Mio 50 / 100SERVICE MANUAL
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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.
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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.
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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
Mechanism Illustrations
HU05U / HU10U / HU10W
Exhaust muffler
Home page Contents
Air cleaner
Fuel tank cap
Start / headlight switch
Battery / Fuse /C.D.I. unit
Front brake lever
Rear brake lever
Back mirror
Luggage box
Luggage box lock
Helmet hook
Winker / Horn /Hazard 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:
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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. Maintenance Information
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.
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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
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2. Maintenance Information
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.
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2. Maintenance Information
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
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2. Maintenance Information
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
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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
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2. Maintenance Information
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
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2. Maintenance Information
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
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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
Parts no. SYM-9121600 Parts no. SYM-9120200 Parts no. SYM-9125500
Name Bearing installer Name Bearing installer Name Bearing installer ψ17mm
Parts no. SYM-9110400 Parts no. SYM-9610000 Parts no. SYM-9620000
(ø28mm) (ø20mm)
(20*32*6)(25*37*6) (27*42*7)
(6301) (6203/6004UZ)(6204)
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Name Bearing remover (inner type) Name Bearing remover (outer type) Name clutch spring compressor
Parts no. SYM-6204002 Parts no. SYM-6204001 Parts no. SYM-2301000
Name Clutch mounting nut wrench Name Universal fixer Name Alternator 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
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NOTE:
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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
Mechanism Illustrations
3
Rock Arm
Cam Shaft
Scoop lubrication
Forcedly lubrication
Forcedly lubrication
Inner passage
Connecting rod
Oil pumpOil strainer
Crankshaft
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3. Lubrication System
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
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3. Lubrication System
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
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3. Lubrication System
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
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3. Lubrication System
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
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3. Lubrication System
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)
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3. Lubrication System
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
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3. Lubrication System
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
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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
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4. Fuel System
4-2
Operational PrecautionsGeneral Information
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
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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
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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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
Mechanism Illustrations
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. Removal & Installation of Engine
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
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5. Removal & Installation of Engine
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
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5. Removal & Installation of Engine
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
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5. Removal & Installation of Engine
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
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5. Removal & Installation of Engine
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.
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5. Removal & Installation of Engine
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
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5. Removal & Installation of Engine
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
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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
Mechanism Illustrations
6
Home page Contents
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. Cylinder Head / Valve
6-2
Operational PrecautionsGeneral Information
Specification Unit: mm
Torque Value
Special service tools
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6. Cylinder Head / Valve
6-3
Troubleshooting
Rough Idle
Low compression pressure1. Valve
2. Cylinder head
3. Piston
High compression pressure
Noise
White smoke
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6. Cylinder Head / Valve
6-4
Cylinder Head Removal 5 Screws
Tensioner
2 bolts
Blow-by system hose
1 bolt
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6. Cylinder Head / Valve
6-5
Caution
4 nuts
Timing mark
2 bolts
1 bolt
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6. Cylinder Head / Valve
6-6
Cylinder Head Disassembly (HU05U)
Special Service Tool:
Special Service Tool:Valve rocker arm shaft puller:SYM-1445100-A1A
Camshaft stopper
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6. Cylinder Head / Valve
6-7
Cylinder Head Disassembly(HU10U/W)
Special Service Tool:
Special Service Tool:Valve rocker arm shaft puller:SYM-1445100-A1A
固定擋板
Intake rockerarm shaft
Exhaust rockerarm shaft
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6. Cylinder Head / Valve
6-8
Camshaft Inspection
Service Limit:(Refer to page 2)
Service Limit:(Refer to page 2)
Service Limit:(Refer to page 2)
Service Limit:(Refer to page 2)
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6. Cylinder Head / Valve
6-9
Valve Disassembly
Special Service Tool:
Caution
Caution
Valve stem
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6. Cylinder Head / Valve
6-10
Cylinder Head InspectionCylinder Head
Service limit: 0.05mm
Valve spring free length
Service limit: 31.5mm
Valve stem
Service Limit: (Refer to page 2)
Valve guide Caution
Special Service Tool:
Service limit: 5.03mm
Service Limit: (Refer to page 2)
5.0mm valve guide reamer
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6. Cylinder Head / Valve
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
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6. Cylinder Head / Valve
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
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6. Cylinder Head / Valve
6-13
Caution
Caution
Old valve seat width
60°
45°
1.0mm
Contact surface too high
32°
Old valve seat width
Contact surface too low
60°
Old valve seat width
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6. Cylinder Head / Valve
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
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6. Cylinder Head / Valve
6-15
Caution
Cylinder Head Installation
Torque value: 1.8~2.2kgf-m
Torque value: 1.0~1.4kgf-m
Caution
Chain plate
Lock pins
Gasket
4 Nuts
Timing mark
2 bolts
1 bolt
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6. Cylinder Head / Valve
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
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6. Cylinder Head / Valve
6-17
5 Screws
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6. Cylinder Head / Valve
6-18
Notes:
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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
Mechanism Illustrations
70.8~1.2kgf-m
Home page Contents
7. Cylinder / Piston
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
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7. Cylinder / Piston
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
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7. Cylinder / Piston
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
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7. Cylinder / Piston
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
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7. Cylinder / Piston
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.
