User manual SYM ORBIT SERVICE MANUAL

[. . . ] SERVICE MANUAL SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle. The manual is shown with illustrations and focused on u Service Proceduresv , u Operation Key Pointsv , and u Inspection Adjustmentv so that provides technician with service guidelines. If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. This manual that contains all data, illustration, indication and specifications is based on current production information. [. . . ] Replace the driving belt if it exceed maintenance limited specification. Service Limit: 16. 80mm Caution Using the genuine parts for replacement. Clean up all grease or dirt before installation. Tooth Width 8-4 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving pulley. Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily. Sliding driven pulley Install the starter gear. Install clutch outer. starter gear sliding pulley clutch outer Install the clutch with universal fixture, and then tighten nut to specified torque value. Torque value: 3. 5~4. 5 kgf-m Nut Clutch outer Universal fixer Caution When install the driving belt, if there is a arrow mark, then the arrow mark must point to rotation motion. If not, the letters on the belt must be forwarded to assembly direction. 8-5 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Starter gear SYM driving pulley nut Remove the driving belt from the pulley. Remove the belt and the starter gear. Sliding pulley Crankshaft Driving pulley hub Remove tilt plate. Tilt plate Remove weight rollers from sliding pulley. Sliding pulley Roller 8-6 SYM Inspection 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Weight roller The operation of sliding pulley is means of the weight roller to pressing on it with centrifuge force. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected. Service limit: 19. 980 mm Measure the pulley hub's inner diameter. Service limit: 20. 150 mm Sliding pulley Pulley hub Assembly/Installation Install the weight rollers. Weight roller Install the title plate guide boot onto the title plate. V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Clean it with cleaning solvent. SYM Pulley surface Install siding pulley assembly onto crankshaft. Sliding pulley Crankshaft Pulley hub DRIVING PULLEY INSTALLATION Press driving belt into pulley groove, and then press down the up & down sides of the driving belt to separate it away from the driving pulley hub. Caution To press down the up & down sides of the driving belt can avoid to pressing and damaging the belt when installing the driving pulley, and also can make sure that the driving pulley can be tighten. Caution Make sure that two sides of pulley surfaces have to be free of grease. Torque value: 5. 0~6. 0 kgf-m Install left crankcase cover. Press down Driving belt 8-8 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Special nut wrench CLUTCH/DRIVEN PULLEY DISASSEMBLY Remove driving belt and clutch/driven pulley. [. . . ] Installation Install the meter in reverse order of removal. 16-16 SYM LIGHT/BULBS Headlight Bulb Replacement Rear the screw of the front cover. Press down the bulb spring locker and then remove the locker with turning it left motion. (12V 35W/35W) Caution Do not touch the bulb surface with fingers because the bulb will create hot-spot so that let it be burnt. Wipe the bulb with cloth to prevent from damaged if the bulb be touched by hands. [. . . ]