Sym Jet 4 125 User manual

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.
ŸBattery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
ŸBattery 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.
ŸIf 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.
ŸKeep 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
ŸAlways use with SANYANG genuine parts
and recommended oils. Using non-designed
parts for SANYANG motorcycle may damage
the motorcycle.
ŸSpecial tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools
may result in parts damaged.
ŸWhen 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.
ŸClean 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.
ŸWash 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.
ŸNever bend or twist a control cable to prevent
stiff control and premature worn out.
ŸRubber 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.
ŸWhen 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.
ŸStore complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
ŸNote the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
ŸComponents 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
ŸThe 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.
ŸTighten assemblies with different dimension
fasteners as follows:
ŸTighten 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.
ŸWhen 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.
ŸRemove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
ŸThe 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.
ŸRubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
ŸThe 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
ŸLubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
ŸCheck if positions and operation for installed
parts is in correct and properly.
ŸMake sure service safety each other when
conducting by two persons.
ŸNote that do not let parts fall down
ŸBefore 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.
ŸAfter 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.
ŸMake sure that the battery post caps are
located in properly after the battery posts had
been serviced.
ŸIf 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
ŸWhen separating a connector, it locker has to
be unlocked firstly. Then, conduct the
service operation.
ŸDo not pull the wires as removing a
connector or wires. Hold the connector
body.
ŸMake sure if the connector pins are bent,
extruded or loosen.
ŸInsert 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.
ŸCheck if the connector is covered by the twin
connector boot completely and secured
properly.
ŸBefore terminal connection, check if the boot
is crack or the terminal is loose.
ŸInsert the terminal completely. Check if the
terminal is covered by the boot. Do not let
boot open facing up.
ŸSecure 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.
ŸWire band and wire harness have to be
clamped secured properly.
ŸDo not squeeze wires against the weld or its
clamp.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS
1-7
ŸDo not let the wire harness contact with
rotating, moving or vibrating components as
routing the harness.
ŸKeep wire harnesses far away from the hot
parts.
ŸRoute wire harness to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
ŸRoute harnesses so that they neither pull too
tight nor have excessive slack.
ŸProtect 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.
ŸSecure the rubber boot firmly as applying it
on wire harness.
ŸNever use wires or harnesses which
insulation has been broken. Wrap electrical
tape around the damaged parts or replace
them.
ŸNever 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
ŸDo not let the wire harness been twisted as
installation.
ŸWire 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.
ŸBefore operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
ŸWith 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 AD12W1-6
Overall Length 1900 mm Front TELESCOPIC FORK
Overall Width 665 mm
Suspen
sion
System
Rear DOUBLE SWING ARM
Overall Height 1040 mm Front 120/60-13 56J
DIMENSION
Wheel Base 1330 mm
Tire
Specifi
cations
Rear 130/70-12 56J
Front 42 kg
Rear 67 kg Front DISK (ø226 mm)
Curb Weight
Total 109kg
Brake
System
Rear DRUM (ø130 mm)
Passengers/
Weight Two men/184 kg Max. Speed 120 km/hr Above
Front 76.5kg
Performa
nce
Climb Ability 22° Below
Rear 186.5 kg Primary Reduction C.V.T.
WEIGHT
Total Weight
Total 263kg 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 ~ 120 km/hr
Cycle/Cooling 4-stroke/forced air
cooled Horn 80~112 dB/A
Bore 52.4 mm Muffler Expansion & Pulse Type
Stroke 57.8 mm Exhaust Pipe Position
and Direction Right side, and Backward
Cylinder
Number/Arra
ngement Single Cylinder Lubrication System Separated-lubrication
Displacement 124.6 cc CO%1.1~1.5
Compression
Ratio 10.5±0.2 : 1
Exhaust
Emission
(IDLE) HC%Less than2000
Idle speed 1800±100 rpm Fuel tank capacity 4.80L
Max. HP 6.5KW/ 7500 rpm Air Filtration Paper filter
Max. Torque 8.6N.m /7000 rpm Noise Emission < 80dB(A)
Ignition C.D.I.
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
A.C. generator flange bolt 260.8~1.2
L side cover plate pan screw 750.5~0.7
RR. brake shoe anchor fixing
nut 181.5~2.0
Rear brake arm flange bolt 160.7~1.1
Engine oil filter screen cover 130 1.0~2.0
Crankcase bolts 260.8~1.2
Oil pump flat screw 260.8~1.2
Cylinder/cylinder head
two
-
ends bolts
480.7~1.1
Tighten to crankcase
Cylinder head left side
bolts
260.7~1.1
Camshaft sprocket bolt 261.0~1.5
Valve adjustment fixing nuts 250.7~1.1 Apply oil to thread
Camshaft chain tensioner
pivot bolts 160.8~1.2
Camshaft chain adjuster
bolts 260.8~1.2
A/I fixing flange bolt 460.8~1.2
Oil pump separator bolt 260.8~1.2
One-way clutch lock nut 122 9.0~10.0 Apply oil to thread
Right crankcase cover bolts 10 60.7~1.1
Pulse generator bolts 250.4~0.6
A.C. generator flange bolt 250.8~1.2
Flywheel nut 112 5.0~6.0
Cooling fan flange bolt 460.8~1.2
Shroud A/B 260.7~1.1
Engine oil draining plug bolt 112 3.5~4.5
Start motor bolts 260.7~1.1
Transmission bolts 782.6~3.0
Gear oil draining plug 181.0~1.5
Gear oil filling bolt 181.0~1.5
Driven pulley nut 112 5.5~6.0
Driving face nut 112 5.0~6.0
Left crankcase cover bolts 860.8~1.2
Cylinder head holder nuts481.8~2.2
Cylinder head cover bolts 460.8~1.2
Spark plug 110 1.0~1.2
Carburetor heat protector
connecting nuts
260.7~1.1
Exhaust pipe bolts 283.0~3.6
Exhaust pipe connecting
nuts
261.0~1.4

