SYM Mio 100 manual

Mio 50 / 100 SER VICE MANUAL FOR W ARD HOW TO USE THIS MANUAL CONTENTS Mechanism Illustrations[...]

Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Mio 50 / 100 scooters. 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 const[...]

How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG Mio 50 / 100 scooters. 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 diagnos[...]

Contents Page Content Index 1-1 ~ 1-18 General Information 1 2-1 ~ 2-18 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~ 4-12 Fuel System 4 5-1 ~ 5-8 Engine Removal 5 6-1 ~ 6-18 Cylinder Head/Valve 6 7-1 ~ 7-8 Cylinder/Piston 7 8-1 ~ 8-14 “V” Type Belt Driving System / Kick-Starter 8 9-1 ~ 9-8 Final Driving Mechanism 9 10-[...]

Mechanism Illustrations HU05U / HU10U / HU10W Exhaust muffler Home page Contents Air cleaner Fuel tank cap Start / headlight switch Battery / Fuse / C.D.I. unit Front brake lever Rear brake lever Back mirror Luggage box Luggage box lock Helmet hook Winker / Horn / Hazard or Seat open switch Front winker Headlight Tail light Main switch Oil gauge Fu[...]

1. General Information 1-1 Symbols and Marks ···························· 1-1 General Sa fety ···································· 1-2 Service Precau tions ··························· 1-3 Specificati ons ···························?[...]

1. General Information 1-2 General Safety Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Exhaust contains toxic gas which may cause one to lose consciousnes[...]

1. General Information 1-3 Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG ATV may damage the ATV. y Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged. y When servicing this A[...]

1. General Information 1-4 y The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts f[...]

1. General Information 1-5 y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y Check if positions and operation for installed parts is in correct and properly. y Make sure service safety each other when conducting by two persons. y Note that do not let parts fall down. y Before battery removal opera[...]

1. General Information 1-6 y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not pull the wires as removing a connector or wires. Hold the connector body. y Make sure if the connector pins are bent, extruded or loosen. y Insert the connector completely. If there are two lockers on two con[...]

1. General Information 1-7 y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Keep wire harnesses far away from the hot parts. y Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws. y Route harnesses so that they neither pull too tight [...]

1. General Information 1-8 y Do not let the wire harness been twisted as installation. 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 operati[...]

1. General Information 1-9 Specifications MAKER SANYANG MODEL HU05U Overall Length 1710 mm Front TELESCOPE Overall Width 700 mm Suspension System Rear UNlT SWING Overall Height 1005 mm Front 3.0-10 42J Dimension Wheel Base 1170 mm Tire Specifications Rear 90/90-10 50J Front 31 kg Rear 49 kg Front DRUM (ø 110 mm) Curb Weight Total 80 kg Brake Syste[...]

1. General Information 1-10 Specifications MAKER SANYANG MODEL HU10U/W Overall Length 1710 mm Front TELESCOPE Overall Width 700 mm Suspension System Rear UNlT SWING Overall Height 1020 mm Front 90/90-10 50J Dimension Wheel Base 1220 mm Tire Specifications Rear 90/90-10 50J Front 32.5 kg DRUM (ø 110 mm) Rear 55 kg Front DISK (ø 160 mm) Curb Weight[...]

1. General Information 1-11 Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 5 mm bolt 、 nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m 6 mm bolt 、 nut 0.8~1.2kgf-m 6[...]

1. General Information 1-12 Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handlebar 1 10 4.0~5.0 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[...]

1. General Information 1-13 Troubles Diagnosis A. Engine hard to start or can not be started To this chapter contents Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carbureto r Fuel supplied tom carburetor sufficient No fuel is supplied to carburetor Remove spark plug, inst[...]

1. General Information 1-14 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 Engine speed can be increased. Engine speed can not be increased. Check ignition timing (Using ignition lamp) Check cylinder compression pressure (using compr[...]

1. General Information 1-15 C. Engine runs sluggish (especially in low speed and idling) D. Engine runs sluggish (High speed) Check and ad j ustment Fault condition Probable causes Check ignition timing (Using ignition lamp) Check for fuel supplying system in automatic fuel cup Check if carburetor clogged 1. Incorrect ignition timing (malfunction o[...]

1. General Information 1-16 E. Clutch, Driving And Driving Pulley 1. Clutch ling spring broken 2. Clutch outer cover stickled with clutch balance weights 3. Connection parts in clutch and shaft worn out or burned Engine can be started but motorcycle can not be moved. FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Drivin[...]

1. General Information 1-17 Lubrication Points Steering shaft bearing Seat locker Clutch bearing Main stand shaft Side stand shaft Speedometer gear/ front wheel bearing Acceleration cable/ Front & rear brake lever pivot To this chapter contents[...]

1. General Information 1-18 Note: To this chapter contents[...]

2. Maintenance Information 2-1 Precautions in Op eration ...................... 2-1 Periodical Maintenance Schedule ........ 2-2 Lubrication Sy stem ............................... 2-3 Fuel Syst em ........................................... 2-4 Air Clean er ............................................. 2-5 Throttle Valve Op eration ...............[...]

2. Maintenance Information 2-2 Periodical Maintenance Schedule No item Initial 300KM 1 Month every 1000KM 3 month every 3000KM 6 month every 6000KM 1 year every 12000KM 1 ☆ Air cleaner I C C R 2 ☆ 2nd air jet leaner I C C R 3 ☆ Fuel filter I I R 4 ☆ Oil filter C C C 5 ☆ Engine oil change R Replacement for every 1000km 6 Tire pressure I I [...]

2. Maintenance Information 2-3 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. Remove dipstick to check the oil level. If oil level is below th[...]

2. Maintenance Information 2-4 Gear Oil 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. Check gear oil if enough. Replacement At first, remove the gear oil refilling bolt, and then remove the drainin[...]

2. Maintenance Information 2-5 Air Cleaner Element Remove the air cleaner cover (7 screws) Remove element. Check the element if dirt or damaged. Replace it with new one if dirt or damaged. Throttle Valve Operation Have a wide open of throttle valve as handle bar in any position and release it to let back original (full closed) position. Check handl[...]

2. Maintenance Information 2-6 Primary adjustment is conducted from cable button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Crankcase Blow-By Ventilation Pull out the plug from draining hose to clean deposits Caution z When always riding in rainy area or ful[...]

2. Maintenance Information 2-7 Valve clearance inspection and adjustment Check & adjust valve clearance with feeler gauge after open the valve adjustment hole cap. Valve clearance: HU10U/W 0.12±0.02mm (IN/EX) HU05U IN: 0.05±0.02mm EX: 0.10±0.02mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution z It has to make sure that[...]

2. Maintenance Information 2-8 Ignition System Ignition Timing Caution z C.D.I ignition system is set by manufacturer so it can not be adjusted z Ignition timing check procedure is for checking whether CDI 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[...]

