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Sym
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HD2 200
Sym HD2 200 User Manual
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MECHANISM ILLUSTRATIONS
HD2 125 / 200
Winker relay
Radiator
Spark plug
Engine number
Engine oil drain bolt
Reserve tank cap
Radiator filler cap
Ignition coil
Horn
Fuel unit
Tail light/
Rear winker light
Fuel tank cap
Battery/CDI
Exhaust muffler
Oil lever / Oil filter
Water pump
AC. G
enerator
Rear brake lever
Front brake lever
Winker light / Horn /
Dimmer & Passing
switches
Headlight/Start switches
Main switch
Gear oil drain bolt
Air cleaner
Luggage box
Front winker light
Headlight
Fuse box /
Regulator rectifier
Starter relay
Headlight relay
Home page
Contents
4
6
Table of Contents
General Information
6
Table of Contents
6
General Safety
7
Service Precautions
8
Specifications
14
Torque Values
18
Troubleshooting-Carburetor Model
20
Troubleshooting-Efi Model
24
Lubrication Points
28
Maintenance Information
30
Periodical Maintenance Schedule
31
Fuel Lines / Cable
32
Air Cleaner
33
Spark Plug
33
Valve Clearance
34
Cylinder Compression Pressure
35
Ignition System
35
Brake System
36
Drive Belt
36
Brake Light Switch/Starting Inhibitor
38
Clutch Disc Wear
38
Headlight Beam Distance
38
Switch
38
Cushion
39
Nuts, Bolts Tightness
39
Side Stand
39
Steering Handle Top Bearing
40
Wheel/Tire
40
Special Tools List
41
Home Page 3. Lubrication System
44
Precautions in Operation
45
Troubleshooting
45
Engine Oil
46
Engine Oil Strainer Clean
46
Oil Pump
47
Gear Oil
50
Fuel System
52
Precautions in Operation
53
Trouble Diagnosis
54
Carburetor Removal
55
Vacuum Chamber
55
Air Cut-Off Valve
57
Auto By-Starter
58
Float Chamber
59
Fuel Tank
61
Air Cleaner
62
Efi System Components
64
Efi System Vehicle Configuration
65
Efi System Operation
66
Efi System Introduction
67
Fuel System
68
Ignition System
69
Sensors / Drives
70
Precautions in Operation
77
Efi System Components Description
78
Efi System Circuit
94
ECU Pin Configuration
95
Troubleshooting
96
Integrated Troubleshooting Procedure
100
Air Cleaner
103
Efi System Diagnosis Methods
104
Check Light Fault Codes Differentiation
105
Fault Code and Sensors Table
106
Fault Code and Check Light Flashing Lighting Identification Table
107
Efi System Diagnostic Tool - V70
108
Troubleshooting Table
121
Comprehensive Maintenance List
122
Engine Removal
124
Engine Removal
125
Engine Hanger Removal
128
Engine Hanger Bush Removal
129
Engine Hanger Installation
130
Engine Installation
130
Home Page 7 . Cylinder Head / Valve
132
Precautions in Operation
133
Troubleshooting
134
Cylinder Head Removal
135
Cylinder Head Disassembly
137
Cylinder Head Inspection
138
Valve Stem Replacement
139
Valve Seat Inspection and Service
140
Cylinder Head Reassembly
142
Cylinder Head Installation
143
Valve Clearance Adjustment
145
Home Page 8. Cylinder / Piston
146
Precautions in Operation
147
Troubleshooting
147
Piston Removal
149
Piston Ring Installation
151
Piston Installation
152
Cylinder Installation
152
V-Belt Drive System
154
Precautions in Operation
155
Troubleshooting
155
Left Crankcase Cover
156
Drive Belt
157
Drive Face
159
Clutch Outer/Driven Pulley
162
Home Page 10. Final Drive Mechanism
168
Precautions in Operation
169
Troubleshooting
169
Final Drive Mechanism Disassembly
170
Final Drive Mechanism Inspection
171
Bearing Replacement
172
Final Drive Mechanism Reassembly
175
AC. Generator / Start Clutch
178
Precautions in Operation
179
ACG. Set Removal
180
Flywheel Removal
180
Right Crankcase Cover Removal
180
Start Clutch
181
ACG. Set Installation
184
Flywheel Installation
184
Right Crankcase Cover Installation
184
Crankcase / Crankshaft
186
Precautions in Operation
187
Troubleshooting
187
Crankcase Disassembly
188
Crankshaft Inspection
190
Crankcase Reassembly
191
Home Page 13. Cooling System
194
Precautions in Operation
195
Troubleshooting
195
System Test
198
Radiator
199
Water Pump
201
Thermostat
205
Home Page 14. Body Cover
208
Mechanism Diagram
208
Maintenance
209
Front Cover
210
Handle Front Cover
211
Handle Rear Cover
212
Side Cover
213
Brake System
224
Rear Brake System Diagram-Drum Brake
225
Rear Brake System Diagram- Disc Brake
226
Precautions in Operation
227
Troubleshooting
228
Hydraulic Disc Brake
229
Air Bleed
230
Brake Caliper
230
Brake Disk Inspection
231
Brake Master Cylinder
231
Home Page 16. Steering / Front Wheel / Front Cushion
236
Precautions in Operation
237
Steering Handle
237
Troubleshooting
237
Front Wheel
240
Front Cushion
243
Steering Stem
244
Precautions in Operation
247
Troubleshooting
247
Muffler
248
Rear Wheel
248
Rear Cushion
250
Mechanism Diagram
252
Precautions in Operation
253
Technical Specification
253
Troubleshooting
254
Battery
256
Charging System
256
Ignition System
259
Starting System
260
Meters
261
Light / Bulb
262
Switch / Horn
265
4
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Sym HD2 200 Specifications
General
Brand
Sym
Model
HD2 200
Category
Motorcycle
Language
English
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