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 410 4.0~5.0
Mounting nut for steering rod 125.4 1.0~2.0
Cone seat for steering rod 125.4 0.2~0.3
Front wheel shaft nut 112 5.0~7.0
Rear wheel shaft nut 116 11.0~13.0
Wheel hub/rim mounting
nuts 882.8~3.2
Speedometer cable locking
screw 150.15~0.3
Front shock absorber
mounting bolts 482.4~3.0
Rear shock absorber upper
connection bolt 110 3.5~4.5
Rear shock absorber lower
connection bolt 182.4~3.0
Brake lever bolts 260.8~1.2
Front brake hose bolts 210 3.3~3.7
Front brake air-bleeding
valve 160.8~1.0
Front brake disc mounting
bolts 410 4.0~4.5
Front brake clipper mounting
bolts 210 3.1~3.5
Drum brake arm bolts
(front/rear)260.8~1.2
Engine suspension bracket
bolts 210 4.5~5.5 On frame side
Engine connection bolt 110 4.5~5.5 On engine side
Main standard nut 110 3.5~4.5
Foot-starting lever bolt 161.6~1.8
Air cleaner bolts 261.0~1.4
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
pressure
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 system
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
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.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM
1-16
LUBRICATION POINTS
Acceleration cable/ Front & rear brake lever pivot
Steering shaft bearing
Seat lock
Speedometer gear /
Front wheel bearing
Side stand shaft
Main stand shaft
Rear wheel bearing

SYM 10. A.C. GENERATOR/STARTING CLUTCH
10-1
MECHANISM DIAGRAM ................... 10-1
PRECAUTIONS IN OPERATION ...... 10-2
A.C.GENERATOR REMOVAL........... 10-3
RIGHT CRANKCASE COVER
REMOVAL ..........................................10-4
STARTING CLUTCH..........................10-5
RIGHT CRANKCASE COVER
INSTALLATION..................................10-8
MOUNTED COIL SET
INSTALLATION..................................10-8
FLY WHEEL INSTALLATION.............10-8
MECHANISM DIAGRAM
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

10. A.C. GENERATOR/STARTING CLUTCH SYM
10-2
PRECAUTIONS IN OPERATION
General information
ŸRefer to chapter 5: Engine removal and installation
ŸRefer to chapter 1: The troubleshooting and inspection of A.C. generator
ŸRefer to chapter 16: The service procedures and precaution items of starter motor
Specification Unit: mm
Item Standard value Service Limit
ID of starting driven gear 32.0 32.060
OD of starting clutch cover 28.0 27.940
Torque value:
Flywheel nut 5.0~6.0kgf-m
Exhaust muffler bolt 8 mm 1.5~2.0kgf-m
Oil screen cover 1.3~1.7kgf-m
Starting clutch hex lock nut 9.0~10.0kgf-m with oil on the thread
Starting clutch hex socket bolt 1.0~1.4kgf-m with adhesive
Special service tools
Flywheel puller
Universal fixture

SYM 10. A.C. GENERATOR/STARTING CLUTCH
10-3
A.C. GENERATOR REMOVAL
Drain out the engine oil.
Remove the body cover.
Remove the exhaust muffler.(2 bolts, 2 nuts)
Remove the fan shroud.(4 bolts)
Remove the fan. (4 bolts)
Hold the flywheel with the universal fixture.
Remove the 10mm nut on the flywheel.
Special Service Tools:
Universal Fixture
Flywheel
Cooling fan
Cooling f
an
shroud
Coil
Pulse generator
Cable guide
Universal fixture
Cooling fan
Exhaust muffler
Cooling fan shroud

10. A.C. GENERATOR/STARTING CLUTCH SYM
10-4
Remove the flywheel with the flywheel puller.
Special service tools:
Flywheel puller
Shaft protector
Caution
Remove the connectors of the A.C.
generator and pulse generator.
Remove the 6 bolts for the pulse generator,
the A.C. generator coil and cable guide.
Then, remove the A.C. generator assembly.
Caution
RIGHT CRANKCASE COVER
REMOVAL
Remove the right crankcase cover.(6 bolts)
Remove setting pin and gasket.
Remove the gasket or foreign materials on
the connection surfaces of both the cover
and crankcase.
Caution
Do not damage the alternator coil.
Do not damage the connection surfaces.
Install a shaft protector on the right end of
crankshaft to avoid damaging the crankshaft
before installing the flywheel puller.
6 bolts
Flywheel puller
Pulse generator
Coil
Cable guide
Generator connector
Pulse generator
connector