2. Maintenance Information 2-9 Cylinder Compression Pressure Warn up engine and then turn off the engine. Remove the trunk and the central cover. Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve, and rotate the engine by means of stepping the foot-starting lever Caution y Rotate the engine until the readin[...]

2. Maintenance Information 2-10 Steering System Caution z 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 alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical dire[...]

2. Maintenance Information 2-11 Front Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found. Caution z In ord[...]

2. Maintenance Information 2-12 ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid Caution z 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[...]

2. Maintenance Information 2-13 Drum Brake System Front Brake Free Play: (Drum brake) Measure free play of rear brake level at the end of the lever. Free play: 10~20mm Adjust the free play by turning the front brake adjustment nut if necessary. Rear Brake Free Play: (Drum Brake Ty pe) Measure the free [lay of the front brake lever at the end of the[...]

2. Maintenance Information 2-14 BRAKE LAMP SWITCH The brake light switch lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. Wheel / Tire Check if the tire pressure of front & rear wheel is within standard. Caution z Tire pressure check should be done as cold tire. Appointed tire pre[...]

2. Maintenance Information 2-15 Battery Battery Removal Open the seat cushion and then the battery cap. (2 screws) 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 rev[...]

2. Maintenance Information 2-16 Special Service Tools Catalogue Name Puller/presser for crankcase bushing Name Puller/presser for crankcase bushing Name Valve spring compressor Parts no. SYM-1120310 Parts no. SYM-1120320 Parts no. SYM-1471110/20 Name Valve spring compressor Name Valve clearance adjustment wrench Name Valve clearance adjuster Parts [...]

2. Maintenance Information 2-17 Name Bearing remover (inner type) Name Bearing remover (outer type) Name clutch spring compressor Parts no. SYM-6204002 Parts no. SYM-6204001 Parts no. SYM-2301000 Name Clutch mounting nut wrench Name Universal fixer Name Alternator flyw heel remover Parts no. SYM-9020200 Parts no. SYM-2210100 Parts no. SYM-3110A01 N[...]

2. Maintenance Information 2-18 NOTE: To this chapter contents[...]

3. Lubrication System 3-1 Mechanism Illu strations ····················· 3-1 Operational Pr ecautions ····················· 3-2 Trouble Dia gnosis ······························· 3-2 Engine OIL ·········································?[...]

3. Lubrication System 3-2 Operational Precautions General Information z This chapter contains maintenance operations for the engine oil pump, engine oil a nd gear oil. Specifications Engine oil quantity Disassembly: HU10U/W 750c.c. HU05U 800c.c. Replacement: HU10U/W 650c.c. HU05U 700c.c. Oil viscosity: SAE 10W-30 or equivalent (Recommended King-Mat[...]

3. Lubrication System 3-3 Engine OIL Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. Oil Replacement Caution z Drain oil as engine warmed up so that make sure oil c[...]

3. Lubrication System 3-4 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[...]

3. Lubrication System 3-5 Oil Pump Oil Pump Removal Remove the alternator (refer to chapter 10). Remove the engine right cover. Remove the one-way clutch and starting gear (1 nut) Special Service Tools: One way clutch socket SYM-9020100 Universal fixer SYM-2210100 Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 scre[...]

3. Lubrication System 3-6 Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit ： below 0.12mm Check clearance between inner and outer rotors. Limit ： below 0.12mm 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 Alig[...]

3. Lubrication System 3-7 Install driving gear and clamp. Caution z Make sure if the oil pump can be rotated smoothly . Oil Pump Inst allation Install the oil pump (2 screws). Install oil pu mp drive ge ar . Install the one-way clutch and starting gear (1nut) Install the engine right cover. Install the alternator (refer to chapter 10). Special Serv[...]

3. Lubrication System 3-8 Gear Oil Oil Level Inspection Park the motorcycle on flat surface with main stand Turn off engine and remove both engine oil filling bolt and oil draining plug. Remove gear oil filling hole bolt and place a measurement cup under the draining plug. Remove the oil draining plug and the pour gear oil into the measurement cup.[...]

4. Fuel System 4-1 Mechanism Illu stration ...................... 4-1 Operational Pr ecautions .................... 4-2 Trouble Dia gnosis .............................. 4-3 Carburetor ........................................... 4-4 Idle Speed Ad justment ...................... 4-8 Fuel Tank ............................................ 4-9 Air Clea[...]

4. Fuel System 4-2 Operational Precautions General Information Wa r n i n g 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. Caution z Do not bend or twist throttle valve cable. Damaged cable will make unst able drive ability . z When disassem[...]

4. Fuel System 4-3 T rouble Diagnosis Poor engine st art y No fuel in fuel tank y Clogged fuel tube y T oo much fuel in cylinder y No spark from spark plug (malfunction of ignition system) y Clogged air cleaner y Malfunction of automatic by-starter y Malfunction of throttle valve operation St all af ter started y Malfunction of automatic by-starter[...]

4. Fuel System 4-4 Carburetor Carburetor Removal Remove the luggage box and seat. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Remove air cut-off valve hose Disconnect automatic by-starter connectors. Release the clamp strip of air cleaner. Release the clamp [...]

4. Fuel System 4-5 Air Cut-off V alve Removal Removal the throttle cable seat (screws x 2) Remove the screws (screw x 2) of the air cut-off valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack. Installation Install the valve as reverse order of removal. Caution z Do not damage the vacuum dia[...]

4. Fuel System 4-6 AUTOMA TIC BY -ST ARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter. Resistance value: Max. 10 Ω (Measured after engine stopped for more than 10 minutes) Replace the automatic by-starter with a new one if resistance value exceeds st[...]

4. Fuel System 4-7 FLOA T CHAMBER Disassembly Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. Checking Check float needle valve and valve seat for drop difference damage, wear out, dirty or clogged. Caution z In case of worn out or dirt, the float valve and valve seat will not tightly close causing f[...]

4. Fuel System 4-8 Assembly Install main jet, fuel needle jet holder, nozzle, idle jet and air-fuel mixture adjustment screw. Caution z Set the adjustment screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking Fuel Level Caution z Check again to ensure float valve, float for proper[...]

4. Fuel System 4-9 Fuel T ank Fuel meter gauge removal Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove fuel unit coupler. Remove the rear bracket (4 bolts & 3 screws) Turn fuel un[...]

4. Fuel System 4-10 Fuel t ank removal Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove fuel unit coupler. Remove the rear bracket (4 bolts & 3 screws) Remove the fuel tank mountin[...]

4. Fuel System 4-1 1 Air Cleaner Removal the element of the air cleaner Remove the air cleaner cover (7 screws). Remove air cleaner element. Inst allation Install the air cleaner in the reverse order of removal. 7 screws T o this chapter contents[...]

