Sym Joyride200 - User Manual

SERVICE MANUAL
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Sym Joyride200 Specifications

General

Transmission	CVT
Front Suspension	Telescopic fork
Rear Suspension	Unit swing
Front Brake	Disc
Rear Brake	Drum
Seat Height	770 mm
Cooling	Air-cooled
Engine Type	Single cylinder, 4-stroke

Summary

Model Illustration

1. General Information

Symbols and Marks

Explains symbols and marks used in the manual for service guidance.

General Safety

Details crucial safety warnings and precautions for operation and maintenance.

Service Precautions

Provides essential guidelines for performing service procedures correctly and safely.

Specifications

Lists key technical data and specifications for different motorcycle models.

Torque Values

Specifies important torque values for assembly and disassembly of components.

Cables and Harness Routing

Outlines proper methods for routing cables and wire harnesses to prevent damage.

Troubleshooting

Offers diagnostic flowcharts for common engine starting and running issues.

Lubrication Points

Identifies specific locations on the motorcycle requiring lubrication.

2. Maintenance Information

Precautions in Operation

General safety and operational precautions for maintenance tasks.

Periodical Maintenance Schedule

Outlines recommended inspection and service intervals for optimal performance.

Fuel Lines

Maintenance procedures for the motorcycle's fuel lines.

Acceleration Operation

Adjusting throttle cable free play for smooth acceleration.

Air Cleaner

Maintenance and replacement procedures for the air cleaner element.

Crankcase Ventilation

Procedures for servicing the crankcase ventilation system.

Spark Plug

Maintenance, gap measurement, and replacement of the spark plug.

Valve Clearance

Inspection and adjustment process for engine valve clearance.

Carburetor Idling Speed Adjustment

Steps to adjust the engine's idling speed for optimal performance.

Ignition System

Checks and troubleshooting for the motorcycle's ignition system.

Cylinder Compression Pressure

Method for measuring engine cylinder compression pressure.

Driving Belt

Inspection and replacement guidelines for the drive belt.

Brake System (Front;Rear Disk Brake)

Adjusting front and rear brake lever free play.

Brake System Hose

Inspection of brake hoses for corrosion or leaks.

Brake Fluid

Checking and maintaining the brake fluid level in the reservoir.

Filling Out Brake Fluid

Procedure for refilling the brake fluid reservoir.

Air Bleed Operation

Steps for bleeding air from the hydraulic brake system.

Added Brake Fluid

Guidance on adding the correct type of brake fluid.

Brake Lining Wear

Inspecting brake lining wear limit for safety and performance.

Brake Lamp Switch;Starting Inhibitor Switch

Checking the function of safety switches for brake light and starter.

Headlamp Beam Distance

Adjusting headlamp beam position according to regulations.

Clutch Disc Wear

Checking the condition of the clutch disc for wear or damage.

Side Stand

Inspection of the side stand's operation and condition.

Shock Absorber

Inspection of front and rear shock absorbers for proper function.

Nut, Bolts Tightness

Ensuring all nuts and bolts are securely tightened according to schedule.

Wheel;Tire

Specifications for tire pressure and tread depth.

Steering Handle Top Bearing

Checking the steering handle top bearing for smooth operation.

3. Lubrication System

Precautions in Operation

General safety precautions for engine oil and gear oil replacement procedures.

Troubleshooting

Diagnosing and resolving issues related to low engine oil level and pressure.

Engine Oil

Procedures for checking, changing, and capacity of engine oil.

Engine Oil Strainer Clean

Steps for cleaning the engine oil strainer and its components.

Oil Pump Removal

Detailed instructions for removing the engine oil pump.

Oil Pump Disassembly

Procedures for disassembling the oil pump assembly.

Oil Pump Inspection

Measuring clearances for oil pump rotors and body.

Oil Pump Re-assembly

Steps for correctly re-assembling the oil pump.

Oil Pump Installation

Instructions for installing the oil pump back into the engine.

Gear Oil

Procedures for checking and changing gear oil and its capacity.

4. Fuel System

Precautions in Operation

Safety precautions when working with gasoline and fuel system components.

Trouble Diagnosis

Troubleshooting common problems with the fuel system.

Air Cut-off Valve

Inspection procedure for the air cut-off valve's functionality.

Auto By-Starter

Inspection, removal, and installation of the auto by-starter mechanism.

Carburetor Removal

Detailed steps for removing the carburetor from the motorcycle.

Vacuum Chamber

Procedures for removing and installing the carburetor's vacuum chamber.

Float Chamber

Disassembly, checking, and assembly of the carburetor float chamber.

Installation of Carburetor

Re-installation of the carburetor and necessary adjustments.

Adjustment of Pilot Screw

Adjusting the pilot screw for idle speed and CO levels.

Fuel Tank

Procedures for fuel unit and tank removal/installation.

Air Cleaner

Steps for removing and installing the air cleaner assembly.

5. Engine Removal

Precautions in Operation

Safety and general information relevant to engine removal procedures.

