Sym Joyride125 User manual

SERVICEMANUAL
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MANUAL CONTENTS

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This service manual contains the technical data of each component inspection
and repair for the Sanyang JOYRIDE 125/150/200 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, JOYRIDE 125/150/200, are
different from that of the photos, pictures shown in this manual, the actual
vehicle shall prevail. Specifications are subject to change without notice.
Service Department
Sanyang Industry Co., LTD.
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How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for Sanyang JOYRIDE 125/150/200 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 information.
Th third to the tenth chapters cover engine and driving systems.
The eleventh to the fourteenth is contained the parts set of assembly body.
The fifteenth chapter is electrical equipment.
The sixteenth chapter is emission control system.
The seventeenth chapter is wiring diagram
Please see index of content for quick having the special parts and system
information.
There are link devices in the “H9A CONTENTS” file. Just only click on the
icon and it will link to the article what you want to see.
All information, illustration, directions and specifications included in this manual
are current as at the time of publication. Sanyang reserves the rights to make
changes at any time without prior notice and without incurring any obligation
whatever. Without written consent by Sangang can not copy any part of this
manual.
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CONTENTS
Page Content Index
1-1 ~ 1-16 GENERAL INFORMATION
1
2-1 ~ 2-12 MAINTENANCE INFORMATION 2
3-1 ~ 3-6 LUBRICATION SYSTEM 3
4-1 ~ 4-9 FUEL SYSTEM 4
5-1 ~ 5-6 ENGINE REMOVAL 5
6-1 ~ 6-14 CYLINDER HEAD/VALVE 6
7-1 ~ 7-8 CYLINDER/PISTON 7
8-1 ~ 8-14 V-BELT DRIVING SYSTEM/FOOT STARTER 8
9-1 ~ 9-8 FINAL DRIVING MECHANISM 9
10-1 ~ 10-6 ALTERNATOR/STARTING CLUTCH 10
11-1 ~ 11-8 CRANKSHAFT/CRANKCASE 11
12-1 ~ 12-11 COOLING SYSTEM 12
13-1 ~ 13-13 BODY COVERS 13
14-1 ~ 14-10 BRAKE 14
15-1 ~ 15-12 STEERING/FRONT WHEEL/FRONT BRAKE/
FRONT CUSHION
15
16-1 ~ 16-5 REAR WHEEL/REAR BRAKE/REAR CUSHION 16
17-1 ~ 17-18 ELECTRICAL SYSTEM 17
18-1 ~ 18-10 SPECIL TOOLS 18
19-1 ~ 19-2 WIRING DIAGRAM 18
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MODEL ILLUSTRATION
Winker relay
Radiator
Fuel tank cap
Spark plug
Front brake disk
Engine number
ENG. Oil drain plug Kick starter pedal
Engine stop /Light /
Starter switch
High & Low beam /
Passing / Turn signal /
Horn switch
Muffler
Reserved tank
cap
Coolant filler
cap
Ignition / Seat open
switch
Fuses / C.D.I.
Gear oil
drain plug
REG/REC.
Start MAG. switch
Battery
IG. coil
Horn
Fuel tank
Fuel pump
Frame number
Oil level
Oil strainer
Water pump
Seat catch A
Seat catch B
Front brake
caliper
Rear brake
disk
Rear brake
caliper
Front brake Rear brake
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1. GENERAL INFORMATION
1-1
Symbols and marks………………….1-1 Torque values……………………….1-8
General safety…………………………1-2 Cables and harness routing………1-10
Service precautions………………….1-3 Troubleshooting…………………….1-11
Specifications…………………………1-5 Lubrication points…………………..1-15
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 20 JASO FC class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: MAX-2 serial oils)
Grease King Mate G-3 is recommended.
Gear oil King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
OIL # 140)
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 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
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1. GENERAL INFORMATION
1-2
General safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if
you have to run your engine in a closed area, be
sure to use an extractor.
Caution
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 air hose or a dry brush to clean
components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Brake fluid
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
•
Battery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
•
Battery 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 and then go to
hospital to see an ophthalmologist.
•
If 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.
