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Sym PA12B User Manual

Sym PA12B
231 pages
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10. Brake System
Troubleshooting
Disk Brake
Soft brake lever Uneven brake
1. Air inside the hydraulic system
2. Hydraulic system leakage
3. Worn master cylinder piston
4. Worn brake pad
5. Poor brake caliper
10-4
6. Worn brake disk
7. Low brake fluid
8. Blocked brake hose
9. Warped / bent brake disk
10. Bent brake lever
Hard brake lever operation
1. Blocked brake system
2. Poor brake caliper
3. Blocked brake hose
4. Seized / worn master cylinder piston
5. Bent brake lever
1. Dirty brake pad / disk
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake disk
5. Restricted brake hose and fittings
Tight brake
1. Dirty brake pad / disk
2. Poor wheel alignment
3. Deformed or warped brake disk
Brake noise
1. Dirty brake pad / disk
2. Deformed brake disk
3. Poor brake caliper installation
4. Imbalanced brake disk / wheel
Drum Brake
Insufficient brake Tight brake pedal
1. Incorrect brake adjustment
2. Worn brake shoe
3. Worn wheel hub
4. Worn brake cam
5. Incorrect brake shoe installation
6. Jammed or interfered brake pedal
7. Contaminated brake shoe
8. Contaminated wheel hub
9. Worn brake shoe / cam contact face
10. Improper brake arm / cam contact face
1. Worn or damaged brake arm return spring
2. Worn wheel hub
3. Contaminated brake shoe
4. Contaminated wheel hub
5. Jammed or interfered brake pedal
6. Worn brake cam
7. Incorrect brake shoe installation
Brake noise
1. Worn brake shoe
2. Worn wheel hub
3. Contaminated brake shoe
4. Contaminated wheel hub

Table of Contents

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Sym PA12B Specifications

General IconGeneral
Fuel SystemCarburetor
Front SuspensionTelescopic fork
Rear BrakeDrum
Seat Height760 mm
Transmission4-speed
Rear SuspensionTwin shocks

Summary

Foreword

How To Use This Manual

Mechanical Layout

General Information

Symbols and Marks

Explains symbols used for warnings and component indications in the manual.

General Safety

Outlines essential safety precautions for operating and servicing the motorcycle.

Service Precautions

Lists critical precautions to follow during service and repair procedures.

Specifications

Details technical specifications for PA12B and PA12C models, including dimensions and capacities.

Torque Values

Provides recommended torque values for various fasteners and components for correct assembly.

Troubleshooting

Diagnostic guide for engine starting and running issues, including flowcharts.

Maintenance Information

Precautions in Operation

General safety and operational precautions for performing maintenance tasks.

Periodical Maintenance Schedule

Schedule outlining routine maintenance checks, inspections, and replacements at specific intervals.

Lubrication System

Details engine oil quantity, checking oil level, and procedures for oil exchange.

Fuel System

Instructions for maintenance of fuel lines, filter, and air cleaner.

Ignition System

Checks and procedures for ignition timing and spark plug inspection.

Cylinder Compression Test

Procedure for testing engine cylinder compression pressure to assess engine health.

Clutch Adjustment

Steps for inspecting and adjusting the clutch lever free play.

Disk Brake System

Instructions for checking brake hoses, pads, and brake fluid level.

Drum Brake System

Procedures for checking rear brake pedal free play and lining wear.

Tire

Instructions for checking tire pressure, condition, and tread depth for safety.

Battery

Procedures for battery removal, installation, and electrolyte level check.

Special Tools

Lists specialized tools required for various maintenance and repair tasks.

Fuel System

Precautions in Operation

Safety precautions for working with the fuel system, emphasizing fire hazards.

Troubleshooting

Common fuel system issues and their probable causes for diagnosis.

Carburetor Removal

Step-by-step guide for removing the motorcycle's carburetor.

Inspection

How to inspect float valve, seat, jets, and related carburetor parts.

Idle Speed Adjustment

Procedure for adjusting the engine's idle speed and CO emission.

Air Cleaner

Instructions for removing, cleaning, and installing the air filter element.

Lubrication / Clutch / Transmission

Precautions in Operation

General information and precautions for lubrication, clutch, and transmission servicing.

Troubleshooting

Common issues related to engine oil, clutch, and gear shifting.

Engine Oil

Instructions for checking engine oil level and performing oil changes.

Oil Pump Removal / Inspection

Detailed steps for removing and inspecting the engine oil pump.

Clutch Disassembly

Step-by-step guide for disassembling the motorcycle's clutch.

Gear Shift Linkage Mechanism

Disassembly and inspection of the gear shift linkage components.

AC Generator / Starter Clutch

Precautions in Operation

General information and precautions for AC generator and starter clutch servicing.

ACG Stator Disassembly

Step-by-step guide for removing the AC generator stator.

ACG Flywheel/ Starter Clutch

Disassembly and inspection of the ACG flywheel and starting clutch.

ACG flywheel/ Start clutch assembly

Steps for assembling the ACG flywheel, starter clutch, and gears.

Engine Removal

Precautions in Operation

General information and precautions for engine removal and servicing.

Engine Removal

Procedures for draining oil and removing the engine from the frame.

Engine Installation

Steps for reinstalling the engine back into the motorcycle frame.

Cylinder Head / Valve

Precautions in Operation

General information and precautions for cylinder head and valve servicing.

Troubleshooting

Diagnosing issues related to poor idling, compression, noise, and smoke.

Cylinder Head

Procedures for removing the cylinder head from the engine.

Camshaft

Instructions for camshaft removal, inspection, and special tools.

Valve

Procedure for disassembling valves and removing carbon deposits.

