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Sym Orbit User Manual
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SYM 1
1.
CRANKCASE/CRANKSHAFT
11
-
1
MECHANISM DIAGRAM
..............
11-1
OPERATIONAL PRECAUTIONS
...
11-2
TROUBLE DIAGNOSIS
................
11-2
DISASSEMBLY OF CRANKCASE
11-3
CRANKSHAFT INSPECTION
.......
11-5
ASSEMBLY OF CRANKCASE
.....
11-6
MECHANISM DIAGRAM
1.5~2.0 kgf-m
0.7~1.1 kgf-m
110
112
Table of Contents
Table of Contents
4
Mechanism Illustrations
5
Special Tools
6
General Information/Trouble Diagnosis
8
Symbols and Marks
8
General Safety
9
Service Precautions
10
Specifications
16
Torque Values
17
Engine Hard to Start or Can Not be Started
19
Engine Run Sluggish (Speed Does Not Pick Up, Lack of Power)
20
Engine Runs Sluggish (Especially in Low Speed and Idling)
21
Engine Runs Sluggish (High Speed)
21
Clutch, Driving and Driving Pulley Troubles
22
Lubrication Points
23
Specification
24
Maintenance Information
24
Periodical Maintenance Schedule
25
Lubrication System
26
Engine Oil Capacity
26
Oil Change
26
Oil Viscosity
26
Fuel System
27
Fuel Pipe
27
Fuel Filter
27
Gear Oil
27
Air Cleaner
28
Throttle Valve Operation
28
Valve Clearance Adjustment
29
Valve Clearance Inspection and Adjustment
30
Carburetor Idle Speed Adjustment
30
Ignition Timing
31
Ignition System
31
Spark Plug
31
Driving System
32
Driving Belt
32
Clutch Pad
32
Cylinder Compression Pressure
32
Steering System
33
Suspension System
33
Front Shock Absorber
33
Rear Shock Absorber
33
Front Disc Brake System
34
Brake System Hose
34
Brake Fluid
34
Air Bleed Operation
34
Added Brake Fluid
35
Brake Lining Wear
35
Brake Confirmation
36
Drum Brake System
36
Rear Brake Free Play: (Drum Brake Type)
36
Wheel/Tire
37
Brake Light Switch
37
Battery Removal
38
Battery Cables Removal
38
Headlight Adjustment
38
Nuts, Bolts Tightness
38
Lubrication System Diagram
39
Lubrication System - Operational Precautions
40
Lubrication System Trouble Diagnosis
40
Engine Oil
41
Cleaning Engine Oil Strainer
41
Oil Pump Removal
42
Oil Pump Inspection
43
Oil Pump Re-Assembly
43
Oil Pump Installation
44
Gear Oil Level Inspection
45
Gear Oil Replacement
45
Fuel System Diagram
46
Fuel System - Precautions in Operation
47
Fuel System Specification
47
Fuel System Trouble Diagnosis
48
Poor Engine Start
48
Stall after Started
48
Mixture too Lean
48
Carburetor Removal
49
Vacuum Chamber Removal
49
Vacuum Chamber Installation
50
Accelerate Pump Removal and Installation
51
Auto By-Starter Inspection
52
Auto By-Starter Removal and Installation
52
Float Chamber
53
Idle Speed Adjustment
54
Fuel Tank Removal
55
Air Cleaner Removal and Installation
56
Engine Removal
57
Engine Diagram
57
Engine Specification
58
Engine Removal
59
Removal of Engine Suspension Bushing
62
Engine Suspension Frame Removal and Installation
63
Installation of Engine
64
Cylinder Head/Valve Diagram
65
Cylinder Head/Valve Specification
66
White Smoke
67
Low Compression Pressure
67
High Compression Pressure
67
Cylinder Head/Valve Troubleshooting
67
Camshaft Removal
68
Camshaft Inspection
69
Disassembly of Camshaft Holder
69
Inspection of Camshaft Holder
69
Cylinder Head Removal
70
Cylinder Head Disassembly
71
Cylinder Head Inspection
72
Valve Guide Replacement
73
Valve Seat Inspection and Service
74
Valve Seat Grinding
74
Cylinder Head Reassembly
76
Camshaft Installation
77
Cylinder Head Installation
77
Valve Clearance Adjustment
78
Cylinder/Piston Diagram
79
Cylinder/Piston Specification
80
Cylinder/Piston Trouble Diagnosis
80
Cylinder Removal
81
Cylinder Inspection
82
Piston Removal
83
Disassemble the Piston Rings
83
Piston Ring Installation
85
Piston Installation
86
Cylinder Installation
86
V-Belt Driving System/Kick Starter Arm/Starter Clutch
87
V-Belt Driving System/Kick Starter Arm/Starter Clutch Specification
88
Left Crankcase Cover Removal
89
Installation of the Left Crankcase Cover
89
V" Type Belt Driving System/Kick Starter Arm/ Starter Clutch
89
Driving Belt Inspection
90
Driving Belt Removal
90
Driving Belt Installation
91
Install the Starter Clutch
91
Sliding Pulley Removal
92
Sliding Pulley Inspection
93
Sliding Pulley Installation
93
