Sym HD 125/200 servicemanual - Scootergrisen

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Steering Stem Remove Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing. Slightly tap the top and bottom ball bearing seats with a plastic hammer to remove the seats. Remove bottom cone race body with a punch. Caution Do not damage the steering stem. Installation Install a new bottom cone race onto the steering stem. Push the cone race until to mounted position. Caution Do not tilt the ball bearing seats as installation. Apply with grease onto the ball bearing seats, and install steel balls onto the seats. (Top: 26 balls, bottom: 29 balls) Lubricate the top cone race seat with grease. Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turns. Torque value: 0.25kgf-m Caution Check the steering stem that should be rotated freely and no clearance in vertical direction. To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Steering lock nut Steering lock nut Top cone-race Steering stem mounting nut Top cone race Top ball bearing seat Bottom ball bearing seat Top cone-race Steel balls Bottom cone race Return 1/2 turns Locking to 1/4~3/8 turns 15-9
Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.0~2.0kgf-m Install in reverse order of removal procedures. Shake steering handle up & down, left & right, and front & rear to check if it is loosen, has too much resistance and pulls to one side. Check steering handle if it is being pulled too tight by the brake cables. To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Steering lock nut Top cone-race 15-10
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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:
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:
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: Front Cushion Remove Remove front c
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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