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Sym X'PRO RV125 User Manual

Sym X'PRO RV125
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 X'PRO RV125 Specifications

General IconGeneral
BrandSym
ModelX'PRO RV125
CategoryScooter
LanguageEnglish

Summary

Foreword

How to Use This Manual

Mechanism Illustration

1. GENERAL INFORMATION

General Safety

Discusses precautions for safe operation, including hazards of exhaust, fuel, and hot components.

Specifications

Details technical specifications for the motorcycle model, covering dimensions, performance, and engine.

Torque Values

Lists essential torque specifications for various bolts and nuts during assembly and maintenance.

Cables and Harness Routing

Provides guidelines for correctly routing wires and cables to prevent damage and ensure safety.

Troubleshooting-Carburetor model

Offers a diagnostic guide for common engine starting and running issues in carburetor models.

Troubleshooting-EFi model

Provides a diagnostic guide for common engine starting and running issues in EFI models.

Lubrication Points

Illustrates key locations requiring lubrication for proper motorcycle operation and maintenance.

2. Maintenance Information

Precautions in Operation

Outlines essential safety and operational warnings before performing maintenance tasks on the motorcycle.

Periodical Maintenance Schedule

Details a recommended schedule for regular inspection, cleaning, and replacement of motorcycle parts.

Fuel Lines

Covers the inspection and maintenance procedures for the motorcycle's fuel delivery system.

Air Cleaner

Describes the procedure for removing and inspecting the air cleaner element for optimal engine performance.

Spark Plug

Details the process for removing, inspecting, and replacing the spark plug, including gap measurement.

Valve Clearance

Explains the steps for checking and adjusting valve clearance to ensure correct engine timing and performance.

Ignition System

Covers the procedure for checking the transistor ignition system's functionality and timing.

Brake System (front/rear disk brake)

Explains the maintenance and inspection of the front and rear hydraulic disc brake systems.

Air Bleed Operation

Explains the step-by-step process for bleeding air from the hydraulic brake system to ensure proper lever feel.

Wheel / Tire

Covers the inspection of tire pressure, surface condition, and thread depth for safe operation.

3. LUBRICATION SYSTEM

Precautions in Operation

Outlines general information and precautions for engine oil pump and gear oil replacement procedures.

Troubleshooting

Provides a guide for diagnosing and resolving issues related to low engine oil level, dirty oil, or low oil pressure.

Engine Oil

Details the procedure for checking, draining, and refilling engine oil, including capacity and torque values.

Oil Pump Inspection

Explains how to measure clearances within the oil pump to ensure it is within service limits.

Gear Oil

Covers the inspection and change procedure for the gear oil, including quantity and torque values.

4. FUEL SYSTEM

Precautions in operation

Highlights safety warnings related to gasoline and precautions for disassembling fuel system components.

Trouble diagnosis

Provides a comprehensive list of common engine starting and running problems with their potential causes.

Air cut-off valve

Explains the inspection procedure for the air cut-off valve, including specified vacuum and air pressure values.

Auto by-starter

Details the inspection, removal, and installation process for the auto by-starter system.

Carburetor removal

Guides through the steps required to safely remove the carburetor assembly from the motorcycle.

Float chamber

Explains the disassembly, checking, and cleaning procedures for the carburetor's float chamber.

Adjustment of pilot screw

Describes the procedure for adjusting the pilot screw for optimal idle speed and CO emissions.

Fuel tank

Covers the removal and installation procedures for the fuel tank and its associated components.

5. Fuel Injection System

EFi System Introduction

Introduces the EFI system, its components, and its advantages over traditional carburetor systems.

EFi System Components

Illustrates the key components of the EFI system, including sensors, ECU, injectors, and fuel pump.

EFi System Location

Shows the physical locations of the various EFI system components on the motorcycle for easy identification.

EFi System Component Description

Provides detailed descriptions of the function and characteristics of major EFI system components like ECU and sensors.

EFi System Circuit

Presents the electrical schematic diagram of the EFI system, detailing wiring and connections between components.

Precautions in Operation

Highlights safety precautions and procedures related to handling fuel pressure and disassembling EFI system parts.

Troubleshooting

Offers a systematic approach to diagnosing EFI system faults using diagnostic codes and circuit inspection.

Throttle Body & By-pass Valve Clean Procedure

Details the recommended cleaning procedure for the throttle body and air by-pass valve for optimal engine performance.

Ignition System

Describes the principle of operation, specifications, and components of the computerized ignition control system.