Driving Pulley Installation
94
Clutch/Drive Pulley Disassembly
95
Driven Pulley Spring
96
Driven Pulley Check
96
Driven Pulley Bearing Inspection
96
Clutch Block Replacement
97
Replacement of Driven Pulley Bearing
98
Installation of Clutch/Driven Pulley
99
Final Driving Mechanism Diagram
100
Final Driving Mechanism Specification
101
Disassembly of Final Driving Mechanism
102
Inspection of Final Driving Mechanism
102
Bearing Replacement
103
Re-Assembly of Final Driving Mechanism
105
AC Generator
106
Generator/Starting Clutch
107
Right Crankcase Cover Removal
108
Right Crankcase Cover Installation
109
Mounted Coil Set Installation
109
Flywheel Installation
109
Crankcase/Crankshaft Diagram
111
Crankcase/Crankshaft - Operating Precautions
112
Crankcase/Crankshaft Specification
112
Crankcase/Crankshaft Trouble Diagnosis
112
Disassembly of Crankcase
113
Crankshaft Inspection
115
Assembly of Crankcase
116
Body Cover Diagram
118
Body Covers Disassemble Sequence
119
Handle Cover Removal
120
Front Cover Removal and Installation
121
Front under Cover Removal and Installation
122
Front Inner Box a Removal
123
Front Inner Box a Installation
124
Body Cover/Rear Center Cover/Rear Fender Removal
125
Body Cover/Rear Center Cover/Rear Fender Installation
126
Front Center Cover Removal and Installation
127
Luggage Box Removal and Installation
127
Floor Panel Removal and Installation
127
Brakes Diagram
128
Brake Specifications
130
Brake - Precautions in Operation
130
Brake Trouble Diagnosis
131
Soft Brake Lever
131
Uneven Brake
131
Poor Brake Performance
131
Hydraulic Brake System Inspection
132
Brake Fluid Add
132
Brake Fluid Replacement/Air-Bleed
133
Brake System
133
Brake Caliper Removal and Installation
134
Brake Pad Replacement
134
Brake Disk Inspection
135
Brake Master Cylinder Removal
135
Brake Master Cylinder Installation
137
Drum Brake-Drum Removal
138
Brake Pad Inspection
138
Brake Panel Removal and Installation
139
Brake Pad Removal and Installation
139
Front Brake Panel
140
Rear Brake Panel
140
Steering/Front Wheel/Front Shock Absorber Diagram
141
Steering/Front Wheel/Front Shock Absorber Data
142
Steering/Front Wheel/Front Shock Absorber Trouble Diagnosis
142
Steering Handle Removal
143
Steering Handle Installation
144
Front Wheel Removal
144
Front Wheel Inspection
145
Wheel Rim Check
145
Wheel Axle Check
145
Bearing Inspection
146
Front Shock Absorber Removal and Installation
148
Front Fork/Steering Column Removal and Installation
148
Rear Wheel/Rear Shock Absorber Diagram
150
Rear Wheel/Rear Shock Absorber Specification
151
Rear Wheel/Rear Shock Absorber Trouble Diagnosis
151
Exhaust Muffler Removal and Installation
152
Rear Wheel Inspection
152
Rear Wheel Removal and Installation
152
Rear Shock Absorber Removal and Installation
153
Electrical Equipment Diagram
154
Electrical Equipment - Precautions in Operation
155
Charging System
155
Ignition System
155
Starting System
155
Electrical Equipment Specifications
156
Electrical Equipment Trouble Diagnosis
157
Charging System
158
Charging Wire Diagram
158
Current Leakage Inspection
158
Battery Voltage Check
160
Battery Charging
160
Charging Voltage/Current Inspection (Battery)
161
Voltage Regulator Inspection
162
Alternator Charging Coil
163
Alternator Lighting Coil
163
Resistor Check
163
Ignition System Circuit
164
CDI Unit
164
Ignition Coil
165
Spark Plug Confirmation
165
Primary Coil Check
165
Secondary Coil
166
Pulse Generator
166
Remove the Luggage Box
167
Starter Magnetic Switch Inspection
167
Starting Circuit
167
Starting System
167
Starting Motor Removal
168
Meter Removal
168
Headlight Bulb Replacement
170
The Headlight Beam Adjustment
170
Front Turn Signal Lamp Bulb Replacement
171
Bulbs Replacement of Tail Light/Brake Light/Rear Turn Signal Light
171
Main Switch/Horn
172
Handle Switch
173
Headlight Switch
173
Starting Switch
173
High/Low Beam Switch/ Passing
173
Turn Signal Light Switch
174
Fuel Unit
175
Wiring Diagram
176
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Sym Orbit Specifications
General
Brand
Sym
Model
Orbit
Category
Scooter
Language
English
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