Sym Mio 50 - 100 (EN)

Mio 50 / 100SERVICE MANUAL

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HOW TO USE THIS MANUAL

CONTENTS

Mechanism Illustrations

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This service manual contains the technical data of each component inspection andrepair for the SANYANG Mio 50 / 100 scooters. The manual is shown withillustrations and focused on “Service Procedures”, “Operation Key Points”, and“Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the scooter, Mio 50 / 100, are different from that ofthe photos, pictures shown in this manual, the actual vehicle shall prevail.Specifications are subject to change without notice.

Service DepartmentSANYANG INDUSTRY CO., LTD.

Homepage Contents

How To Use This Manual

This service manual describes basic information of different system parts andsystem inspection & service for SANYANG Mio 50 / 100 scooters. In addition,please refer to the manual contents in detailed for the model you serviced ininspection and adjustment.

The first chapter covers general information and trouble diagnosis.The second chapter covers service maintenance information and special toolsmanual.The third to the 11th chapters cover engine and driving systems.The 12th chapter is cooling system.The 13th to the 16th chapter is contained the parts set of assembly frame body.The 17th chapter is electrical equipment.The 18th chapter is wiring diagram.Please see index of content for quick having the special parts and systeminformation.

There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and“Mechanism Illustrations” on the CD-R version, and can be access to these itemsby click the mouse.If user wants to look for the content of each chapter, selecting the words of eachchapter on the contents can reach to each chapter. There are two buttons,“Homepage and contents, onto the top line of first page of the each chapter. Thus,if the user needs to check other chapters, he can click the top buttons to back thehomepage or contents. The content of each chapter can be selected too.Therefore, when needs to checking the content inside of the chapter, click thecontent words of the chapter so that can back to the initial section of the content.In addition, there is a “To this chapter contents” button at the second page of eachcontents so that clicking the button can back to the contents of this chapter.

Homepage Contents

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

10-1 ~ 10-8 Alternator 10

11-1 ~ 11-8 Crankshaft / Crankcase 11

12-1 ~ 12-16 Body Cover 12

13-1 ~ 13-14 Brake 13

14-1 ~ 14-12 Steering / Front Wheel / Front Cushion 14

15-1 ~ 15-4 Rear Wheel / Rear Cushion 15

16-1 ~ 16-26 Electrical Equipment 16

17-1 ~ 17-8 Emission Control System 17

18-1 ~ 18-2 Electrical Diagram 18

Homepage


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 orSeat open switch

Front winker

Headlight

Tail light

Main switch

Oil gauge

Fuel tank

Rear winker

Symbols and marks are used in this manual to indicate what and where the special service are needed, incase supplemental information is procedures needed for these symbols and marks, explanations will beadded to the text instead of using the symbols or marks.

WarningMeans that serious injury or even death may result if procedures are notfollowed.

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

Engine oil

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover thedamage that caused by not apply with the limited engine oil.(Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended.

Gear oilKing Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL# 140)

Locking sealantApply sealant; medium strength sealant should be used unless otherwisespecified.

Oil seal Apply with lubricant.。

Renew Replace with a new part before installation.

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

Special tools Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

Components assembly directions each other.

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

If you must run your engine, ensure the place iswell ventilated. Never run your engine in a closedarea. Run your engine in an open area, if youhave to run your engine in a closed area, be sureto use an extractor.

Exhaust contains toxic gas which may cause oneto lose consciousness and even result in death.

Gasoline is a low ignition point and explosivematerial. Work in a well-ventilated place, no flameor spark should be allowed in the work place orwhere gasoline is being stored.

Gasoline is highly flammable, and may explodeunder some conditions, keep it away fromchildren.

Prolonged contact with used engine oil (ortransmission oil) may cause skin cancer althoughit might not be verified.We recommend that you wash your hands withsoap and water right after contacting. Keep theused oil beyond reach of children.

Components of the engine and exhaust systemcan become extremely hot after engine running.They remain very hot even after the engine hasbeen stopped for some time. When performingservice work on these parts, wear insulatedgloves and wait until cooling off.

‧ Battery emits explosive gases; flame is strictlyprohibited. Keeps the place well ventilatedwhen charging the battery.

‧ Battery contains sulfuric acid (electrolyte)which can cause serious burns so be carefuldo not be spray on your eyes or skin. If youget battery acid on your skin, flush it offimmediately with water. If you get battery acidin your eyes, flush it off immediately withwater and then go to hospital to see anophthalmologist.

‧ If you swallow it by mistake, drink a lot ofwater or milk, and take some laxative such ascastor oil or vegetable oil and then go to see adoctor.

‧ Keep electrolyte beyond reach of children.

Do not use an air hose or a dry brush to cleancomponents of the brake system; use a vacuumcleaner or the equivalent to avoid dust flying.

Inhaling brake shoe or pad ash may causedisorders and cancer of the breathing system

Spilling brake fluid on painted, plastic, or rubberparts may cause damage to the parts. Place aclean towel on the above-mentioned parts forprotection when servicing the brake system.Keep the brake fluid beyond reach of children.

Always use with SANYANG genuine parts andrecommended oils. Using non-designed partsfor SANYANG ATV may damage the ATV.

Special tools are designed for remove andinstall of components without damaging theparts being worked on. Using wrong tools mayresult in parts damaged.

When servicing this ATV, use only metric tools.Metric bolts, nuts, and screws are notinterchangeable with the English system, usingwrong tools and fasteners may damage thisvehicle.

Clean the outside of the parts or the coverbefore removing it from the ATV. Otherwise, dirtand deposit accumulated on the part's surfacemay fall into the engine, chassis, or brakesystem to cause damage.

Wash and clean parts with high ignition pointsolvent, and blow dry with compressed air. Payspecial attention to O-rings or oil seals becausemost cleaning agents have an adverse effect onthem.

Never bend or twist a control cable to preventunsmooth control and premature worn out.

Rubber parts may become deteriorated whenold, and prone to be damaged by solvent and oil.Check these parts before installation to makesure that they are in good condition, replace ifnecessary.

When loosening a component which hasdifferent sized fasteners, operate with adiagonal pattern and work from inside out.Loosen the small fasteners first. If the biggerones are loosen first, small fasteners mayreceive too much stress.

Store complex components such astransmission parts in the proper assemble orderand tie them together with a wire for ease ofinstallation later.

Note the reassemble position of the importantcomponents before disassembling them toensure they will be reassembled in correctdimensions (depth, distance or position).

Components not to be reused should bereplaced when disassembled including gasketsmetal seal rings, O-rings, oil seals, snap rings,and split pins.

The length of bolts and screws for assemblies,cover plates or boxes is different from oneanother, be sure they are correctly installed. Incase of confusion, Insert the bolt into the hole tocompare its length with other bolts, if its lengthout side the hole is the same with other bolts, itis a correct bolt. Bolts for the same assemblyshould have the same length.

Tighten assemblies with different dimensionfasteners as follows: Tighten all the fastenerswith fingers, then tighten the big ones withspecial tool first diagonally from inside towardoutside, important components should betightened 2 to 3 times with appropriateincrements to avoid warp unless otherwiseindicated. Bolts and fasteners should be keptclean and dry. Do not apply oil to the threads.

When oil seal is installed, fill the groove withgrease, install the oil seal with the name of themanufacturer facing outside, and check theshaft on which the oil seal is to be installed forsmoothness and for burrs that may damage theoil seal.

Remove residues of the old gasket or sealantbefore reinstallation, grind with a grindstone ifthe contact surface has any damage.

The ends of rubber hoses (for fuel, vacuum, orcoolant) should be pushed as far as they can goto their connections so that there is enoughroom below the enlarged ends for tightening theclamps.

Rubber and plastic boots should be properlyreinstalled to the original correct positions asdesigned.

The tool should be pressed against two (innerand outer) bearing races when removing a ballbearing. Damage may result if the tool ispressed against only one race (either inner raceor outer race). In this case, the bearing shouldbe replaced. To avoid damaging the bearing,use equal force on both races.

Lubricate the rotation face with specifiedlubricant on the lubrication points beforeassembling.

Check if positions and operation for installedparts is in correct and properly.

Make sure service safety each other whenconducting by two persons.

Note that do not let parts fall down.

Before battery removal operation, it has toremove the battery negative (-) cable firstly.Notre tools like open-end wrench do not contactwith body to prevent from circuit short andcreate spark.

After service completed, make sure allconnection points is secured.Battery positive (+) cable should be connectedfirstly.

And the two posts of battery have to be greasedafter connected the cables.

Make sure that the battery post caps arelocated in properly after the battery posts hadbeen serviced.

If fuse burned, it has to find out the cause andsolved it. And then replace with specifiedcapacity fuse.

When separating a connector, it locker has tobe unlocked firstly. Then, conduct the serviceoperation.

Do not pull the wires as removing a connectoror wires. Hold the connector body.

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

Insert the connector completely.If there are two lockers on two connector sides,make sure the lockers are locked in properly.Check if any wire loose.

Check if the connector is covered by the twinconnector boot completely and securedproperly.

Before terminal connection, check if the boot iscrack or the terminal is loose.

Insert the terminal completely.Check if the terminal is covered by the boot.Do not let boot open facing up.

Secure wires and wire harnesses to the framewith respective wire bands at the designatedlocations. Tighten the bands so that only theinsulated surfaces contact the wires or wireharnesses.

Wire band and wire harness have to beclamped secured properly.

Do not squeeze wires against the weld or itsclamp.

Do not let the wire harness contact with rotating,moving or vibrating components as routing theharness.

Keep wire harnesses far away from the hotparts.

Route wire harnesses to avoid sharp edges orcorners and also avoid the projected ends ofbolts and screws.

Route harnesses so that they neither pull tootight nor have excessive slack.

Protect wires or wire harnesses with electricaltape or tube if they contact a sharp edge orcorner. Thoroughly clean the surface wheretape is to be applied.

Secure the rubber boot firmly as applying it onwire harness.

Never use wires or harnesses which insulationhas been broken. Wrap electrical tape aroundthe damaged parts or replace them.

Never clamp or squeeze the wire harness asinstalling other components.

Do not let the wire harness been twisted asinstallation.

Wire harnesses routed along the handlebarshould not be pulled too tight or have excessiveslack, be rubbed against or interfere withadjacent or surrounding parts in all steeringpositions.

Before operating a test instrument, operatorshould read the operation manual of theinstrument. And then, conduct test inaccordance with the instruction.

With sand paper to clean rust on connectorpins/terminals if found. And then conductconnection operation later.

Overall Length Front

Overall Width

SuspensionSystem Rear

Overall Height Front

Dim

ensi

on

Wheel Base

TireSpecifications Rear

Front

RearFrontCurb

Weight

Total

Brake System

Rear

Passengers/Weight Max. Speed

FrontPerformance

Climb Ability °

Rear PrimaryReduction

Wei

ght

TotalWeight

Total SecondaryReduction

Type Clutch

Installation andarrangement °

Reduction

Transmission

Fuel Used Speedometer

Cycle/Cooling Horn

Bore Muffler

Stroke Exhaust Pipe Position andDirection

Cyl

inde

r

Number/Arrangement Lubrication System

Displacement Solid Particulate

Compression Ratio CO 以下

Max. HP

Exha

ust

Con

cent

ratio

n

HC

Max. Torque E.E.C.

Ignition P.C.V.

Eng

ine

Starting System Catalytic reaction controlsystem

Overall Length Front

Overall Width

SuspensionSystem Rear

Overall Height Front

Dim

ensi

on

Wheel Base

TireSpecifications Rear

Front

RearFrontCurb

Weight

Total

Brake System

Rear

Passengers/Weight Max. Speed

FrontPerformance

Climb Ability °

Rear PrimaryReduction

Wei

ght

TotalWeight

Total SecondaryReduction

Type Clutch

Installation andarrangement °

Reduction

Transmission

Fuel Used Speedometer

Cycle/Cooling Horn

Bore Muffler

Stroke Exhaust Pipe Position andDirection

Cyl

inde

r

Number/Arrangement Lubrication System

Displacement Solid Particulate

Compression Ratio CO 以下

Max. HP

Exh

aust

Con

cent

ratio

n

HC

Max. Torque E.E.C.

Ignition P.C.V.

Eng

ine

Starting System Catalytic reaction controlsystem

The torque values listed in above table are for more important tighten torque values. Please see standardvalues for not listed in the table.

5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m6 mm bolt、nut 0.8~1.2kgf-m 6 mm screw、SH nut 0.7~ 1.1kgf-m8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m12 mm bolt、nut 5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m

Cylinder stud bolt 4 8 0.7~1.0 Tighten to crankcaseCylinder head nut 4 8 1.8~2.2 Apply oil to threadCylinder head left bolt 2 6 1.0~1.4Cylinder head side cover bolt 2 6 1.0~1.4Valve adjustment cap 2 30 1.3~1.7Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to threadSpark plug 1 10 1.0~1.4Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.0Cylinder head stud bolt (EX. pipe) 2 6 0.7~1.0Tensioner lifter bolt 2 6 1.0~1.4Tensioner bolt 1 6 0.8~1.2 Socket boltCarburetor insulator bolt 2 6 0.7~1.0Oil pump screw 2 3 0.1~0.3Engine left cover bolt 7 6 1.0~1.5Engine oil draining bolt 1 12 3.5~4.5Engine oil strainer cap 1 30 1.3~1.7Mission draining bolt 1 8 0.8~1.2Mission filling bolt 1 10 1.0~1.4Clutch driving plate nut 1 28 5.0~6.0Clutch outer nut 1 12 5.0~6.0Drive face nut 1 12 5.0~6.0ACG. Flywheel nut 1 12 5.0~6.0Crankcase bolts 7 6 1.5~2.0Mission case bolt 7 8 2.0~2.4One-way clutch tighten bolts 3 6 1.0~1.4 Apply locking sealantOne-way clutch tighten nut 1 22 9.0~10.0 Apply oil to threadExhaust pipe bolts 2 8 3.0~3.6Exhaust pipe connection nuts 2 6 1.0~1.4

Mounting bolt for steeringhandlebar 1 10 4.0~5.0

Mounting nut for steering rod 1 25.4 1.0~2.0Cone seat for steering rod 1 25.4 0.2~0.3Front wheel shaft nut 1 12 5.0~7.0Rear wheel shaft nut 1 16 11.0~13.0Wheel hub/rim mounting nuts 8 8 2.8~3.2Speedometer cable locking screw 1 5 0.15~0.3Front shock absorber mountingbolts 4 8 2.4~3.0

Rear shock absorber upperconnection bolt 1 10 3.5~4.5

Rear shock absorber upperconnection bolt 1 8 2.4~3.0

Brake lever bolts 2 6 0.8~1.2Front brake hose bolts 2 10 3.3~3.7Front brake air-bleeding valve 1 6 0.8~1.0Front brake disc mounting bolts 4 10 4.0~4.5Front brake clipper mounting bolts 2 10 3.1~3.5Drum brake arm bolts (front/rear) 2 6 0.8~1.2Engine suspension bracket bolts 2 10 4.5~5.5 On frame sideEngine connection bolt 1 10 4.5~5.5 On engine sideMain standard nut 1 10 3.5~4.5Foot-starting lever bolt 1 6 1.6~1.8Air cleaner bolts 2 6 1.0~1.4

Loosen carburetor drain boltto check if there is gasoline

inside the carburetor

Fuel supplied tomcarburetor sufficient

No fuel is supplied tocarburetor

Remove spark plug, install itinto spark plug cap, and

perform a spark test againstengine ground.

