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Orbit II 50 4T
Sym Orbit II 50 4T User Manual
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SYM
10.
A.C. GENER
ATOR/STARTING CLUTCH
10
-
9
Install the cooling fan
.
(4 bolts)
Torque value: 0.
8
~1.
2
kg
f-
m
Install the cooling fan shroud
.
(4 bolts)
Install the exhaust
muffler
.
(2 bolts, 2 nuts)
Install the
body
c
ove
r
.
Add some engine oil according the
specified quantit
y.
Cooling fan
E
xhaust
muffler
Cooling f
an shroud
24
26
Table of Contents
General Information/Trouble Diagnosis
1
Symbols and Marks
1
Carbon Monoxide
2
Gasoline
2
General Information/Trouble Diagnosis
2
General Safety
2
Used Engine Oil
2
Service Precautions
3
Specifications
9
Torque Values (Engine)
10
Standard Torque Values for Reference
11
Torque Values (Frame)
11
Engine Hard to Start or Can Not be Started
12
Troubles Diagnosis
12
Engine Run Sluggish
13
Engine Runs Sluggish
14
Engine Runs Sluggish (High Speed)
14
Clutch, Driving and Driving Pulley
15
Lubrication Points
16
A.C. Generator/Starting Clutch
17
Mechanism Diagram
17
General Information
18
Precautions in Operation
18
Specification
18
Torque Value
18
A.C. Generator Removal
19
Right Crankcase Cover Removal
20
Starting Clutch
21
Starting Clutch Inspection
21
Starting Clutch Removal
21
Starting Clutch Installation
23
Flywheel Installation
24
Mounted Coil Set Installation
24
Right Crankcase Cover Installation
24
Crankcase/Crankshaft
26
Engine Noise
27
Operational Precautions
27
Trouble Diagnosis
27
Disassembly of Crankcase
28
Bearing Inspection
30
Crankshaft Inspection
30
Assembly of Crankcase
31
Body Cover
33
Body Covers Disassemble Sequence
34
Maintenance Information
34
Handle Cover
35
Front Cover
36
Front Inner Box
37
Body Cover/Rear Center
38
Cover/Rear Fender
38
Front Center Cover
40
Luggage Box
40
Floor Panel
41
Side Cover
42
Under Cover
42
Brake
43
Front Disc Brake System
43
Rear Drum Brake System
44
Disc Brake
46
Hard Operation of Brake Lever
46
Soft Brake Lever
46
Trouble Diognosis
46
Brake Fluid Add
47
Hydraulic Brake System Inspection
47
Brake Fluid Replacement/Air-Bleed
48
Brake Caliper
49
Brake Lining Replacement
49
Brake Disc Inspection
50
Brake Master Cylinder
50
Brake Drum
53
Brake Lining
53
Drum Brake-Drum
53
Brake Panel
54
Front Brake Panel
55
Rear Brake Panel
55
Steering/Front Wheel/Front Shock Absorber
56
Front Wheel Wobbling
57
Hard Steering Stem
57
Soft Front Suspension
57
Steering Stem off Center
57
Steering Handle
58
Disc Brake Type
59
Front Wheel
59
Wheel Axle
60
Wheel Rim
60
Front Fork/Steering Column
64
Front Shock Absorber
64
Rear Wheel/Rear Shock Absorber
66
Braking Noise
67
Poor Brake Performance
67
Rear Wheel Wobbling
67
Shock Absorber too Soft
67
Exhaust Muffler
68
Rear Wheel
68
Rear Shock Absorber
69
Electrical Equipment
70
Charging System
71
Ignition System
71
Starting System
71
Charging System Failure
73
Intermittent Power Supply
73
Low Voltage
73
No Power Supply
73
Charging Wire Diagram
74
Current Leakage Inspection
74
Voltage Check
76
Charging Voltage/Current Inspection
77
Main Wire Circuit Inspection
78
Voltage Regulator Check
78
Voltage Regulator Inspection
78
Alternator Charging Coil
79
Alternator Lighting Coil
79
Resistor Check
79
CDI Unit
80
Ignition System Circuit
80
Ignition Coil
81
Primary Coil Check
81
Spark Plug Confirmation
81
Pulse Generator
82
Secondary Coil
82
Starter Magnetic Switch Inspection
83
Starting Circuit
83
Meter
84
Starting Motor Removal
84
Headlight Bulb Replacement
86
Light/Bulbs
86
Front Turn Signal Lamp Bulb Replacement
87
Main Switch/Horn
88
Handle Switch
89
Headlight Switch
89
High/Low Beam Switch/ Seat Open
89
Starting Switch
89
Brake Light Switch
90
Horn
90
Turn Signal Light Switch
90
Fuel Unit
91
Wiring Diagram
92
