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JD05W
Sym JD05W User Manual
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14. Rear Wheel / Rear Cushion
14-4
Brake disc removal / install
Installation
Install the rear wheel and tighten the nut.
Tighten torque: 11.0~13.0kgf-m
Install exhaust pipe & muffler.
Tighten torque (bolt): 2.4~3.0kgf-m
Tighten torque (nut): 0.8~1.2kgf-m
Shaft nut
2 nuts
3 bolts
62
64
Table of Contents
Table of Contents
4
Mechanism Illustrations
5
General Information/Trouble Diagnosis
7
Symbols and Marks
7
General Safety
8
Carbon Monoxide
8
Gasoline
8
Battery
8
Service Precautions
9
Specifications
12
Lubrication System
12
Torque Values (Engine)
13
Standard Torque Values for Reference
14
Torque Values (Frame)
14
Engine Hard to Start or Can Not be Started
15
Troubles Diagnosis
15
Engine Run Sluggish (Speed Does Not Pick Up, Lack of Power)
16
Engine Runs Sluggish (Especially in Low Speed and Idling)
17
Engine Runs Sluggish (High Speed)
17
Clutch, Driving and Driving Pulley
18
Lubrication Points
19
Crankcase/Crankshaft
20
Engine Noise
21
Maintenance Information
21
Torque Values
21
Troubleshooting
21
Crankcase Disassembly
22
Crankshaft Removal
22
Crankshaft Inspection
23
Crankcase Installation
24
Body Cover
26
Body Covers Disassemble Sequence
27
Handle Cover
28
Front Cover
29
Front Inner Box
30
Body Cover/Rear Center Cover/Rear Fender
31
Floor Panel
33
Front Center Cover
33
Luggage Box
33
Side Cover
34
Under Cover
35
Brake System
36
Disc Brake System
36
Rear Drum Brake System
37
Precautions in Operation
38
Brake Noise
39
Hard Operation of Brake
39
Soft Brake Lever
39
Tight Brake
39
Hydraulic Disc Brake
40
Recommended Brake Fluid
40
Disc Brake -Air Bleed
41
Brake Pad Replacement
42
Disc Brake - Caliper
42
Front Brake
42
Brake Disc
44
Disc Brake - Master Cylinder
44
Master Cylinder Removal
44
Master Cylinder Assembly
45
Master Cylinder Inspection
45
Rear Drum Brake
47
Steering / Front Wheel / Front Cushion
50
Hard to Steer
51
Soft Cushion
51
The Front Wheel Wobbling
51
The Steering Handle Is Tilted
51
Steering Handle
52
Front Wheel
54
Bearings Replacement
55
Inner Bearing Puller
55
Front Cushion
57
Steering Stem
58
Rear Wheel / Rear Cushion
60
Cushion too Soft
61
Poor Brake Performance
61
Rear Wheel Wobbling
61
Rear Wheel
62
Brake Disc Removal / Install
63
Rear Cushion
64
Electrical Equipment
66
Charging System
67
Ignition System
67
Precautions in Operation
67
Starting System
67
Intermittent Power Supply
69
Low Voltage
69
No Power Supply
69
Trouble Diagnosis
69
Charging System
70
Charging Wire Diagram
70
Current Leakage Inspection
70
Voltage Check
72
Charging Voltage/Current Inspection
73
Control Charging Voltage
73
Specified Charging Current
73
Main Wire Circuit Inspection
74
Voltage Regulator Check
74
Voltage Regulator Inspection
74
Alternator Charging Coil
75
Alternator Lighting Coil
75
Resistor Check
75
CDI Unit
76
Ignition System Circuit
76
Ignition Coil
77
Spark Plug Confirmation
77
Pulse Generator
78
Secondary Coil
78
Remove the Luggage Box
79
Starter Magnetic Switch Inspection
79
Starting Circuit
79
Starting System
79
Starter Motor Pinion
80
Starter Motor Pinion Inspection
80
Armature Inspection
81
Starter Motor Re-Assembly/Installation
81
Starter Motor Removal/Disassembly
81
Oil Level Switch
82
Carburetor Heater
83
Fuel Unit
84
Lights
85
Meter
86
Starting Motor Installation
86
Starting Motor Removal
86
Headlight Bulb Replacement
88
Lights/Bulbs
88
The Headlight Beam Adjustment
88
Bulbs Replacement of Tail Light/Brake
89