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7. Cylinder / Piston
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
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7. Cylinder / Piston
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)
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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
Mechanism Illustrations
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. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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8. V-Belt Drive System / Kick Starter
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
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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. Final Drive Mechanism
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.
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9. Final Drive Mechanism
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
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9. Final Drive Mechanism
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.
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9. Final Drive Mechanism
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
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9. Final Drive Mechanism
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
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9. Final Drive Mechanism
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
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9. Final Drive Mechanism
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)
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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
Mechanism Illustrations
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. Alternator / Starting Clutch
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
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10. Alternator / Starting Clutch
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
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10. Alternator / Starting Clutch
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
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10. Alternator / Starting Clutch
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
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10. Alternator / Starting Clutch
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
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10. Alternator / Starting Clutch
10-7
InstallationInstall the components in the reverse proceduresof removal.
CautionAdd adhesive onto the thread of hex socketbolt.
Torque value: 1.0~1.4kgf-m
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
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10. Alternator / Starting Clutch
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
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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
Mechanism Illustrations
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. Crankcase / Crankshaft
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
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11. Crankcase / Crankshaft
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
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11. Crankcase / Crankshaft
11-4
Remove the oil seal of left-side crankcase.
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11. Crankcase / Crankshaft
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
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11. Crankcase / Crankshaft
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
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11. Crankcase / Crankshaft
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
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11. Crankcase / Crankshaft
11-8
Notes:
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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
Mechanism Illustrations
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
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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
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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
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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.
InstallationInstall according to the reverse procedure ofremoval.
Couplers
2 bolts
1 screw
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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.
InstallationInstall according to the reverse procedure ofremoval.
Speedometer cableFront brake cable
1 nut
2 bolt
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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.
InstallationInstall according to the reverse procedure ofremoval.
2 screws
10 screws
2 bolts
Couplers
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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
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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.
InstallationInstall according to the reverse procedure ofremoval.
4 Bolts
Start control switch coupler
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12. Body Cover
12-10
Rear CarrierRemove the rear carrier mounting bolts and nuts(2 bolts & 2 nuts)
Remove rear carrier.
InstallationInstall according to the reverse procedure ofremoval.
Battery CoverRemove batter cover screws (2 screws).
Remove batter cover.
InstallationInstall according to the reverse procedure ofremoval.
2 bolts
2 screws
2 nuts
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12. Body Cover
12-11
Side CoverRemovalRemove the 2 screws on both left & right sidescovers.
Remove right and left side covers.
InstallationInstall according to the reverse procedure ofremoval.
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.
InstallationInstall according to the reverse procedure ofremoval.
1 screw on each side
2 bolts
2 nuts
1 screw
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12. Body Cover
12-12
Center CoverRemovalRemove center cover upper screw. (1 screw)
Remove center cover right and left screws. (2screws)
Remove center cover.
InstallationInstall according to the reverse procedure ofremoval.
1 screw
1 screw on each side
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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.
InstallationInstall according to the reverse procedure ofremoval.
1 screw on each side
Seat lock cable
1 screw on each side
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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.
InstallationInstall according to the reverse procedure ofremoval.
4 plugs
4 bolts
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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.
InstallationInstall according to the reverse procedure ofremoval.
2 bolts
1 bolt on each side
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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.