Periodical Maintenance Schedule
94
Cleaning the Oil Strainer
95
Engine Oil Capacity
95
Lubrication System
95
Oil Change
95
Fuel Filter
96
Fuel Pipe
96
Fuel System
96
Gear Oil
96
Air Cleaner
97
Throttle Valve Operation
97
Crankcase Ventilation
98
Valve Clearance Adjustment
98
Carburetor Idle Speed Adjustment
99
Emission Adjustment in Idle Speed
99
Valve Clearance Inspection and Adjustment
99
Ignition Timing
100
Spark Plug
100
Clutch Pad
101
Cylinder Copmression Pressure
101
Driving Belt
101
Driving System
101
Steering System
102
Suspension System
102
Air Bleed Operation
103
Brake Fluid
103
Brake System Hose
103
Filling out Brake Fluid
103
Added Brake Fluid
104
Brake Lining Wear
104
Brake Confiramtion
105
Drum Brake System
105
Rear Brake Free Play
105
Appointed Tire
106
Appointed Tire Pressure
106
Wheel/Tire
106
Battery Cables Removal
107
Battery Removal
107
Headlight Adjustment
107
Nuts, Bolts Tighteness
107
Dirty Oil
109
Low Engine Oil Level
109
Low Oil Pressure
109
Lubrication System
109
Cleaning Engine Oil Strainer
110
Engine Oil
110
Oil Pump Disassembly
111
Oil Pump Removal
111
Oil Pump Inspection
112
Oil Pump Re-Assembly
112
Oil Pump Installation
113
Gear Oil Replacement
114
Fuel System
116
Mixture too Lean
117
Poor Engine Start
117
Rough Idle
117
Stall after Started
117
Carburetor Removal
118
Vacuum Chamber
118
Air Cut-Off Valve
120
Auto By-Starter
121
Valve Inspection
121
Float Chamber
122
Checking Fuel Level
123
Idle Speed Adjustment
123
Installation of Carburetor
123
Standard Turns
123
Fuel Tank Installation
124
Fuel Tank Removal
124
Fuel Unit Installation
124
Fuel Unit Removal
124
Air Cleaner Element Cleaning
125
Removal of Engine
126
Engine Removal
128
Pressing in
131
Pressing out
131
Suspension Bushing
131
Engine Suspension Frame
132
Engine Suspension Nut
133
Installation of Engine
133
Rear Shock Absorber Bolt
133
Rear Wheel Axle Nut
133
Cylinder Head/Valve
134
Cylinder Head/Valve
135
Camshaft Removal
137
Camshaft Inspection
138
Cylinder Head Disassembly
139
Cylinder Head Removal
139
Cylinder Head Inspection
140
Valve Spring Free Length
140
Valve Guide
141
Valve Guide Replacement
141
Valve Stem
141
Valve Seat Inspection and Service
142
Valve Seat Grinding
143
Valve Seat Inspection
143
Valve Seat Width
143
Cylinder Head Reassembly
144
Cylinder Head Installation
145
Cylinder/Piston
147
Cylinder/Piston
148
Engine Overheat
148
Knock or Noise
148
Low or Unstable Compression Pressure
148
Smoking in Exhaust Pipe
148
Cylinder Removal
149
Disassemble the Piston Rings
151
Piston Removal
151
Piston Ring Installation
153
Cylinder Installation
154
Piston Installation
154
V-Belt Driving System/Kick Starter Arm
155
Engine Can be Started but Motorcycle Can Not be Moved
156
Insufficient Horsepower or Poor High Speed Performance
156
Shudder or Misfire When Driving
156
Installation of the Left Crankcase Cover
157
Left Crankcase Cover
157
V" Type Belt Driving System/Kick Starter Arm
157
Driving Pulley Install
162
Clutch/Driven Pulley
163
Clutch Lining
164
Driven Pulley
164
Driven Pulley Bearing Inspection
164
Driven Pulley Spring
164
Clutch Block Replacement
165
Replacement of Driven Pulley Bearing
166
Installation of Clutch/Driven Pulley
167
Final Driving Mechanism
168
Final Driving Mechanism
169
Gear Oil Leaks
169
Noise
169
Disassembly of Final Driving Mechanism
170
Inspection of Final Driving Mechanism
170
Bearing Replacement
171
Re-Assembly of Final Driving Mechanism
173
Electrical Equipment
176
Wiring Diagram
176
Table of Contents
177
Mechanism Illustrations
178
4
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Sym Orbit II 50 4T Specifications
General
Brand
Sym
Model
Orbit II 50 4T
Category
Scooter
Language
English
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