Perform cylindercompression pressure test.

Check if sparks Weak sparks, no sparkat all

Cylinder compressionpressure normal

Low compressionpressure or no pressure

Re-start by following thestarting procedures

No ignition There are some signs ofignition, nut engine can

not be started

Remove the spark plug againand check it.

Remove carburetor after 30minutes and connect a hoseonto fuel rich circuit. Then

blow the hose with air

Dry spark plug Wet spark plug

Blowing in normal Blowing clogged

1. No fuel in fuel tank2. Check if the pipes, fuel tank to carburetor

and intake vacuum, are clogged.3. Float valve clogged4. Lines in fuel tank evaporation system

clogged5. Malfunction of fuel pump6. Loosen or damaged fuel pump vacuum

hose7. Fuel filter clogged

1. Malfunction of spark plug2. Spark plug foul3. Malfunction of CDI set4. Malfunction of AC generator5. Ignition coil is in open or short circuit6. Ignition coil leads open or short circuit7. Malfunction of main switch

1. Piston ring seized2. Malfunction of cylinder valves3. Worn cylinder and piston ring4. Cylinder gasket leak5. Sand hole in compression parts

1. Malfunction of throttle valve operation2. Air sucked into intake manifold3. Incorrect ignition timing

1. Fuel level in carburetor too high2. Malfunction of throttle valve operation3. Throttle valve opening too wide

1. Malfunction of automatic by- starter

Try gradual acceleration andcheck engine speed

Engine speed can beincreased.

Engine speed can not beincreased.

Check ignition timing(Using ignition lamp)

Check cylinder compressionpressure (using compression

pressure gauge)

Ignition timing correct Incorrect ignition timing

Compression pressurecorrect

No compression pressure

Check if carburetor jet isclogged

No clogged Clogged

Remove spark plug

Check if engine over heat

No foul or discoloration Fouled and discoloration

No knock Knock

1. Air cleaner clogged1. Poor fuel supply2. Lines in fuel tank evaporation system

clogged3. Exhaust pipe clogged4. Fuel level too low in carburetor5. Fuel nozzle clogged in carburetor.

1. Malfunction of CDI2. Malfunction of AC alternator

1. Cylinder & piston ring worn out2. Cylinder gasket leaked3. Sand hole in compression parts4. Valve deterioration5. Seized piston ring

1. Remove foreign

1. Remove dirt2. Incorrect spark plug heat range

1. Piston and cylinder worn out2. Lean mixture3. Poor fuel quality4. Too much carbon deposited in

combustion chamber5. Ignition timing too advanced6. Poor circuit on the cooling system

Normal Engine overheat

Continually drive inacceleration or high speed

1. Too much carbon deposited incombustion chamber

2. Lean mixture3. Poor fuel quality4. Ignition timing too advanced

Check ignition timing(Using ignition lamp)

Check for fuel supplyingsystem in automatic fuel cup

Check if carburetor clogged

1. Incorrect ignition timing (malfunctionof CDI or AC alternator)

1. Rich mixture (loosen the screw)2. Lean mixture (tighten the screw)

1. Poor heat insulation gasket2. Carburetor lock loose3. Poor intake gasket4. Poor carburetor O-ring5. Vacuum hose crack

1. Spark plug fouled2. Malfunction of CDI3. Malfunction of AC generator4. Malfunction of ignition coil5. Open or short circuit in spark plug

leads6. Malfunction of main switch

1. Insufficient fuel in fuel tank2. Fuel filter clogged3. Restricted fuel tank vent

Good Poor

Good spark Poor

No air sucked Air sucked

Good Poor

Normal Abnormal

Air sucked throughcarburetor gasket

Adjust the air screw ofcarburetor

Remove spark plug, installspark plug into spark plugcap and perform spark test

against engine ground

Check ignition timing

1. Malfunction of CDI2. Malfunction of AC alternator

Normal Abnormal

No clogged Clogged 1. Cleaning

1. Clutch ling spring broken2. Clutch outer cover stickled with clutch balance

weights3. Connection parts in clutch and shaft worn out or

burned

Engine can be started butmotorcycle can not be moved.

1. Driving belt worn out or deformation2. Driving disk damaged3. Driving pulley spring broken4. Clutch ling broken5. Driving slide-shaft gear groove broken6. Transmission gear damaged

Engine running and misfire asmotorcycle initial forward moving or

jumping suddenly (rear wheelrotating as engine in running)

Poor initial driving (Poor climbing performance)

1. Driving belt worn out or deformation2. Balance weight roller worn out3. Driving sliding gear shaft worn out4. Driving disk spring deformation5. Driving sliding gear shaft worn out6. Greased in driving belt and sliding gear.

Steering shaft bearing Seat locker

Clutch bearingMain stand shaftSide stand shaftSpeedometer gear/front wheel bearing

Acceleration cable/Front & rear brake lever pivot

1. General Information

1-18

Note:

To this chapter contents

2. Maintenance Information

2-1

Precautions in Operation...................... 2-1Periodical Maintenance Schedule........ 2-2Lubrication System ............................... 2-3Fuel System ........................................... 2-4Air Cleaner ............................................. 2-5Throttle Valve Operation....................... 2-5Crankcase Blow-By Ventilation............ 2-6Valve Clearance Adjustment ................ 2-6Carburetor Idle Speed Adjustment ...... 2-7Ignition System...................................... 2-8Spark Plug.............................................. 2-8

Cylinder Compression Pressure..... 2-9Driving System ................................. 2-9Steering System ............................... 2-10Suspension System ......................... 2-10Front Disk Brake System................. 2-11Drum Brake System ......................... 2-13Wheel / Tire ....................................... 2-14Battery............................................... 2-15Headlight Adjustment ...................... 2-15Nuts、Bolts Tightness..................... 2-15

Special Service Tools Catalogue .... 2-16

Precautions in OperationSpecification

Model HU05U HU10U/WFuel Tank Capacity 4800c.c. 4800 c.c.

capacity 800 c.c. 750 c.c.Engine Oil

change 700 c.c. 600 c.c.capacity 100 c.c. 110 c.c.Transmission

Gear oil change 90 c.c. 100 c.c.Clearance of throttle valve 2~6 mmSpark plug NGK C6HSA Clearance:0.6~0.7 mm〝F〞Mark in idling speed TDC 13º / 1700 rpm TDC 13º / 1700 rpmFull timing advanced TDC 26º / 4000 rpm TDC 22º / 4000 rpmIdling speed 2000±100 rpm 1700±100 rpmCylinder compression pressure 9 kgf/cm² 12 kgf/cm²

IN 0.05±0.02 mmValve clearance

EX 0.1±0.02 mm0.12±0.02 mm

Tire dimension Front / Rear 3.00-10/ 90-90 10 90-90 10 50J

single Front:1.5 kg/cm²Rear:2.25 kg/cm²

Front:2.00 kg/cm²Rear:2.25 kg/cm²Tire pressure

(cold)Two persons Front:1.5 kg/cm²

Rear:2.50 kg/cm²Front:2.00 kg/cm²Rear:2.50 kg/cm²

Battery 12V4Ah (MF battery) YTX5L-BS / GTX5L-BSPlay of drum brake lever 10~20 mm

2

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2-2

Periodical Maintenance Schedule

No itemInitial

300KM

1 Monthevery

1000KM

3 monthevery

3000KM

6 monthevery

6000KM

1 yearevery

12000KM1 ☆Air cleaner I C C R2 ☆2nd air jet leaner I C C R3 ☆Fuel filter I I R4 ☆Oil filter C C C5 ☆Engine oil change R Replacement for every 1000km6 Tire pressure I I7 Battery inspection I I8 Brake & free play check I I9 Steering handle check I I10 Cushion operation check I I11 Every screw tightening check I I12 Gear oil check for leaking I I13 ☆Spark plug check or change I I R14 ☆Gear oil change R Replacement for every 5000km15 Frame lubrication L16 Exhaust pipe I I17 ☆Ignition timing I I18 ☆emission check in Idling A I19 ☆Throttle operation I I20 ☆Engine bolt tightening I I21 ☆CVT driving device(belt﹞ I R22 ☆CVT driving device(roller) C23 Lights/electrical equipment/ mutli-meters I I24 Main/side stands & springs I I25 Fuel lines I I27 Shock absorbers I I28 Cam chain I A29 ☆Valve clearance I C30 ☆Crankcase vapor control System I Replacement for every 2000km31 ☆Crankcase blow-by over-flow pipe I I C32 ☆2nd air jet system I

Code: I ~ Inspection, cleaning, and adjustment R ~ ReplacementC ~ Cleaning (replaced if necessary) L ~ Lubrication

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.Remarks: 1. These marks” ☆” in the schedule are emission control items. According to EPA regulations, these items must be

perform normally periodical maintenance following the use r manual instructions. They are prohibited to be adjusted orrepaired by unauthorized people. Otherwise, SYM is no responsible for the charge.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in theHeavily- polluted environment.

3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after themotorcycle has accumulated a higher mileage.

4. Preventive maintenancea. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn,

overheating occur.b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power

is obvious lower. Than everc. Replace worn out pistons, cylinder head.



2-3

Lubrication SystemEngine Oil Capacity

Caution The vehicle must be parked on a level

ground when checking oil capacity. Run the engine for 2-3 minutes then stop,

wait about 2-3 more minutes allowing engineoil to settle before checking the oil level.

Remove dipstick to check the oil level. If oil level isbelow the lower limit mark, add oil to the specifiedupper limit mark.

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

CautionWarm up the engine. This will make the oilflow out easily.

Add oil to the specified capacity.Oil Viscosity: SAE 10W-30, recommended usingKing-Mate serial oil.Engine oil capacity:Disassembly HU10U/W 750c.c.

HU05U 800c.c.Change HU10U/W 650c.c.

HU05U 700c.c.When checking for oil leak, run the engine at idlespeed for a few minutes, then check oil capacitywith dipstick.

Cleaning the oil strainerDrain oil from engine, remove the strainer cover,spring and strainer.If there is an accumulation on the screen, wash itoff with suitable solvent (recommended usingcompressed air). Check O-ring for damage,replace if necessary.Reinstall strainer, spring, O-ring and strainercover.Torque value: 1.3~1.7kgf-m



2-4

Gear OilInspectionCheck gear oil if leaking.Park the motorcycle with main stand on flat levelplace.Turn off engine and remove the gear oil drainingplug.Place a measurement cup under the draining hole.Check gear oil if enough.ReplacementAt first, remove the gear oil refilling bolt, and thenremove the draining plug. Install the draining plugafter drained oil out.Torque value: 0.8~1.2kgf-m

CautionInspect if washer is in good condition.Replace it with new one if it was deformed ordamaged.

Check if the seal washer is good, and replace it ifdeformed or damaged.Torque value: 1.0~1.4 kgf-mQuantity: HU10U/W 100 c.c.

HU05U 90 c.c.Recommended: King-Mate HYPOID GEAR OIL( #140 ).

Fuel SystemFuel LinesRemove trunk, side cover, central cover, bodyframe cover, and pedal, as well as front glove boxCheck all lines, and replace it when they aredeterioration, damage or leaking

WarningGasoline is a low ignition material so any kindof fire is strictly prohibited as dealing.

Oil draining bolt

Oil refilling bolt



2-5

Air CleanerElementRemove 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 OperationHave a wide open of throttle valve as handle bar inany position and release it to let back original (fullclosed) position.Check handle bar if its operation is smooth.Check throttle valve cable and replace it ifdeteriorated, twisted or damaged.Lubricate the cable if operation is not smoothMeasure handle bar free play in its flange part.Free play：2~6 mm

Adjustment can be done in either ends.Secondary adjustment is conducted from top side.Remove rubber boot, loosen fixing nut, and thenadjust it by turning the adjustment nut.

2~6 mm

Rubber boot

Fixing nut

Adjustment nut



2-6

Primary adjustment is conducted from cablebutton side.Loosen fixing nut, and adjust by turning theadjustment nut.Tighten the fixing nut, and check accelerationoperation condition.

Crankcase Blow-By VentilationPull out the plug from draining hose to cleandeposits

CautionWhen always riding in rainy area or fullthrottle position, maintenance travel must beshorted. The deposits can be seen in thetransparent section of draining hose.

Valve Clearance Adjustment CautionChecks and adjustment must be performedwhen engine is cold (below 35℃).

Remove trunkRemove central coverRemove cylinder head side-cap.Remove the cooling fan cover.With T type wrench, turn crankshaft in clockwisemotion so that mark (T) on the generator flywheelaligns with the mark on the crankshaft, andcamshaft is at TDC position also as same as levelof cylinder head top-end. A single hole oncamshaft sprocket is forward to up. (Piston is atTDC position in the compression stroke.)