4. Fuel System 4-12 Removal of Air Cleaner Open the seat. Remove the luggage box (chapter 12). Remove the left side cover (chapter 12). Loose the air cleaner adapting-pipe clamp. Remove the EEC, PCV, AI system hoses. Remove the mounting bolts of the air cleaner body. (2 bolts) Remove the air cleaner assembly . Installation Install the air cleaner i[...]

5. Removal & Inst allation of Engine 5-1 Mechanism Illu strations ····················· 5-1 Operational Pr ecautions ····················· 5-2 Engine Re moval ·································· 5-3 Removal of Engi ne Bush ····················· 5-6 E[...]

5. Removal & Inst allation of Engine 5-2 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 inst alled on the frame. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3. Final reduction gear mechanism Spe[...]

5. Removal & Inst allation of Engine 5-3 Engine Removal Open the seat. Remove the luggage box (Bolt× 4, Nut×1). Remove battery cover. Remove the battery negative (-) cable. Remove the battery positive (+) cable. Remove right and left side covers (1 screw on each side.). Remove the power connector of auto by-starter. Remove the generator power[...]

5. Removal & Inst allation of Engine 5-4 Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor . Loose the strap screw of the air cleaner guide, and then the air cleaner guide. Remove the exhaust muffler (2 Bolts, 2 Nuts). Remove the air cleaner connection bolts (2 bolt s). Remove the rear brake cable nut and cable. 2 [...]

5. Removal & Inst allation of Engine 5-5 Remove the rear cushion lower bolt (1 bolt). Remove the engine hanger nuts and bolt s (engine side), and then remove the engine. With a bracket to support the engine to prevent from it damage by falling down as removing the engine. Remove the rear wheel with air tools after the engine removed. 1 bolt 螺[...]

5. Removal & Inst allation of Engine 5-6 Removal of Engine Bush If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then, with the bush remover / presser, ø28mm & ø20mm, to press the bush out, and replace it with new one. Engine hanger bush: ø 28mm Rear cushion bush: ø 20mm Pressing out Place the detent section o[...]

5. Removal & Inst allation of Engine 5-7 Engine Hanger Removal Remove the right side bolt of engine hanger. (1 bolt on each side) Remove the engine hanger . Check if the engine hanger bush and cushion rubber for damage. If so, replace with new ones. Inst allation Tighten the bolts and nuts of engine hanger. Engine hanger nut: T orque V alue: 4.[...]

5. Removal & Inst allation of Engine 5-8 Installation of Engine Install the engine according to the reversing order of removal. Caution z Note both feet and hands safety for squeezing as engine inst allation. z Do not bent or squeeze each wires or hose. z Route all cables and wires in accordance with the routine layout. Engine hanger nut: T orq[...]

6. Cylinder Head / V alve 6-1 Mechanism Illu strations ····················· 6-1 Operational Pr ecautions ····················· 6-2 Troubleshootin g ·································· 6-3 Cylinder Head Removal ······················ 6-4 Cylinder Head D[...]

6. Cylinder Head / V alve 6-2 Operational Precautions General Information y This chapter is contained maintenance and service for cylinder head, valve, and camshaf t as well as rocker arm. y Cylinder head service cannot be carried out when engine is in frame. Specification Unit: mm Model HU10U/W HU05U Item S tandard Limit S tandard Limit V alve cle[...]

6. Cylinder Head / V alve 6-3 T roubleshooting Engine performance will be affected by troubles on engine to p end. The troubles usually can be determinate or by performing cylinder compressi on test and judging the abnormal noise generated. Rough Idle Low compression pressure Low compression pressure 1. Valve y Improper valve adjustment y Burnt or [...]

6. Cylinder Head / V alve 6-4 Cylinder Head Removal Remove the right cooling shroud from the engine outer cover. (5 screws) Remove the left cooling shroud (1 bolt). Remove the crankcase blow-by system hose from the cylinder head. Remove the cam chain tensioner (2 bolts). Remove the cylinder head side cover . (2 bolts) 5 Screws Tensioner 2 bolts Blo[...]

6. Cylinder Head / V alve 6-5 T urn the flywheel in counter clockwise motion with T type wrench until the “T iming” mark on camshaft aligned with the mark on the cylinder head. Remove camshaft sprocket mounting bolt and remove the sprocket. Remove the left side cylinder head and cylinder connection bolts (2 bolt s) Remove the cylinder head moun[...]

6. Cylinder Head / V alve 6-6 Cylinder Head Disassembly (HU05U) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wrench: SYM-ALL12361 Remove the camshaft stopper of the rocker arm shaft (1 bolt) . With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker ar[...]

6. Cylinder Head / V alve 6-7 Cylinder Head Disassembly (HU10U/W) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wrench: SYM-ALL12361 Remove the camshaft stopper of the rocker arm shaft (1 bolt) . With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker [...]

6. Cylinder Head / V alve 6-8 Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit: (Refer to page 2) Inspect the camshaft bearing for looseness or wear out. If any damaged, replace whole set of camshaft and bearing. Measure the cam rocker arm I.D. Service Limit: (Refer to page 2) Measure the active O.D. of th[...]

6. Cylinder Head / V alve 6-9 V alve Disassembly Remove the valves Special Service T ool: V alve remover/installer SYM-1471 1 10/20 Caution z Place a rag under the bottom of the combustion chamber as disassembling to prevent from valve stem deformation. Remove the valve spring retainer, valve springs and valves. Clean carbon deposits in combustion [...]

6. Cylinder Head / V alve 6-10 Cylinder Head Inspection Cylinder Head Check if spark plug and valve holes are crack. Measure cylinder head wrap age with a straightedge and flat feeler gauge. Service limit: 0.05mm Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: 31.5mm Valve stem Check if valve ste[...]

6. Cylinder Head / V alve 6-1 1 Caution z 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[...]

6. Cylinder Head / V alve 6-12 V alve 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 z Do not let emery enter into between valve stem and valve guide. z Clean up the emery after corr[...]

6. Cylinder Head / V alve 6-13 Use 60° cutter to cut a quarter lower part s out. Remove the cutter and check new valve seat. Use 45° cutter to grind the valve seat to specified width. Caution z Make sure that all roughness and uneven faces had been grinded. Grind valve seat again if necessary . Coat the valve seat surface with red paint. Install [...]

6. Cylinder Head / V alve 6-14 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. Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Inst[...]

6. Cylinder Head / V alve 6-15 Assembly the cylinder head. Caution z The tangent of rocker shaf t of intake valve should match with the bolt hole of camshaft mounting seat. Cylinder Head Inst allation Install the lock pins and new cylinder head gasket onto the cylinder. Install the camshaft chain plate. Tighten the cylinder head nuts (4 nuts) At fi[...]

