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Sym JOYRIDE 125 Service Manual

Sym JOYRIDE 125
275 pages
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Joyride 125 / 200i EVO
X’PRO RV125 / 200 EFi
SERVICE MANUAL
Foreword
How to Use This Manual
Contents
Mechanism Illustration

Table of Contents

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Sym JOYRIDE 125 Specifications

General IconGeneral
Displacement124.6 cc
Fuel SystemElectronic Fuel Injection
TransmissionCVT
Front SuspensionTelescopic fork
Rear SuspensionUnit Swing
Front BrakeDisc
Rear BrakeDrum
Length1900 mm
Engine Type4-stroke
Cooling SystemAir-cooled

Summary

1. General Information

General Safety

Provides essential safety precautions for operating and servicing the vehicle.

Service Precautions

Details important guidelines for servicing to prevent damage and ensure proper function.

2. Maintenance Information

Periodical Maintenance Schedule

Details the recommended schedule for routine maintenance checks and replacements.

Brake System (Front/Rear Disk Brake)

Covers maintenance of the front and rear brake systems, including fluid and lines.

3. Lubrication System

Engine Oil

Details procedures for checking, filling, and replacing engine oil.

4. Fuel System

Trouble Diagnosis

Lists common engine starting, stalling, and running issues and their potential causes.

5. Fuel Injection System

EFi System Diagram

Illustrates the overall EFI system components and their connections.

EFi System Component Description

Provides detailed descriptions of the function and specifications of EFi system components.

EFi System Circuit

Presents the electrical schematic diagram for the EFi system.

EFi Components Malfunction Check & Replacement Procedure

Details diagnostic and replacement procedures for various EFi system components.

6. Engine Removal

Engine Removal – Carburetor Model

Details the step-by-step procedure for removing the engine from carburetor models.

Engine Removal – EFi Model

Details the step-by-step procedure for removing the engine from EFi models.

Engine Installation

Provides instructions and torque values for reinstalling the engine into the frame.

7. Cylinder Head / Valve

Cylinder Head Removal

Details the procedure for removing the cylinder head assembly.

Cylinder Head Disassembly

Explains how to disassemble the cylinder head, including valves and camshaft.

Cylinder Head Reassembly

Guides on reassembling the cylinder head with valves, springs, and retainers.

Cylinder Head Installation

Provides steps for installing the cylinder head, camshaft, and checking valve clearance.

8. Cylinder / Piston

Cylinder Removal

Details the procedure for removing the cylinder from the engine.

Piston Removal

Explains how to remove the piston, rings, and pin from the cylinder.

Piston Ring Installation

Guides on cleaning and installing piston rings correctly into the piston.

Piston Installation

Covers the procedure for installing the piston into the cylinder and reassembling the cylinder head.

9. V-Belt Drive System

Drive Belt

Covers removal, inspection, and installation of the drive belt and related pulleys.

Clutch Outer / Driven Pulley

Details the disassembly, inspection, and installation of the clutch outer and driven pulley.

10. Final Drive Mechanism

Final Drive Mechanism Disassembly

Details the steps for disassembling the final drive mechanism.

Bearing Replacement

Explains the procedure for replacing bearings in the final drive mechanism.

Final Drive Mechanism Reassembly

Covers the reassembly of the final drive mechanism components.

11. AC. Generator / Start Clutch

Start Clutch

Details the removal and inspection of the start clutch assembly.

12. Crankshaft / Crankcase

Crankcase Disassembly

Details the step-by-step procedure for disassembling the crankcase.

Crankshaft Inspection

Explains how to inspect the crankshaft for run-out, bearing condition, and clearances.

Crankcase Assembly

Guides on assembling the crankcase, including bearing and crankshaft installation.

13. Cooling System

Coolant Change

Explains the procedure for draining, refilling, and bleeding the cooling system.

15. Brake System

Hydraulic Disk Brake

Details procedures for brake fluid replacement and system bleeding.

Air Bleed

Explains the step-by-step process for bleeding air from the brake system.

Brake Master Cylinder

Covers removal, inspection, assembly, and precautions for the brake master cylinder.

16. Steering / Front Wheel / Front Cushion

Front Wheel

Covers removal, inspection, and installation of the front wheel, including axle and bearings.

Front Fork / Steering Stem

Covers the removal, inspection, and replacement of front fork and steering stem components.

17. Muffler / Rear Wheel / Rear Cushion

Troubleshooting

Covers issues related to rear wheel runout, noisy brakes, and poor brake performance.

18. Electrical System

Troubleshooting

Covers electrical issues like no voltage, low voltage, no spark, starter motor problems, and charging system faults.

Battery

Details battery removal, voltage inspection, and charging procedures.

Charging System

Covers the charging system circuit, regulator rectifier inspection, and charging circuit checks.

Ignition System

Details ignition coil and CPS inspection procedures.

Starting System

Explains starter relay inspection, starter motor removal, and installation.

20. Wiring Diagram

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