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Sym RV 250i User Manual

Sym RV 250i
275 pages
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GTS 250i / RV 250i
GTS 300i / JOYMAX 300i
SERVICE MANUAL
FOREWORD
HOW TO USE THIS MANUAL
CONTENTS
SERIAL NUMBER

Table of Contents

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Sym RV 250i Specifications

General IconGeneral
Fuel SystemElectronic Fuel Injection
Front SuspensionTelescopic Fork
Starting SystemElectric
Engine Type4-Stroke
TransmissionCVT
BrakesFront: Disc
Fuel Capacity12 liters

Summary

General Information

General Safety

Essential safety precautions for vehicle and component handling.

Trouble Diagnosis

Guides on identifying and diagnosing common engine and vehicle system problems.

Maintenance Information

Periodical Maintenance Schedule

Schedule for regular maintenance tasks at specified intervals (km/months).

Valve Clearance

Details the procedure for checking and adjusting valve clearance.

Spark Plug

Covers spark plug selection, gap measurement, and installation torque.

Cylinder Compression Pressure

Explains how to measure cylinder compression pressure and interpret results.

Drive Belt

Covers drive belt inspection, width limit, and replacement criteria.

Disk Brake System

Covers brake system hoses and brake fluid checks, filling, and air bleeding.

Lubrication System

Engine Oil

Procedures for checking and changing engine oil, including capacities and recommended types.

Oil Pump Inspection

Details how to inspect the oil pump for wear and correct clearances.

Oil Pump Installation

Guides on reinstalling the oil pump assembly with proper torque specifications.

Gear Oil

Covers gear oil change procedures, quantities, and torque values.

Fuel Injection System

ECU (Electronic Control Unit)

Functional description, testing procedures, and troubleshooting for the ECU.

Throttle Body

Describes the throttle body's function and troubleshooting.

MAP Sensor

Functional description, testing, and troubleshooting for the MAP sensor.

TA Sensor

Details the TA sensor's function, testing, and troubleshooting.

TPS

Explains the TPS principle, function, testing, and detection.

TW Sensor

Describes the TW sensor's function, testing, and troubleshooting.

O2 Sensor

Explains O2 sensor testing for voltage and resistance.

ISC (stepper motor)

Explains the ISC stepper motor's function, testing, and troubleshooting.

Fuel Pump

Covers fuel pump functional description, testing procedures, and detection judges.

Fuel Injector

Details fuel injector resistance confirmation and injection state examination.

Transistor ignition coil

Explains the ignition coil's function, resistance testing, and troubleshooting.

Crankshaft position sensor

Describes the CPS function, testing, and troubleshooting.

ECU Pin Configuration

Provides ECU pin assignment configuration for reference.

Integrated Troubleshooting Procedure

Flowchart-based procedure for integrated EFI system troubleshooting.

Removal & Installation of Engine

Engine Removal

Step-by-step guide for removing the engine from the motorcycle frame.

Engine Installation

Instructions for reinstalling the engine onto the motorcycle frame, including torque values.

Cylinder Head / Valve

Cylinder Head Removal

Step-by-step procedure for removing the cylinder head from the engine.

Cylinder Head Installation

Guides on installing the cylinder head, gasket, and timing marks.

Cylinder / Piston

Cylinder / Piston Removal

Step-by-step guide for removing the cylinder, piston, and related components.

V-Belt Drive System

Drive Belt

Covers drive belt removal, inspection, service limits, and installation.

Final Drive Mechanism

Final Drive Mechanism Disassembly

Step-by-step instructions for disassembling the final drive mechanism.

Final Drive Mechanism Reassembly

Steps for reassembling the final drive mechanism, including torque values and oil filling.

AC. Generator / Start Clutch

Crankshaft / Crankcase

Crankcase Disassembly

Detailed steps for disassembling the crankcase, including chains and bolts.

Crankcase Assembly

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

Cooling System

Diagnosis for Cooling System

Flowchart for diagnosing cooling system problems, starting with high temperature.

Brake System

Brake Fluid Replacement / Air-bleed

Detailed steps for replacing brake fluid and bleeding air from the brake system.

Rear Wheel / Rear Fork / Rear Cushion

Troubleshooting

Lists common rear wheel, fork, and cushion issues like run-out, soft cushion, and brake noise.

Electrical System

Troubleshooting

Lists common electrical system problems and potential causes.

Battery

Covers battery removal, voltage check, and charging procedures.

Ignition System

Shows the ignition circuit diagram and ECU coupler pin assignments.

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