6. Cylinder Head / V alve 6-16 V alve Clearance Adjustment Install the auto-chain te nsioner . Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut. St and[...]

6. Cylinder Head / V alve 6-17 Install the cooling shroud of the engine body outer cover. (5 bolts) Install the engine onto the frame. (Refer to chapter 5) 5 Screws T o this chapter contents[...]

6. Cylinder Head / V alve 6-18 Notes: T o this chapter contents[...]

7. Cylinder / Piston 7-1 Mechanism Illu strations ····················· 7-1 Operational Pr ecautions ····················· 7-2 Trouble Dia gnosis ······························· 7-2 Cylinder Removal ································ 7-3 Piston Re[...]

7. Cylinder / Piston 7-2 Operational Precautions General Information y Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit: mm Model HU10U/W HU05U Item S tandard Limit S tandard Limit ID 49.995~50.015 50.500 37.015~36.995 37.500 Bend / wrap age － 0.050 － 0.050 Cylindrical roundness － 0.050 ?[...]

7. Cylinder / Piston 7-3 Cylinder Removal Remove cylinder head. (Refer to chapter 6) Remove cam chain plate. Remove cylinder . Remove cylinder gasket and lock pins. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution z T o soap[...]

7. Cylinder / Piston 7-4 Inspection Check if the inner diameter of cylinder is worn out or damaged. In the 3 positions (top, center and bottom) of cylinder, measure the X and Y direction values respective in the cylinder. Service limit: (Refer to page 2) Calculate both the real roundness (the difference between X and Y motion values) and the cylind[...]

7. Cylinder / Piston 7-5 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 z Pay attention to remove piston ri[...]

7. Cylinder / Piston 7-6 Measure the outer diameter of piston pin. Service Limit: (Refer to page 2) Measure the inner diameter of connecting rod small end. Service Limit: (Refer to page 2) Measure the inner diameter of piston pin hole. Service Limit: (Refer to page 2) Calculate clearance between piston pin and it s hole. Service Limit: (Refer to pa[...]

7. Cylinder / Piston 7-7 Piston Ring Inst allation Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston car efully . Place the openings of piston ring as diagram shown below . Caution z Do not damage piston and piston rings as installation. z All marks on the piston rings must be forwarded to up side. z Make sure [...]

7. Cylinder / Piston 7-8 Piston Inst allation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution z Do not let the opening of piston pin snap ring align with the opening piston ring. z Place a piece of cloth between piston skirt section and crankcase in orde[...]

8. V-Belt Drive System / Kick Starter 8-1 Mechanism Illustrations ···················· 8-1 Operational Pr ecautions ···················· 8-2 Trouble Dia gnosis ······························ 8-2 Left Crankcase Cover ························8-3 Kick Starte [...]

8. V-Belt Drive System / Kick Starter 8-2 Operational Precautions General Information y Movable drive face, clutch, and driven pulley can be serviced on the motorcycle. y Drive belt and driven pulley surface must be free of grease. Specification Unit: mm HU10U/W HU05U Item Standard value Limit Standard value Limit Drive belt width 17.800~18.200 17.[...]

8. V-Belt Drive System / Kick Starter 8-3 Lef t Crankcase Cover Lef t crankcase cover removal Remove body cover Remove air cleaner (2 bolts) Remove left crankcase cover (8 bolts). Installation of the left crankcase cover Install the left crankcase cover (8 bolts) Tighten the air cleaner (2 bolts) Kick S t arter Disassembly Remove left crankcase cov[...]

8. V-Belt Drive System / Kick Starter 8-4 Remove the inner plate inside of left crankcase cover. (6 screws) Install kick starter arm, rotate the lever slightly and then remove driven gear and washer. Remove the kick starter arm, kick starter spindle, spindle bush and return spring as well as socket. Inspection Check if kick starter spindle, kick sp[...]

8. V-Belt Drive System / Kick Starter 8-5 Drive Belt Removal Remove left crankcase cover Hold drive face with universal fixture, and remove nut and drive face. Special Service Tool: Universal fixture SYM-2210100 Hold the clutch outer with the universal fixture, and the remove the nut and the clutch outer. Caution z Using special service tools for t[...]

8. V-Belt Drive System / Kick Starter 8-6 Inst allation Pull out the sliding driven face and then insert the drive belt into the driven pulley. Caution z Pull out sliding driven face and then insert the drive belt into the driven pulley so that the drive belt set can be installed onto pulley more easily. Install the clutch set with drive belt onto [...]

8. V-Belt Drive System / Kick Starter 8-7 Movable Drive Face Removal Remove left crankcase cover. Hold drive face with universal fixture, and then remove drive face nut. Remove drive face. Special Service Tool: Universal fixture SYM-2210100 Take out the drive belt from the drive face. Remove movable drive face set and drive face boss from crankshaf[...]

8. V-Belt Drive System / Kick Starter 8-8 Inspection The operation of movable drive face is means of the weight roller to pressing on it with centrifuge force. And then the speed is changed by the ramp 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. Repl[...]

8. V-Belt Drive System / Kick Starter 8-9 Apply with some grease to inside of drive face boss hole, and install drive face boss. Caution z The drive face surface has to be free of grease. Clean it with cleaning solvent. Install movable drive face assembly onto crankshaft. Movable Drive Face Inst allation Press drive belt into movable drive face, an[...]

8. V-Belt Drive System / Kick Starter 8-10 Clutch / Driven Pulley Disassembly Remove drive 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 z Do not press the compressor too much. Hold the clutch spring compressor onto bench vise, and [...]

8. V-Belt Drive System / Kick Starter 8-11 Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 2.0mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit Service limit: HU01U/W 156.0mm HU05U 87.9mm Driven pulley Check following items: y If both surfa[...]

8. V-Belt Drive System / Kick Starter 8-12 Clutch Block Replacement Remove snap and washer, and the remove clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins. Apply with grease onto s[...]

8. V-Belt Drive System / Kick Starter 8-13 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing Remove inner bearing. Caution z If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly. z If the pulley equipped with ball bearing, it has to remove snap ring [...]

8. V-Belt Drive System / Kick Starter 8-14 Inst allation of Clutch / Driven Pulley Assembly Install new oil seal and O-ring onto sliding driven face. Apply with specified grease to lubricate the inside of sliding driven face. Install sliding driven face onto driven face. Install guide pin and guide pin roller. Install oil seal collar. Install drive[...]

9. Final Drive Mechanism 9-1 Mechanism Illu strations ····················· 9-1 Operational Pr ecautions ····················· 9-2 Trouble Dia gnosis ······························· 9-2 Disassembly of Final Drive Mechanism ···························[...]