•
Kee
p
electrol
y
te be
y
ond 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 verified.
We recommend that you wash your hands
with soap and water right after contacting.
Keep the used oil beyond reach of children.
Inhaling brake shoe or pad ash 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 the 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.
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1. GENERAL INFORMATION
1-3
Service Precautions
z
Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
z
Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools
may result in parts damaged.
z
When 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.
z
Clean 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.
z
Wash 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.
z
Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
z
Rubber 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.
z
When 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.
z
Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
z
Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
z
Components not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.
Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.
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1. GENERAL INFORMATION
1-4
z
The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed.
In case of confusion, Insert the bolt into the
hole to compare its length with other bolts, if
its length out side the hole is the same with
other bolts, it is a correct bolt. Bolts for the
same assembly should have the same length.
z
Tighten assemblies with different dimension
fasteners as follows: Tighten 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.
z
When 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.
z
Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
z
The 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.
z
Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
z
The 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.
z
Lubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.
Manufacturer's
name
Groove
Clamp
Connection
Boots
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1. GENERAL INFORMATION
1-5
Specifications
Make SANYANG MODEL LA12W
Overall Length 2010 mm Front TELESCOPIC FORK
Overall Width 760 mm Suspension
System Rear UnlT SWING
Overall Height 1155 mm Front 110 / 80-12 61L
Wheel Base 1440 mm Tire
Specifications Rear 130 / 70-12 64L
Front 55 kg Front
DlSK (ψ273mm)
Rear 89 kg
Brake System Rear DlSK (ψ200mm)
Curb
Wei
g
ht
Total 144 kg
Passengers/
Weight Two /110 kg Max. Speed 99 km/hr Above
Front 79 kg Climb Ability 28° above
Rear 175 kg Primary Reduction BELT
WEIGHT DIMENSION
Total Weight
Total 254 kg Secondary
Reduction GEAR
Type Gasoline Clutch
3-piece centrifugal, dry
type
Position and
arrangement Horizontal, below center, CYL incline 80°
PERFORMANCE
Transmission C.V.T.
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 57 mm Muffler Expansion & Pulse Type
Stroke 48.8 mm
Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arra
ngement Single Cylinder Lubrication System Forced pressure and wet sump
Displacement 124.5 cc Solid Particulate
Compression
Ratio 10.5 : 1 CO 3.5 % ↓
Max. HP 11.4 / 8500 ps/rpm
Exhaust
Concentration
HC Below 2000 ppm
Max. Torque 1.01 / 7000 kg-m/rpm E.E.C. Non-equipped
Ignition C.D.I. P.C.V. Equipped
ENGINE
Starting System Power & Foot Catalytic reaction
control system Non-equipped
Remark:
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1. GENERAL INFORMATION
1-6
Specifications
Make SANYANG MODEL LA15W
Overall Length 2010 mm Front TELESCOPIC FORK
Overall Width 760 mm Suspension
System Rear UNlT SWING
Overall Height 1155 mm Front 110 / 80-12 61L
Wheel Base 1440 mm Tire
Specifications Rear 130 / 70-12 64L
Front 55 kg Front
DlSK (ψ273mm)
Rear 89 kg
Net
Weight
Total 144 kg
Brake System Rear DlSK (ψ200mm)
Passengers/
Weight Two /110 kg Max. Speed 100 km/hr Above
Front 79 kg Climb Ability 28° above
Rear 175 kg Primary Reduction BELT
WEIGHT DIMENSION
Total Weight
Total 254 kg Secondary
Reduction GEAR
Type Gasoline Clutch
3-piece centrifugal, dry
type
Position and
arrangement Horizontal, below center, CYL incline 80°
PERFORMANCE
Transmission C.V.T.
