Sym HD 125/200 servicemanual - Scootergrisen

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Bearing Replacement Caution Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove driving shaft bearing and counter shaft bearing from left crankcase using following tools: Special tool: Inner bearing puller Install new drive shaft bearing and counter shaft bearing into left crankcase. Special tool: Bearing driver (6301) Remove oil seal, and then remove final shaft bearing from left crankcase. Special tool: Inner bearing puller To this chapter contents 9. FINAL DRIVING MECHANISM 9-5
9. FINAL DRIVING MECHANISM Install new final shaft seal. Special tool: Oil seal driver (27*42*7) Install new final shaft bearing. Special tool: Bearing driver (6203/6004UZ) Press out the drive shaft from gear box cover. Using shaft protector as operation. Remove oil seal from gear box cover and discard the seal. Use inner bearing puller to remove the final shaft bearing and counter shaft bearing from the cover. Special tool: Inner bearing puller If the drive shaft is pulled out with its bearing, then remove the bearing with bearing puller and shaft protector. Special tool: Multi-functional bearing puller or Outer bearing puller Shaft protector 9-6 To this chapter contents Bearing puller Oil seal driver Bearing driver Inner bearing puller Protector
Page 1:
FORWARD HOW TO USE THIS MANUAL CONT
Page 5:
MECHANISM ILLUSTRATIONS LH12W / LH1
Page 9 and 10:
1. GENERAL INFORMATION The length
Page 11 and 12:
1. GENERAL INFORMATION When separa
Page 13:
1. GENERAL INFORMATION Do not let
Page 18:
Troubles Diagnosis A. Engine hard t
Page 22 and 23:
Parts to Be Greased Steering shaft
Page 24:
Precautions in Operation ·····
Page 30 and 31:
Ignition System Caution C.D.I igni
Page 32 and 33:
Filling Out Brake Fluid Tighten the
Page 34:
Side Stand Check side stand spring
Page 38 and 39:
To this chapter contents 2. MAINTEN
Page 40:
Precautions in Operation ·····
Page 46 and 47:
Gear Oil Oil level inspection Park
Page 48 and 49:
Precautions in Operation...........
Page 50 and 51:
Trouble Diagnosis Poor engine start
Page 52 and 53:
Check if the vacuum piston for wear
Page 55:
4. FUEL SYSTEM Float Chamber Disass
Page 59 and 60: 4. FUEL SYSTEM Notes: 4-12 To this
Page 61 and 62: 5. ENGINE REMOVAL Removal of Engine
Page 63: 5. ENGINE REMOVAL Remove the mounti
Page 68: Mechanism Diagram ········
Page 72: Remove the 2 cylinder head mounting
Page 78: After the valve seat ground, coat v
Page 85: 7. CYLINDER/PISTON Piston Removal P
Page 89 and 90: 7. CYLINDER/PISTON Notes: 7-8 To th
Page 92 and 93: Left Crankcase Cover Left crankcase
Page 94 and 95: Installation Caution Pull out drive
Page 96 and 97: Inspection The weight rollers are t
Page 98 and 99: Clutch Outer/Driven Pulley Disassem
Page 100 and 101: Clutch weight Replacement Remove sn
Page 102 and 103: Installation of Clutch OUTER/Driven
Page 104 and 105: Mechanism Diagram ········
Page 106 and 107: Disassembly of Final Driving Mechan
Page 110 and 111: Install a new drive shaft bearing o
Page 112 and 113: Apply with grease onto new oil seal
Page 114 and 115: Mechanism Diagram ········
Page 116 and 117: Right Crankcase Cover Removal Remov
Page 118 and 119: Starting Clutch Inspection Check th
Page 120 and 121: Flywheel Installation Align the key
Page 125 and 126: 11. CRANKCASE / CRANK Remove crank
Page 127 and 128: 11. CRANKCASE / CRANK Assembly of c
Page 129 and 130: 11. CRANKCASE / CRANK Tighten 4 bol
Page 134 and 135: System Test Test on the filler cap
Page 136 and 137: Remove coolant outlet pipe and rese
Page 138 and 139: Check any wear and damage of the me
Page 140 and 141: Install the seal washer into the ro
Page 143 and 144: 12. COOLING SYSTEM Notes: To this c
Page 145 and 146: 13. BODY COVER Maintenance Body cov
Page 147 and 148: 13. BODY COVER Handle front cover D
Page 149 and 150: 13. BODY COVER Side cover Remove Lo
Page 152 and 153: Rear carrier Remove Loosen 4 bolts
Page 154 and 155: Inner box Remove Remove the front c
Page 156 and 157: Front fender Remove Remove right &
Page 158 and 159:
Rear fender Remove luggage box and
Page 160 and 161:
Mechanism Diagram-Front Disk Brake
Page 162 and 163:
Maintenance Description Operational
Page 164 and 165:
Disk Brake System Inspection Inspec
Page 166 and 167:
Brake fluid replacement / Air-bleed
Page 168:
Brake Disk Inspection Visually chec
Page 171 and 172:
14. BRAKE Rear Drum Brake Remove br
Page 173 and 174:
14. BRAKE Notes: 14-14 To this chap
Page 175 and 176:
15. STEERING / FRONT WHEEL / FRONT
Page 177 and 178:
Installation Install handle and ali
Page 179 and 180:
Wheel Place the wheel on to a rotat
Page 181 and 182:
Front Cushion Remove Remove front c
Page 183 and 184:
Install the steering stem mounting
Page 185 and 186:
16. REAR WHEEL / REAR FORK / REAR C
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
17. ELECTRICAL SYSTEM Maintenance D
Page 194 and 195:
Charging System Charging circuit Ma
Page 196 and 197:
Inspection on regulator rectifier R
Page 199 and 200:
17. ELECTRICAL SYSTEM Starting Syst
Page 201 and 202:
17. ELECTRICAL SYSTEM Light / Bulb
Page 204:
Dimmer and Passing switch Pin Posit
Page 209 and 210:
17. ELECTRICAL SYSTEM Notes: 17-20
Page 211:
18. ELECTRICAL DIAGRAM Notes: 18-2
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Sym HD 125/200 servicemanual - Scootergrisen

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