CautionThe model that equipped with startingcompression pressure reduction system cannot be rotated in counter-clockwise to preventfrom operating compression pressurereduction function so that valve clearancecan not be measured.

Ignition timing mark

TDC mark

Adjustment nut

Blow-by hose



2-7

Valve clearance inspection and adjustmentCheck & adjust valve clearance with feeler gaugeafter 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±0.02mmLoosen fixing nut and turn the adjustment nut foradjustment.

CautionIt has to make sure that valve rock-arm is beadjusted to standard level when adjusting it,and re-check the valve clearance aftertightened the fixing nut.

Carburetor Idle Speed Adjustment CautionInspection & adjustment for idle speedhave to be performed after all other parts inengine that needed adjustment have beenadjusted.Idle speed check and adjustment have tobe done after engine is being warn up.(around 10 minutes.)

Park the motorcycle with main stand and warn upengine.Connect tachometer (the wire clamp of tachometeris connected to the high voltage coil).Remove the trunk and seat cushion.Turn the throttle valve stopper screw to specifiedidle speed.Specified idle speed:HU10U/W 1700±100 rpmHU05U 2000±100 rpm

Emission adjustment in Idle speedWarm up the engine for around 10 minutes andthen conduct this adjustment.1. Connect the tachometer onto engine.2. Adjust the idle speed adjustment screw and let

engine runs in 1700±100 rpm.3. Insert the exhaust sampling pipe of exhaust

analyzer into the front section of exhaust pipe.Adjust the air adjustment screw so thatemission value in idle speed is within standard.

4. Slightly accelerate the throttle valve andrelease it immediately. Repeat this for 2~3times.

5. Read engine RPM and value on the exhaustanalyzer. Repeat step 2 to step 4 proceduresuntil measured value within standard.

Emission standard: CO: below 3.0%HC: below 2000 P.P.M.

Throttle valve stopper screw

High voltage coil cable

Mixture adjustment screw



2-8

Ignition SystemIgnition Timing

CautionC.D.I ignition system is set by manufacturerso it can not be adjustedIgnition timing check procedure is forchecking whether CDI function is in normal ornot.

Remove right side cover.Remove ignition timing hole cap located on thecooling fan cap. Or remove the cooling fan cover.Connect tachometer and ignition lamp.Start engineSet engine idle speed in1700 rpm, and if the markaligns with the “F”, then it means that ignitiontiming is correct.Increase engine speed to 4000 rpm to checkignition timing advance. If the detent aligns withadvance mark “II”, then it means ignition timingadvance is in functional. If not, check CDI set,pulse flywheel, and pulse generator. Replacethese components if malfunction of these parts arefound.

Spark PlugAppointed spark plug：CR6HSA (NGK)Remove luggage box.Remove center coverRemove spark plug capClean dirt around the spark plug hole.Remove spark plugMeasure spark plug gapSpark plug gap：0.6~0.7 mmCarefully bend ground electrode of the plug toadjust the gap if necessaryHold spark plug washer and install the spark plugby screwing it.Tighten the plug by turning 1/2 turn more with plugsocket after installed.Torque value: 1.0~1.2kgf-mConnect spark plug cap.

“F” Mark

0.6~0.7mm

Side electrode

Center electrode

Plug cap



2-9

Cylinder Compression PressureWarn up engine and then turn off the engine.Remove the trunk and the central cover.Remove spark plug cap and spark plugInstall compression gaugeFull open the throttle valve, and rotate the engineby means of stepping the foot-starting lever

Caution Rotate the engine until the reading in the

gauge no more increasing. Usually, the highest pressure reading will be

obtained in 4~7 seconds.Compression pressure:HU10U/W 12±2 Kg/cm²HU05U 9±2 Kg/cm²。Check following items if the pressure is too low:˙ Incorrect valve clearance˙ Valve leaking˙ Cylinder head leaking, piston, piston ring and

cylinder worn outIf the pressure is too high, it means carbondeposits in combustion chamber or piston head.

Driving SystemDRIVING BELTRemove left side coverRemove mounting bolt located under air cleaner.Remove 8 bolts of the engine left side cover andthe coverCheck if the belt is crack or worn out.Replace the belt if necessary or in accord with theperiodical maintenance schedule to replace it.Width limit: 16.5mm

Clutch padStart the motorcycle and gradually increasethrottle valve openness to check clutch padoperation.If the motorcycle moves with shaking, then checkits clutch pad for wearing.Replace it if necessary.

Gear teethWidth

Cylinderpressuregauge

Clutch pad

Spark plug cap



2-10

Steering System CautionCheck all wires and cables if they areinterfered with the rotation of steering handlebar.

Lift the front wheel out of ground.Turn handle from right to left alternative and checkif turning is smoothly.If handle turning is uneven and bending, or thehandle can be operated in vertical direction, thenadjust the handle top bearing.

Suspension System CautionDo not ride the motorcycle with poor shockabsorber.Looseness, wear or damage shock absorberwill make poor stability and drive ability.

Front shock absorberHold front brake lever and press down the frontshock absorber for several times to check itsoperation.Hold front brake lever and push forward the frontshock absorber for several times to check itslocking status.Check if it is scratched or leaking.Replace damaged and non-repairablecomponents.Tighten all nuts and bolts.

Rear Shock absorberPress down the rear shock absorber for severaltimes to check its operation.Check if it is scratched or leaking.Replace damaged and non-repairablecomponents.Park the motorcycle with main standard.Start engine and let the rear wheel rotate afterincreased engine rpm.Check engine for any parts loose or shaking.Also check the engine suspension bushing forwear out. Replace the bushing if worn out.Tighten all nuts and bolts.



2-11

Front Disk Brake SystemBrake System HoseMake sure the brake hoses for corrosion orleaking oil.

Brake FluidCheck brake fluid level in the brake fluid reservoir.If the level is lower than the LOWER limit, addbrake fluid to UPPER limit. Also check brakesystem for leaking if low brake level found.

CautionIn order to maintain brake fluid in thereservoir in horizontal position, do not removethe cap until handle bar stop.Do not operate the brake lever after the caphad been removed. Otherwise, the brakefluid will spread out if operated the lever.Do not mix non-compatible brake fluidtogether.

Filling Out Brake FluidTighten the drain valve, and add brake fluidOperate the brake lever so that brake fluidcontents inside the brake system hoses.

AIR BLEED OPERATIONConnect a transparent hose to draining valve.Hold the brake lever and open air bleeding valve.Perform this operation alternative until there is noair inside the brake system hoses.

CautionBefore closing the air bleed valve, do notrelease the brake lever.

Transparentdraining hose

BubblesDraining valve

Lower limit

Master cylinder cap

Upper limit

Brake fluid



2-12

ADDED BRAKE FLUIDAdd brake fluid to UPPER limit lever.Recommended brake fluid: DOT3 or DOT4 WELLRUN brake fluid

CautionNever mix or use dirty brake fluid to preventfrom damage brake system or reducing brakeperformance.

BRAKE LINING WEARThe indent mark on brake lining is the wearlimitation.Replace the brake lining if the wear limit markclosed to the edge of brake disc.

CautionIt is not necessary to remove brake hosewhen replacing the brake lining.

Remove the brake clipper bolt, and take out theclipper.

CautionDo not operate the brake lever after theclipper removed to avoid clipping the brakelining.

Pry out the brake lining with a flat driver if lining beclipped.

Remove brake lining bolt.Take out the lining

CautionIn order to maintain brake power balance, thebrake lining must be replaced with one set.

Brake lining wear limit

Brake clipperBrake disc

Brakeclipperbolts

Pin bolts

Brake lining

Master cylinder cap

Upper limit

Brake fluid



2-13

Drum Brake SystemFront Brake Free Play: (Drum brake)Measure free play of rear brake level at the end ofthe lever.Free play: 10~20mm

Adjust the free play by turning the front brakeadjustment nut if necessary.

Rear Brake Free Play: (Drum Brake Type)Measure the free [lay of the front brake lever at theend of the lever.Free play: 10~20 mmAdjust the free play by turning the front brakeadjustment nut if necessary.

Brake Confirmation CautionAfter brake adjustment, it has to check thebrake operation to make sure the front andrear wheel can be braked.Pull the brake lever, and make sure that thewear limit marks of brake ling on the bothfront & rear brake arm are closer and touch tothe △’ marks. If so, replace the brake lingwith new one.

10� 20mm

Adjustment nut

Decreasingfree playIncreasingfree play

“△”mark

“△”mark

Adjustment nut

Decreasingfree play

Increasingfree play



2-14

BRAKE LAMP SWITCHThe brake light switch lit up brake light as brakeapplied.Make sure that electrical starter can be operatedonly under brake applying.

Wheel / TireCheck if the tire pressure of front & rear wheel iswithin standard.

CautionTire pressure check should be done as coldtire.

Appointed tire pressure (HU05U)

Tire size Front tire Rear tire

Single 1.5 2.25Tire pressureas cold tire(Kg/cm²) Two persons 1.5 2.50

Appointed tire pressure (HU10U/W)

Tire size Front tire Rear tire

Single 1.75 2.25Tire pressureas cold tire(Kg/cm²) Two persons 1.75 2.50

Appointed Tire:HU05U Front/Rear wheel: 3.00-10/ 90-90 10HU10U/W Front & Rear wheel: 90/90 50JCheck if tire surface is ticked with nails, stones orother materials.Check if tire surface or wall for crack or damaged,and replace it if necessary.The tire tread depth can be checked by visualinspection or depth gauge.‧ Replace the tire if tire tread dent or unusual

wearing out.‧ The tire should be replaced if the wear limit

mark “△” is in visible.Measure tire thread depth from tire centralsurface.Replace the tire if the depth is not come withfollowing specification:

Front tire：1.5 mmRear tire：2.0 mm

CautionThe wear limit marks “△” are located aroundthe tire wall even for inspection.

Rear brake lightswitch

“△”mark

Brake light switch-front disc brake

Wear limit indictor



2-15

BatteryBattery RemovalOpen 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 “+” cable3. Remove the battery.

If there is some rust on battery posts, clean it withsteel brush.Install the battery in the reverse procedures ofremoval.

CautionIf there is rust on the posts very serious,spray some hot water on the posts. Then,clean it with steel brush so that can removerust for more easily.Apply some grease on the posts after rustremoved to prevent from rust again.

Headlight AdjustmentTurn on main switchTurn the headlight adjustment screw to adjustheadlight beam height.

CautionTo adjust the headlight beam follows relatedregulations.Improper headlight beam adjustment willmake in coming driver dazzled or insufficientlighting.

Nuts、Bolts TightnessPerform periodical maintenance in accord with thePeriodical Maintenance ScheduleCheck if all bolts and nuts on the frame aretightened securely.Check all fixing pins, snap rings, hose (pipe)clamps, and wire holders for security.

Headlight adjustment screw



2-16

Special Service Tools Catalogue

Name Puller/presser for crankcasebushing 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 adjustmentwrench Name Valve clearance adjuster

Parts no. SYM-1471100 Parts no. SYM-9001200 Parts no. SYM-9001210

Name Oil seal tapping installer Name Valve spring compressor Name Valve spring compressor


Name Bearing installer Name Bearing installer Name Bearing installer ψ17mm


(ø28mm) (ø20mm)

(20*32*6)(25*37*6) (27*42*7)

(6301) (6203/6004UZ)(6204)



2-17

Name Bearing remover (inner type) Name Bearing remover (outer type) Name clutch spring compressor


Name Clutch mounting nut wrench Name Universal fixer Name Alternator flywheel remover

Parts no. SYM-9020200 Parts no. SYM-2210100 Parts no. SYM-3110A01

Name Cylinder head/oil filter capwrench Name Valve rocker arm puller

Parts no. SYM-ALL23461 Parts no. SYM-1445100-A1A



2-18

NOTE:


3. Lubrication System

3-1

Mechanism Illustrations ····················· 3-1Operational Precautions····················· 3-2Trouble Diagnosis ······························· 3-2Engine OIL ··········································· 3-3

Cleaning Engine Oil Strainer···············3-4Oil Pump ··············································· 3-5Gear Oil ················································· 3-8


3

Rock Arm

Cam Shaft

Scoop lubrication

Forcedly lubrication

Forcedly lubrication

Inner passage

Connecting rod

Oil pumpOil strainer

Crankshaft

Home page Contents


3-2

Operational PrecautionsGeneral Information

This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.

SpecificationsEngine oil quantityDisassembly: HU10U/W 750c.c.

HU05U 800c.c.Replacement: HU10U/W 650c.c.

HU05U 700c.c.Oil viscosity: SAE 10W-30 or equivalent(Recommended King-Mate serial oils)

Gear OilDisassembly: HU10U/W 110c.c.

HU05U 100c.c.Replacement: HU10U/W 100c.c.

HU05U 90c.c.Oil viscosity of gear oil: SAE 85W-140(Recommended King-Mate gear oil seriesSYM HYPOID GEAR OIL)

Oil viscosity

Unit: mm

Items Standard(mm) Limit(mm)

Inner rotor clearance - 0.12Clearance between outer rotor and body - 0.12Oil pumpClearance between rotor side and body 0.05~0.10 0.20

Torque valueOil draining plug 3.5~4.5kgf-mOil screen cap 1.3~1.7kgf-mGear oil draining bolt 0.8~1.2kgf-mGear oil filling bolt 1.0~1.4kgf-mOil pump connection screw 0.1~0.3kgf-m

Special Service ToolsStrainer cap wrench SYM-ALL12361One way clutch socket SYM-9020100Universal fixer SYM-2210100

Trouble DiagnosisLow engine oil levelOil leakingValve guide or seat worn outPiston ring worn out

Low Oil PressureLow engine oil levelClogged in oil strainer, circuits or pipesOil pump damage

Dirty oilNo oil change in periodicalCylinder head gasket damagePiston ring worn out



3-3

Engine OILTurn off engine, and park the motorcycle in flatsurface with main stand.Check oil level with oil dipstickDo not screw the dipstick into engine as checking.If oil level is nearly low level, fill out recommendedoil to upper level.

