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. Specifications are subject to change without notice. [. . . ] Worn clutch lining Insufficient horsepower or poor high speed performance 1. Insufficient spring capacity of driven pulley 3. Driven pulley operation un-smoothly 8-2 SYM 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM air cleaner lock nut LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent. Remove engine left-side cover (8 bolts). kick starter arm KICK STARTER ARM Disassembly Remove the return spring, starter shaft. Remove driving gear, friction spring and washer. Inspection Check if starter shaft, driving gear, for wear or damage. Check the return spring for spring force or damaged. Replace it with one if poor parts found. Reassembly Apply with some specified grease on the gear, shaft. Install the friction spring of driving gear onto convex part of the case cover. Install, return spring and starter shaft as diagram shown. Rotate the lever and then align driving gear with width-tooth on the starter shaft. Install thrust washer and socket onto starter shaft. Starter shaft Friction spring Starter shaft Return spring Driving gear starter shaft gear driving gear Strap Bolts Installation of the left crankcase cover Install the left crankcase cover. (8 bolts) Install front vent tube of left cover and tighten the strap. (2 bolts) Kick starter arm shaft 8-3 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVING BELT Removal Remove left crankcase cover. Hold the sliding pulley with a universal fixture, and then remove the nut and sliding pulley. sliding pulley SYM Universal fixer Hold driving pulley with universal fixture, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake only will damage reduction gear system. driving pulley Nut Universal fixer Push the driving belt into belt groove as diagram shown so that the belt can be loosened, and then remove. Driving belt and clutch at same time. Driving belt Inspection Check the driving belt for crack or wear. [. . . ] Front turn signal light Pull out the bulb and replace it with new one. (12V 5W) the wire connector of the turn signal light Installation Install the bulb in reverse order of removal. bolts x4 Bulbs Replacement of tail light/brake light/rear turn signal light. Remove the seat and luggage box . (Bolts x4) Remove the rear carrier. (Bolts x3) Remove the rear center cover. Remove the 2 bolts of the rear fender. bolts x2 16-18 SYM Remove the tail light assembly. 16. [. . . ]