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 70 – 90 dB/A
Bore Ø 57 mm Muffler Expansion & Pulse Type
Stroke 58.6 mm
Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arra
ngement Single Cylinder Lubrication System Forced pressure and wet sump
Displacement 149.5 cc Solid Particulate
Compression Ratio 10.5 : 1 CO 3.5 % ↓
Max. HP 13 / 8000 ps/rpm
Exhaust
Concentratio
n
HC Below 2000 ppm
Max. Torque 1.2 / 6000 kg-m/rpm E.E.C. Non-equipped
Ignition C.D.I. P.C.V. Equipped
ENGINE
Starting System Power & Foot Catalytic reaction
control system Non-equipped
Remark:
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1. GENERAL INFORMATION
1-7
Specifications
Make SANYANG MODEL LA18W
Overall Length 2010 mm Front TELESCOPIC FORK
Overall Width 760 mm Suspension
System Rear UNlT SWING
Overall Height 1155 mm Front 110 / 80-12 61L
Wheel Base 1440 mm Tire
Specifications Rear 130 / 70-12 64L
Front 55 kg Front
DlSK (ψ273mm)
Rear 89 kg
Brake System Rear DlSK (ψ200mm)
Curb
Wei
g
ht
Total 144 kg
Passengers/
Weight Two /110 kg Max. Speed 100 km/hr Above
Front 79 kg Climb Ability 28° above
Rear 175 kg Primary Reduction BELT
WEIGHT DIMENSION
Total Weight
Total 254 kg Secondary
Reduction GEAR
Type Gasoline Clutch
3-piece centrifugal, dry
type
Position and
arrangement Horizontal, below center, CYL incline 80°
PERFORMANCE
Transmission C.V.T.
Fuel Used >92 Unleaded gasoline Speed meter 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93 – 112 dB/A
Bore Ø 61 mm Muffler Expansion & Pulse Type
Stroke 58.6 mm
Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arra
ngement Single Cylinder Lubrication System Forced pressure and wet sump
Displacement 171.2 cc Solid Particulate
Compression
Ratio 10 : 1 CO 3.5 % ↓
Max. HP 14.5 / 8000 ps/rpm
Exhaust
Concentration
HC Below 2000 ppm
Max. Torque 1.4 / 6500 kg-m/rpm E.E.C. Non-equipped
Ignition C.D.I. P.C.V. Non-equipped
ENGINE
Starting System Power & Foot Catalytic reaction
control system Non-equipped
Remark:
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1. GENERAL INFORMATION
1-8
Torque values
Item Q’ty
Thread Dia.
(mm) Torque Value
(Kgf-m) Remarks
Cylinder head bolt 4 8 2.0-2.4
Valve clearance adjust nut 4 5 0.7-1.1 Apply oil to thread
Spark plug 1 10 1.0-1.4
L. Crankcase cover bolts 7 6 1.1-1.5
Crankcase bolts 7 6 0.8-1.2
Oil drain bolt 1 8 1.1-1.5
Oil strainer cap 1 30 1.3-1.7
Gear oil drain bolt 1 6 1.0-1.4
Gear oil inspection bolt 1 6 1.0-1.4
Transmission cover bolt 7 6 1.0-1.4
Flywheel bolt 1 14 5.0-6.0
Clutch driving plate bolt 1 28 5.0-6.0
Driving disc nut 1 12 5.0-6.0
Clutch outer cover nut 1 10 3.5-4.5
Transmission cover bolts 7 6 1.0-1.4
Stopper nut for engine hanger
bracket 1 8 1.8-2.2
Nut for engine hanger bracket 1 10 4.0-5.0
Bolt for engine hanger bracket 1 10 4.0-5.0
Engine mounting bolt 1 10 3.5-4.5
Front wheel shaft nut 1 12 5.0-7.0
Rear wheel shaft nut 1 14 11.0-13.0
Bolt for rear shock absorber (upper) 2 10 3.5-4.5
Bolt for rear shock absorber (under) 2 8 2.4-3.0
Bolt for steering rod 1 10 4.0-5.0
Front shock absorber 4 8 2.4-3.0
Brake arm bolts 2 6 0.8-1.2
Brake hose bolts 4 10 3.3-3.7
Bolt for brake caliper 4 10 3.0-3.5
Bolts for the lining guide pin 4 6 1.6-2.0
Brake disk bolts 7 10 4.0-4.5
Mounting screw for speedometer
cable 1 5 0.15-0.3
Muffler bolts 4 8 3.2-3.8
Mounting bolts for exhaust pipe
connection 2 7 1.0-1.2
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
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1. GENERAL INFORMATION
1-9
Standard Torque Values for Reference
Type Torque value kgf-m
5 mm Bolt, Nut 0.45 - 0.6
6 mm Bolt, Nut 0.8 - 1.2
8 mm Bolt, Nut 1.8 - 2.5
10 mm Bolt, Nut 3.0 - 4.0
12 mm Bolt, Nut 5.0 - 6.0
5 mm Screw 0.35 - 0.5
6 mm Screw & 6mm bolt with 8mm head 0.7 - 1.1
6 mm Flange bolt, nut 1.0 - 1.4
8 mm Flange bolt, nut 2.4 - 3.0
10 mm Flange bolt, nut 3.5 - 4.5
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1. GENERAL INFORMATION
1-10
Cables and harness routing
Note the following when routing cables
and wire harnesses:
• A loose wire, cable or harness may cause
safety hazard. After clamping, check each
wire to make sure it is secured.
