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Sym HD2 200 User Manual

Sym HD2 200
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 200 Specifications

General IconGeneral
Fuel SystemCarburetor
Front BrakeDisc
Rear BrakeDrum
Front SuspensionTelescopic fork
Rear SuspensionUnit swing
EngineSingle-cylinder, 4-stroke
TransmissionCVT
Max Power12.5 HP @ 7500 rpm

Summary

General Information and Safety

General Safety Precautions

Outlines essential safety guidelines for operating and servicing the motorcycle.

Motorcycle Maintenance Procedures

Maintenance Precautions and Schedule

Covers general safety and planned maintenance intervals for the motorcycle.

Fuel System Service and Troubleshooting

Fuel System Precautions and Diagnostics

Outlines safety, specifications, and common fuel system issues and diagnosis.

Fuel Injection System Overview and Operation

EFI System Troubleshooting and Diagnostics

Provides comprehensive procedures for diagnosing EFI system faults using tools and manual checks.

Engine Removal and Installation Procedures

Engine Removal Precautions and Steps

Outlines safety measures and the sequence for removing the motorcycle engine.

Engine Installation Process

Covers the steps and checks required for reinstalling the engine onto the frame.

Cylinder Head and Valve System Service

Cylinder Head Removal and Disassembly

Step-by-step guide for removing and taking apart the cylinder head assembly.

Cylinder Head and Valve Inspection

Procedures for checking cylinder head warp, valve stems, and guides for wear.

Cylinder Head Reassembly and Installation

Steps for putting the cylinder head back together and installing it onto the engine.

Valve Clearance Adjustment

Instructions for measuring and setting the valve clearance using a feeler gauge.

Cylinder and Piston Assembly Service

Cylinder and Piston Precautions and Troubleshooting

Covers safety, specifications, and common issues related to cylinder and piston.

Cylinder Removal and Inspection

Details on removing the cylinder and inspecting its bore for wear or damage.

Piston and Ring Service Procedures

Explains piston removal, ring installation, and piston installation steps.

Cylinder Installation Process

Steps for reinstalling the cylinder, including piston and ring placement.

V-Belt Drive System Maintenance

V-Belt System Precautions and Troubleshooting

Covers safety, specifications, and common problems affecting the V-belt drive.

Final Drive Mechanism Service

Final Drive Precautions and Troubleshooting

Covers safety, specifications, and common issues related to the final drive.

Disassembly and Inspection Procedures

Details on dismantling and checking the final drive gears, shafts, and bearings.

Reassembly of Final Drive Mechanism

Steps for putting the final drive mechanism back together after servicing.

AC Generator and Start Clutch Service

Crankcase and Crankshaft Service

Cooling System Maintenance and Diagnosis

Cooling System Troubleshooting Guide

Provides a flowchart for diagnosing cooling system issues like overheating or leaks.

Brake System Service and Troubleshooting

Brake System Troubleshooting Guide

Provides common issues and solutions for disk and drum brake systems.

Steering, Front Wheel, and Cushion Service

Rear Wheel, Fork, and Cushion Service

Electrical System Diagnostics and Service

Electrical System Troubleshooting Guide

Lists common electrical issues and their causes, with diagnostic steps.

Wiring Diagrams

HD2 125 Wiring Diagram

Provides the electrical schematic for the HD2 125 motorcycle model.

HD2 200 Wiring Diagram

Provides the electrical schematic for the HD2 200 motorcycle model.

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