Oil Replacement CautionDrain oil as engine warmed up so that makesure oil can be drained smoothly andcompletely.

Place an oil pan under the motorcycle, andremove oil strainer cap.Make sure if the aluminum washer of the drainingbolt is damaged. If so, replace it with new one.Install the drain bolt and tighten it.Torque value: 3.5~4.5kgf-m

Engine oil replacement quantity:HU10U/W 650c.c.HU05U 700c.c.

Draining bolt



3-4

Cleaning Engine Oil StrainerRemove the oil strainer cap.Remove oil strainer and springClean oil strainer (recommended usingcompressed air to clean dirty foreign.)Check if the strainer and O-ring of the oil strainerare broken. Replace with new one if found.Install the oil strainer and spring.Install the oil strainer cap and tighten it.Special Service Tools:Strainer cap wrench SYM-ALL12361Torque value：1.3~1.7kgf-mFill out oil to the oil filler (Oil viscosity SAE10W-30)(Recommended King-Mate serial oils)

After oil replaced, insert ignition key into the re-setbottom under instrument panel so that the oilindicator is changed from red to green and set oilreplacement mileage to zero.Install dipstick, start the engine for running severalminutes.Turn off engine, and check oil level again if withinstandard level after 3-5 minutes.Check if engine oil leaks.

Re-set bottom



3-5

Oil PumpOil Pump RemovalRemove the alternator (refer to chapter 10).Remove the engine right cover.Remove the one-way clutch and starting gear (1nut)Special Service Tools:One way clutch socket SYM-9020100Universal fixer SYM-2210100

Make sure that the pump axle can be rotatedfreely.Remove the oil pump cover (2 screws).

Remove the oil pump.

Oil Pump DisassemblyRemove the oil pump screw (1 screw) Take outthe oil pump cover, inner & outer rotors. Checkthese parts after cleaned.

2 screws

Universal fixer

One way clutch socket



3-6

Oil Pump InspectionCheck the clearance between oil pump body andouter rotorLimit：below 0.12mm

Check clearance between inner and outer rotors.Limit：below 0.12mm

Check clearance between rotor side face andpump bodyLimit：below 2.0 mm

Oil Pump Re-assemblyInstall inner and outer rotors into the pump bodyAlign the indent on driving shaft with that of innerrotor. Install the driving shaftInstall the oil pump cover and fixing pin properlyand then tighten screw. (1 screw)



3-7

Install driving gear and clamp.

CautionMake sure if the oil pump can be rotatedsmoothly.

Oil Pump InstallationInstall the oil pump (2 screws).

Install oil pump drive gear.

Install the one-way clutch and starting gear (1nut)Install the engine right cover.Install the alternator (refer to chapter 10).Special Service Tools:One way clutch socket SYM-9020100Universal fixer SYM-2210100

Oil pump drive gear

2 screws

Universal fixer

One way clutch socket



3-8

Gear OilOil Level InspectionPark the motorcycle on flat surface with mainstandTurn off engine and remove both engine oil fillingbolt and oil draining plug.

Remove gear oil filling hole bolt and place ameasurement cup under the draining plug.Remove the oil draining plug and the pour gear oilinto the measurement cup. Measure the gear oilquantity if within standard value. Add specifiedgear oil if the oil level too low.Standard quantity:HU10U/W 110c.c. / replacement: 100c.c.HU05U 100c.c. / replacement: 90c.c.

Gear Oil ReplacementRemove the gear oil filling bolt and its drainingplug and then drain oil completely.Install the draining plug and tighten it (Make sure ifthe plug washer is damaged. If so, replace it withnew one.)Torque Value：0.8~1.2kgf-mAdd new gear oil from the gear oil filling hole andthen install the gear oil filling hole bolt after addedoil. And then, tighten the bolt.Torque Value：1.0~1.4kgf-m

※Recommended to apply with SYM HYPOIDGEAR OIL (SAE 85W-140)Start engine and run it for 2~3 minutes.Turn of f engine and check if oil leaking.

Refill plug of gear oil

Draining plug


4. Fuel System

4-1

Mechanism Illustration ......................4-1Operational Precautions....................4-2Trouble Diagnosis ..............................4-3Carburetor...........................................4-4

Idle Speed Adjustment ...................... 4-8Fuel Tank ............................................ 4-9Air Cleaner.......................................... 4-11

Mechanism IllustrationFuel tank capFuel vapor separator

Fuel unit

Fuel tank

Vacuum hose

Vacuum type fuel coke

Carburetor

Fuel hose

Fuel drain screw

Mixture adjustment screw

Throttle valve stopper screw

4

Home page Contents

4. Fuel System

4-2


WarningGasoline is a low ignition point and explosive materials, so always work in a well-ventilated place andstrictly prohibit flame when working with gasoline.

CautionDo not bend or twist throttle valve cable. Damaged cable will make unstable drive ability.When disassembling fuel system parts, pay attention to O-ring position, replace with new one asre-assemblyThere is a drain screw in the float chamber for draining residual gasoline.Do not disassemble automatic by-starter and air cut-off valves arbitrarily.

SpecificationSpecification

ItemHU10U/W HU05U

Venturi diameter 20 mm 16.6 mm

I.D. number 049B 001

Fuel level 16.0mm 17.75mm

Main injector # 95 # 88

Idle injector # 38 # 35

Idle speed 1700±100 rpm 2000±100 rpm

Throttle handle free play 2~6 mm 2~6 mm

Fuel quantity adjustment screw 2 5/8±3/4 turns 2±1/2 turns

Torque valueFuel valve tightening nut: 1.5~2.0Kgf-m

Special service toolsVacuum/air pressure pump

General service toolsFuel level gauge


4. Fuel System

4-3

Trouble DiagnosisPoor engine start No fuel in fuel tank Clogged fuel tube Too much fuel in cylinder No spark from spark plug (malfunction of ignition

system) Clogged air cleaner Malfunction of automatic by-starter Malfunction of throttle valve operation

Stall after started Malfunction of automatic by-starter Incorrect ignition timing Malfunction of carburetor Dirty engine oil Air existing in intake system Incorrect idle speed

Rough idle Malfunction of ignition system Incorrect idle speed Malfunction of carburetor Dirty fuel

Intermittently misfire as acceleration Malfunction of ignition system

Late ignition timing Malfunction of ignition system Malfunction of carburetor

Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system

Mixture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogged fuel tank cap vent Clogged fuel filter Obstructed fuel pipe Clogged air vent hose Air existing in intake system

Mixture too rich Clogged air injector Malfunction of float valve Fuel level too high in float chamber Malfunction of automatic by-starter Dirty air cleaner


4. Fuel System

4-4

CarburetorCarburetor RemovalRemove the luggage box and seat.Loosen the adjustment nut and fixing nut of throttlevalve cable, and release the cable fromcarburetor.Remove fuel pipe, vacuum hose.Remove air cut-off valve hoseDisconnect automatic by-starter connectors.Release the clamp strip of air cleaner.Release the clamp strip of carburetor isolator.Take the carburetor out.

Vacuum Chamber RemovalLoosen drain screw, and drain out residual fuel infloat chamber.Remove screws (2 screws) of vacuum chambercover and the cover.

Remove compress spring and vacuum piston.

Remove fuel needle seat, spring, and injectorneedle.Check if the vacuum piston for wear out, crack orother damage.Check if the diaphragm for damage or crack.

CautionDo not damage vacuum diaphragm.

InstallationInstall in reverse order of removal procedures.

2 Screws

Adjustment nut

Heat-isolator clampAir cleaner clamp


4. Fuel System

4-5

Air Cut-off ValveRemovalRemoval the throttle cable seat (screws x 2)

Remove the screws (screw x 2) of the air cut-offvalve and its cover.

Remove the spring and vacuum diaphragm.Check if the diaphragm for deterioration or crack.

InstallationInstall the valve as reverse order of removal.

CautionDo not damage the vacuum diaphragm or inopposite installation direction.

2 screws


4. Fuel System

4-6

AUTOMATIC BY-STARTER

InspectionTurn off engine and waiting for over 10 minutes forcooling.Check resistance across the two terminals of theautomatic by-starter.Resistance value: Max. 10Ω (Measured afterengine stopped for more than 10 minutes)Replace the automatic by-starter with a new one ifresistance value exceeds standard.

Remove the carburetor, allow it to cool off for 30minutes.Connect a pressure tester form air pump.Connect fuel rich circuit.Pump compressed air to the circuit.Replace the automatic by-starter if the circuitclogged.

Connect battery posts (12V) to starter’sconnectors. After 5 minutes, test the rich circuitwith compressed air.If air flow through the circuit, then replace theby-starter.

RemovalRemove fixing plate screw, and then remove theplate and automatic by-starter from carburetor.

Valve inspectionCheck if automatic by-starter and valve needle fordamage or wear out.

InstallationInstall automatic by-starter to the carburetor body.Install fixing plate to the upper groove of automaticby-starter, and install its flat surface to carburetor.Install screw and tighten it.

CautionAlign the round point of the starter with thescrew hole of air intake side.


4. Fuel System

4-7

FLOAT CHAMBERDisassemblyRemove 4 mounting screws and then the floatchamber cover.Remove the float pin and float valve.

CheckingCheck float needle valve and valve seat for dropdifference damage, wear out, dirty or clogged.

CautionIn case of worn out or dirt, the float valve andvalve seat will not tightly close causing fuellevel to increase and as a result, fuelflooding. A worn out or dirty float valve mustbe replaced with a new a new one.

Remove main jet, fuel needle jet holder, nozzle,idle jet, air-fuel mixture adjustment screw.

CautionTake care not to damage jets and adjustscrew.Before removing adjustment screw, turn it allthe way down and note the number of turns.Do not turn adjustment screw forcefully toavoid damaging valve seat face.

Clean jets with cleaning fluid.Then use compressed air to blow dirt off.Blow carburetor body passages with compressedair.

FloatFloat pin

Float valve

Drain screw

Main jetIdle jet

Nozzle

Fuel needleholder

Air-fuel mixtureadjustment screw

Main jetNozzle Fuel needle holder

Idle jet


4. Fuel System

4-8

AssemblyInstall main jet, fuel needle jet holder, nozzle, idlejet and air-fuel mixture adjustment screw.

CautionSet the adjustment screw in according tonumber of turns noted before it was removed.

Install the float valve, float, and float pin.

Checking Fuel Level

CautionCheck again to ensure float valve, float forproper installation.To ensure correct measurement, position thefloat meter in such a way so that floatchamber face is vertical to the main jet.

Fuel level：16.0 mm

Installation of carburetorInstall carburetor in the reverse order of removal.Following adjustments must be made afterinstallation. Throttle valve cable clearance adjustment. Idle speed adjustment.

Idle Speed Adjustment CautionAir amount adjust screw was set at factory,so no adjustment is needed. Note the numberof turns it takes to screw it all the way in forease of installation.Never screw in forcedly to avoid damagingthe screw seat.The main stand must be used to support themotorcycle to perform the adjustments.

Use a tachometer when adjusting engine RPM.Screw in adjustment screw gently, then back up tostandard turns.After warm up engine, then adjust the stopperscrew of throttle valve to standard RPM.Connect the sampling hose of exhaust analyzer toexhaust front end. Press test key on the analyzer.Adjust the fuel amount adjustment screw and readCO reading on the analyzerCO standard value：1.3~2.0 %Accelerate in gradual increments, and make sureboth rpm and CO value are in standard valuesafter engine running in stable. If rpm and COvalue fluctuated, repeat the procedures describedabove

Air-fuel mixture

Float level gauge

Adjustment nut of throttle cable

The stopper screw of throttle valve

Air-fuel mixture adjustment screw


4. Fuel System

4-9

Fuel TankFuel meter gauge removalRemove 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 forthese components above.)Remove fuel unit coupler.

Remove the rear bracket (4 bolts & 3 screws)

Turn fuel unit setting plate to the left, and thenremove fuel unit.Special Service Tools:Universal fixer SYM-2210100

Check if the float and washer is damaged.Replace it with new ones if damaged.

CautionDo not bend the float arm of fuel meteringgauge.Do not fill out too much fuel to fuel tankbefore operation.

Fuel unit coupler

Each side 2 bolts

3 screws


4. Fuel System

4-10

Fuel tank removalRemove 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 forthese components above.)Remove fuel unit coupler.Remove the rear bracket (4 bolts & 3 screws)

Remove the fuel tank mounting bolts (4 bolts).Remove the all lines from the fuel tank.

Remove fuel tank cap open cable (2 screws).

Remove the fuel tank.

CautionReplace the fuel tank immediately if it isbroken or leakage.

Fuel Tank InstallationInstall the tank in the reverse order of removal.

Vacuum hose / Fuel hose

Fuel vapor separator

4 bolts

2 screws

Each side 2 bolts

3 screws


4. Fuel System

4-11

Air CleanerRemoval the element of the air cleanerRemove the air cleaner cover (7 screws).

Remove air cleaner element.

InstallationInstall the air cleaner in the reverse order ofremoval.

7 screws


4. Fuel System

4-12

Removal of Air CleanerOpen 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.

InstallationInstall the air cleaner in the reverse order ofremoval.

2 bolts


5. Removal & Installation of Engine

5-1

Mechanism Illustrations ····················· 5-1Operational Precautions····················· 5-2Engine Removal ·································· 5-3

Removal of Engine Bush·····················5-6Engine Hanger······································5-7Installation of Engine···························5-8


53.5~4.5kgf-m

2.4~3.0kgf-m

4.5~5.5kgf-m

4.5~5.5kgf-m

4.5~5.5kgf-m

Home page Contents


5-2

Operational PrecautionsGeneral Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame.

1. Carburetor2. Driving disk, driving belt, clutch, and transporting disk3. Final reduction gear mechanism

SpecificationSpecification

ItemMIO 50 MIO 100

Replacement 700 c.c. 650 c.c.Engine Oil Capacity

Disassemble 800 c.c. 750 c.c.

