SANYANG INDUSTRY CO. SYM User manual

SERVICE MANUAL

SYM FORWARD
This service manual contains the technical data of each component
inspection and repair for the SYM series motorcycle. The manual is shown
with illustrations and focused on 「Service Procedures」, 「Operation Key
Points」, and「Inspection Adjustment」so that provides technician with service
guidelines.
If the style and construction of the motorcycle are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
This manual that contains all data, illustration, indication and specifications
is based on current production information. SYM reserves the right to make
changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SYM.
SERVICE DEPARTMENT
SANYANG INDUSTRY CO., LTD.

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

SYM CONTENTS
CONTENTS
GENERAL INFORMATION/TROUBLE DIAGNOSIS...................................1
MAINTENANCE INFORMATION .................................................................2
LUBRICATION SYSTEM..............................................................................3
FUEL SYSTEM.............................................................................................4
ENGINE REMOVAL......................................................................................5
CYLINDER HEAD/VALVE............................................................................6
CYLINDER/PISTON......................................................................................7
"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM/ STARTER CLUTCH.......8
FINAL DRIVING MECHANISM.....................................................................9
A.C. GENERATOR/STARTING CLUTCH....................................................10
CRANKCASE/CRANKSHAFT .....................................................................11
BODY COVER..............................................................................................12
BRAKE SYSTEM..........................................................................................13
STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER........................14
REAR WHEEL/SUSPENSION......................................................................15
ELECTRICAL EQUIPMENT.........................................................................16
ELECTRICAL DIAGRAM .............................................................................17
SPECIAL TOOL............................................................................................18

MECHANISM ILLUSTRATIONS SYM
Light/starter switch
Front disk brake
Exhaust muffler
Ignition switch
Gea
r
oil draining
bolt
Battery/Fuse/CDI
Front brake lever
Rea
r
brake leve
r
Air cleaner
Gea
r
oil filling
bolt
Oil level
Tail light
Front turn
signal light Fuel tank / Fuel unit
High&Low beam/Seat
open/turn signal/horn
Head light/
Position light
Rear turn
signal light
Engine number/engine
oil draining bolt
Ignition coil
Frame number
Meter
A.C. Generator
Start magnetic switch
Horn/REG.REC
RR. turning
signal light
Winker relay
Engine control
switch

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-1
SYMBOLS AND MARKS....................1-1
GENERAL SAFETY............................1-2
SERVICE PRECAUTIONS.................1-3
SPECIFICATIONS..............................1-9
TORQUE VALUES (ENGINE)..............1-10
TORQUE VALUES (FRAME)...............1-11
TROUBLES DIAGNOSIS.....................1-12
LUBRICATION POINTS.......................1-16
SYMBOLS AND MARKS
Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information is procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are not
followed.
Caution Means that equipment damages may result if procedures are not followed.
Engine oil Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
Gear oil Limits to use SAE 85W-140 class oil. Warranty will not cover the damage
that caused by not apply with the limited gear oil.
Grease King Mate G-3 is recommended.
Locking sealant
Apply sealant, medium strength sealant should be used unless otherwise
specified.
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 service tools.
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-2
GENERAL SAFETY
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if
you have to run your engine in a closed area, be
sure to use an extractor.
Caution
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no
flame or spark should be allowed in the work
place or where gasoline is being stored.
Caution
Used engine oil
Caution
Hot components
Caution
Battery
Caution
Brake shoe
Do not use an compressed air or a dry brush to
clean components of the brake system, use a
vacuum cleaner or the equivalent to avoid
asbestos dust flying.
Caution
Brake fluid
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
yBattery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
yBattery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
do not be spray on your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery
acid in your eyes, flush it off immediately
with water, then go to hospital to see an
ophthalmologist.
yIf you swallow it by mistake, drink a lot of
water or milk, and take some laxative such
as castor oil or vegetable oil, and then go to
see a doctor.
yKeep electrolyte beyond reach of children.
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verdict. Inhaling asbestos dust may cause disorders
and cancer of the breathing system.
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep brake fluid beyond reach of children.
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-3
SERVICE PRECAUTIONS
yAlways use with SANYANG genuine parts
and recommended oils. Using non-designed
parts for SANYANG motorcycle may damage
the motorcycle.
ySpecial tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools
may result in parts damaged.
yWhen servicing this motorcycle, use only
metric tools. Metric bolts, nuts, and screws
are not interchangeable with the English
system, using wrong tools and fasteners may
damage this vehicle.
yClean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on
the part's surface may fall into the engine,
chassis, or brake system to cause a damage.
yWash and clean parts with high ignition point
solvent, and blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most cleaning agents have an
adverse effect on them.
yNever bend or twist a control cable to prevent
stiff control and premature worn out.
yRubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
yWhen loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
yStore complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
yNote the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
yComponents not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-4
yThe length of bolts and screws for
assemblies, cover plates or boxes is different
from one another, be sure they are correctly
installed. In case of confusion, Insert the bolt
into the hole to compare its length with other
bolts, if its length out side the hole is the
same with other bolts, it is a correct bolt.
Bolts for the same assembly should have the
same length.
yTighten assemblies with different dimension
fasteners as follows:
yTighten all the fasteners with fingers, then
tighten the big ones with special tool first
diagonally from inside toward outside,
important components should be tightened 2
to 3 times with appropriate increments to
avoid warp unless otherwise indicated. Bolts
and fasteners should be kept clean and dry.
Do not apply oil to the threads.
yWhen oil seal is installed, fill the groove with
grease, install the oil seal with the name of
the manufacturer facing outside, check the
shaft on which the oil seal is to be installed
for smoothness and for burrs that may
damage the oil seal.
yRemove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
yThe ends of rubber hoses (for fuel, vacuum,
or coolant) should be pushed as far as they
can go to their connections so that there is
enough room below the enlarged ends for
tightening the clamps.
yRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
yThe tool should be pressed against two (inner
and outer) bearing races when removing a
ball bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Both of these examples can result in bearing
damage.
Manufacturer's
name
Groove
Clamp
Connector
Boots

