 FLY WHEEL INSTALLATION 10 8 MECHANISM DIAG...

Page 107: ...recaution items of starter motor Specification Unit mm Item Service Limit ID of starting driven gear 32 060 OD of starting clutch cover 27 940 Torque value Flywheel nut 5 0 6 0kgf m Exhaust muffler bo...

Page 108: ...ove the fan shroud 4 bolts Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the 10mm nut on the flywheel Special Service Tools Universal Fixture Flywheel Cooling fan Cooling...

Page 109: ...on RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 6 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcas...

Page 110: ...driven gear Remove starting clutch starting reduction gear and shaft Starting Clutch Inspection Install the starting clutch onto the starting driven gear Hold the starting clutch and turn the startin...

Page 111: ...the starting reduction gear Service Limit ID 9 94 mm or above Disassembly Remove the hex blots 3 bolts inside the starting clutch Separate the clutch body and the clutch cover Remove the rollers plugs...

Page 112: ...to the starting clutch Hold the starting driven gear with the universal fixture Tighten the 22mm anti loosen lock nut and gasket Caution Special service tools Anti loosen lock nut socket Universal fix...

Page 113: ...e guide 2 bolts Torque 0 8 1 2kgf m Tie the wire harness hose onto the indent of crankcase Caution Install A C generator connector and pulse generator connector FLYWHEEL INSTALLATION Make sure that th...

Page 114: ...Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Cooling fan Exhaust muffler Cool...

Page 115: ...MECHANISM DIAGRAM 11 1 OPERATIONAL PRECAUTIONS 11 2 TROUBLE DIAGNOSIS 11 2 DISASSEMBLY OF CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 0 8 1 2 kgf m 0 7 1 0...

Page 116: ...cation 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 0...

Page 117: ...e 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 Special Service Tools Crankcase remover set Never pry...

Page 118: ...gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase Do not damage contact surface of the crankcase Soap the gasket residues into solvent and the residues...

Page 119: ...s 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 Bearing Inspection Rotate the bearing with fingers and make sure...

Page 120: ...ket Install the right crankcase and tighten the crankcase bolts 2 bolts Torque value 0 8 1 2 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Ap...

Page 121: ...th 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 ins...

Page 122: ...LUGGAGE BOX 12 9 FLOOR PANEL 12 9 Front center cover Frame number cover Left body cover Inner box Double Seat Rear carrier Luggage box Floor panel Front cover Under cover Rear fender Rear handle cover...

Page 123: ...the guards with slot on the covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly Battery cover Luggage...

Page 124: ...he rear handle cover Remove the mounting screws 4 screws between the front handle cover and the rear handle cover Remove the headlight connector Remove the front handle cover Remove the front handle c...

Page 125: ...r and meter Remove the left right handle switch connectors Remove the rear handle cover Installation Install according to the reverse procedure of removal FRONT COVER Removal Remove the 1 mounting bol...

Page 126: ...Remove the 1 2 mounting screws between the left right side cover and the floor panel Remove the 1 2 mounting screws between the left right side cover and the frame Remove the 2 2 mounting bolts betwee...

Page 127: ...screws of front cover from the inner box Remove the 1 2 mounting screws of front spoiler from the inner box Remove the 1 2 mounting screws of front spoiler from the inner box Remove the screw on the...

Page 128: ...n Install the inner box A and the front inner box B according to the reverse procedure of removal BODY COVER REAR FENDER Removal Open the seat Remove the luggage box 6 bolts Remove the rear carrier 3...

Page 129: ...the floor panel Remove the 1 mounting screw between the body cover and front center cover Remove the 2 mounting bolts of the rear fender Remove the left right body cover Remove the rear fender Install...

Page 130: ...on Install the cover according to the reverse procedure of removal LUGGAGE BOX Removal Open the seat Remove the 6 bolts from the luggage box Remove the luggage box and the double seat Remove the engin...

Page 131: ...unting screw Remove the 1 2 screws between the body cover and the floor panel Remove the 1 2 screws between the left right side cover and the floor panel Remove the floor panel Installation Install th...

Page 132: ...ORMATION 13 4 TROUBLE DIAGNOSIS 13 5 HYDRAULIC BRAKE SYSTEM INSPECTION 13 6 BRAKE FLUID REPLACEMENT AIR BLEED 13 7 BRAKE CALIPER 13 8 BRAKE DISC 13 9 BRAKE MASTER CYLINDER 13 9 DRUM BRAKE DRUM 13 12 B...

Page 133: ...13 BRAKE SYM 13 2 MECHANISM DIAGRAM Front Drum Brake System 0 8 1 2 kgf m 11 0 13 0 kgf m 2 8 3 2 kgf m http www motorcycle in th...

Page 134: ...SYM 13 BRAKE 13 3 MECHANISM DIAGRAM Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m http www motorcycle in th...

Page 135: ...The thickness of front brake 3 50 2 00 Front brake disc eccentricity 0 15 0 30 Master cylinder inner diameter 25 40 ID of front rear brake drums 130 00 131 00 OD of front brake disc 130 00 Thickness...

Page 136: ...disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel DRUM BRAKE Poor brake pe...

Page 137: ...LLRUN DOT 3 brake fluid CAUTION Brake Fluid Add Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or rubber...