9. Final Drive Mechanism 9-2 Operational Precautions Specification Application gear oil: GEAR OIL SAE 85W-140 Recommended oil: KING MA TE serial gear oils Oil quantity: HU10U/W 1 10 c.c. (100 c.c. when replacing) HU05U 100 c.c. (90 c.c. when replacing) T orque value Gear box cover 2.0~2.4kgf-m Gear oil drain plug 1.0~1.4kgf-m Gear oil filling bolt [...]

9. Final Drive Mechanism 9-3 Disassembly of Final Drive Mechanism HU05U Remove the rear wheel (refer to chapter 15). Remove the clutch. Drain gear oil out from gear box. Remove gear box cover and then remove the cover and the drive shaft. (7 screws) Remove counter shaft and gear . Remove final driven gear and shaft. Remove drive shaft. Remove gaske[...]

9. Final Drive Mechanism 9-4 Inspection of Final Drive Mechanism Check if the countershaft and the gear are worn out or damage. Check if the final driven shaf t and gear are wear out or damage. Check bearings on gear box and cover . Rotate each bearing’ s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also chec[...]

9. Final Drive Mechanism 9-5 Bearing Replacement Caution z Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove drive shaft bearing from left crankcase using following tools; Special Service Tool: Inner type bearing puller SYM-6204002 Install new drive shaft bearing into left crankcase. Special Service Tool:[...]

9. Final Drive Mechanism 9-6 Install a new drive shaft bearing onto gear box cover. Then, install the drive shaft. Special Service Tool: Bearing (6204) installer SYM-9110400 Install the drive shaft. Special Service Tool: Drive shaft puller SYM-11300 10 Puller set SYM-1130000-L Install new oil seal with the specia l service tool. Special Service Too[...]

9. Final Drive Mechanism 9-7 Re-assembly of Final Driven Mechanism HU05U Apply with grease onto the oil seal lip of final driven shaft. Install final driven shaft and final driven gear, countershaft, and countershaft gear. Install the dowel pins (2 pins) and new gasket. Install the gear box cover and 7 bolts (tighten the bolts). Torque value: 2.0~2[...]

9. Final Drive Mechanism 9-8 Install the dr iven pulley / clutch outer / belt / movable drive face / drive face. Install the left crankshaft cover and kick start er. Install the rear wheel. Add gear oil. Recommended usage: SYM HYPOID GEAR ※ OIL (SAE 85W-140) T o this chapter contents[...]

10. Alternator / S tarting Clutch 10-1 Mechanism Illu strations ····················· 10-1 Operational Pr ecautions ····················· 10-2 Alternator Removal ····························· 10-3 Right Crankcase Cover Removal ······· 10-4 Starting Cl utch ·······?[...]

10. Alternator / S tarting Clutch 10-2 Operational Precautions General information y Refer to chapter 5: Engine removal and inst allation y Refer to chapter 1 : The troubleshooting and inspection of alternator y Refer to chapter 16: The service procedures and precaution items of st arter motor Specification Unit: mm Item Service Limit ID of startin[...]

10. Alternator / S tarting Clutch 10-3 Alternator Removal Drain out the engine oil. Remove the right side cover. Remove the exhaust pipe (2 bolts, 2 nuts). Remove the fan shroud (2 screws, 2 bolts). Remove the cooling fan (4 bolts). Hold the flywheel with the universal fixture. Remove the 10mm nut on the flywheel. Special Service Tools: Universal F[...]

10. Alternator / S tarting Clutch 10-4 Remove the flywheel with the flywheel puller . Special service tools: Flywheel puller SYM-31 10000 Caution z Install a shaf t protector on the right end of crankshaft t o avoid damaging the crankshaft before installing the flywheel puller . Remove the connectors of the alternator and pulse generator . Remove t[...]

10. Alternator / S tarting Clutch 10-5 S t arting Clutch St arting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen mounting nut and gasket. Special service tools: Nut puller of starter gear SYM-9020100 Universal fixture SYM-2210100 Caution z The mounting nut is left-turn thread. Remove the starti[...]

10. Alternator / S tarting Clutch 10-6 Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear . Service Limit: ID: 32.06 mm or less Check the starting idle gear and shaft for wear or damage. Measure the ID of the starting idle gear . Service Limit: ID: 10.05 mm or less Measure the OD of the starting idle gear.[...]

10. Alternator / S tarting Clutch 10-7 Inst allation Install the components in the reverse procedures of removal. Caution z Add adhesive onto the thread of hex socket bolt. T orque value: 1.0~1.4kgf-m St arting clutch Inst allation Install idle gear shaf t and idle gear . Install st arting clutch and the starting clutch. Hold the starting driven ge[...]

10. Alternator / S tarting Clutch 10-8 Alternator Coil Set Inst allation Install the coil set onto r ight crankcase cover . (2 bolts) Install pulse generator (2 bolts) Tighten the cable guide (2 bolts) Torque: 1.5~2.0kgf-m Tie the wire harness hose onto the indent of crankcase Caution z Make sure that the wire harness is placed under the pulse gene[...]

1 1. Crankcase / Crankshaft 11 - 1 Mechanism Illu strations ····················11-1 Operational Pr ecautions ···················· 11-2 Trouble Dia gnosis ······························ 11-2 Disassembly of Cr ankcase ·················· 11-3 Crankshaft Insp ectio[...]

1 1. Crankcase / Crankshaft 11 - 2 Operational Precautions General information y This Section contains descriptions concerning disassembly of the crankca se so that the crankshaft can be serviced. y Complete following operations before disassembling crankcase. Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston Chapter 7 V -belt Drive pull[...]

1 1. Crankcase / Crankshaft 11 - 3 Disassembly of Crankcase Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase. Remove the connection bolts (2 bolt s) of the right-side crankcase. Remove the right-side crankcase. Slightly shake the crankshaft and then remove it and the chain. Remove the gasket and the 2 dowel pins. Scr[...]

1 1. Crankcase / Crankshaft 11 - 4 Remove the oil seal of left-side crankcase. T o this chapter contents[...]

1 1. Crankcase / Crankshaft 11 - 5 Crankshaf t 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: Replace when it is more than 0.05 mm. Place the crankshaf t onto a V -block and measure run[...]

1 1. Crankcase / Crankshaft 11 - 6 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 then install two and new crankcase gasket. Install the right crankcase and tight en[...]

1 1. Crankcase / Crankshaft 11 - 7 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: Oil seal installer (25x37x6) SYM-9120200 Oil seal installer T o this chapter contents[...]

1 1. Crankcase / Crankshaft 11 - 8 Notes: T o this chapter contents[...]

12. Body Cover 12-1 Mechanism Illu strations ····················12-1 Maintenance In formation ··················· 12-2 Front Co ver ········································· 12-3 Handle Co ver ······································[...]

