Sym Orbit 125 Manuel utilisateur

SERVICE MANUAL

Orbit 125

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 「Service Procedures」, 「Operation Key

Points」, and 「Inspection Adjustment」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.

This manual that contains all data, illustration, indication and specifications

is based on current production information. SYM reserves the right to make

changes at any time without notice and without incurring any obligation

whatever. No part of this manual can be duplicated by any means without

written permission of SANYANG.

SERVICE DEPARTMENT

SAN YANG INDUSTRY CO., LTD.

HOW TO USE THIS MANUAL SYM

This service manual describes basic information of different system parts and

system inspection & service for SYM series motorcycles. In addition, please

refer to the manual contents in detailed for the model you serviced in

inspection and adjustment.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance.

The third to the eleventh chapters cover engine and driving systems.

The twelfth to fifteenth chapters are contained the parts set of assembly

body.

The sixteenth chapter is electrical equipment.

The seventh chapter is for wiring diagram.

Please see index of content for quick having the special parts and system

information.

SYM CONTENTS

CONTENTS

GENERAL INFORMATION/TROUBLE DIAGNOSIS...................................1

MAINTENANCE INFORMATION .................................................................2

LUBRICATION SYSTEM..............................................................................3

FUEL SYSTEM.............................................................................................4

ENGINE REMOVAL......................................................................................5

CYLINDER HEAD/VALVE............................................................................6

CYLINDER/PISTON......................................................................................7

"V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......................8

FINAL DRIVING MECHANISM.....................................................................9

A.C. GENERATOR/STARTING CLUTCH....................................................10

CRANKCASE/CRANKSHAFT .....................................................................11

BODY COVER..............................................................................................12

BRAKE SYSTEM..........................................................................................13

STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER........................14

REAR WHEEL/SUSPENSION......................................................................15

ELECTRICAL EQUIPMENT.........................................................................16

ELECTRICAL DIAGRAM .............................................................................17

MECHANISM ILLUSTRATIONS SYM

Light/starter switch

Front disk brake

Exhaust muffler

Ignition switch

Gea

oil draining

bolt

Battery/Fuse/CDI Front brake lever

Rea

brake leve

cleane

Gea

oil filling

bolt

Oil level

Tail light

Front turn

signal light Fuel tank / Fuel unit

High&Low beam/Seat

open/turn signal/horn

Head light/

Position light

Rear turn

signal light

Engine number/engine

oil draining bolt

Ignition coil

Frame numbe

Meter

A.C. Generator

Start magnetic switch

Horn/REG.REC

RR. turning

signal light

Tail light Front turn

signal light

Winker relay

Engine control

switch

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-1

SYMBOLS AND MARKS ....................1-1

GENERAL SAFETY............................1-2

SERVICE PRECAUTIONS .................1-3

SPECIFICATIONS..............................1-9

TORQUE VALUES (ENGINE).............. 1-10

TORQUE VALUES (FRAME) ............... 1-11

TROUBLES DIAGNOSIS ..................... 1-12

LUBRICATION POINTS ....................... 1-16

SYMBOLS AND MARKS

Symbols and marks are used in this manual to indicate what and where the special service are

needed, in case supplemental information is procedures needed for these symbols and marks,

explanations will be added to the text instead of using the symbols or marks.

Warning Means that serious injury or even death may result if procedures are not

followed.

Caution Means that equipment damages may result if procedures are not followed.

Engine oil

Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the

damage that caused by not apply with the limited engine oil.

Grease King Mate G-3 is recommended.

Locking sealant

Apply sealant, medium strength sealant should be used unless otherwise

specified.

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools Special service tools.

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions.

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross

through the component (invisibility).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-2

GENERAL SAFETY

Carbon monoxide

If you must run your engine, ensure the place is

well ventilated. Never run your engine in a

closed area. Run your engine in an open area, if

you have to run your engine in a closed area, be

sure to use an extractor.

Caution

Gasoline

Gasoline is a low ignition point and explosive

material. Work in a well-ventilated place, no

flame or spark should be allowed in the work

place or where gasoline is being stored.

Caution

Used engine oil

Caution

Hot components

Caution

Battery

Caution

Brake shoe

Do not use an compressed air or a dry brush to

clean components of the brake system, use a

vacuum cleaner or the equivalent to avoid

asbestos dust flying.

Caution

Brake fluid

Caution

Exhaust contains toxic gas which may cause

one to lose consciousness and even result in

death.

 Battery emits explosive gases; flame is

strictly prohibited. Keep the place well

ventilated when charging the battery.

 Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful

do not be spray on your eyes or skin. If you

get battery acid on your skin, flush it off

immediately with water. If you get battery

acid in your eyes, flush it off immediately

with water, then go to hospital to see an

ophthalmologist.