Removal of Engine

Detailed step-by-step guide for removing the engine from the frame.

Removal of Engine Mounting Bracket

Instructions for safely removing the engine mounting bracket.

Engine Mounting Bracket Installation

Procedures for correctly installing the engine mounting bracket.

Engine Installation

Steps for reinstalling the engine back into the motorcycle frame.

6. Cylinder Head;Valve

Mechanism Diagram

Exploded view illustrating cylinder head and valve components.

Precautions in Operation

General information and specifications for cylinder head and valve service.

Cylinder Head Removal

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

Cylinder Head Disassembly

Procedures for disassembling the cylinder head components.

Valve Stem Replacement

Detailed process for replacing worn or damaged valve stems.

Valve Seat Inspection and Service

Methods for inspecting and servicing valve seats for optimal sealing.

Cylinder Head Reassembly

Steps for correctly reassembling the cylinder head components.

Cylinder Head Installation

Instructions for reinstalling the cylinder head onto the engine block.

7. Cylinder;Piston

Mechanism Diagram

Exploded view of cylinder and piston assembly parts.

Precautions in Operation

General information and precautions for cylinder and piston service.

Trouble Diagnosis

Troubleshooting common issues related to cylinder and piston performance.

Cylinder Removal

Step-by-step instructions for removing the cylinder.

Piston Removal

Procedures for removing the piston from the cylinder.

Piston Ring Installation

Correct method for installing piston rings onto the piston.

Piston Installation

Steps for installing the piston into the cylinder.

Cylinder Installation

Steps for reinstalling the cylinder onto the crankcase.

8. V-Belt Driving System;Kick Starter

Mechanism Diagram

Exploded view of V-belt drive and kick starter components.

Maintenance Description

Precautions and specifications for V-belt system maintenance.

Trouble Diagnosis

Troubleshooting common V-belt drive and kick starter issues.

Left Crankcase Cover

Procedures for removing the left crankcase cover.

Kick Starter

Disassembly and inspection of the kick starter mechanism.

Driving Belt

Steps for removing, inspecting, and installing the drive belt.

Drive Face

Procedures for removing and inspecting the drive face.

Clutch Outer;Driven Pulley

Disassembly and inspection of clutch outer and driven pulley.

Clutch Lining

Measuring clutch weight thickness and driven pulley spring length.

Driven Pulley Spring

Measuring the free length of the driven pulley spring.

Driven Pulley

Checking the driven pulley for wear and damage.

Driven Pulley Bearing Inspection

Inspecting the driven pulley bearing for proper function.

Clutch Weight Replacement

Procedures for replacing clutch weights in the clutch assembly.

Replacement of Driven Pulley Bearing

Steps for replacing the driven pulley bearing.

Installation of Clutch OUTER;Driven Pulley Assembly

Instructions for installing the clutch outer and driven pulley assembly.

9. Final Driving Mechanism

Mechanism Diagram

Exploded view of the final driving mechanism components.

Precautions in Operation

Specifications and torque values for the final drive mechanism.

Trouble Diagnosis

Troubleshooting common issues with the final driving mechanism.

Disassembly of Final Driving Mechanism

Steps to disassemble the final driving mechanism.

Inspection of Final Driving Mechanism

Inspection procedures for the final driving mechanism parts.

Bearing Replacement

Steps for replacing bearings in the final driving mechanism.

Re-assembly of Final Driving Mechanism

Instructions for re-assembling the final driving mechanism.

10. Alternator;Starting Clutch

Precautions in Operation

General information and specifications for alternator and starting clutch service.

Right Crankcase Cover Removal

Steps for removing the right crankcase cover.

A.C.G. Set Removal

Procedures for removing the A.C.G. (Alternating Current Generator) set.

Flywheel Removal

Steps for removing the engine flywheel.

Starting Clutch

Procedures for removing and inspecting the starting clutch.

Flywheel Installation

Instructions for installing the engine flywheel.

A.C.G. Set Installation

Steps for installing the A.C.G. set.

Right Crankcase Installation

Instructions for installing the right crankcase cover.

11. Crankshaft;Crankcase

General Information

General information and precautions for crankshaft and crankcase service.

Trouble Diagnosis

Troubleshooting common engine noises related to the crankshaft.

Disassembly of Crankcase

Detailed steps for disassembling the engine crankcase.

Crankshaft

Measuring crankshaft dimensions and checking bearing condition.

Assembly of Crankcase

Instructions for correctly assembling the engine crankcase.

12. Cooling System

General Information

General precautions and technical specifications for the cooling system.

Trouble Diagnosis

Troubleshooting common issues with the engine's cooling system.

System Test

Procedures for testing the radiator cap and checking for coolant leaks.

Change of Coolant

Steps for draining, refilling, and bleeding the cooling system.

Radiator

Procedures for removing, cleaning, and inspecting the radiator.

Water Pump

Inspection, disassembly, and replacement of the water pump.

