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Sym HD2 125 User Manual

Sym HD2 125
273 pages
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HD2 125 / 200
SERVICE MANUAL
20110209
Foreword
How to Use This Manual
Contents
Mechanism Illustration

Table of Contents

Questions and Answers:

Sym HD2 125 Specifications

General IconGeneral
BrandSym
ModelHD2 125
CategoryMotorcycle
LanguageEnglish

Summary

General Information

General Safety Precautions

Safety precautions for operating and maintaining the motorcycle.

Service Precautions and Guidelines

Guidelines for proper service procedures and handling of parts.

Troubleshooting Carburetor and EFI Models

Diagnostic guides for engine starting issues with carburetor and EFI models.

Maintenance Information

Periodical Maintenance Schedule

Table detailing scheduled maintenance tasks and intervals.

Fuel Injection System

EFI System Circuit and ECU Pin Configuration

Wiring diagram and ECU pin assignments for the EFI system.

EFI Troubleshooting Procedures

Flowcharts and tables for diagnosing EFI system faults.

Diagnostic Tool Usage

Method of use and notes for the EFI System Diagnostic Tool.

Engine Removal and Installation

Precautions and Engine Removal

Precautions and general information for engine removal.

Engine Installation Procedure

Steps for reinstalling the engine onto the frame.

Cylinder Head and Valve Service

Troubleshooting Cylinder Head Issues

Common issues like low compression, high compression, and noise.

Cylinder Head Removal and Disassembly

Step-by-step guide to removing and disassembling the cylinder head.

Cylinder Head and Valve Inspection

Methods for inspecting cylinder head warp, valve springs, and stems.

Valve Stem and Seat Service

Procedures for replacing valve stems, guides, and servicing valve seats.

Cylinder Head Reassembly and Installation

Steps for reassembling and installing the cylinder head.

Valve Clearance Adjustment

Method for adjusting valve clearance.

Cylinder and Piston Service

Troubleshooting Cylinder/Piston Issues

Common issues like low compression, knock, smoking exhaust, and overheating.

Cylinder and Piston Removal

Steps for removing the cylinder, piston, and piston rings.

Piston Ring and Piston Installation

Correct methods for installing piston rings and pistons.

Cylinder Installation

Procedure for installing the cylinder onto the crankcase.

V-Belt Drive System Service

Troubleshooting V-Belt Drive Issues

Common issues like engine starting but no movement, or shuddering.

Final Drive Mechanism Service

Final Drive Mechanism Disassembly

Steps for disassembling the final drive mechanism.

Final Drive Mechanism Reassembly

Steps for reassembling the final drive mechanism.

AC Generator and Start Clutch Service

Crankcase and Crankshaft Service

Crankcase Disassembly

Step-by-step guide to disassembling the crankcase.

Crankcase Reassembly

Procedures for reassembling the crankcase components.

Cooling System Service

Trouble Diagnosis Flowchart

Flowchart for diagnosing cooling system temperature issues.

Brake System Service

Precautions and Troubleshooting

Safety precautions and troubleshooting for brake systems.

Brake Caliper and Fluid Bleeding

Caliper installation and step-by-step guide to bleeding the brake system.

Steering, Front Wheel, and Front Cushion

Troubleshooting Steering and Suspension

Common issues with steering, front wheel, and front cushion.

Rear Wheel, Rear Fork, and Rear Cushion

Troubleshooting Rear Components

Common issues with rear wheel, brake performance, and cushion.

Electrical System

Wiring Diagram

HD2 125 Wiring Diagram

Wiring diagram for the HD2 125 model.

HD2 200 Wiring Diagram

Wiring diagram for the HD2 200 model.

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