InstallationInstall according to the reverse procedure ofremoval.
3 bolts
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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
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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
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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
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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:
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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
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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
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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
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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
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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
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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
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13. Brake
13-11
Installation
Torque value: 3.3~3.7kgf-m
Caution
Caution
Split ringMounting seat
“UP” mark
Brake hose
Sealing washer
Hose bolt
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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
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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
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13. Brake
13-14
InstallationFront brake panel
Torque: 0.8~1.2kgf-m
Rear Brake Panel
Torque: 0.8~1.2kgf-m
Brake arm
Return springWear indicator
Brake cam
Bolt
Brake arm
Wear indicator
Brake camRear
Nut
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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
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14. Steering / Front Wheel / Front Cushion
14-2
Operational PrecautionsGeneral information
Torque values
Special service tools
Trouble diagnosisHard steering stem
Steering stem off center
Front wheel wobbling
Soft front suspension
Front suspension noise
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14. Steering / Front Wheel / Front Cushion
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
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14. Steering / Front Wheel / Front Cushion
14-4
Disc Brake Type
Caution
Installation
Split ring 2 bolts
Handle bolt Handle nut
Handle switch screw
Handle switch screw
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14. Steering / Front Wheel / Front Cushion
14-5
Front WheelRemovalDisc Brake
Caution
Drum Brake
Wheel axle nut
Screw
Brake cable Wheel axle nutSpeedometercable
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14. Steering / Front Wheel / Front Cushion
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
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14. Steering / Front Wheel / Front Cushion
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
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14. Steering / Front Wheel / Front Cushion
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
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14. Steering / Front Wheel / Front Cushion
14-9
Drum Brake
Disc Brake
Disc Brake
Torque value: 5.0~7.0kgf-m
Drum Brake
Torque value: 5.0~7.0kgf-m
Speedometer cableWheel axle nut
Stopper
Disc brake Drum brake
Brake cable Wheel axle nutSpeedometercable
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14. Steering / Front Wheel / Front Cushion
14-10
Front CushionRemoval
Installation
Torque value: 2.4~3.0kgf-m
Front Fork / Steering ColumnRemoval
Caution
Brake fluidhose clipper
Cable guide
Disc brake
Bolts
Drum brake
Steering column nut
Top cone race
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14. Steering / Front Wheel / Front Cushion
14-11
Caution
Installation
Caution
Torque value: 0.2~0.3kgf-mCaution
Torque value: 1.0~2.0kgf-m
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
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14. Steering / Front Wheel / Front Cushion
14-12
Note:
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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
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15. Rear Wheel / Rear Cushion
15-2
Operational PrecautionsGeneral information
Specification Unit: mm
Torque values:
Trouble DiagnosisRear wheel wobbling
Cushion too soft
Braking Noise
Poor brake performance
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15. Rear Wheel / Rear Cushion
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
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15. Rear Wheel / Rear Cushion
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
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℃
℃
℃
℃ 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
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17. Emission Control System
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 vapor separator
Fuel tank cap (closed type)
Fuel tank
Fuel hose
Vapor hose
Vapor purgecontrol solenoid
Air cleaner
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17. Emission Control System
17-3
Evaporative Emission Control System (EEC)1. Visual check:
1) Check the outside of canister for damage.2) Check all hoses for breakage.
2. Leak test:1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a
pressure gauge and a pressure source as shown below:
2) Plug canister 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
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17. Emission Control System
17-4
Catalytic Converting System (CATA)1. Construction:
2. Description:
Engine Exhaust muffler
Catalytic converter
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17. Emission Control System
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
Fuel vapor separator
Crankcase
Blow-by pipe
Piston
Flesh air
Mixture gas
Blow-by
Engine oil
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17. Emission Control System
17-6
Inspection ItemsSecondary air injection system
Fuel Evaporation Control System
Catalytic converter
Fuel Supply System
Ignition system
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17. Emission Control System
17-7
Countermeasure for Emission Pollutants Not Within Standard as In IdleSpeed (4-Stroke Engine)
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17. Emission Control System
17-8
Note:
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18. Electrical Diagram
18-1
HU
05UElectrical D
iagram
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18. Electrical Diagram
18-2
HU
10U/W
Electrical Diagram
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