Replacement 90 c.c. 100 c.c.Gear Oil Capacity

Disassemble 100 c.c. 110 c.c.

Torque ValuesEngine hanger bolt (frame side) 4.5~5.5kgf-mEngine hanger nut (engine side) 4.5~5.5kgf-mBolt of rear cushion upper connection 3.5~4.5kgf-mBolt of rear cushion lower connection 2.4~3.0kgf-m



5-3

Engine RemovalOpen 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 oneach side.).

Remove the power connector of auto by-starter.Remove the generator power wire and pulsegenerator connector.Remove the starter motor wire.

Remove the spark plug cap.

Connectors of the by-starterand the pulse generator

Spark plug cap

Each side 1 screw



5-4

Remove the fuel line, vacuum hose, and throttlevalve cable from the carburetor.Loose the strap screw of the air cleaner guide, andthen the air cleaner guide.

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

Remove the air cleaner connection bolts (2 bolts).

Remove the rear brake cable nut and cable.

2 Nuts

2 Bolts

2 Bolts

Rear brake cable nut



5-5

Remove the rear cushion lower bolt (1 bolt).

Remove the engine hanger nuts and bolts (engineside), and then remove the engine.

With a bracket to support the engine to preventfrom it damage by falling down as removing theengine.Remove the rear wheel with air tools after theengine removed.

1 bolt

螺栓×1



5-6

Removal of Engine BushIf engine hanger frame and the cushion rubber ofrear cushion bush damaged. Then, with the bushremover / presser, ø28mm & ø20mm, to press thebush out, and replace it with new one.

Engine hanger bush: ø 28mmRear cushion bush: ø 20mm

Pressing outPlace the detent section of the bush removertoward the bush, and drive both the pressing ringand bolt in to press the bush out.Special Service Tools:Crankcase bush remover/presser SYM-1120310Crankcase bush remover/presser SYM-1120320

Pressing InPlace the flat section of the remover toward thebush, and then drive the bush, pressing ring, andbolt in to install the bush.



5-7

Engine HangerRemovalRemove the right side bolt of engine hanger. (1bolt on each side)

Remove the engine hanger.

Check if the engine hanger bush and cushionrubber for damage. If so, replace with new ones.

InstallationTighten the bolts and nuts of engine hanger.

Engine hanger nut:Torque Value: 4.5~5.5kgf-m

1 bolt on each side



5-8

Installation of EngineInstall the engine according to the reversing orderof removal.

CautionNote both feet and hands safety forsqueezing as engine installation.Do not bent or squeeze each wires or hose.Route all cables and wires in accordance withthe routine layout.

Engine hanger nut:Torque Value: 4.5~5.5kgf-m

Rear cushion bolt:Torque Value: upper：3.5~4.5kgf-m

under：2.4~3.0kgf-m

Rear wheel axle nut:Torque Value: 11.0~13.0kgf-m


6. Cylinder Head / Valve

6-1

Mechanism Illustrations ····················· 6-1Operational Precautions····················· 6-2Troubleshooting·································· 6-3Cylinder Head Removal ······················ 6-4Cylinder Head Disassembly (HU05U) 6-6Cylinder Head Disassembly (HU10U/W)······························································ 6-7Valve Disassembly······························ 6-9

Cylinder Head Inspection·················· 6-10Valve Seat Inspection and Service ··· 6-12Cylinder Head Reassembly··············· 6-14Cylinder Head Installation················· 6-15Valve Clearance Adjustment············· 6-16


6

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1.0~1.4kgf-m

0.7~1.1kgf-m

1.0~1.4kgf-m

1.8~2.2kgf-m

1.0~1.4kgf-m


6-2


Specification Unit: mm

Torque Value

Special service tools



6-3

Troubleshooting

Rough Idle

Low compression pressure1. Valve

2. Cylinder head

3. Piston

High compression pressure

Noise

White smoke



6-4

Cylinder Head Removal 5 Screws

Tensioner

2 bolts

Blow-by system hose

1 bolt



6-5

Caution

4 nuts

Timing mark

2 bolts

1 bolt



6-6

Cylinder Head Disassembly (HU05U)

Special Service Tool:

Special Service Tool:Valve rocker arm shaft puller:SYM-1445100-A1A

Camshaft stopper



6-7

Cylinder Head Disassembly(HU10U/W)


Special Service Tool:Valve rocker arm shaft puller:SYM-1445100-A1A

固定擋板

Intake rockerarm shaft

Exhaust rockerarm shaft



6-8

Camshaft Inspection

Service Limit:(Refer to page 2)






6-9

Valve Disassembly


Caution

Caution

Valve stem



6-10

Cylinder Head InspectionCylinder Head

Service limit: 0.05mm

Valve spring free length


Valve stem

Service Limit: (Refer to page 2)

Valve guide Caution



Service Limit: (Refer to page 2)

5.0mm valve guide reamer



6-11

Caution

Caution

Valve stem replacement℃

Caution

Special Service Tool:Valve guide driver: 5.0mm

Caution

℃

Special Service Tool:Valve guide driver: 5.0mm

Caution

Special Service Tool: Valve reamer: 5.0mm

Valve guidedriver 5.0mm

13 mm(0.15in)

Valve guide driver 5.0mm

Valve guidedriver 5.0mm



6-12

Valve Seat Inspection and Service

Caution

Caution

Valve seat inspection

Valve seat widthService limit: 1.6mm

Valve seat grinding

Caution

Valve seat width

45°

Roughness

32°

Old valve seat width



6-13

Caution

Caution


60°

45°

1.0mm

Contact surface too high

32°


Contact surface too low

60°




6-14

Cylinder Head Reassembly

Caution

Special Service Tool:Valve remover / installer SYM-1471110/20.

Caution

Caution

Valve stemoil seal

Valvespring

Valve springretainer

Valve split lock

Valve



6-15

Caution

Cylinder Head Installation

Torque value: 1.8~2.2kgf-m


Caution

Chain plate

Lock pins

Gasket

4 Nuts

Timing mark

2 bolts

1 bolt



6-16

Valve Clearance Adjustment

Standard Value: (Refer to page 2)Special Service Tool:Valve clearance adjustment wrenchSYM-9001200 or valve clearance adjusterSYM-9001210.

Auto-chain tensioner

2 bolts

Blow-by system hose

1 bolt



6-17

5 Screws



6-18

Notes:


7. Cylinder / Piston

7-1

Mechanism Illustrations ····················· 7-1Operational Precautions····················· 7-2Trouble Diagnosis ······························· 7-2Cylinder Removal ································ 7-3

Piston Removal ····································7-5Piston Ring Installation ·······················7-7Piston Installation ································7-8Cylinder Installation·····························7-8


70.8~1.2kgf-m

Home page Contents


7-2

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

Specification Unit: mmModel HU10U/W HU05U

Item Standard Limit Standard 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 － 0.050Cylinder

Cylindrical roundness － 0.050 － 0.050

top ring 0.015~0.050 0.090 0.015~0.050 0.090Clearancebetween pistonrings 2nd ring 0.015~0.050 0.090 0.015~0.050 0.090

top ring 0.100~0.250 0.500 0.100~0.250 0.500

2nd ring 0.100~0.250 0.500 0.100~0.250 0.500Ring-end gap

oil ring 0.300~0.900 － 0.2~0.7 －

OD of piston 49.970~49.990 49.900 36.985~37.005 36.900

Piston OD measurementposition

Lower-end up 9mmof piston skirt －

Lower-end up 9mmof piston skirt －

Clearance between pistonand cylinder 0.005~0.015 0.100 0.005~0.015 0.100

Piston/Piston ring

ID of piston pin boss 13.002~13.008 13.040 10.002~10.008 10.040

OD of piston pin 12.994~13.000 12.960 10.000~10.006 9.966

Clearance between piston and piston pin 0.002~0.014 0.020 0.002~0.014 0.020

ID of connecting rod small-end 13.016~13.034 13.060 10.016~10.034 10.060

Trouble DiagnosisLow or Unstable Compression PressureCylinder or piston ring worn out

High compression PressureCarbon deposit onto piston and combustionchamber

Knock or NoiseCylinder or piston ring worn outCarbon deposits on cylinder head top-sidePiston pin hole and piston pin wear out

Smoking in Exhaust PipePiston or piston ring worn outPiston ring installation improperlyCylinder or piston damage

Engine OverheatCarbon deposits on cylinder head top side



7-3

Cylinder RemovalRemove 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 witha piece of cloth.Clean up all residues or foreign materials from thetwo matching surfaces of cylinder and crankcase.

CautionTo soap the residues into solvent so that theresidues can be removed more easily.

Cam chain plate



7-4

InspectionCheck if the inner diameter of cylinder is worn outor damaged.In the 3 positions (top, center and bottom) ofcylinder, measure the X and Y direction valuesrespective in the cylinder.Service limit: (Refer to page 2)Calculate both the real roundness (the differencebetween X and Y motion values) and thecylindrical roundness (the difference in the top,center or bottom positions of X or Y motion values.)Then, determinate by the max. valueService limit:Real roundness: correct or replace as over0.05mmCylindrical roundness: correct or replace asover 0.05mm

Check Cylinder Wrap age.Service limit: 0.05mm

Top

Center

Bottom

Exhaust side Intake side



7-5

Piston RemovalPlug crankcase opening with a cleaning cloth toprevent from piston pin snap ring or other partsfalling into crankcase when disassembling.Hold another snap ring with pliers.Push out the piston pin from the side that notremoved the snap ring.

Remove piston rings.

CautionPay attention to remove piston rings becausethey are fragile.

Disassemble the piston rings.Check if the piston rings are damaged or itsgrooves are worn.Cleaning carbon deposit onto the piston ringgrooves.

Install the piston rings and then measureclearance 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 piston rings and place themrespective into cylinder below 20mm of cylindertop. Measure each piston ring gaps.

CautionPush the piston rings into cylinder with pistontop-end in parallel motion.

Service Limit: Top ring: replace if over 0.5mm2nd ring: replace if over 0.5mm

Push in

Feeler gauge

Piston ring

Piston

Piston rings



7-6

Measure the outer diameter of piston pin.Service Limit: (Refer to page 2)

Measure the inner diameter of connecting rodsmall 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 itshole.Service Limit: (Refer to page 2)

Measure piston outer diameter.

CautionThe measurement position is 10 mm distancefrom piston bottom side, and 90° to pistonpin.

Service Limit: (Refer to page 2)Compare measured value with service limit tocalculate the clearance between piston andcylinder.



7-7

Piston Ring InstallationClean up piston top, ring groove, and piston shirt.Install the piston ring onto piston carefully.Place the openings of piston ring as diagram shown below.

CautionDo not damage piston and piston rings as installation.All marks on the piston rings must be forwarded to up side.Make sure that all piston rings can be rotated freely after installed.

120°

Top groove

2nd groove

Oil groove

Top ring

2nd ring

Oil ringSpacer

Side ring

Side ring

Over 20mm



7-8

Piston InstallationInstall piston and piston pin, and place the INmarks on the piston top side forward to intakevalve.Install new piston pin snap ring.

CautionDo not let the opening of piston pin snap ringalign with the opening piston ring.Place a piece of cloth between piston skirtsection and crankcase in order to preventsnap ring from falling into crankcase asoperation.

Cylinder InstallationClean up all residues and foreign materials on thematching surface of crankcase. Pay attention tonot let these residues and foreign materials fallinto crankcase.

CautionTo soap the residues into solvent so that theresidues can be removed more easily.

Coat engine oil to inside of cylinder, piston andpiston rings.Care to be taken when installing piston intocylinder. Press piston rings in one by one asinstallation.

CautionDo not push piston into cylinder forcefullybecause this will cause the piston and thepiston rings to be damaged.

Install the cam chain plate, the cylinder gasket andlock pins.Install cylinder head (refer to Chapter 6)Install the cam chain auto-tensioner. (2 bolts)


8. V-Belt Drive System / Kick Starter

8-1

Mechanism Illustrations ····················8-1Operational Precautions····················8-2Trouble Diagnosis ······························8-2Left Crankcase Cover ························8-3

Kick Starter········································· 8-3Drive Belt ············································ 8-5Movable Drive Face ··························· 8-7Clutch / Driven Pulley ························ 8-10


8

5.0~6.0kgf-m

5.0~6.0kgf-m

5.0~6.0kgf-m

1.0~1.5kgf-m

Home page Contents


8-2

Operational PrecautionsGeneral Information Movable drive face, clutch, and driven pulley can be serviced on the motorcycle.

Drive belt and driven pulley surface must be free of grease.Specification Unit: mm

HU10U/W HU05UItem Standard value Limit Standard value Limit

Drive belt width 17.800~18.200 17.200 17.800~18.200 17.200ID of movable drive face 23.989~24.052 24.060 23.964~23.985 24.015OD of drive face boss 23.960~23.974 23.940 23.910~23.926 23.890OD of roller 15.920~16.080 15.400 15.920~16.080 15.400ID of clutch outer 112.000~122.200 112.500 107.000~107.200 107.500Thickness of clutch lining 2.000 1.500 2.00 1.500Free length of driven pulley spring ── 156.000 ── 87.900OD of driven pulley 33.965~33.985 33.940 33.965~33.985 33.940ID of sliding driven pulley 34.000~34.025 34.060 34.000~34.025 34.060

Torque value:Movable drive face nut: 5.0~6.0kgf-mClutch outer nut: 5.0~6.0kgf-mDriven pulley nut: 5.0~6.0kgf-m

Special Service ToolsClutch spring compressor SYM-2301000Bearing puller (inner type) SYM-6204002Clutch mounting nut wrench SYM-9020200Universal fixture SYM-2210100

Trouble DiagnosisEngine can be started but motorcycle cannot be moved1. Worn drive Belt2. Worn ramp plate3. Worn or damaged clutch lining4. Broken driven pulley

Shudder or misfire when driving1. Broken clutch lining2. Worn clutch lining

Insufficient horsepower or poor highspeed performance1. Worn drive belt2. Insufficient spring capacity of driven pulley3. Worn roller4. Driven pulley operation un-smoothly



8-3

Left Crankcase CoverLeft crankcase cover removalRemove body coverRemove air cleaner (2 bolts)

Remove left crankcase cover (8 bolts).