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-5
yLubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
yCheck if positions and operation for installed
parts is in correct and properly.
yMake sure service safety .
yNote that do not let parts fall down
yBefore battery removal operation, it has to
remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not
contact with body to prevent from circuit short
and create spark.
yAfter service completed, make sure all
connection points is secured. Battery
positive (+) cable should be connected firstly.
And the two posts of battery have to be
greased after connected the cables.
yMake sure that the battery post caps are
located in properly after the battery posts had
been serviced.
yIf fuse burned, it has to find out the cause
and solved it. And then replace with
specified capacity fuse.
capacity
verification

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-6
yWhen separating a connector, it locker has to
be unlocked firstly. Then, conduct the
service operation.
yDo not pull the wires as removing a
connector or wires. Hold the connector
body.
yMake sure if the connector pins are bent,
extruded or loosen.
yInsert 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.
yCheck if the connector is covered by the twin
connector boot completely and secured
properly.
yBefore terminal connection, check if the boot
is crack or the terminal is loose.
yInsert the terminal completely. Check if the
terminal is covered by the boot. Do not let
boot open facing up.
ySecure wires and wire harnesses to the
frame with respective wire bands at the
designated locations. Tighten the bands so
that only the insulated surfaces contact the
wires or wire harnesses.
yWire band and wire harness have to be
clamped secured properly.
yDo not squeeze wires against the weld or its
clamp.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-7
yDo not let the wire harness contact with
rotating, moving or vibrating components as
routing the harness.
yKeep wire harnesses far away from the hot
parts.
yRoute wire harness to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
yRoute harnesses so that they neither pull too
tight nor have excessive slack.
yProtect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.
ySecure the rubber boot firmly as applying it
on wire harness.
yNever use wires or harnesses which
insulation has been broken. Wrap electrical
tape around the damaged parts or replace
them.
yNever clamp or squeeze the wire harness as
installing other components.
Do not touch it.
Do not extend
it too much.
Please do not clip or
squeeze the wire.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-8
yDo not let the wire harness been twisted as
installation.
yWire harnesses routed along the handlebar
should not be pulled too tight or have
excessive slack, be rubbed against or
interfere with adjacent or surrounding parts in
all steering positions.
yBefore operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
yWith sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Do you know how to set the
instrument to its measurement
position and the insert locations
of its two probes?
Clean rust.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-9
SPECIFICATIONS
MAKER SANYANG MODEL AY05W-6
Overall Length 2000mm Front TELESCOPIC FORK
Overall Width 690mm
Suspen
sion
System
Rear UNIT SWING ARM
Overall Height 1125mm Front 90/80-16 51N
DIMENSION
Wheel Base 1330 mm
Tire
Specifi
cations
Rear 90/80-16 51N
Front 40 kg
Rear 60 kg Front DISK (ø 226 mm)
Curb Weight
Total 100 kg
Brake
System
Rear DRUM (ø 130 mm)
Passengers/
Weight Two men/175 kg Max. Speed Less than 45 km/hr
Front 85kg
Performa
nce
Climb Ability 22° Below
Rear 165 kg Primary Reduction C.V.T.
WEIGHT
Total Weight
Total 250kg Secondary
Reduction GEAR
Type 4-STROKE ENGINE Clutch Centrifugal, dry type
Installation and
arrangement Vertical, below center, incline 80°
Deceleration
equipment
Transmission V-belt
Fuel Used Unleaded (93/95) Speedometer 0 ~ 80 km/hr
Cycle/Cooling 4-stroke/forced air
cooled Horn 80~112 dB/A
Bore 37.0 mm Muffler Expansion & Pulse Type
Stroke 46.0 mm Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arran
gement Single Cylinder Lubrication System Separated-lubrication
Displacement 49.6 cc CO <12.0 g/km
Compression
Ratio 12.6±0.2 : 1
Exhaust
Emission HC <1.0 g/km
Idle Speed 2100±100 Fuel tank capacity 4.80L
Max. HP 2.3KW/ 7500 rpm Air Filtration Paper filter
Max. Torque 3.1N.m /6500 rpm Noise Emission < 80dB(A)
Ignition C.D.I. Fuel tank capacity 4.8L
ENGINE
Starting System Electrical & Kick starter