12. Body Cover 12-2 Maintenance Information Body covers disassemble sequence: z Be careful not to damage various covers in disassembly or re-assembly operation. z Never injure hooks molded on the body covers in disassembly or re-assembly operation. z Align the buckles on the guards with slot on the covers. z Make sure that each hook is properly ins[...]

12. Body Cover 12-3 Front Cover Removal Remove the mounting screws (2 screws) of front cover from the front inner cover side. Remove the front mounting screw (1 screw) of the front cover. Push the front cover upward and then pull it forward so that the lower mounting groove of front cover can be separated from the front under spoiler. Disconnect th[...]

12. Body Cover 12-4 Handle Cover Removal Loosen the handle front cover mounting screws (2 screws) of the handle from the handle rear cover. Push the two side screws, then hooks of handle two sides so that the handle covers can be separated. Remove two side screws. Remove handle front cover. Push 2 Screws To this chapter contents[...]

12. Body Cover 12-5 Remove the speedometer cable. Disconnect the instrument panel and switch wiring couplers. Remove the handle rear cover rear side screw (1 screw). Remove meter mounting bolts (2 bolts). Remove handle rear cover and meter. Installation Install according to the reverse procedure of removal. Couplers 2 bolts 1 screw To this chapter [...]

12. Body Cover 12-6 Front Fender Remove speedometer cable (1 screw). Remove front brake cable (drum brake type). Remove front brake caliper (disk brake type). Remove the front wheel. (1 nut) Remove the inner-up bolts (2 bolts) from the front fender. Remove front fender. Installation Install according to the reverse procedure of removal. Speedometer[...]

12. Body Cover 12-7 Front under S poiler Remove front cover. Remove the 10 screws on left & right both sides of rear-end from the inner cover. Remove the front-upper screws, bolts. (2 screws & 2 bolts) Disconnect the winker light couplers. Remove the front under spoiler. Inst allation Install according to the reverse procedure of removal. 2[...]

12. Body Cover 12-8 Front Inner Cover Removal Remove the front cover and the front under spoiler. Remove the main switch cap. (1 screw) Remove the rear mounting screw (1 screw) of the inner cover. Remove winker relay and meter control unit. Pry out all wire clamps and then take out the front inner cover. Installation Install the front inner cover a[...]

12. Body Cover 12-9 Luggage Box Remove the mounting bolts (4 bolts) from the luggage box. Disconnect the engine start control switch coupler. Remove luggage box. Inst allation Install according to the reverse procedure of removal. 4 Bolts Start control sw itch coupler To this chapter contents[...]

12. Body Cover 12-10 Rear Carrier Remove the rear carrier mounting bolts and nuts (2 bolts & 2 nuts) Remove rear carrier. Inst allation Install according to the reverse procedure of removal. Battery Cover Remove batter cover screws (2 screws). Remove batter cover. Inst allation Install according to the reverse procedure of removal. 2 bolts 2 sc[...]

12. Body Cover 12-11 Side Cover Removal Remove the 2 screws on both left & right sides covers. Remove right and left side covers. Inst allation Install according to the reverse procedure of removal. Rear Center Cover Remove the rear carrier mounting bolts and nuts (2 bolts & 2 nuts) Remove rear center cover mounting screw (1 screw). Remove [...]

12. Body Cover 12-12 Center Cover Removal Remove center cover upper screw. (1 screw) Remove center cover right and left screws. (2 screws) Remove center cover. Inst allation Install according to the reverse procedure of removal. 1 screw 1 screw on each sid e To this chapter contents[...]

12. Body Cover 12-13 Body Cover Removal Remove the right and left side covers (2 screws). Remove the luggage box (4 bolts). Remove the rear carrier (2 bolts & 2 nuts). Remove the body cover two side screws. (1 screw on each side) Remove the body cover rear side screws. (1 screw on each side) Remove seat lock cable. Remove body cover. Inst allat[...]

12. Body Cover 12-14 Floor Panel Removal Remove the center cover, side covers, luggage box and body cover as well as body cover. Remove the 4 floor panel plugs. There are 4 floor panel mounting bolts. Remove battery cover, and then remove battery. Caution z At first, remove the negative “-“ cable z Then, remove the positive “+” cable z Remo[...]

12. Body Cover 12-15 Rear Fender Remove the rear fender rear bolts (2 bolts). Remove the 2 bolts on the two sides. (1 bolts on each side). Remove rear fender. Inst allation Install according to the reverse procedure of removal. 2 bolts 1 bolt on each side To this chapter contents[...]

12. Body Cover 12-16 Rear Mudguard Remove the rear mudguard right side bolt (1 bolt). Loosen air cleaner mounting bolts, and then remove the rear mudguard left side bolts (2 bolts). Remove the rear mudguard. Inst allation Install according to the reverse procedure of removal. 3 bolts To this chapter contents[...]

13. Brake 13-1 Mechanism Diagram-Front Disc Brake System ················································· 13-1 Mechanism Diagram-Front Drum Brake System ················································· 13-2 Mechanism Diagram-Rear Drum Brake System ·[...]

13. Brake 13-2 Mechanism Diagram-Front Drum Brake System 0.8~1.2kgf-m 2.8~3.2kgf-m 5.0~7.0kgf-m To this cha p ter contents[...]

13. Brake 13-3 Mechanism Diagram-Rear Drum Brake System 2.8~3.2kgf-m 11.0~13.0kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m To this cha p ter contents[...]

13. Brake 13-4 Operational Precautions General information Caution ● Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. y The brake caliper can be removed without removing the hydraulic system. y After the hydr[...]

13. Brake 13-5 Trouble Diagnosis Disc Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disc 7. Low brake fluid 8. Blocked brake pipe 9. Warp/bent brake disc 10. Bent brake lever Hard operation of brake lever 1. Blocked brake syste[...]

13. Brake 13-6 Hydraulic Brake Sy stem Inspection Inspection of Hydraulic Brake Sy stem Inspection Visual inspect for brake fluid leaking or damage. Check if brake hose connections 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 o[...]

13. Brake 13-7 Remove the master cylinder cap and diaphragm. Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. Clean dirty brake disc. Caution ● The dirty brake lining or disc will reduce the brake performance. ● The mixed non-compatible brake fluid will reduce brake performance. ● Foreign materia[...]

13. Brake 13-8 Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses. Caution ● 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 groove clo[...]

13. Brake 13-9 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 Remove the brake disc from wheel. Check the disc for deformation and bend. Allowable limit: 0.30 mm Caution ● Do not let grease to[...]

13. Brake 13-10 Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Service limit: 11.055 mm Measure the outer diameter of the piston. Replace the piston if its mea[...]

13. Brake 13-11 Installation Place the master cylinder onto handlebar, and install the split ring and bolts. The “UP” mark on the split ring should face upward. Align the split ring on the master cylinder seat with the alignment point on the handlebar. Tighten the upper bolt of the seat to specified torque value, and then tighten lower bolt to [...]