Crankshaft Position Sensor

Explains the function and operation of the crankshaft position sensor in determining engine speed and timing.

EFi Troubleshooting and Solution

Explains how to interpret check lamp signals (Service Priority and Flash Codes) for diagnosing EFI system faults.

6. Engine Removal

Precautions in Operation

Outlines general information and precautions for engine removal, emphasizing the need for special tools and frame support.

Engine Removal – Carburetor Model

Provides a step-by-step guide for removing the engine from the motorcycle when equipped with a carburetor system.

Engine Removal – EFi Model

Details the procedure for removing the engine from the motorcycle when equipped with an Electronic Fuel Injection (EFI) system.

Engine Hanger

Covers the removal and installation of the engine hanger, including inspection of its rubber bush for damage.

Engine Installation

Guides through the process of reinstalling the engine, emphasizing safety, wire routing, and torque values.

7. Cylinder Head / Valve

Mechanism Diagram

Illustrates the components of the cylinder head and valve train assembly, including torque specifications for key parts.

Precautions in Operation

Details general information and specifications related to cylinder head, valve, and camshaft service.

Cylinder Head Removal

Provides a step-by-step guide for removing the cylinder head assembly from the engine.

Cylinder Head Disassembly

Explains the process of disassembling the cylinder head, including valve removal and spring compression.

Valve Stem Replacement

Guides through the procedure for replacing valve stems, including heating the cylinder head and using specific tools.

Valve Seat Inspection

Describes methods for inspecting valve seats, including checking width, contact condition, and grinding procedures.

Cylinder Head Reassembly

Details the steps for reassembling the cylinder head, including valve stem oil seal installation and spring compression.

Cylinder Head Installation

Guides through the process of installing the cylinder head back onto the engine, including torque values and gasket placement.

8. Cylinder / Piston

Mechanism Diagram

Illustrates the components of the cylinder and piston assembly, showing their interrelationships.

Precautions in Operation

Provides general information and specifications for cylinder and piston service, applicable when the engine is mounted.

Troubleshooting

Lists common issues related to cylinder and piston performance, such as low compression, noise, smoking, and overheating.

Cylinder Removal

Details the step-by-step procedure for removing the cylinder from the engine block.

Piston Removal

Explains how to safely remove the piston from the cylinder, including precautions for handling piston rings.

Piston Ring Installation

Guides through the proper installation of piston rings into their grooves on the piston, emphasizing correct orientation.

Piston Installation

Describes the procedure for installing the piston into the cylinder, including lubrication and alignment marks.

9. V-Belt Drive System

Mechanism Diagram

Shows an exploded view of the V-belt drive system components, including torque specifications for assembly.

Precautions in Operation

Outlines general precautions and service data for the V-belt drive system, emphasizing grease-free components.

Troubleshooting

Lists common issues and their probable causes related to the V-belt drive system, such as inability to move or poor performance.

Drive Belt

Explains the removal, inspection, and installation of the drive belt, including service limits for belt width.

Drive Face

Covers the removal and inspection procedures for the drive face components, including measuring diameters and checking for wear.

Clutch Outer / Driven Pulley

Details the disassembly and inspection of the clutch outer and driven pulley, including measurements and component checks.

10. Final Drive Mechanism

Mechanism Diagram

Illustrates the components of the final drive mechanism, showing their arrangement and torque values.

Precautions in Operation

Provides specifications for application oil, torque values, tools, and troubleshooting tips for the final drive system.

Troubleshooting

Lists common problems related to the final drive, such as engine not moving, noise, and gear oil leaks, with their causes.

Final Drive Mechanism Disassembly

Guides through the steps for disassembling the final drive mechanism, including draining gear oil and removing covers.

Bearing Replacement

Details the procedure for inspecting and replacing bearings in the final drive mechanism, emphasizing the use of specific tools.

Final Drive Mechanism Reassembly

Guides through the reassembly process of the final drive mechanism, including bearing installation and lubrication.

11. AC. Generator / Start Clutch

Mechanism Diagram

Shows an exploded view of the AC generator and start clutch components with torque specifications for assembly.

Precautions in Operation

Provides general information, specifications, torque values, and special tools required for AC generator and start clutch service.

Start Clutch

Covers the removal, inspection, and disassembly of the start clutch assembly and its related gears.

Flywheel Installation

Details the procedure for installing the flywheel onto the crankshaft, including pin alignment and nut tightening.