Installation of the left crankcase coverInstall the left crankcase cover (8 bolts)Tighten the air cleaner (2 bolts)

Kick StarterDisassemblyRemove left crankcase cover.Remove kick starter arm (1 bolt).

Remove snap ring and thrust washer from leftcrankcase cover.

2 bolts

8 bolts

Snap ring

1 bolt



8-4

Remove the inner plate inside of left crankcasecover. (6 screws)

Install kick starter arm, rotate the lever slightly andthen remove driven gear and washer. Removethe kick starter arm, kick starter spindle, spindlebush and return spring as well as socket.

InspectionCheck if kick starter spindle, kick spindle bush,kick driven gear for wear or damage.Replace it with new one if necessary.Check the return spring and friction spring forspring force or damaged.Replace it with one if poor parts found.

ReassemblyInstall socket, return spring and starter shaft asdiagram shown.Install thrust washer and snap ring onto startershaft.Install kick starter lever temporary.Rotate the lever and then align driving gear withwidth-tooth on the starter shaft.Install the friction of driving gear onto convex partof the cover.Install the left crankcase cover.

6 screws

Kick starter spindle Driven gear

Return spring



8-5

Drive BeltRemovalRemove left crankcase coverHold drive face with universal fixture, and removenut and drive face.Special Service Tool:Universal fixture SYM-2210100

Hold the clutch outer with the universal fixture, andthe remove the nut and the clutch outer.

CautionUsing special service tools for tightening orloosening the nut. Fixed rear wheel or rearbrake only will damage reduction gearsystem.

Special Service Tool:Universal fixture SYM-2210100

Push the drive belt into belt groove as diagramshown so that the belt can be loosened, and thenremove.Drive belt and clutch at same time.

InspectionCheck the drive belt for crack or wear. Replace itif necessary.Measure the width of drive belt as diagram shown.Replace the belt if exceeds the service limit.Service Limit: 17.2mm

CautionUsing the genuine parts for replacement.The surfaces of drive belt or pulley must befree of grease.Clean up all grease or dirt before installation.

Universal fixture

ToothWidth

Nut

Drive belt

Universal fixture



8-6

InstallationPull out the sliding driven face and then insert thedrive belt into the driven pulley.

CautionPull out sliding driven face and then insert thedrive belt into the driven pulley so that thedrive belt set can be installed onto pulleymore easily.

Install the clutch set with drive belt onto the driveshaft.The other end of belt install onto the movable driveface.Install the clutch outer.

Install the clutch with universal fixture, and thentighten nut to specified torque value.Torque value: 5.0~6.0kgf-mSpecial Service Tool:Universal fixture SYM-2210100

CautionWhen install the drive belt, if there is a arrowmark, then the arrow mark must point torotation motion. If not, the letters on the beltmust be forwarded to assembly direction.

Slidingdriven face

Universal fixer

Nut

Clutch outer



8-7

Movable Drive FaceRemovalRemove left crankcase cover.Hold drive face with universal fixture, and thenremove 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 faceboss from crankshaft.

Remove ramp plate.

Remove weight rollers from movable drive face.Movable drive face

Weight roller

Movable drive faceDrive face boss

Ramp plate

Crankshaft

Universal fixture



8-8

InspectionThe operation of movable drive face is means ofthe weight roller to pressing on it with centrifugeforce. And then the speed is changed by the rampplate rotation.Thus, if weight rollers are wear out or damage, thecentrifuge force will be effected.Check if rollers are wear out or damage. Replaceit if necessary.Measure each rollers’ outer diameter. Replace it ifexceed the service limit.Service limit: 15.4mm

Check the drive face boss if damaged or wear out.Replace it if necessary.Measure the drive face boss outer diameter.Replace it if exceed the service limitService limit:HU01U/W 23.94mmHU05U 23.89mmMeasure the drive face boss’s inner diameter.Replace it if exceed the service limit.Service limit:HU01U/W 24.060mmHU05U 24.015mm

Assembly / InstallationInstall the weight roller.

CautionThe both ends of weight roller are different.In order to prolong the roller life span andprevent abnormal wearing out, install theclosed end onto the movable drive face in themovement of CCW.

Install the ramp plate slide pieces (3 pieces) ontothe ramp plate.Install the ramp plate.

Weight roller

Slide pieces

Ramp plate

Movable drive face

Drive face boss

Closed end

Weight roller



8-9

Apply with some grease to inside of drive faceboss hole, and install drive face boss.

CautionThe drive face surface has to be free ofgrease. Clean it with cleaning solvent.

Install movable drive face assembly ontocrankshaft.

Movable Drive Face InstallationPress drive belt into movable drive face, and thenpress down the up & down sides of the drive beltto separate it away from the drive face boss.

CautionTo press down the up & down sides of thedrive belt can avoid to pressing anddamaging the belt when installing the driveface, and also can make sure that the driveface can be tighten.

Install drive face, washer and nut. CautionMake sure that two sides of pulley surfaceshave to be free of grease. Clean it withcleaning solvent.

Holds drives face with universal fixture.Tighten nut to specified torque.Torque value: 5.0~6.0kgf-mInstall left crankcase cover.

Drive face surface

Drive belt

Press down

Movable drive faceDrive face boss

Crankshaft

Universal fixture



8-10

Clutch / Driven PulleyDisassemblyRemove drive belt and clutch / driven pulley.Install clutch spring compressor onto the pulleyassembly, and operate the compressor to let nutbe installed more easily.

CautionDo not press the compressor too much.

Hold the clutch spring compressor onto bench vise,and then remove mounting nut with special nutwrench.Release the clutch spring compressor and removeclutch and spring from driven pulley.Special Service Tool:Clutch spring compressor SYM-2301000Clutch mounting nut wrench SYM-9020200

Remove oil seal collar from driven pulley.

Remove guide pin, guide pin roller, and slidingdriven face, and then remove O-ring & oil sealseat from sliding pulley.

InspectionClutch outerMeasure the inner diameter of clutch outer frictionface. Replace the clutch outer if exceed servicelimit.Service limit:HU01U/W 112.5mmHU05U 107.5mm

Special nut wrench

Guide pin roller

Guide pinOil sealSliding driven face

Oil seal collar

Clutch spring compressor

O-ring

Clutch outer

Innerdiameter



8-11

Clutch liningMeasure each clutch lining thickness. Replace itif exceeds service limit.Service limit: 2.0mm

Driven pulley springMeasure the length of driven pulley spring.Replace it if exceeds service limitService limit:HU01U/W 156.0mmHU05U 87.9mm

Driven pulleyCheck following items:

If both surfaces are damage or wear.If guide pin groove is damage or wear.Replace damaged or worn components.

Measure the outer diameter of driven surface andthe inner diameter of driven pulley.Replace it if exceeds service limit.Service limit: Outer diameter 33.94mm

Inner diameter 34.06mm

Driven Pulley Bearing InspectionCheck if the inner bearing oil seal is damage.Replace it if necessary.Check if needle bearing is damage or too bigclearance. Replace it if necessary.Rotate the inside of inner bearing with fingers tocheck if the bearing rotation is in smooth and silent.Also check if bearing outer is installed properly.Replace it if necessary.

Guide pin groove

Driven face

Free length

Sliding driven face

Clutch

Clutch lining

Needle bearing

Ball bearing



8-12

Clutch Block ReplacementRemove snap and washer, and the remove clutchblock and spring from driving plate.Check if spring is damage or insufficient elasticity.

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

Apply with grease onto setting pins. But, theclutch block should not be greased. If so, replaceit.Install new clutch block onto setting pin and thenpush to specified location.

CautionGrease or lubricant will damage the clutchblock and affect the block’s connectioncapacity.

Install the spring snap into groove with pliers.

Clutch block

Shock absorption rubber

Snap ring

Spring

Spring

Drive plate

Clutch block

Setting pin

Shock absorptionrubber



8-13

Install snap ring and mounting plate onto settingpin.

Replacement of Driven Pulley BearingRemove inner bearing.

CautionIf the inner bearing equipped with oil seal onone side in the driven pulley, then remove theoil seal firstly.If the pulley equipped with ball bearing, it hasto remove snap ring and then the bearing.

Remove snap ring and then push bearing forwardto other side of inner bearing.Place new bearing onto proper position and itssealing end should be forwarded to outside.Apply with specified grease.Recommended to use the KING MATE G-3.Install the snap ring and hold the bearing.

Install a new inner bearing. CautionIts sealing end should be forwarded tooutside as bearing installation.Install needle bearing with hydraulic presser.Install ball bearing by means of hydraulicpresser.

Align oil seal lip with bearing, and then install thenew oil seal (if necessary).

Sealing endOuter bearing

Snap ring

Snap ring

Outer bearing

Inner needlebearing

Oil seal

Specified grease

Snapring

Inner bearing

Sealing end



8-14

Installation of Clutch / Driven PulleyAssemblyInstall new oil seal and O-ring onto sliding drivenface. Apply with specified grease to lubricate theinside of sliding driven face.

Install sliding driven face onto driven face.Install guide pin and guide pin roller.

Install oil seal collar.

Install driven pulley spring and clutch into clutchspring compressor, and press down the assemblyby turning manual lever until mounting nut that canbe installed.Hold the compressor by bench vise and tightenthe mounting nut to specified torque with specialnut wrench.Remove the clutch spring compressor.Torque value: 5.0~6.0kg-mInstall clutch/driven pulley and driving belt ontodriving shaft.

Oil seal

O-ring

Specifiedgrease

Guide pin roller

Guide pinOil sealSliding driven face

O-ring

Special nut wrench

Clutch spring compressor

Oil seal collar


9. Final Drive Mechanism

9-1

Mechanism Illustrations ····················· 9-1Operational Precautions····················· 9-2Trouble Diagnosis ······························· 9-2Disassembly of Final Drive Mechanism······························································ 9-3

Inspection of Final Drive Mechanism···9-4Bearing Replacement ····························9-5Re-assembly of Final Driven Mechanism·································································9-7

Mechanism Illustrations HU10U/W

HU05U

9

ContentsHome page


9-2

Operational PrecautionsSpecificationApplication gear oil: GEAR OIL SAE 85W-140Recommended oil: KING MATE serial gear oilsOil quantity:HU10U/W 110 c.c. (100 c.c. when replacing)HU05U 100 c.c. (90 c.c. when replacing)

Torque valueGear box cover 2.0~2.4kgf-mGear oil drain plug 1.0~1.4kgf-mGear oil filling bolt 0.8~1.2kgf-m

Special service toolsInner type bearing puller SYM-6204002Outer type bearing puller SYM-6204001Gear box oil seal installer SYM-9120200Gear box bearing installer SYM-9125500Bearing (6204) installer SYM-9110400Bearing (6301) installer SYM-9610000Bearing (6203/6004UZ) installer SYM-9620000Drive shaft puller SYM-13000Puller set SYM-13000-01

Trouble DiagnosisEngine can be started but motorcycle can not be moved. Damaged drive gear. Burnt out drive gear. Broken drive belt.

Noise Worn or burnt gear. Worn gear.

Gear oil leaks Excessive gear oil. Worn or damage oil seal.



9-3

Disassembly of Final DriveMechanismHU05URemove the rear wheel (refer to chapter 15).Remove the clutch.Drain gear oil out from gear box.Remove gear box cover and then remove thecover and the drive shaft. (7 screws)

Remove counter shaft and gear.Remove final driven gear and shaft.Remove drive shaft.Remove gasket and dowel pins.

HU10U/WRemove the rear wheel (refer to chapter 15).Remove the clutch.Drain gear oil out from gear box.Remove gear box cover and then remove thecover and the drive shaft. (7 screws)

Remove counter shaft and gear.Remove final driven gear and shaft.Remove gasket and dowel pins.

7 screws

HU05U

Final drivenshaft / Gear

Counter shaft/ gear

Dowel pin

Drive shaft

Final driven shaft

Counter shaft / gear

Dowel pin

Gasket

Final driven Gear



9-4

Inspection of Final Drive MechanismCheck if the countershaft and the gear are wornout or damage.

Check if the final driven shaft and gear are wearout 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 andsilent, and also check if bearing outer ring ismounted on gear box & cover tightly.If bearing rotation is uneven, noising, or loosebearing mounted, then replace it.Check oil seal for wear or damage, and replace itif necessary.

CautionDo not remove the drive shaft from the coveror case top side.If remove the drive shaft from the gear box,then its bearing has to be replaced.

Check drive shaft and gear for wear or damage.



9-5

Bearing Replacement Caution

Never install used bearings. Once bearingremoved, it has to be replaced with new one.

Remove drive shaft bearing from left crankcaseusing following tools;Special Service Tool:Inner type bearing puller SYM-6204002

Install new drive shaft bearing into left crankcase.Special Service Tool:Bearing (6204) installer SYM-9110400Bearing (6301) installer SYM-9610000Bearing (6203/6004UZ) installer (Ø17) SYM-9620000

Press out the drive shaft from the gear box cover.Remove oil seal from the gear box cover.Remove the drive shaft bearing from the gear boxcover with the inner type bearing puller.

CautionUsing the bearing protector as pressing outthe driving shaft from the gear box cover.

Special Service Tool: Shaft protector

If the driving shaft is pulled out with its bearing,then remove the bearing with bearing puller andbearing protector.Special Service Tool:Multi-functional bearing puller or Outer typebearing puller SYM-6204001

Shaft protector

Outer type bearing puller

Shaft protector



9-6

Install a new drive shaft bearing onto gear boxcover.Then, install the drive shaft.Special Service Tool:Bearing (6204) installer SYM-9110400Install the drive shaft.Special Service Tool:Drive shaft puller SYM-1130010Puller set SYM-1130000-L

Install new oil seal with the special service tool.Special Service Tool:Oil seal (20x32x6) installer SYM-9120200



9-7

Re-assembly of Final DrivenMechanismHU05UApply with grease onto the oil seal lip of finaldriven 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 thebolts).Torque value: 2.0~2.4kgf-m

HU10U/WApply with grease onto the oil seal lip of finaldriven 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 thebolts).Torque value: 2.0~2.4kgf-m

Final drivenshaft / Gear

Counter shaft/ gear

Dowel pin

Drive shaft

7 screws

Final driven shaft

Counter shaft / gear

Dowel pin

Gasket

Final driven Gear



9-8

Install the driven pulley / clutch outer / belt /movable drive face / drive face.