13. Brake 13-12 Drum Brake System Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust. Caution ● Inhaling asbestos 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 li[...]

13. Brake 13-13 Removal Caution ● Brake linings must be replaced as a set. Remove brake shoes from the brake panel by pulling out the brake linings. Inst allation Apply a thin coat of grease to the brake cam and the anchor pin. Hook the brake spring onto the brake cam. Pull out the brake linings and install them onto the brake panel. Wipe off the[...]

13. Brake 13-14 Inst allation Front brake p anel Apply a thin cost of grease onto the brake cam shaft. Install the brake cam. Apply a thin cost of grease onto the oil seal lip and then install the oil seal onto the brake cam shaf t. Finally , install it on the brake p anel. Align the end-part of the brake return spring with the hole of brake panel.[...]

14. S t eering / Front Wheel / Front Cushion 14-1 Mechanism Di agram ·························· 14-1 Operational Pr ecautions ···················· 14-2 Trouble dia gnosis ······························ 14-2 Steering Ha ndle ·························[...]

14. S t eering / Front Wheel / Front Cushion 14-2 Operational Precautions General information y Before remo ve front wheel, use a jack to lif t 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, disk or linings. T orque values Front wheel axle nut 5.0~7.[...]

14. S t eering / Front Wheel / Front Cushion 14-3 Steering Handle Removal Remove handle front & rear covers, meter and the front cover (refer to chapter 12). Drum Brake T ype Remove the rear brake lever bolt & nut, and then remove the front brake cable. Remove left handle screw and cable clamp. Remove the left handle switch. Remove the fron[...]

14. S t eering / Front Wheel / Front Cushion 14-4 Disc Brake T ype Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring. Caution z Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder . Remove handle switch screw and then remove the thro[...]

14. S t eering / Front Wheel / Front Cushion 14-5 Front Wheel Removal Disc Brake Support body bottom and lift front wheel free of ground with a stand. Remove the screw, and disconnect speedometer cable from the gear box. Remove the wheel axle nut and pull out the axle. Then, remove the front wheel. Caution z Do not operate the front brake lever to [...]

14. S t eering / Front Wheel / Front Cushion 14-6 Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: above 0.2 mm. 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 : above 0.2 mm Axial : above 0.2 mm Disassembly (Disc [...]

14. S t eering / Front Wheel / Front Cushion 14-7 Disassembly (Drum Brake Type) Remove the right dust seal. Remove the bearing with the inner type bearing remover. Take out the bearing spacer and then remove the other bearing. Tool: Inner type bearing remover SYM-6204002 Bearing Inspection Turn the inner race of bearing with fingers. The bearing sh[...]

14. S t eering / Front Wheel / Front Cushion 14-8 Installation Disc Brake Apply with some grease inside of the dust seal. Install the dust seal and the front wheel side collar. Apply with some grease on both sides of the speedometer gear oil seal, and then install the seal. Drum Brake Apply with some grease inside of the dust seal, and then install[...]

14. S t eering / Front Wheel / Front Cushion 14-9 Place the front wheel between the front cushions. Drum Brake Align the brake panel slot with the stopper of the cushion. Disc Brake Align the flange part on the speedometer gear with the slot of cushion stopper. Disc Brake Install the front wheel axle from right cushion side. Install the wheel axle [...]

14. S t eering / Front Wheel / Front Cushion 14-10 Front Cushion Removal Remove the front fender, front lower spoiler, front cover, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left cushion. (1 bolt) As for disc brake, remove the cable guide on the right cushion. (1 bolt) Remove the to[...]

14. S t eering / Front Wheel / Front Cushion 14-1 1 With a plastic hammer t a p 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 z Do not damage the frame and the steering column. Installation Install a new top-cone bearing seat onto the top o f steer[...]

14. S t eering / Front Wheel / Front Cushion 14-12 Note: T o this chapter contents[...]

15. Rear Wheel / Rear Cushion 15-1 Mechanism Di agram ··························· 15-1 Operational Pr ecautions ····················· 15-2 Trouble Dia gnosis ······························· 15-2 Exhaust Mu ffler ·····························?[...]

15. Rear Wheel / Rear Cushion 15-2 Operational Precautions General information As for the wheel removal, service, and installatio n procedures, please refers to the service manual of high speed tire. Specification Unit: mm Items S tandard (mm) Limit (mm) Radial - 2.0 Wheel wobbling Axial - 2.0 Thickness of rear brake lining 4.0 2.0 Torque values: R[...]

15. Rear Wheel / Rear Cushion 15-3 Exhaust Muffler Removal Remove the front-end nut of the exhaust muffler. (2 nuts) Remove the bolts. (2 bolts) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal. Caution ● Replace the exhaust muffler gasket if it is broken or deformed. Before tighte[...]

15. Rear Wheel / Rear Cushion 15-4 Rear Cushion Removal Remove the left & right side covers. (2 screws) Remove the luggage box. (4 bolts) Remove the rear carrier. (2 bolts, 2 nuts) Remove the body cover (4 screws) Remove the air cleaner bolts (2 bolts) Remove the lower nut of the rear cushion (1 bolt) Remove the upper nut of the rear cushion (1[...]

16. Electrical Equipment 16-1 Mechanism Di agram ·························· 16-1 Operational Pr ecautions ···················· 16-2 Specificatio n ······································· 16-3 Trouble Dia gnosis ···························[...]

16. Electrical Equipment 16-2 Operational Precautions Charging System y When remove the battery , the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positiv e cable terminal.) y MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water . y[...]

16. Electrical Equipment 16-3 S pecification Charging System S pecification Items HU10U/W HU05U Capacity/type 12V4Ah / YTX5L-BS or GTX5L-BS Charging rate STD: 0.4A/5~10hrs, emergency charging: 4A/0.5hrs Full charged 13.0~13.2V Battery V olt age (20 ℃ ) Under charged 12.3V Capacity 14V / 3A Lighting coil resist ance (20 ℃ ) Between yellow-white:[...]

16. Electrical Equipment 16-4 T rouble Diagnosis Charging System No power supply y Dead battery y Disconnect battery cable y Fuse burned out y Faulty main switch Low voltage y Weak battery y Loose battery connection y Charging system failure y V oltage-current regulator failure Intermittent power supply y Loose charging system cables y Loose batter[...]

16. Electrical Equipment 16-5 Charging System Wire Diagram Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal (as shown on left diagram). Caution ● In the current leakage test, set the[...]

16. Electrical Equipment 16-6 BA TTER Y Removal Remove the battery cover (2 screws) 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 are spread by[...]