Valve Guide Replacement

Detailed steps for replacing valve guides, including heating and reaming.

Valve Seat Inspection and Refacing

Procedures for inspecting and grinding valve seats for proper sealing.

Cylinder Head Assembly

Steps for installing valves, springs, and camshaft into the cylinder head.

Cylinder Head Installation

Procedures for installing the cylinder head onto the engine block.

Valve Clearance Adjustment

Detailed steps for inspecting and adjusting valve clearance.

Cylinder / Piston

Precautions in Operation

General information and precautions for cylinder and piston servicing.

Troubleshooting

Common issues related to cylinder and piston performance.

Cylinder Removal / Inspection

Procedures for removing and inspecting the engine cylinder.

Piston Removal / Inspection

Steps for removing and inspecting the piston and piston rings.

Piston Rings Installation

How to correctly install piston rings onto the piston.

Piston Installation

Steps for installing the piston into the cylinder.

Cylinder Installation

Procedures for installing the cylinder and related components.

Crankshaft / Crankcase / Transmission / Kick Starter

Precautions in Operation

General information and precautions for crankcase and transmission servicing.

Troubleshooting

Common issues related to engine noise, shifting, and gear engagement.

Crankcase Disassembly

Step-by-step guide for disassembling the engine crankcase.

Crankshaft Inspection

How to measure crankshaft clearances and run-out.

Transmission Disassembly

Procedures for disassembling the transmission system components.

Kick Starter Disassembly

Procedures for removing and inspecting kick starter components.

Crankcase Assembly

Procedures for cleaning gasket residue and assembling the crankcase.

Brake System

Precautions in Operation

Safety precautions and general information for brake system maintenance.

Troubleshooting

Diagnosing issues with disk and drum brake systems (soft lever, noise, etc.).

Disk Brake System Inspection

Inspecting brake hoses, pads, and fluid level.

Brake Fluid Replacement / Air Bleed

Procedure for replacing brake fluid and bleeding air from the system.

Brake Caliper

Removal, inspection, and installation of the front brake caliper.

Brake pad replacement

Detailed steps for replacing front brake pads.

Brake Disk

Inspecting the brake disk for wear, damage, and run-out.

Brake Master Cylinder

Removal and inspection of the brake master cylinder components.

Brake Drum

Procedures for removing and inspecting the rear brake drum.

Brake Shoe

How to inspect and replace rear brake shoes.

Brake Panel

Removal and installation of the rear brake panel components.

Steering / Front Wheel / Front Fork

Precautions in Operation

General information and precautions for steering, wheel, and fork maintenance.

Troubleshooting

Common issues related to steering, suspension, and wheel runout.

Headlight

Procedures for removing and installing the motorcycle's headlight assembly.

Steering Handlebar

Removal of the headlight, switches, and throttle cable.

Front Wheel

Procedures for removing and inspecting the front wheel axle and bearings.

Front Fork

Removal of front wheel parts and loosening of fork bolts.

Steering Stem

Removal of top bridge, locknuts, and steering stem.

Rear Wheel / Rear Cushion / Swingarm

Precautions in Operation

General information and precautions for rear wheel, cushion, and swingarm.

Troubleshooting

Common issues related to rear wheel wobble, suspension, and hardness.

Rear Wheel

Procedures for removing exhaust pipe, swingarm pivot bolt nut, and rear brake rod.

Inspection

How to inspect wheel axle runout, bearings, wheel rim, and brake drum.

Drive Chain / Sprocket / Flange

Procedures for removing the left crankcase rear cover and drive chain.

Rear Cushion

Procedures for removing and installing the rear cushion (shock absorber).

Swingarm

Removal and inspection of the swingarm and its components.

Rear Brake Pedal

Removal, installation, and adjustment of the rear brake pedal.

Electrical System

Precautions in Operation

General information and precautions for electrical system maintenance.

Technical Specification

Specifications for battery, AC generator, ignition, and starting systems.

Troubleshooting

Diagnosing issues with charging, ignition, and starting systems.

Charging System

Procedures for battery removal, installation, and electrolyte inspection.

Battery voltage inspection

How to measure battery voltage and perform charging.

Charging voltage / current inspection

How to measure charging voltage and current to diagnose system issues.

Ignition System

Diagram of the ignition system and inspection of ignition/exciter coils.

Starter System

Diagram of the starting circuit and starter relay inspection.

Light System

Diagram of the motorcycle's lighting system, including indicators and lamps.

Headlight bulb replacement

Instructions for replacing the headlight bulb.

Winker bulb replacement

Procedure for replacing the motorcycle's winker (turn signal) bulbs.

Taillight / brake light Bulb replacement

Instructions for replacing the taillight and brake light bulbs.

Meter bulb replacement

How to replace bulbs for the tachometer and speedometer indicators.

Switch / Horn

Inspection and replacement of the main switch.

Handlebar switch

Inspection of light, hazard, and starting switches.

Left / right handlebar switch

Checking electrical circuits for high/low beam, winker, and horn switches.

Brake switch

Checking the continuity of brake switches.

Fuel Unit / Fuel Level Warning Switch

Inspection of fuel level warning switch and fuel unit resistance.

Emission Control System

Emission Control System Mechanism

Overview of the emission control system mechanisms.

Fuel Evaporative Emission Control System (E.E.C.)

Details on the fuel vapor control system, its construction, and operation.

Catalytic Converting System (CATA)

Description of the catalytic converter's function in reducing exhaust emissions.

Secondary Air Introduction System

Construction and operational principles of the secondary air system.

Inspection Items

Lists inspection procedures for various emission control systems.

Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed

Procedure to address emission pollutants outside standard idle speed.

Wiring Diagram

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