Install the left crankshaft cover and kick starter.Install the rear wheel.Add gear oil.

Recommended usage: SYM HYPOID GEAR※OIL (SAE 85W-140)


10. Alternator / Starting Clutch

10-1

Mechanism Illustrations ····················· 10-1Operational Precautions····················· 10-2Alternator Removal ····························· 10-3Right Crankcase Cover Removal ······· 10-4

Starting Clutch ·····································10-5Right Crankcase Cover Installation···· 10-7Alternator Coil Set Installation············10-8Flywheel Installation····························10-8


10

9.0~10.0kgf-m

1.0~1.4kgf-m

1.5~2.0kgf-m

1.3~1.7kgf-m

5.0~6.0kgf-m

0.1~0.3kgf-m

ContentsHome page


10-2

Operational PrecautionsGeneral information Refer to chapter 5: Engine removal and installation Refer to chapter 1 : The troubleshooting and inspection of alternator Refer to chapter 16: The service procedures and precaution items of starter motor

Specification Unit: mmItem Service Limit

ID of starting driven gear 32.060

OD of clutch cover 27.940

Torque value:Flywheel nut 5.0~6.0kgf-mPipe bolt 8mm 1.5~2.0kgf-mOil screen cover 1.3~1.7kgf-mStarting clutch hex mounting nut 9.0~10.0kgf-m with oil on the threadStarting clutch hex socket bolt 1.0~1.4kgf-m with adhesive

Special service toolsFlywheel puller SYM-3110A01Universal fixture SYM-2210100Anti-loosen mounting nut socket of starter gear SYM-A12590201



10-3

Alternator RemovalDrain 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 Fixture SYM-2210100

Universal fixture

Cooling fan

2 Nuts

2 Bolts

2 Bolts

2 Bolts



10-4

Remove the flywheel with the flywheel puller.Special service tools:Flywheel puller SYM-3110000

CautionInstall a shaft protector on the right end ofcrankshaft to avoid damaging the crankshaftbefore installing the flywheel puller.

Remove the connectors of the alternator and pulsegenerator.

Remove the 6 bolts for the pulse generator, thealternator coil and cable guide. Then, remove thealternator assembly.

CautionDo not damage the alternator coil.

Right Crankcase Cover RemovalRemove the right crankcase cover (6 bolts)Remove dowel pin and gasket.Remove the gasket or foreign materials on theconnection surfaces of both the cover andcrankcase.

CautionDo not damage the connection surfaces.

9 bolts

Flywheel puller

Connectors



10-5

Starting ClutchStarting Clutch RemovalHold the starting driven gear with the universalfixture.Remove the 22mm anti-loosen mounting nut andgasket.Special service tools:Nut puller of starter gear SYM-9020100Universal fixture SYM-2210100

CautionThe mounting nut is left-turn thread.

Remove the starting driven gear.

Remove starting clutch, starting idle-gear, andshaft.

Starting Clutch InspectionInstall the starting clutch onto the starting drivengear.Hold the starting clutch and turn the starting drivengear.The starting driven gear should can be turned inthe motion of C.W. and can not be turned inC.C.W.

Mounting nut

Mounting nut socket



10-6

Check the starting driven gear for wear ordamage.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 ordamage.Measure the ID of the starting idle gear.Service Limit:ID: 10.05 mm or less

Measure the OD of the starting idle gear.Service Limit:OD: 9.94 mm or less

DisassemblyRemove the hex blots (3 bolts) inside the startingclutch.Separate the clutch body and the clutch cover.Remove the rollers, plugs, and springs on the oneway clutch.Check each rollers and plugs for wear or damage.Install rollers, plugs and springs.

Measure the OD of the starting clutch cover.Service Limit:OD: 27.94 mm or less

Spring

Roller

Plug

Clutch body

Clutch cover



10-7

InstallationInstall the components in the reverse proceduresof removal.

CautionAdd adhesive onto the thread of hex socketbolt.


Starting clutch InstallationInstall idle gear shaft and idle gear.Install starting clutch and the starting clutch.

Hold the starting driven gear with the universalfixture.Tighten the 22mm anti-loosen mounting nut andgasket.

CautionAdd engine oil onto the thread of mountingnut.

Special service tools:Anti-loosen mounting nut socket of startergear SYM-A12590201Universal fixture SYM-2210100Torque value: 9.0~10.0kgf-m

Right Crankcase Cover InstallationInstall dowel pin and new gasket on thecrankcase.Replace the right crankshaft oil seal of thecrankcase and apply some oil onto the oil seal lip.Install right crankcase cover onto the rightcrankcase (9 bolts)Torque value: 1.5~2.0kgf-m

Spring

Roller

Plug

Clutch body

Clutch cover

9 bolts



10-8

Alternator Coil Set InstallationInstall the coil set onto right crankcase cover. (2bolts)Install pulse generator (2 bolts)Tighten the cable guide (2 bolts)Torque: 1.5~2.0kgf-mTie the wire harness hose onto the indent ofcrankcase

CautionMake sure that the wire harness is placedunder the pulse generator.

Install both the AC generator and the pulsegenerator connectors.

Flywheel InstallationMake sure that there is no magnetic powder. Ifso, clean up it.Align insert on crankshaft with the flywheel groove,and then install the flywheelHold the flywheel with flywheel holder, and tightenits nut.Torque value: 5.0~6.0kgf-mSpecial service tool:Universal fixture SYM-2210100

Install the cooling fan (4 bolts).Install the cooling fan shroud (2 screws, 2 bolts)Install the exhaust pipe (2 bolts, 2 nuts)Install the right side cover. (1 screw)Add some engine oil according the specifiedquantity.

Connectors


11. Crankcase / Crankshaft

11-1

Mechanism Illustrations ····················11-1Operational Precautions····················11-2Trouble Diagnosis ······························11-2

Disassembly of Crankcase··················11-3Crankshaft Inspection ·························11-5Assembly of Crankcase·······················11-6


11

0.8~1.2kgf-m

0.8~1.2kgf-m

3.5~4.5kgf-m

1.5~2.0kgf-m

1.0~1.4kgf-m

0.7~1.0kgf-m

ContentsHome page


11-2

Operational PrecautionsGeneral information This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can

be serviced.

Complete following operations before disassembling crankcase.Engine Chapter 5Cylinder head Chapter 6Cylinder and piston Chapter 7V-belt Drive pulley Chapter 8Alternator/Foot Starting Clutch Chapter 10Start motor Chapter 16

If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have to replaced.

Specification Unit: mmItem Standard Limit

Left, right clearance of the big end of the connecting rod 0.100~0.300 0.550

Right angle clearance of the big end of the connecting rod 0.000~0.008 0.050

Run-out ─ 0.100

Torque valueBolts for crankcase 1.5 ~ 2.0kgf-mBolts for cylinder/cylinder head 0.7 ~ 1.0kgf-mEngine oil draining plug 3.5 ~ 4.5kgf-mBolts for cam chain tensioner 0.8 ~ 1.2kgf-m

Special Service ToolsOil seal (25X37X6) pressing tools SYM-9121600

Trouble DiagnosisEngine noise Loose crankshaft bearing Loose crankshaft pin bearing Wear piston pin or piston pin hole



11-3

Disassembly of CrankcaseRemove the cam chain tensioner (hex socket bolt)from the left side of crankcase.Remove the connection bolts (2 bolts) of theright-side crankcase.

Remove the right-side crankcase.

Slightly shake the crankshaft and then remove itand the chain.

Remove the gasket and the 2 dowel pins.Scrape gasket residues off the crankcase contactsurface.

CautionDo not damage contact surface of thecrankcase.Soap the gasket residues into solvent and theresidues will be removed easily.

螺栓×2



11-4

Remove the oil seal of left-side crankcase.



11-5

Crankshaft InspectionMeasure left and right clearance of connecting rodbig end.Service limit: Replace when it is more than0.55 mm.

Measure the radical clearance of the big end atthe vertical directions.Service limit: Replace when it is more than0.05 mm.

Place the crankshaft onto a V-block and measurerun-out of the crankshaft with dial gauge.Service limit: Replace when it is more than 0.10mm.

Bearing InspectionRotate the bearing with fingers and make sure thebearing can be rotated smoothly and quietly.Check if the inner ring is connected onto thecrankshaft tightly.Replace crankshaft as a set when noise orlooseness is detected.

60 mm 90 mm

Clearance

Clearance



11-6

Assembly of CrankcaseInstall cam chain into the chain hole of the leftcrankcase, and then split out the cam chain.

CautionDo not damage the cam chain as installingthe crankshaft.

Install crankshaft into the left crankcase and theninstall two and new crankcase gasket.

Install the right crankcase and tighten thecrankcase bolts (2 bolts).Torque value: 1.5~2.0kgf-m

Install the cam chain tensioner.Install a new O-ring onto the mounting bolt of thechain tensioner.Apply some oil on the O-ring and tighten the bolt.Torque value: 0.8~1.2kgf-m

CautionThe O-ring must be installed into the bolt’sgroove.

Socket-hex head bolt

Dowel pins

2 bolts



11-7

Apply with some grease onto the oil seal lip andthen install it onto the left crankcase.

Press-fit the oil seal to specified position with theoil seal installer (25x37x6)Special service tools:Oil seal installer (25x37x6) SYM-9120200

Oil seal installer



11-8

Notes:


12. Body Cover

12-1

Mechanism Illustrations ····················12-1Maintenance Information···················12-2Front Cover·········································12-3Handle Cover ······································12-4Front Fender ·······································12-6Front under Spoiler ····························12-7Front Inner Cover ·······························12-8Luggage Box·······································12-9Rear Carrier·········································12-10

Battery Cover ····································· 12-10Side Cover ·········································· 12-11Rear Center Cover ····························· 12-11Center Cover ······································ 12-12Body Cover········································· 12-13Floor Panel ········································· 12-14Rear Fender ········································ 12-15Rear Mudguard··································· 12-16


12

Luggage box

Rear fender

Seat

Handle rear cover

Handle front cover

Front inner cover

Front cover

Front fender

Floor panel

Center cover Left body cover

Right body cover

Right side cover

Left side cover

Rear center cover

Under cover

Front under spoiler

Battery cover

Rear mudguard

Front winker garnish

Frame No. cover

Fuel tank cap cover

Meter cover

Home page Contents

12. Body Cover

12-2

Maintenance InformationBody covers disassemble sequence:

Be careful not to damage various covers in disassembly or re-assembly operation.Never injure hooks molded on the body covers in disassembly or re-assembly operation.Align the buckles on the guards with slot on the covers.Make sure that each hook is properly installed during the assembly.Never compact forcefully or hammer the guard and the covers during assembly.

Right/left side cover

Front cover

Front under spoiler

Luggage box & seat

Rear carrierUnder cover

Front inner cover

Handle front cover

Right/left body cover

Handle rear cover

Floor panel

Rear fender

Center cover

Front fender

Battery cover

Rear mudguard


12. Body Cover

12-3

Front CoverRemovalRemove the mounting screws (2 screws) of frontcover from the front inner cover side.

Remove the front mounting screw (1 screw) of thefront cover.Push the front cover upward and then pull itforward so that the lower mounting groove of frontcover can be separated from the front underspoiler.

Disconnect the headlight and position light wirecoupler.

Remove the front cover.

InstallationInstall according to the reverse procedure ofremoval.

1 screw

Light coupler

2 Screws


12. Body Cover

12-4

Handle CoverRemovalLoosen the handle front cover mounting screws (2screws) of the handle from the handle rear cover.Push the two side screws, then hooks of handletwo sides so that the handle covers can beseparated.

Remove two side screws.

Remove handle front cover.

Push

2 Screws


12. Body Cover

12-5

Remove the speedometer cable.

Disconnect the instrument panel and switch wiringcouplers.

Remove the handle rear cover rear side screw (1screw).

Remove meter mounting bolts (2 bolts).Remove handle rear cover and meter.


Couplers

2 bolts

1 screw


12. Body Cover

12-6

Front FenderRemove 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 frontfender.

Remove front fender.


Speedometer cableFront brake cable

1 nut

2 bolt


12. Body Cover

12-7

Front under SpoilerRemove front cover.Remove the 10 screws on left & right both sides ofrear-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.


2 screws

10 screws

2 bolts

Couplers


12. Body Cover

12-8

Front Inner CoverRemovalRemove the front cover and the front underspoiler.Remove the main switch cap. (1 screw)

Remove the rear mounting screw (1 screw) of theinner cover.

Remove winker relay and meter control unit.

Pry out all wire clamps and then take out the frontinner cover.

InstallationInstall the front inner cover according to thereverse procedure of removal.

1 screw

1 screw

Meter control unit

Winker relay


12. Body Cover

12-9

Luggage BoxRemove the mounting bolts (4 bolts) from theluggage box.

Disconnect the engine start control switch coupler.

Remove luggage box.


4 Bolts

Start control switch coupler


12. Body Cover

12-10

Rear CarrierRemove the rear carrier mounting bolts and nuts(2 bolts & 2 nuts)

Remove rear carrier.


Battery CoverRemove batter cover screws (2 screws).

Remove batter cover.


2 bolts

2 screws

2 nuts


12. Body Cover

12-11

Side CoverRemovalRemove the 2 screws on both left & right sidescovers.

Remove right and left side covers.


Rear Center CoverRemove the rear carrier mounting bolts and nuts(2 bolts & 2 nuts)Remove rear center cover mounting screw (1screw).

Remove rear center cover.


1 screw on each side

2 bolts

2 nuts

1 screw


12. Body Cover

12-12

Center CoverRemovalRemove center cover upper screw. (1 screw)

Remove center cover right and left screws. (2screws)

Remove center cover.