16. Electrical Equipment 16-7 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 (-) ter[...]

16. Electrical Equipment 16-8 Charging V oltage/Current Inspection Caution y Before conducting the inspection, b e sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.0 V . If undercharged, the current may change dramatically . y While st arting the engine, the st arter motor draws large amount of cur[...]

16. Electrical Equipment 16-9 V oltage Regulator Inspection Remove the front fender. (4 screws) Disconnect the 4P coupler 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 ground. Battery voltage C[...]

16. Electrical Equipment 16-10 Alternator charging coil Caution ● The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 4P coupler of the alternator. Measure the resistance between the white wire on the alternator and frame ground with a multi-meter. Standard value: 0.2-[...]

16. Electrical Equipment 16-1 1 Ignition System Ignition System Circuit Spark plug IGN. Coil C.D.I Unit G B/Y G B/R B/W B R Battery Main switch L/Y ENG. Start control switch W-White Y-Yellow G-Green R-Red B-Black P-Pink L-Blue Main switch Exciter coil Alternator Pulse Generator T o this chapter contents[...]

16. Electrical Equipment 16-12 CDI. Unit Removal Remove the battery cover. Remove the CDI. Inspection Disconnect the coupler from the CDI unit. Make the following inspection at each terminal of the harness side coupler. S tandard (at 20 ℃ ) ITEM Measure at: HU10U/W HU05U Main Switch Black/white-green Continuity as main switch OFF Main Switch Blac[...]

16. Electrical Equipment 16-13 Ignition coil Removal Remove the luggage box, body cover and floor panel. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix screws for the ignition coil, and remove the coil. Install the coil in reverse order of removal. Caution ● Install primary coil with black/yellow lead connect[...]

16. Electrical Equipment 16-14 Secondary coil Attached the sp ark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7~12k Ω (20°C) Remove the spark plug cap, measure the resistance between plug cap side an d green terminal. Standard value: HU10U/W 3~5K Ω ±10% (20°C) HU05U 4.0K Ω ±15% (20°C) Second[...]

16. Electrical Equipment 16-15 S tart Sy stem St art Circuit Start relay inspection Turn main switch ON. Operate the brake lever. Press start button. If there a click sound, the start circuit is normal. Remove the luggage box assembly. Disconnect the battery negative (-) terminal. Remove the battery positive (+) connection and start motor wires fro[...]

16. Electrical Equipment 16-16 St art Motor Removal Remove the right side cover. (1 screw) Remove the air cleaner mounting bolts. (2 bolts) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the start motor power wire. Remove the start motor mounting bolts and motor. (2 bolts[...]

16. Electrical Equipment 16-17 Remove handle rear cover and meter set (2 bolts & 1 screw). Remove meter mounting screws (3 screws), and then remove meter . Starting Motor Installation Install the meter in reverse order of removal. T o this chapter contents[...]

16. Electrical Equipment 16-18 Light / Bulb Headlight Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight wire coupler. Remove the rubber boot. 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 30W/30W) Caution z Do not[...]

16. Electrical Equipment 16-19 Position light Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight and position light wire coupler. Pull out the bulb and replace it with new one. (12V/10W) Front T urn Winker Light Bulb Replacement Remove the front cover. (3 screws) Turn left and pull out the bulb seat. Pull out the bulb and r[...]

16. Electrical Equipment 16-20 Bulbs Replacement of T ail Light / Brake Light Remove the rear light lens screws. (2 screws) Remove the rear light lens. Push and turn left the bulb, and then remove the bulb. Replace the bulbs of the t ail light, brake light (12V 5W/18W). Installation Install the bulb in reverse order of removal. T o this chapter con[...]

16. Electrical Equipment 16-21 Bulbs Replacement of Rear Winker Light Remove the rear winker light lens screws. (1 screw) Pull out the bulb and replace it with new one. (12V/10W) Bulbs Replacement of Speedometer Remove the handle front cover. (3 screws) Pull out the bulb and replace it with new one. T o this chapter contents[...]

16. Electrical Equipment 16-22 Switch / Horn Main Switch Check Remove front cover. (3 screws) Disconnect main switch leads coupler. Check coupler terminals as following pins for continuity. Pin Location BA T1 BA T2 IG E LOCK ● ● OFF ● ● ON ● ● Wire color Red Black Black/ White Green Replacement Remove main switch cover. (1 screw) Remove[...]

16. Electrical Equipment 16-23 Right Handle Switch Seat open switch Pin Location BA T HO FREE PUSH ● ● Wire color Black Purple Horn switch Pin Location BA T HO FREE ● ● Wire color Black Light green Winker switch Pin Location W R L ● ● FROM R ● ● PUSH OFF N FROM L ● ● ● ● Wire color Gray light blue Orange Winker switch Seat o[...]

16. Electrical Equipment 16-24 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 fender. Connect the light blue wire on the horn to the battery positive (+) terminal, and the gr[...]

16. Electrical Equipment 16-25 Fuel Unit Fuel Unit Remove Fuel T ank Removal (Please refer to chapter 4 for more detailed.) Disconnect the fuel unit sender coupler. Remove the fuel level sender. 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 posi[...]

16. Electrical Equipment 16-26 Note: T o this chapter contents[...]

17. Emission Control System 17-1 Names of Mechanisms in the Emission Control Sy stem ···································· 17-1 Function of Mechanisms in the Emission Control Sy stem ···································· 17-1 Fuel Evaporative Emission Control System (E.E.C.) ··[...]

17. Emission Control System 17-2 Fuel Evaporative Emission Control System (E.E.C.) 1. Construction: y Reduce HC to pollute air. y To absorber fuel vapor and saving fuel consumption 2. Principle of operation ● Vapor generated in fuel tank and fuel system through evaporation is contained in the confined system to prevent it from escaping into the a[...]

17. Emission Control System 17-3 Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: 2) Plug canister ve[...]

17. Emission Control System 17-4 Catalytic Converting Sy stem (CATA) 1. Construction: 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO 2 , H 2 O, N 2 gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the [...]

17. Emission Control System 17-5 Positive Crankcase Ventilation System (P.C.V.) 1. Construction 2. Principle of operation: y Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum. y Drill a hole in the air cleaner and install a vapor separator, so that blow-by from crankcase will flow th[...]

17. Emission Control System 17-6 Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1. Visual inspect the carbon canister and hoses for damage. 2. Leaking check. 3.[...]

17. Emission Control System 17-7 Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Note 1: Test it according to the idling test procedure. Note 2: Adjustment the idle adjustment screw. Set the engine rpm in specified speed, and test CO, HC at idling. And then adjust the air adjustment screw at the same ti[...]

17. Emission Control System 17-8 Note: To this chapter contents[...]

18. Electrical Diagram 18-1 HU05U Electrical Diagram Home page Contents[...]

18. Electrical Diagram 18-2 HU10U/W Electrical Diagram Home page Contents[...]