Front Turn Signal Lamp Bulb Replacement
89
Main Switch/Horn
90
Handle Switch
91
Headlight Switch
91
High/Low Beam Switch/ Passing
91
Starting Switch
91
Brake Light Switch
92
Horn
92
Turn Signal Light Switch
92
Fuel Unit
93
Wiring Diagram
94
Special Tool
95
Service Maintenance Information
96
General Information
96
Periodical Maintenance Schedule
97
Air Cleaner
98
Fuel Lines
98
Fuel Filter
99
Engine Oil Line
99
Battery Removal
100
Oil Pump Control Cable
100
Tire
101
Recommended Tire and Tire Pressure
101
Rear Drum Brake Free Play
101
Disc Brake System Hose
102
Brake Fluid
102
Filling out Brake Fluid
102
Air Bleed Operation
102
Brake Lining Wear
103
Brake Pad Wear
103
Steering System
104
Suspension
104
Front Shock Absorber
104
Rear Shock Absorber
104
Recommended Plug
105
Leak
105
Spark Plug
105
Transmission Oil
105
Control Cable Lubrication
106
Driver Belt
106
Ignition Timing
106
Throttle Valve Operation
106
Carburetor Idle Speed Adjustment
107
Cylinder Compression Pressure Test
107
Compression Pressure
107
Headlight Adjustment
108
Nuts, Bolts Tighteness
108
Lubrication System
109
Lubrication System Diagram
109
Piston Seized
110
Too Much Smoke, Carbon in Spark Plug
110
Over Heat
110
Lubricant
110
Oil Pump Removal
111
Oil Pump Installation
111
Oil Pump/Oil Tube Air Bleeding
112
Oil Tube/Oil Pump
112
Oil Tube Air Bleeding
112
Oil Tank
113
Fuel System
115
Precautions in Operations
116
Engine Cannot be Started
116
Stall after Started
116
Lean Mixture
116
Throttle Valve
117
Auto By-Starter
118
Carburetor Remove
118
Auto By-Starter Removal/Installation
119
Float/Float Valve/Jet
120
Float Level Inspection
121
Carburetor Installation
121
Reed Valve
121
Engine Removal
124
Engine Hanger Bracket
129
Engine Installation
129
Cylinder Head/Cylinder/Piston
130
Compression Pressure too Low/Difficult to Start/Rough Idling
131
Piston Noise
131
Piston Ring Noise
131
Compression Pressure too High/Overheat/Knock
131
Cylinder Head Removal
132
Cylinder Head Installation
133
Cleaning Carbon in Combustion Chamber
133
Cylinder Head Inspection
133
Cylinder/Piston
134
Cylinder Removal
134
Piston Removal
134
Piston Ring Removal
134
Piston Ring Inspection
136
Connecting Rod Inspection
136
Piston/Cylinder Installation
137
A.C. Generator
139
Coil Resistance Value for the A.C. Generator
140
AC. Generator
140
Generator Removal
141
Generator Installation
142
"V" Type Belt Drive System/Kick-Starter
143
Engine Can be Started but Motorcycle Cannot be Moved
144
Shudder or Misfire When Drive
144
Insufficient Horsepower or Poor High-Speed Performance
144
Left Crankcase Cover
145
Left Crankcase Cover Removal
145
Disassembly of Kick Starter
145
Inspection of Kick Starter
145
Reassembly of Kick Starter
146
Installation of the Left Crankcase Cover
146
Drive Belt
147
Movable Drive Face
148
Drive Face Installation
151
Clutch/Driven Pulley
152
Clutch Outer
152
Driven Pulley Bearing Inspection
153
Driven Pulley Spring
153
Driven Pulley
153
Clutch Weight
153
Clutch Block Replacement
154
Replacement of Driven Pulley Bearing
155
Installation of Clutch/Driven Pulley
156
Final Driving Mechanism
157
Engine Can be Started but Scooter Cannot be Moved
158
Noise
158
Gear Oil Leaks
158
Disassembly of Final Driving Mechanism
159
Special Tool
160
Inspection of Final Driving Mechanism
162
Bearing Replacement
163
Re-Assembly of Final Driving Mechanism
164
4
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Sym JD05W Specifications
General
Brand
Sym
Model
JD05W
Category
Scooter
Language
English
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