Temperature Sensor

Inspection and installation procedures for the temperature sensor.

Thermostat

Removal, inspection, and installation of the engine thermostat.

13. Body Covers

Mechanical Illustration

Overview illustration of all body cover components.

Maintenance

Sequence for disassembling and assembling body covers.

Steering Handlebar Guard

Disassembly and assembly of the steering handlebar cover.

Front Guard

Disassembly and assembly of the front cover assembly.

Front Lower Spoiler

Disassembly and assembly of the front under spoiler.

Luggage Box

Procedures for removing and installing the luggage box.

Side Cover

Disassembly and assembly steps for the motorcycle's side covers.

Body Cover

Procedures for removing and installing the main body cover.

Central Cover

Disassembly and assembly of the central cover section.

Floor Panel

Steps for removing and installing the motorcycle's floor panel.

Inner Cover

Disassembly and assembly procedures for the inner cover components.

Front Fender

Steps for removing and installing the front fender.

14. Brake

Illustration - Front Disc Brake System

Exploded view of the front disc brake system components.

Illustration - Rear Disc Brake System

Exploded view of the rear disc brake system components.

Maintenance Description

Precautions and specifications for brake system maintenance.

Trouble Diagnosis

Troubleshooting common issues with the brake system's performance.

Hydraulic Disc Brake

Procedures for servicing the hydraulic disc brake system.

Air Bleed

Step-by-step guide for bleeding air from the hydraulic brake system.

Brake Calliper

Procedures for removing and installing the brake caliper.

Brake Disc

Inspection and replacement guidelines for the brake disc.

Brake Master Cylinder

Removal, inspection, and assembly of the brake master cylinder.

15. Steering;Front Wheel;Front Brake;Front Cushion

Mechanical Illustration

Exploded view of front steering, wheel, brake, and cushion components.

Operational Precautions

General precautions for servicing front end steering, wheel, and brake systems.

Trouble Diagnosis

Troubleshooting common issues with steering and front end components.

Steering Handlebar

Steps for removing and installing the steering handlebar assembly.

Front Wheel

Procedures for removing and installing the front wheel.

Front Brake

Steps for removing and inspecting the front brake disc.

Front Shock Absorber

Procedures for removing and installing the front shock absorber.

Front Fork;Steering

Detailed steps for servicing the front fork and steering system.

16. Rear Wheel;Rear Brake;Rear Cushion

Mechanical Illustration

Exploded view of rear wheel, brake, and cushion components.

Operational Precaution

Precautions and service data for rear wheel and brake maintenance.

Trouble Diagnosis

Troubleshooting common issues with the rear wheel and brake system.

Muffler

Steps for removing and installing the exhaust muffler.

Rear Wheel

Procedures for removing and inspecting the rear wheel.

Rear Cushion

Steps for removing and installing the rear shock absorbers.

17. Electrical System

Mechanical Illustration

Diagram illustrating the location of electrical system components.

Maintenance Data

Specifications for charging and ignition systems.

Trouble Diagnosis

Troubleshooting common problems within the electrical system.

Battery

Procedures for battery removal, voltage check, and charging.

Charging System

Charging circuit diagram and current leakage testing.

Ignition System

Ignition circuit diagram and checks for system components.

Starting System

Starting circuit diagram and starter relay inspection.

Lamp;Bulb

Procedures for replacing headlamp and winker light bulbs.

Switch;Horn

Inspection of the main switch and horn operation.

Fuel Gauge

Inspection and testing procedures for the fuel gauge system.

Thermal Switch

Testing the thermal switch that controls the cooling fan motor.

Sensor

Testing the oil temperature sensor's resistance at various temperatures.

Digital Meters Trouble Diagnosis

Troubleshooting guide for issues with the digital meter display.

18. Special Tools

Special Tools List

Comprehensive list of special tools with part numbers and prices.

How to Use Special Tools

General guidance on the correct usage of specialized tools.

R;L. Crank Case Disassemble; Install Tools

Instructions for using specific tools for crankcase disassembly and assembly.

Bearing Driver

Guidance on the proper use of bearing drivers for installation and removal.

Water Pump Bearing; Seal Driver

Instructions for using tools to service water pump bearings and seals.

Crank Case; Transmission Oil Seal Driver

Usage guidelines for tools designed for crankcase/transmission oil seals.

A.C.G. Flywheel Puller

Instructions for using the AC.G. flywheel puller tool.

Valve Cotter Remover; Install Driver

Procedures for using tools to remove and install valve cotters.

Outer; Inner Bearing Puller

Instructions for using bearing pullers to remove bearings.

Crank Case Bush Puller

Usage instructions for tools used to remove and install crankcase bushes.

19. Wiring Diagram

LA12 W; LA15 W SERIER WIRING DIAGRAM

Wiring diagram for LA12W and LA15W motorcycle models.

LA18 W SERIER WIRING DIAGRAM

Wiring diagram specific to the LA18W motorcycle model.