• Do not squeeze wires against the weld or its
clamp.
• Secure 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.
• Route harnesses so that they neither pull too
tight nor have excessive slack.
• Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
• Route wire harnesses to avoid sharp edges
or corners.
• Avoid the projected ends of bolts and screws.
• Keep wire harnesses far away from the
exhaust pipes and other hot parts.
• Be sure grommets are seated in their groves
properly.
• After clamping, check each harness to be
certain that it is not interfered with any
moving or sliding parts.
• After routing, check that the wire harnesses
are not twisted or kink.
• Wire harnesses routed along the handlebar
should not be pulled too tight or have
excessive slack, be rubbed against or
interfere with adjacent or surrounding parts in
all steering positions.
• Thoroughly clean the surface where tape is
to be applied.
• Wrap electrical tape around the damaged
parts or replace them.
○
○○
○：
：：
：correct
╳
╳╳
╳：
：：
：wrong
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1. GENERAL INFORMATION
1-11
Troubleshooting
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 from
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 Week sparks or no spark
at all
cylinder compression pressure normal Low compression
pressure or no pressure
Re-start by following the
starting procedures
No ignition There are some signs of
ignition, but engine can
not be started
Remove the spark plug
again and check it.
Remove carburetor after 30
minutes and connect a hose
onto fuel supplement 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 auto-starter
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1. GENERAL INFORMATION
1-12
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 pressure
Check if carburetor is
clogged
Normal 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
1. Malfunction of CDI
2. Malfunction of AC generator
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
1. Remove dirt
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
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. Lean mixture
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1. GENERAL INFORMATION
1-13
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition Probable causes
Check ignition timing
(using ignition lamp)
Check for fuel supplying
system in automatic fuel cup
Check if carburetor clogged
1. Incorrect ignition timing (malfunction of
CDI or AC generator)
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
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
Good spark Poor
No air sucked Air sucked
Good Poor
Normal 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
CHECK AND ADJUSTMENT FAULT CONDITION PROBABLE CAUSES
Check ignition timing
1. Malfunction of CDI
2. Malfunction of AC generator
Normal Abnormal
Normal Clogged 1. Cleaning
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1. GENERAL INFORMATION
1-14
E. CLUTCH, DRIVING AND DRIVING PULLEY
1. Clutch lining spring broken
2. Clutch outer stuck with clutch balance weights
3. Connection parts in clutch and shaft worn out or
burned
Engine can be started but
motorcycle can not be driving
FAULT CONDITION PROBABLE CAUSES
1. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch lining broken
5. Driving shaft groove broken
6. Transmission gear damage
7. Transmission gear worn out or burned
Engine running and misfire as
motorcycle initial forward moving
or jumping sudden (rear wheel
rotating as engine in running)
Poor initial driving (Poor climbing
performance)
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.
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1. GENERAL INFORMATION
1-15
LUBRICATION POINTS
Engine suspension bushing
Seat lock
Rear wheel bearing
Steering shaft bearing
Speedometer gear/ front
wheel bearing
Side stand shaft
Main stand shaft
Throttle cable/
Front & rear brake lever pivot
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