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Sym JOYMAX 250 User Manual

Sym JOYMAX 250
248 pages
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GTS 250
JOYMAX 250
SERVICE MANUAL
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HOW TO USE THIS MANUAL
CONTENTS
SERIAL NUMBER

Table of Contents

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Sym JOYMAX 250 Specifications

General IconGeneral
Displacement249.4 cc
Fuel SystemElectronic Fuel Injection
Cooling SystemLiquid cooled
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDisc
Seat Height770 mm
Dry Weight182 kg
Width760 mm
Height1, 420 mm
Wheelbase1, 550 mm
Engine Type4-stroke, Single cylinder
TransmissionCVT
Fuel Capacity12 L
Length2190 mm

Summary

General Information

Symbols and Marks

Explains warning, caution, and various service symbols used in the manual.

General Safety

Outlines essential safety precautions for operating and servicing the vehicle.

Service Precautions

Details important guidelines for performing service and maintenance tasks correctly.

Maintenance Information

Precautions in Operation

General safety and operational guidelines before starting maintenance.

Periodical Maintenance Schedule

Outlines recommended service intervals for various vehicle components.

Engine Oil

Instructions for checking and changing the engine oil, including capacity and type.

Lubrication System

Precautions in Operation

Guidelines for safe and effective lubrication system maintenance.

Oil Pump

Procedures for removing, disassembling, inspecting, and re-assembling the oil pump.

Fuel System

Precautions in Operation

Safety warnings and handling procedures for fuel system components.

Trouble Diagnosis

Lists common fuel system issues and their potential causes.

Removal & Installation of Engine

Operational Precautions

Important safety and procedural notes before engine removal or installation.

Engine Removal

Detailed steps for safely removing the engine from the motorcycle frame.

Cylinder Head / Valve

Precautions in Operation

Safety and procedural guidelines for cylinder head and valve servicing.

Troubleshooting

Common issues related to cylinder head, valve, and camshaft performance.

Cylinder / Piston

Precautions in Operation

Safety and handling notes for cylinder and piston servicing.

Cylinder and Piston Removal

Detailed steps for removing the cylinder and piston assembly.

V-Belt Driving System

Maintenance Description

General information and specifications for the V-belt drive system.

Trouble Diagnosis

Common issues and symptoms related to the V-belt drive system.

Final Driving Mechanism

Precautions in Operation

Safety guidelines for working on the final drive system.

Trouble Diagnosis

Common problems like motorcycle not moving or unusual noises in the final drive.

Alternator / Starting Clutch

Precautions in Operation

Safety notes for alternator and starter motor maintenance.

Starting Clutch

Inspection and replacement of the starting clutch components.

Crankcase / Crank

Disassembly of Crankcase

Detailed steps for disassembling the crankcase.

Crankshaft Inspection

Procedures for inspecting the crankshaft for run-out and bearing condition.

Cooling System

General Information

Safety warnings and general procedures for the cooling system.

Trouble Diagnosis for Cooling System

Flowchart for diagnosing cooling system issues like overheating.

Body Cover

Maintenance

Sequence for disassembling and assembling body covers, emphasizing care.

Handle Cover

Steps for removing and installing the handle cover and related panels.

Brake System

Trouble Diagnosis

Common brake system issues like soft lever, uneven, or noisy brakes.

Front Brake Caliper

Procedures for removing, installing, and replacing brake pads on the front caliper.

Steering / Front Wheel / Front Cushion

Trouble Diagnosis

Common problems like hard steering, tilted handlebar, or front cushion issues.

Steering Stem

Detailed instructions for removing, installing, and adjusting the steering stem and bearings.

Rear Wheel / Rear Fork / Rear Cushion

Trouble Diagnosis

Common issues with rear wheel run-out, soft suspension, and brake noise.

Rear Cushion

Procedures for removing and installing the rear suspension shock absorbers.

Electrical System

Trouble Diagnosis

Troubleshooting guide for common electrical system problems.

Battery

Procedures for removing, checking voltage, and charging the battery.

Ignition System

Inspection and testing of ignition coil and pulse generator.

Electrical Diagram

1. ECU (Engine Control Unit)

Check procedure

Steps for connecting diagnostic tools and checking ECU parameters and codes.

2. PM Sensor (Manifold Pressure Sensor)

Check procedure

Steps for checking PM sensor voltage using a multimeter.

3. TPS (Throttle Position Sensor)

Check procedure

Steps for checking TPS working voltage and output voltage with a multimeter.

4. TW Sensor (Water Temp. Sensor)

Check procedure

Method for measuring TW sensor resistance at different temperatures.

6. O2 Sensor (Exhaust Gas Oxygen Sensor)

Check procedure

Steps for checking O2 Sensor heater voltage and electrical resistance.

8. Fuel Pump

Check procedure

Steps for confirming fuel pump working voltage and liquid-level gauge function.

9. Fuel Injector

Check procedure

Steps for measuring fuel injector resistance and observing spray pattern.

10 Crank Position Sensor

Check procedure

Method for measuring the resistance value of the pulse sensor.

SYM Keihin EFI System CHK light Diagnose (LM25W1-T / JOYMAX 250)

CHK light error message chart and Counter Measure

Overview of check light errors and general countermeasures.

2. Removed TB code manually

Manual procedure for clearing trouble codes from the ECU.

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