1 screw



12. Body Cover

12-13

Body CoverRemovalRemove 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 screwon each side)

Remove the body cover rear side screws. (1 screwon each side)

Remove seat lock cable.

Remove body cover.



Seat lock cable



12. Body Cover

12-14

Floor PanelRemovalRemove the center cover, side covers, luggagebox 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.

CautionAt first, remove the negative “-“ cableThen, remove the positive “+” cableRemove the battery

Remove the floor panel mounting bolts (4 bolts).

Remove floor panel.


4 plugs

4 bolts


12. Body Cover

12-15

Rear FenderRemove the rear fender rear bolts (2 bolts).

Remove the 2 bolts on the two sides. (1 bolts oneach side).

Remove rear fender.


2 bolts

1 bolt on each side


12. Body Cover

12-16

Rear MudguardRemove the rear mudguard right side bolt (1 bolt).Loosen air cleaner mounting bolts, and thenremove the rear mudguard left side bolts (2 bolts).

Remove the rear mudguard.


3 bolts


13. Brake

13-1

Mechanism Diagram-Front Disc BrakeSystem ················································· 13-1Mechanism Diagram-Front Drum BrakeSystem ················································· 13-2Mechanism Diagram-Rear Drum BrakeSystem ················································· 13-3Operational Precautions····················· 13-4Trouble Diagnosis ······························· 13-5Hydraulic Brake System Inspection ·· 13-6

Brake Fluid Replacement / Air-Bleed ·13-7Brake Caliper········································13-8Brake Disc ············································13-9Brake Master Cylinder ·························13-9Drum Brake System····························· 13-12Brake Lining ········································· 13-12Brake Panel ··········································13-13

Mechanism Diagram-Front Disc Brake System

13

5.0~7.0kgf-m

4.0~4.5kgf-m

0.8~1.0kgf-m

3.3~3.7kgf-m

2.8~3.2kgf-m

Home page Contents

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


13. Brake

13-3

Mechanism Diagram-Rear Drum Brake System

2.8~3.2kgf-m

11.0~13.0kgf-m0.8~1.2kgf-m

0.8~1.2kgf-m


13. Brake

13-4

Operational PrecautionsGeneral information

Caution

Specifications Unit: mm

3.50 2.00

0.10 0.30

11.000~11.043 11.055HU10U/W：110/110

HU05U：110/95

HU10U/W：110.50

HU05U：95.50

160.00 ─

─

─

─

Torque values:


13. Brake

13-5

Trouble DiagnosisDisc BrakeSoft brake lever

Hard operation of brake lever

Uneven brake

Tight brake

Brake noise

Drum BrakePoor brake performance Tight operation or low return speed of brake

lever

Brake noise


13. Brake

13-6

Hydraulic Brake System InspectionInspection of Hydraulic Brake SystemInspection

Recommended brake fluid: WELLRUN DOT 3brake fluid

Caution

Brake Fluid Add

Caution

Master cylinder cap

Lower level

Brake caliper Brake disc

Brake lining wearlimitation groove

Lowerlevel

Hose connection


13. Brake

13-7

Caution

Brake Fluid Replacement / Air-Bleed

Caution

1.

Caution

2.

3.

4.

5.

Transparent draining hose

Bubble

Drain valve

Drain valve

Master cylinder cap

Diaphragm


13. Brake

13-8

Brake CaliperRemoval

Caution

Brake Lining Replacement

Installation

Torque: 3.1~3.5kgf-mCaution

Torque: 3.3~3.7kgf-m

Brake lining

Locking spring

Brake lining

Brake caliper

Brake lining wearlimitation groove

Calipermounting plate

2 BoltsHose bolt

Piston

Locking spring


13. Brake

13-9

Brake DiscInspection

Allowable limit: 2.0 mm

Allowable limit: 0.30 mmCaution

Brake Master CylinderRemoval

Caution

Caution

Cir clip

Piston

Rubberwasher

Brake hose

2 Bolts

Brake disc

Micrometer

Rubberboot

Brake lightswitch

Mastercylinder

Spring


13. Brake

13-10

Inspection

Service limit: 11.055 mm

Service limit: 10.945 mm

AssemblyCaution

Caution

Master cylinder

Dial

Piston

Micrometer

Cir clip

Piston

Rubberwasher

Rubberboot

Brake lightswitch

Mastercylinder

Spring


13. Brake

13-11

Installation


Caution

Caution

Split ringMounting seat

“UP” mark

Brake hose

Sealing washer

Hose bolt


13. Brake

13-12

Drum Brake SystemBrake DrumRemoval

Caution

Inspection

Service limit: HU10U 111.5 mmHU05U 95.50 mm

Caution

Brake LiningInspection

Service limit: Front 2.0 mmRear 2.0 mm

Front brake drum

Brake lining

Brake lining

Rear brake drum


13. Brake

13-13

RemovalCaution

Installation

Caution

Brake PanelFront Brake Panel Removal

Rear Brake Panel Removal

Bolt

Brake arm

Returni

Brake cam

Brakeshoes

Brake camAnchor pin

Front

Anchor pin

Brake spring

Brake cam

Brake shoes

Bolt

Brake arm

Return spring

Wear indicator

Brake cam


13. Brake

13-14

InstallationFront brake panel


Rear Brake Panel


Brake arm

Return springWear indicator

Brake cam

Bolt

Brake arm

Wear indicator

Brake camRear

Nut


14. Steering / Front Wheel / Front Cushion

14-1

Mechanism Diagram ··························14-1Operational Precautions····················14-2Trouble diagnosis ······························14-2Steering Handle ··································14-3

Front Wheel ········································ 14-5Front Cushion ···································· 14-10Front Fork / Steering Column ··········· 14-10

Mechanism Diagram

3.1~3.5kgf-m

1.0~2.0kgf-m

5.0~7.0kgf-m

0.2~0.3kgf-m

4.0~5.0kgf-m

5.0~7.0kgf-m

2.4~3.0kgf-m

14

Home page Contents


14-2


Torque values

Special service tools

Trouble diagnosisHard steering stem

Steering stem off center

Front wheel wobbling

Soft front suspension

Front suspension noise



14-3

Steering HandleRemoval

Drum Brake Type

Brake lever screw

Brake lever nut

Handle switch screw

Handle switch screw

Cable clamp

Handle switch screw Brake lever screw

Brake lever nut

Handle switch screw

Cable clamp



14-4

Disc Brake Type

Caution

Installation

Split ring 2 bolts

Handle bolt Handle nut

Handle switch screw

Handle switch screw



14-5

Front WheelRemovalDisc Brake

Caution

Drum Brake

Wheel axle nut

Screw

Brake cable Wheel axle nutSpeedometercable



14-6

InspectionWheel axle

Service limit: above 0.2 mm.

Wheel Rim

Service limit:Radial : above 0.2 mmAxial : above 0.2 mm

Disassembly (Disc brake type)

Tool:Inner type bearing remover SYM-6204002

Speedometergear dust seal

Wheel axle

Dust seal

Wheel side collar

Bearing

Bearing spacer

DISC BRAKE

Bearing



14-7

Disassembly (Drum Brake Type)

Tool:Inner type bearing remover SYM-6204002

Bearing Inspection

Caution

Installation

Caution

Tool:C-type compressor or bearing compressor

Clearance

Clearance

Bearing spacer

DRUM BRAKE

Bearing

Dust seal

Bearing

Both samples will damage the bearing



14-8

InstallationDisc Brake

Drum Brake

Drum Brake

Caution

Disc brake Drum brake

Speedometergear dust seal

Dust seal

Wheel side collar

Bearing

Bearing spacer

DISC BRAKE

Bearing

Bearing spacer

DRUM BRAKE

Bearing

Dust seal

Bearing



14-9

Drum Brake

Disc Brake

Disc Brake


Drum Brake


Speedometer cableWheel axle nut

Stopper

Disc brake Drum brake

Brake cable Wheel axle nutSpeedometercable



14-10

Front CushionRemoval

Installation


Front Fork / Steering ColumnRemoval

Caution

Brake fluidhose clipper

Cable guide

Disc brake

Bolts

Drum brake

Steering column nut

Top cone race



14-11

Caution

Installation

Caution

Torque value: 0.2~0.3kgf-mCaution


Caution

Steering column nut

Topcone-race

Top ball bearing seat

Lower ball bearing seat

Lower cone-race

Balls

Balls

Steeringcolumn nut

Top cone-race

Locking to 1/4~3/8turns

Return 1/2 turns

Steering column nut

Top cone-race



14-12

Note:


15. Rear Wheel / Rear Cushion

15-1

Mechanism Diagram ··························· 15-1Operational Precautions····················· 15-2Trouble Diagnosis ······························· 15-2

Exhaust Muffler ····································15-3Rear Wheel ···········································15-3Rear Cushion········································ 15-4

Mechanism Diagram

15

11.0~13.0kgf-m

3.0~3.6kgf-m

1.0~1.4kgf-m

0.8~1.2kgf-m

2.4~3.0kgf-m

3.5~4.5kgf-m

Home page Contents


15-2


Specification Unit: mm

Torque values:

Trouble DiagnosisRear wheel wobbling

Cushion too soft

Braking Noise

Poor brake performance



15-3

Exhaust MufflerRemoval

Installation

Caution

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

Rear WheelInspection

Service limit:Radial: 2.0mmAxial: 2.0mm

Removal

Installation

Torque value: rear wheel nut 11.0~13.0kgf-m

2 Nuts

2 Bolts



15-4

Rear CushionRemoval

Installation

Caution

Torque valuesRear cushion lower mount bolt 2.4~3.0kgf-mRear cushion upper mount bolt 3.5~4.5kgf-m

2 Bolts


℃

℃

℃

℃ Ω

℃ Ω

───

───

〝

℃

℃

---

---

----

---

℃

℃

-

-

-

-

--

-

∞ ∞

∞

∞ ∞ ∞

∞ ∞

℃

Ω

℃℃

17. Emission Control System

17-1

Names of Mechanisms in the EmissionControl System···································· 17-1Function of Mechanisms in the EmissionControl System···································· 17-1Fuel Evaporative Emission Control System(E.E.C.) ················································· 17-2Evaporative Emission Control System(EEC) ···················································· 17-3

Catalytic Converting System (CATA) ·17-4Positive Crankcase Ventilation System(P.C.V.) ·················································· 17-5Inspection Items···································17-6Countermeasure for Emission PollutantsNot Within Standard as In Idle Speed(4-Stroke Engine) ·································17-7

Names of Mechanisms in the Emission Control SystemFour-Stroke Engine Model1. Catalyst converter (CATA)2. Evaporative Emission Control System (EEC)3. Positive Crankcase Ventilation System (PCV)

Function of Mechanisms in the Emission Control SystemGeneralThe emission control strategy of this model was formulated basing on a four-stroke SOHC carburetorsingle cylinder engine. It adopts secondary air introducing device to purify the exhaust, in addition, it alsoadopts a charcoal canister to absorb the fuel vapor generated through evaporation in the fuel system.

※ Engine refinements －Four Valves designed combustion chamber, together with optimum compression ratio, ignition timing,intake and exhaust timing, have all contributed to maximize the intake/exhaust efficiency andcombustion efficiency.

※ Secondary air introducing system －It is used to introduce secondary air into exhaust manifold so that incomplete burned exhausts, CO &HC, may be burned again and to be harmless gases.

System Device Components Purpose & function

Combustionchamber

Combustionchamber

4-valve combustionchamber

The semi-circular combustion chamber isdesigned to balancing the air stream to achievethe combustion stability.

Exhaustsystem

Post-treatmentdevice Catalytic converter

Installed a three-way catalytic converter in themiddle of exhaust pipe to oxidize the CO, HC inthe exhaust gas.

EEC systemEvaporativeemission controlsystem

Charcoal canisterPurge control valve

A canister is used to absorb vapor from fuel tankand to introduce it into carburetor at anopportune timing.

PCV system Crankcase blow-byintroducing device Vapor separator

To introduce blow-by into combustion chambervia a vapor separator for burning thendischarging.

17

Home page Contents


17-2

Fuel Evaporative Emission Control System (E.E.C.)1. Construction:

2. Principle of operation

3. Trouble Diagnosis:

4. Cautions:

Automatic controlfuel cup

Active carboncanister

Vacuum hose

Flesh air inlet

Blow-by hose

Flesh airFuelFuel vaporVacuum

Engine


Fuel tank cap (closed type)

Fuel tank

Fuel hose

Vapor hose

Vapor purgecontrol solenoid

Air cleaner



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 vent.3) Apply 100mmAq into pressure source inlet then plug it. The pressure at the gauge should not

drop to below 10mmAq within 10 seconds.

3. PCV Function Test1) Disconnect the hose of connection to the active carbon canister, and then connect a T-type hose

connector to pressure source as shown below:

2) Apply 100mmAq into pressure source inlet as engine stopped then plug it. The pressure at thegauge should not drop to below 10mmAq within 10 seconds.

Pressure source

Pressure gauge

Fuel tank

Active carbon canister

Plugged

To air filter

engine vacuum

Vapor purge control solenoid

Pressure gauge

Pressure source



17-4

Catalytic Converting System (CATA)1. Construction:

2. Description:

Engine Exhaust muffler

Catalytic converter



17-5

Positive Crankcase Ventilation System (P.C.V.)1. Construction

2. Principle of operation:

3. Service MethodsVisual check:

Cylinderhead

Carburetor

Flesh air

Exhaust pipe

Air filter


Crankcase

Blow-by pipe

Piston

Flesh air

Mixture gas

Blow-by

Engine oil



17-6

Inspection ItemsSecondary air injection system

Fuel Evaporation Control System

Catalytic converter

Fuel Supply System

Ignition system



17-7

Countermeasure for Emission Pollutants Not Within Standard as In IdleSpeed (4-Stroke Engine)



17-8

Note:


18. Electrical Diagram

18-1

HU

05UElectrical D

iagram

Home page Contents

18. Electrical Diagram

18-2

HU

10U/W

Electrical Diagram

Home page Contents

Date post:	13-Apr-2015
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