Page 138: ...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 2 Slowl...

Page 139: ...the brake caliper at first as installation Install the inner brake lining firstly and then install the outer brake lining INSTALLATION Install the brake caliper and tighten the attaching bolts securel...

Page 140: ...cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder Remove the rubber pad Remove the circlip Remove the piston and the spring Clean the master cylinder with recommen...

Page 141: ...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 Insta...

Page 142: ...stall the brake lever and connect leads to 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 i...

Page 143: ...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 Rea...

Page 144: ...tly grind the brake lining surfaces with sand paper to clean the surfaces Caution BRAKE PANEL Removal Remove the brake arm bolt and then remove the brake arm wear indicator brake return spring and bra...

Page 145: ...ar indicator and the mark on the brake arm with the indent gear of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2 kgf m REAR BRAKE PANEL Apply a thin cost...

Page 146: ...AUTIONS IN OPERATION 14 2 TROUBLE DIAGNOSIS 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT SHOCK ABSORBER 14 9 FRONT FORK STEERING COLUMN 14 9 MECHANISM DIAGRAM 3 1 3 5kgf m 1 0 2 0kgf m 5 0 7 0kgf...

Page 147: ...gf 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...

Page 148: ...ke master cylinder and then take out the master cylinder and the split ring Caution Remove acceleration handlebar screw and then remove the handlebar acceleration cable and handlebar cover seat Remove...

Page 149: ...alling the acceleration handlebar seat acceleration handlebar and acceleration cable FRONT WHEEL Removal Disc Brake type Support body bottom and lift front wheel free of ground Remove the bolts and di...

Page 150: ...e front brake panel and the front wheel Inspection Wheel axle Set the axle in V blocks and measure the run out Service limit 0 2 mm Wheel Rim Place the wheel onto a rotated bracket Turn the wheel with...

Page 151: ...ng with fingers 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 da...

Page 152: ...ust seal and then install the seal and the front wheel side collar Installation Drum Brake Apply with some grease on the speedometer driving gear and then install washer driving gear into the brake pa...

Page 153: ...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 Drum Brake Install the front whe...

Page 154: ...ck 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...

Page 155: ...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 Caution Install the steering...

Page 156: ...DIAGRAM 15 1 PRECAUTIONS IN OPERATION 15 2 TROUBLE DIAGNOSIS 15 2 EXHAUST MUFFLER 15 3 REAR WHEEL 15 3 REAR SHOCK ABSORBER 15 4 MECHANISM DIAGRAM 0 8 1 2kgf m 3 0 3 6kgf m 11 0 13 0kgf m 1 0 1 4kgf m...

Page 157: ...ck 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 bend wheel rim poor tire loosen...

Page 158: ...4kgf m 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 mig...

Page 159: ...ove the upper nut of the rear shock absorber bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution Torque values Re...

Page 160: ...METER 16 15 LIGHTS BULBS 16 17 MAIN SWITCH HORN 16 19 FUEL UNIT 16 22 MECHANISM DIAGRAM Spark plug Alternator Fuel unit Ignition coil Battery fuse box C D I Main switch REG REC Horn Resistor Starter...

Page 161: ...hen charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devices when curre...

Page 162: ...5 5 Resistor Resistance 20 30W7 5 7 0 8 0 Ignition System Item Specification Standard NGK CR7HSA Recommended usage Hot type NGK CR8HSA Cold type NGK CR6HSA Spark plug Spark plug gap 0 6 0 7 mm Primar...

Page 163: ...or is out of work Engine does not crank smoothly Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch Secondary coil circuit Poor ignition coil Poor spark p...

Page 164: ...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 In the current leakage test set...

Page 165: ...ted 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...

Page 166: ...grease Strictly keep flames away from a charging battery The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires Turn the charger s switch OFF at fi...

Page 167: ...ry is aged and does not have enough capacity 2 The charging voltage is normal but the current is not The replacement battery is aged and does not have enough capacity Battery used do not have enough e...

Page 168: ...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 wir...

Page 169: ...between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 1 20 Replace the alternator lighting coil if the measured value exceeds standard Resistor check Remove the fro...

Page 170: ...rminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200 Primary Black yellow green 0 21 10 Green high voltage cable w o cap 3 5K Ignition Coil Sec...

Page 171: ...k yellow and green and frame ground 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 sid...

Page 172: ...ured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution Check Remove...

Page 173: ...on 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 pi...

Page 174: ...e 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...

Page 175: ...aution Installation Install the meter in reverse order of removal Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components High Beam Indicator F...

Page 176: ...b has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment bolt located under t...

Page 177: ...der of removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the tail light assembly Replace the bulbs of the tail light brake light 12V 5W 21W Replace the...

Page 178: ...s connector Check connector terminals for continuity color Location Black Black white Red Green Green 2 LOCK OFF ON Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the m...

Page 179: ...reen FREE High Low beam switch seat open color Location blue white brown white black purple seat open Horn switch color Location Black Light green FREE headlight switch starting switch turn signal swi...

Page 180: ...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 batt...

Page 181: ...value E empty 97 5 107 5 F full 4 10 DOWN empty Connect the fuel unit to the main harness Turn the main switch ON position Move the float arm in UP DOWN and then check if the fuel unit indication nee...

Page 182: ...http www motorcycle in th...