Sym HD 125/200 servicemanual - Scootergrisen

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Maintenance Description Operational precautions Caution 14. BRAKE Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system. While refilling brake fluid, care should be taken not to let the foreign material entering into the brake system. Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage. Check the operation of the brake system before riding. Specifications Item Standard (mm) Limit (mm) The thickness of front and rear brake disk 4.000 2.500 Front and rear brake disk eccentricity < 0.100 0.300 Master cylinder inner diameter 11.000 - 11.043 11.055 Master cylinder outer diameter 10.957 - 10.984 10.945 Diameter of front disk 220.000 - Diameter of rear brake drum 130.000 - Thickness of front brake lining 5.100 2.000 Thickness of rear brake lining 5.100 2.000 Torque values To this chapter contents Front brake hose bolts 3.0~4.0kgf-m Bolt for front brake caliper 3.0~3.5kgf-m Bolts for the front brake disk 4.0~4.5kgf-m Brake lever nut 0.8~1.2kgf-m Nut for the rear brake arm 0.5~0.6kgf-m Air-bleed valve 0.5~0.6kgf-m 14-3
14. BRAKE Trouble Diagnosis Disk Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8. Blocked brake hose 9. Warp/bent brake disk 10. Bent brake lever Hard operation of brake lever 1. Blocked brake system 2. Poor brake caliper 3. Blocked brake pipe 4. Seized/worn master cylinder piston 5. Bent brake lever Drum Brake Poor brake performance 1. Improper brake adjustment 2. Worn brake lining 3. Worn brake drum 4. Worn brake cam 5. Improper brake lining installation 6. Seized brake cable 7. Dirty brake lining 8. Dirty brake drum 9. Brake pad worn in brake cam area. 10. Poor contact between brake arm and camshaft indent 14-4 To this chapter contents Uneven brake 1. Dirty brake lining/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 lining/disk 2. Poor wheel alignment 3. Deformed or warped brake disk Brake noise 1. Dirty lining 2. Deformed brake disk 3. Poor brake caliper installation 4. Imbalance brake disk or wheel Tight operation or low return speed of brake lever 1. Worn/broken/crack return spring 2. Worn drum 3. Dirty brake lining 4. Brake seized caused from dirty brake drum 5. Seized brake cable 6. Worn brake cam 7. Improper brake lining installation Brake noise 1. Worn brake lining 2. Worn drum 3. Dirty brake lining 4. Dirty brake drum
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 82:
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:
Page 106 and 107:
Disassembly of Final Driving Mechan
Page 108 and 109:
Bearing Replacement Caution Never
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 122: Mechanism Diagram ········
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 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 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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