 If you swallow it by mistake, drink a lot of

water or milk, and take some laxative such

as castor oil or vegetable oil, and then go to

see a doctor.

 Keep electrolyte beyond reach of children.

Gasoline is highly flammable, and may explode

under some conditions, keep it away from

children.

Prolonged contact with used engine oil (or

transmission oil) may cause skin cancer

although it might not be verdict.

Inhaling asbestos dust may cause disorders

and cancer of the breathing system.

Spilling brake fluid on painted, plastic, or rubber

parts may cause damage to the parts. Place a

clean towel on the above-mentioned parts for

protection when servicing the brake system.

Keep brake fluid beyond reach of children.

Components of the engine and exhaust system

can become extremely hot after engine running.

They remain very hot even after the engine has

been stopped for some time. When performing

service work on these parts, wear insulated

gloves and wait until cooling off.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-3

SERVICE PRECAUTIONS

 Always use with SANYANG genuine parts

and recommended oils. Using non-designed

parts for SANYANG motorcycle may damage

the motorcycle.

 Special tools are designed for remove and

install of components without damaging the

parts being worked on. Using wrong tools

may result in parts damaged.

 When servicing this motorcycle, use only

metric tools. Metric bolts, nuts, and screws

are not interchangeable with the English

system, using wrong tools and fasteners may

damage this vehicle.

 Clean the outside of the parts or the cover

before removing it from the motorcycle.

Otherwise, dirt and deposit accumulated on

the part's surface may fall into the engine,

chassis, or brake system to cause a damage.

 Wash and clean parts with high ignition point

solvent, and blow dry with compressed air.

Pay special attention to O-rings or oil seals

because most cleaning agents have an

adverse effect on them.

 Never bend or twist a control cable to prevent

stiff control and premature worn out.

 Rubber parts may become deteriorated when

old, and prone to be damaged by solvent and

oil. Check these parts before installation to

make sure that they are in good condition,

replace if necessary.

 When loosening a component which has

different sized fasteners, operate with a

diagonal pattern and work from inside out.

Loosen the small fasteners first. If the bigger

ones are loosen first, small fasteners may

receive too much stress.

 Store complex components such as

transmission parts in the proper assemble

order and tie them together with a wire for

ease of installation later.

 Note the reassemble position of the important

components before disassembling them to

ensure they will be reassembled in correct

dimensions (depth, distance or position).

 Components not to be reused should be

replaced when disassembled including

gaskets metal seal rings, O-rings, oil seals,

snap rings, and split pins.

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM

1-4

 The length of bolts and screws for

assemblies, cover plates or boxes is different

from one another, be sure they are correctly

installed. In case of confusion, Insert the bolt

into the hole to compare its length with other

bolts, if its length out side the hole is the

same with other bolts, it is a correct bolt.

Bolts for the same assembly should have the

same length.

 Tighten assemblies with different dimension

fasteners as follows:

 Tighten all the fasteners with fingers, then

tighten the big ones with special tool first

diagonally from inside toward outside,

important components should be tightened 2

to 3 times with appropriate increments to

avoid warp unless otherwise indicated. Bolts

and fasteners should be kept clean and dry.

Do not apply oil to the threads.

 When oil seal is installed, fill the groove with

grease, install the oil seal with the name of

the manufacturer facing outside, check the

shaft on which the oil seal is to be installed

for smoothness and for burrs that may

damage the oil seal.

 Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if

the contact surface has any damage.

 The ends of rubber hoses (for fuel, vacuum,

or coolant) should be pushed as far as they

can go to their connections so that there is

enough room below the enlarged ends for

tightening the clamps.

 Rubber and plastic boots should be properly

reinstalled to the original correct positions as

designed.

 The tool should be pressed against two (inner

and outer) bearing races when removing a

ball bearing. Damage may result if the tool is

pressed against only one race (either inner

race or outer race). In this case, the bearing

should be replaced. To avoid damaging the

bearing, use equal force on both races.

Both of these examples can result in bearing damage.

Manufacturer's

name

Groove

Clamp

Connector

Boots

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS

1-5

 Lubricate the rotation face with specified

lubricant on the lubrication points before

assembling.

 Check if positions and operation for installed

parts is in correct and properly.

 Make sure service safety each other when

conducting by two persons.

 Note that do not let parts fall down

 Before battery removal operation, it has to

remove the battery negative (-) cable firstly.

Notre tools like open-end wrench do not

contact with body to prevent from circuit short

and create spark.

 After service completed, make sure all

connection points is secured. Battery

positive (+) cable should be connected firstly.

And the two posts of battery have to be

greased after connected the cables.

 Make sure that the battery post caps are

located in properly after the battery posts had

been serviced.

 If fuse burned, it has to find out the cause

and solved it. And then replace with

specified capacity fuse.

capacity

verification

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