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JOYMAX 250
Sym JOYMAX 250 User Manual
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8. V
-Belt Dri
ving System
8-3
Left Crankcase C
over
Left crankcase cover removal
Loosen 4 bolts fro
m left side
crank out cover &
remove it.
Remove left cran
kcase cover. (8
bol
ts)
Remove 2 dow
el pin and gasket.
Left crankcase cover install
Install left cran
kcase cover in the rev
erse
procedures of
removal.
To this chapter contents
8
bolts
Left cover plat
e
Bearing setting p
late
Drive shaft holder
bearing
95
97
Table of Contents
2. Maintenance Information
20
Service Manual
1
Service Precautions
6
Specifications
12
Torque Values
13
Lubrication Points
19
Table of Contents
20
Maintenance Information
20
Periodical Maintenance Schedule
21
Engine Oil
22
Engine Oil Strainer Clean
22
Gear Oil
23
Fuel Lines / Cable
23
Air Cleaner
24
P.C.V. System
25
Valve Clearance
25
Carburetor Idle Speed Adjustment
26
Ignition System
27
Spark Plug
27
Cylinder Compression Pressure
28
Drive Belt
28
Steering Handle Top Bearing
29
Cushion
29
Disk Brake System
30
Brake Light Switch/Starting Inhibitor
32
Switch
32
Headlight Beam Distance
32
Wheel / Tire
32
Battery
33
Nuts, Bolts Tightness
33
3. Lubrication System
38
Lubrication System
38
Precautions in Operation
39
Troubleshooting
39
Engine Oil
40
Engine Oil Strainer Clean
40
Oil Pump
41
Gear Oil
44
4. Fuel System
46
Fuel System
46
Precautions in Operation
47
Fuel System
47
Trouble Diagnosis
48
Carburetor Remove / Install
49
Vacuum Chamber
49
Air Cut-Off Valve
51
Automatic By-Starter
52
Float Chamber
53
Adjustment of Idle Speed
55
Fuel Tank
56
Fuel Pump
58
Air Cleaner
59
5. Removal & Installation of Engine
60
Engine Removal
60
Engine Removal
61
Engine Hanger
65
Rear Fork
66
Removal of Engine Bush
68
Installation of Engine
69
6. Cylinder Head / Valve
70
Cylinder Head / Valve
70
Precautions in Operation
71
Troubleshooting
72
Cylinder Head Removal
73
Cylinder Head Disassembly
75
Cylinder Head Inspection
77
Valve Stem Replacement
79
Valve Seat Inspection and Service
80
Cylinder Head Reassembly
82
Cylinder Head Installation
83
Valve Clearance Adjustment
85
7. Cylinder / Piston
86
Cylinder / Piston
86
Precautions in Operation
87
Trouble Diagnosis
87
Cylinder and Piston Removal
88
Piston Ring Installation
91
Cylinder Installation
92
Piston Installation
92
8. V-Belt Driving System
94
Mechanism Diagram
94
Maintenance Description
95
Trouble Diagnosis
95
Left Crankcase Cover
96
Drive Belt
98
Drive Face
100
Clutch Outer/Driven Pulley
103
9. Final Driving Mechanism
108
Final Driving Mechanism
108
Precautions in Operation
109
Trouble Diagnosis
109
Disassembly of Final Driving Mechanism
110
Inspection of Final Driving Mechanism
111
Bearing Replacement
112
Re-Assembly of Final Driving Mechanism
115
10. Alternator / Starting Clutch
116
Alternator
116
Precautions in Operation
117
Right Crankcase Cover Removal
118
AC.G. Set Removal
119
Right Cover Bearing
119
Flywheel Removal
120
Starting Clutch
121
AC.G. Flywheel Installation
123
AC.G. Set Installation
124
Right Crankcase Cover Installation
124
11. Crankcase / Crank
126
General Information
127
Trouble Diagnosis
127
Disassembly of Crankcase
128
Crankshaft Inspection
129
Assembly of Crankcase
131
12. Cooling System
134
Cooling System
134
General Information
135
Trouble Diagnosis
135
Trouble Diagnosis for Cooling System
136
Change of Coolant
138
Radiator
139
Water Pump
141
Thermostat
145
Body Cover
145
13. Body Cover
148
Body Cover
148
Maintenance
149
Handle Cover
150
Front Cover
151
Meter Panel
153
Inner Box
154
Side Cover
156
Front under Spoiler
157
Rear Carrier
157
Luggage Box
158
Rear Body Cover
159
Floor Panel
160
Front Fender
160
Rear Fender
161
14. Brake System
162
Brake System
162
Maintenance Description
163
Trouble Diagnosis
164
Disk Brake System Inspection
165
Adding Brake Fluid
166
Brake Fluid Replacement / Air-Bleed
167
Rear Brake Caliper
169
Brake Disk
170
Master Cylinder
170
15. Steering / Front Wheel / Front Cushion
174
Operational Precautions
175
Trouble Diagnosis
175
Steering Handle
176
Front Wheel
178
Front Cushion
181
Steering Stem
182
16. Rear Wheel / Rear Fork / Rear Cushion
184
Operational Precaution
185
Trouble Diagnosis
185
Muffler
186
Rear Wheel
186
Rear Fork
188
Rear Cushion
189
17. Electrical System
190
Electrical System
190
Maintenance Data
191
Technical Specification
191
Trouble Diagnosis
192
Charging System
195
Starting System
200
Meters
202
Light / Bulb
204
Switch / Horn
208
Fuel Unit
210
Cooling Fan Thermo Switch
211
Thermo Sensor
212
Water Temperature Meter
212
Electrical Diagram
214
Roll over Sensor
231
Fuel Injector
235
5
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Sym JOYMAX 250 Specifications
General
Brand
Sym
Model
JOYMAX 250
Category
Scooter
Language
English
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