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Sym
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Jet 100
Sym Jet 100 User Manual
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VICE MANU
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Table of Contents
Page Content Index
4
Service Manual
1
Table of Contents
4
1. General Information 1
8
General Information
8
General Safety
9
General Information
9
Service Precautions
10
Specifications
12
Torque Values
14
Cables and Harness Routing
16
Troubleshooting
20
Lubrication Points
24
2. Service Maintenance Information
26
Service Maintenance Information
26
Periodical Maintenance Schedule
27
Air Cleaner
28
Fuel Lines
28
Engine Oil Line
29
Fuel Filter
29
Oil Pump Control Cable
30
Battery
31
Battery Removal
31
Tire
31
Rear Brake Free Play: (Drum Brake Type)
32
Brake System Hose
33
Type)
33
Steering System
35
Suspension
35
Spark Plug
36
Transmission Oil
36
Control Cable Lubrication
37
Driver Belt
37
Ignition Timing
37
Throttle Valve Operation
37
Carbon Removing for Exhaust Pipe
38
Carburetor Idle Speed Adjustment
38
Cylinder Compression Pressure Test
38
Muffle
38
Headlight Adjustment
39
3. Lubrication System
40
Lubrication System
40
Precautions in Operation
41
Lubricant
41
Trouble Shooting
41
Oil Pump Removal
42
Oil Pump Installation
42
Oil Pump/Oil Tube Air Bleeding
43
Oil Tank
44
Engine Removal
46
Engine Installation
49
Cylinder Head/Cylinder/Piston
50
Cylinder Head
52
Alternator
58
7. "V" Type Belt Drive System/Kick-Starter
62
Maintenance Information
63
Trouble Shooting
63
Left Crankcase Cover
64
Cover
65
Installation of the Left Crankcase
65
Reassembly of Kick Starter
65
Drive Belt
66
Movable Driven Pulley
66
Movable Drive Face
67
Clutch/Driven Pulley
71
8. Final Driving Mechanism
76
Final Driving Mechanism
76
Maintenance Information
77
Troubleshooting
77
Disassembly of Final Driving
78
Mechanism
78
Inspection of Final Driving Mechanism
79
Bearing Replacement
79
Re-Assembly of Final Driving
79
9. Crankcase/Crankshaft
82
Crankcase/Crankshaft
82
Maintenance Information
83
Troubleshooting
83
Crankcase Disassembly
84
Crankshaft Removal
84
Crankshaft Inspection
85
Crankcase Installation
86
10. Fuel System
88
Fuel System
88
Maintenance Information
89
Troubleshooting
89
Throttle Valve
90
Auto By-Starter
91
Carburetor Remove
91
Float/Float Valve/Jet
93
Carburetor Installation
94
Flaot Level Inspection
94
Reed Valve
94
Fuel Pump
95
Air Cleaner
96
11. Brake System
98
Brake System
98
Rear Drum Brake System
99
Maintenance Information
100
Troubleshooting
101
Hydraulic Disc Brake
102
Disc Brake - Caliper
103
Disc Brake -Air Bleed
103
Brake Disc
104
Disc Brake - Master Cylinder
104
Rear Drum Brake
107
Body Overview
110
Maintenance Information
111
Luggage Box
112
Side Covers
112
12. Body Cover
114
Front Cover
115
Front under Spoiler
116
Front Inner Box
117
Floor Panel
118
Front Fender
118
Steering Handle Cover
119
Under Cover
120
Steering/Front Wheel/Suspension
122
Front Wheel
125
Front Shock Absorber
129
Front Fork
130
Rear Wheel/Suspension
132
15. Electrical Equipment
136
Electrical Equipment
136
Charging System
137
Ignition System
137
Maintenance Information
137
Starting System
148
Oil Level Switch
150
Fuel Unit
151
Switch/Horn
152
Bulb Replacement
154
Headlight/Position Light
154
Electrical Diagram
158
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Sym Jet 100 Specifications
General
Fuel System
Carburetor
Rear Brake
Drum
Engine
4-Stroke
Cooling
Air-cooled
Transmission
Automatic
Engine Type
Single Cylinder
Top Speed
85 km/h
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