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Sym RS-50 User Manual
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RS-50
SER
VICE MANUAL
FORW
ARD
HOW TO USE THIS MANUAL
CONTENTS
MECHANISM ILLUSTRA
TIONS
2
Table of Contents
Page Content Index
4
Service Manual
1
General Information
3
Table of Contents
4
General Safety
7
Service Precautions
8
Lubrication System
10
Specifications
11
Torque Values
13
Troubleshooting
18
Lubrication Points
22
2. Service Maintenance Information
24
Periodical Maintenance Schedule
25
Service Maintenance Information
26
Air Cleaner
26
Fuel Lines
26
Engine Oil Line
27
Fuel Filter
27
Oil Pump Control Cable
28
Battery
29
Tire
29
Rear Brake Free Play
30
Type)
30
Steering System
33
Suspension
33
Spark Plug
34
Transmission Oil
34
Control Cable Lubrication
35
Driver Belt
35
Ignition Timing
35
Throttle Valve Operation
35
Carbon Removing for Exhaust Pipe
36
Carburetor Idle Speed Adjustment
36
Cylinder Compression Pressure Test2-13
36
Muffle
36
Headlight Adjustment
37
3. Lubrication System
38
Lubricant
39
Precautions in Operation
39
Trouble Shooting
39
Oil Pump Installation
40
Oil Pump Removal
40
Oil Pump/Oil Tube Air Bleeding
41
Oil Tank
42
Engine Removal
44
Engine Installation
47
Cylinder Head/Cylinder/Piston
48
Cylinder Head
50
Alternator
56
7. "V" Type Belt Drive System/Kick-Starter
60
Maintenance Information
61
Trouble Shooting
61
Left Crankcase Cover
62
Installation of the Left Crankcase Cover
63
Reassembly of Kick Starter
63
Drive Belt
64
Movable Driven Pulley
64
Movable Drive Face
65
Clutch/Driven Pulley
69
8. Final Driving Mechanism
74
Final Driving Mechanism
74
Maintenance Information
75
Troubleshooting
75
Disassembly of Final Driving Mechanism
76
Bearing Replacement
77
Re-Assembly of Final Driving Mechanism
77
9. Crankcase/Crankshaft
80
Crankcase/Crankshaft
80
Maintenance Information
81
Troubleshooting
81
Crankcase Disassembly
82
Crankshaft Removal
82
Crankshaft Inspection
83
Crankcase Installation
84
10. Fuel System
86
Fuel System
86
Maintenance Information
87
Troubleshooting
87
Throttle Valve
88
Auto By-Starter
89
Carburetor Remove
89
Float/Float Valve/Jet
91
Carburetor Installation
92
Float Level Inspection
92
Reed Valve
92
Air Cleaner
93
11. Brake System
94
Brake System
94
Rear Drum Brake System
95
Maintenance Information
96
Troubleshooting
97
Hydraulic Disc Brake
98
Disc Brake - Caliper
99
Disc Brake -Air Bleed
99
Brake Disc
100
Disc Brake - Master Cylinder
100
Rear Drum Brake
103
12. Body Cover
106
Maintenance Information
107
Front Cover
108
Handle Cover
109
Front Fender
111
Left & Right Side-Covers
111
Luggage Box
112
Rear Carrier
112
Center Cover
113
12. Body Cover
114
Left & Right Side Foot Plates
115
Floor Panel
116
Front under Spoiler
117
Inner Cover
118
Rear Inner Fender
120
Under Cover
120
13. Steering/Front Wheel/Front Shock Absorber
122
Precautions in Operation
123
Trouble Diagnosis
123
Steering Handle
124
Front Wheel
125
Front Cushion
128
Front Fork/Steering Column
128
14. Rear Wheel/Suspension
130
Rear Wheel/Suspension
130
Maintenance Information
131
Troubleshooting
131
Rear Wheel
132
Rear Shock Absorber
133
15. Electrical Equipment
134
Electrical Equipment
134
Maintenance Information
135
Troubleshooting
136
Battery
137
Charging System
138
Ignition System
142
Starting System
145
Oil Level Switch
148
Fuel Unit
149
Switch / Horn
151
Bulb Replacement
153
Electrical Diagram
157
4
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Sym RS-50 Specifications
General
Fuel System
Carburetor
Rear Brake
Drum
Front Tire
120/70-12
Rear Tire
130/70-12
Transmission
Automatic
Engine Cooling
Air-cooled
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