Sym DD Servicemanual - Scootergrisen

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Maintenance Information ···················5-2 Troubleshooting ·································5-2 Home page Contents 5. CYLINDER HEAD/CYLINDER/PISTON Cylinder Head·····································5-3 Cylinder/Piston···································5-5 5-1 5
5. CYLINDER HEAD/CYLINDER/PISTON Maintenance Information Precautions in Operation The inspection and maintenance of the cylinder head, cylinder and piston can be carried as engine mounted on the body. It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. Remove all washes from the interfaces of cylinder head, cylinder and crankcase. Be careful do not damage cylinder head, cylinder and piston when removing. Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces before installation. Specification Item FT05 series Standard value (mm) Limit (mm) Cylinder head Deformation - 0.100 Piston OD 39.030~39.045 38.935 Clearance between cylinder and piston 0.040~0.050 0.100 Piston pin hole 12.002~12.008 12.030 Piston Piston pin OD 11.994~12.000 11.970 Clearance between piston and piston pin 0.002~0.014 0.030 Piston ring end gap 0.100~0.250 0.400 ID of connecting rod small end 17.05~17.015 17.025 Cylinder ID Deformation 39.000~39.015 - 39.050 0.100 ID: inner diameter OD: outer diameter Tighten torque value Cylinder head 1.0kgf-m Spark plug 1.4kgf-m Troubleshooting Compression Pressure Too Low/Difficult To Start/Rough Idling 1. Cylinder head gasket leaking 2. Spark plug not tighten enough 3. Worn, seized or crack piston ring 4. Damaged, worn cylinder or piston 5. Poor reed Compression Pressure Too High/Overheat/Knock 1. Too much carbon deposit built up in combustion chamber 5-2 This chapter Contents Exhaust pipe connection nut 1.2kgf-m Exhaust muffler mounting bolt 3.3kgf-m Piston Noise 1. cylinder and piston worn out 2. piston pin or piston pin hole worn out 3. connecting rod small end bearing worn out Piston Ring Noise 1. Worn, seized or crack piston ring 2. Cylinder worn out or damaged
Page 1 and 2: FORWARD HOW TO USE THIS MANUAL DD 5
Page 3 and 4: How to Use This Manual This service
Page 5 and 6: MODEL ILLUSTRATION FT05V Front turn
Page 8 and 9: Symbols and Marks ········
Page 11: 1. GENERAL INFORMATION The length
Page 14: Frame Bolt for engine suspension It
Page 17 and 18: 1. GENERAL INFORMATION 1-10 Spark p
Page 19 and 20: 1. GENERAL INFORMATION B. Engine ru
Page 21 and 22: 1. GENERAL INFORMATION E. CLUTCH, D
Page 23: 1. GENERAL INFORMATION Note: 1-16 T
Page 28: Oil Pump Control Cable Caution To a
Page 33 and 34: 2. SERVICE MAINTENANCE INFORMATION
Page 37 and 38: 2. SERVICE MAINTENANCE INFORMATION
Page 39 and 40: 3. LUBRICATION SYSTEM Precautions I
Page 41 and 42: 3. LUBRICATION SYSTEM Oil Pump/Oil
Page 43 and 44: 3. LUBRICATION SYSTEM Notes: 3-6 Th
Page 45 and 46: 4. ENGINE REMOVAL Maintenance Infor
Page 47 and 48: 4. ENGINE REMOVAL Remove rear brake
Page 49: 4. ENGINE REMOVAL Note: 4-6 This ch
Page 53 and 54: 5. CYLINDER HEAD/CYLINDER/PISTON Cy
Page 55 and 56: 5. CYLINDER HEAD/CYLINDER/PISTON Us
Page 58: Maintenance Information ·····
Page 61 and 62: 6. ALTERNATOR Disconnect alternator
Page 63 and 64: 7. “V” TYPE BELT DRIVE SYSTEM/K
Page 78 and 79: Disassembly of Final Driving Mechan
Page 80 and 81: Install countershaft, final driven
Page 82: Maintenance Information ·····
Page 85 and 86: 9. CRANKCASE/CRANKSHAFT Crankshaft
Page 87 and 88: 9. CRANKCASE/CRANKSHAFT Assemble th
Page 90: Throttle Valve Removal Remove the b
Page 94 and 95: Float Level Inspection Measure floa
Page 96 and 97: Air Cleaner Removal/Installation Re
Page 98 and 99: Front Disc Brake System ·····
Page 100 and 101:
Rear Drum Brake System 11.0kgf-m 2.
Page 102 and 103:
Troubleshooting Disc Brake Soft bra
Page 104 and 105:
Disc Brake -Air Bleed 1. Tightly ho
Page 106 and 107:
Master Cylinder Inspection Check th
Page 108 and 109:
Drum Brake To use vacuum cleaner or
Page 110 and 111:
Body Overview···········
Page 112 and 113:
Maintenance Information Body covers
Page 114 and 115:
Luggage Box 1. Removal: Lift up se
Page 116 and 117:
Remove 1 screw from the front side.
Page 118 and 119:
Front under Spoiler Removal: Remov
Page 120 and 121:
Floor Panel 1. Removal: Remove the
Page 122 and 123:
Under Cover 1. Removal: Remove the
Page 124:
Maintenance Information ·····
Page 127 and 128:
13. STEERING/FRONT WHEEL/SUSPENSION
Page 129 and 130:
Page 131 and 132:
Page 133 and 134:
Page 135 and 136:
14. REAR WHEEL/SUSPENSION Maintenan
Page 137 and 138:
14. REAR WHEEL/SUSPENSION Installat
Page 139 and 140:
15. ELECTRICAL EQUIPMENT Maintenanc
Page 142 and 143:
Charging System AC. Generator White
Page 146:
Ignition System Blue/Yellow Black/R
Page 151:
15. ELECTRICAL EQUIPMENT Oil Level
Page 154 and 155:
Headlight Switch Wire color Brown Y
Page 156 and 157:
Home page Contents 16. ELECTRICAL D
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Sym DD Servicemanual - Scootergrisen

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