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

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-11
TORQUE VALUES (FRAME)
ITEM Q'TY
THREAD DIA
(mm) TORQUE VALUE(Kg-m) REMARKS
Mounting Hex socket bolt for steering
handlebar 4 10 4.0~5.0
Mounting nut for steering rod 1 25.4 1.0~2.0
Cone seat for steering rod 1 25.4 0.2~0.3
Front wheel shaft nut 1 12 5.0~7.0
Rear wheel shaft nut 1 16 11.0~13.0
Wheel hub/rim mounting nuts 8 8 2.8~3.2
Speedometer cable locking screw 1 5 0.15~0.3
Front shock absorber mounting bolts 4 8 2.4~3.0
Rear shock absorber upper connection
bolt 1 10 3.5~4.5
Rear shock absorber lower connection
bolt 1 8 2.4~3.0
Brake lever bolts 2 6 0.8~1.2
Front brake hose bolts 2 10 3.3~3.7
Front brake air-bleeding valve 1 6 0.8~1.0
Front brake disc mounting bolts 4 10 4.0~4.5
Front brake clipper mounting bolts 2 10 3.1~3.5
Drum brake arm bolts (front/rear) 2 6 0.8~1.2
Engine suspension bracket bolts 2 10 4.5~5.5 On frame side
Engine connection bolt 1 10 4.5~5.5 On engine side
Main standard nut 1 10 3.5~4.5
Foot-starting lever bolt 1 6 1.6~1.8
Air cleaner bolts 2 6 1.0~1.4
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference
TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE
5mm bolt、nut 0.45~0.60kgf-m 3mm screw 0.05~0.08kgf-m
6mm bolt、nut 0.80~1.20kgf-m 4mm screw 0.10~0.15kgf-m
8mm bolt、nut 1.80~2.50kgf-m 5mm screw 0.35~0.50kgf-m
10mm bolt、nut 3.00~4.00kgf-m 6mm screw、SH nut 0.70~1.10kgf-m
12mm bolt、nut 5.00~6.00kgf-m 6mm bolt、nut 1.00~1.40kgf-m
8mm bolt、nut 2.40~3.00kgf-m
10mm bolt、nut 3.50~4.50kgf-m

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-12
TROUBLES DIAGNOSIS
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carburetor
Fuel supplied tom
carburetor sufficient No fuel is supplied to
carburetor
Remove spark plug, install
it into spark plug cap, and
perform a spark test
against engine ground.
perform cylinder
compression pressure test.
Check if sparks Weak sparks, no spark
at all
Low compression
pressure or no pressure
Re-start by following the
starting procedures
No ignition There are some signs of
ignition, nut engine can
not be started
Remove the spark plug
again and check it.
Remove carburetor after 30 minutes
and connect a hose onto 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 tank
2. Check if the pipes, fuel tank to
carburetor and intake vacuum,
are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation
system clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump
vacuum hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short
circuit
6. Ignition coil leads open or short
circuit
7. Malfunction of main switch
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
1. Malfunction of throttle valve
operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve
operation
3. Throttle valve opening too wide
1. Malfunction of automatic by-
starter
cylinder compression
pressure normal

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-13
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
Try gradual acceleration
and check engine speed
Engine speed can be
increased. Engine speed can not be increased.
Check ignition timing
(Using ignition lamp)
Check cylinder compression
pressure (using compression
pressure gauge)
Ignition timing correct Incorrect ignition timing
Compression pressure correct No compression
Check if carburetor jet is
clogged
No clogged Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration Fouled and discoloration
No knock Knock
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation
system clogged
4. Exhaust pipe clogged
5. Fuel level too low in carburetor
6. Fuel nozzle clogged in
carburetor.
1. Malfunction of CDI
2. Malfunction of AC alternator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
1. Remove foreign
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling
s
y
stem
Normal Engine overheat
Continually drive in
acceleration or high speed
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-14
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
Check ignition timing
(using ignition lamp)
Good spark Poor
No air sucked Air sucked
Good Poor
Abnormal
Air sucked through
carburetor gasket
Adjust the air screw of
carburetor
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
Normal
Check and adjustment Fault condition Probable causes
Check for fuel supplying
system in automatic fuel cup
Check if carburetor clogged
1. Incorrect ignition timing (malfunction
of CDI or AC alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good Poor
Check and adjustment Fault condition Probable causes
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC alternator
Normal Abnormal
No clogged Clogged 1. Cleaning

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-15
E. CLUTCH, DRIVING AND DRIVING PULLEY
1. Clutch ling spring broken
2. Clutch outer stick with clutch balance weights
3. Connection parts in clutch and shaft worn out
or burned
Engine can be started but
motorcycle can not be moved.
FAULT CONDITIONS PROBABLE CAUSES
1. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damaged
Engine running and misfire as
motorcycle initial forward moving
or jumping suddenly (rear wheel
rotating as engine in running)
Poor initial driving ( Poor
climbin
g
p
erformance
)
1. Driving belt worn out or deformation
2. Balance weight roller worn out
3. Driving sliding gear shaft worn out
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.