AC. Generator Installation

Explains how to install the AC generator assembly onto the right crankcase cover, ensuring secure wire harness placement.

12. Crankshaft / Crankcase

Mechanism Diagram

Illustrates the crankshaft and crankcase components, showing their arrangement and torque values.

General Information

Provides operational precautions and service data for crankshaft and crankcase disassembly and assembly.

Troubleshooting

Lists common engine noises and their potential causes related to crankshaft and crankcase components.

Crankcase Disassembly

Details the step-by-step procedure for disassembling the crankcase, including cam chain and tensioner removal.

Crankshaft Inspection

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

Crankcase Assembly

Guides through the process of assembling the crankcase, including bearing installation and crankshaft placement.

13. Cooling System

Mechanism Diagram

Shows a diagram of the cooling system components, including the radiator, water pump, and thermostat.

General Information

Provides technical specifications, torque values, tools, and safety warnings for the cooling system.

Troubleshooting

Lists common problems related to engine temperature (too high or too low) and coolant leaks, with their causes.

System Test

Explains how to test the cooling system's filler cap and check for overall system leakage.

Coolant Change

Details the procedure for safely draining, refilling, and bleeding the cooling system of air.

Water Pump

Explains the inspection and replacement of the water pump's mechanical seal and shaft assembly.

Thermostat

Guides through the removal, inspection, and testing of the thermostat to ensure proper engine temperature regulation.

14. Body Cover

Mechanism Diagram

Illustrates the various body cover components of the motorcycle, showing their locations and relationships.

Maintenance

Provides a sequence for disassembling body covers and outlines general precautions for assembly and disassembly operations.

Steering Handle Cover

Details the removal and installation procedures for the steering handle covers, including screw locations.

Wind Screen

Explains how to remove and install the wind screen and its garnish, specifying the number of screws required.

Front Cover

Guides through the removal and installation process for the front cover assembly, including screw locations.

Meter Cover

Covers the removal and installation of the meter cover assembly, including wire coupler disconnection.

Side Cover

Details the removal and installation procedure for the left and right side covers of the motorcycle.

Luggage Box

Covers the removal and installation of the luggage box assembly, including disconnection of the engine start control switch.

Body Covers / Rear Fender

Guides through the removal and installation of the body covers and rear fender assembly, including coupler disconnection.

Floor Panel

Covers the removal and installation of the floor panel, specifying bolt locations on the upper and side panels.

15. Brake System

Front Brake System Diagram

Illustrates the components of the front brake system, showing their arrangement and torque values.

Rear Brake System Diagram

Shows the components of the rear brake system, including their arrangement and torque values.

Maintenance Description

Provides operational precautions, specifications for brake components, and torque values for brake system maintenance.

Troubleshooting

Lists common brake system issues, such as soft lever, hard operation, uneven braking, and noise, with their probable causes.

Hydraulic Disc brake

Details the procedure for hydraulic disc brake maintenance, including fluid replacement and bleeding.

Air Bleed

Explains the step-by-step process for bleeding air from the hydraulic brake system to ensure proper lever feel.

Brake Master Cylinder

Details the inspection and assembly procedures for the brake master cylinder, including measurement of component diameters.

16. Steering / Front Wheel / Front Cushion

Mechanism Diagram

Illustrates the components of the steering, front wheel, and front suspension system with associated torque values.

Precautions in Operation

Provides general precautions, torque values, tools, and troubleshooting tips for steering and front wheel/suspension maintenance.

Troubleshooting

Lists common issues related to steering (hard to steer, tilted handlebar), front wheel run-out, and front shock absorber problems.

Steering Handlebar

Details the removal and installation procedures for the steering handlebar assembly, including switch removal.

Front Wheel

Covers the removal and inspection of the front wheel, including wheel axle and bearing checks for run-out and smoothness.

Front Cushion

Explains the removal and installation of the front shock absorbers, including tightening procedures and alignment.

Front Fork / Steering Stem

Details the removal, inspection, and replacement of front fork and steering stem components, including bearing carriers.

17. Muffler / Rear Wheel / Rear Cushion

Mechanical Illustration

Shows an exploded view of the muffler, rear wheel, and rear suspension components with torque specifications.

Precautions in Operation

Provides general precautions, service data for the rear wheel and brake lining, and torque values for related parts.

Troubleshooting

Lists common issues related to the rear wheel (run-out), suspension (soft), and brake system (noisy, poor performance).

Muffler

Covers the removal and installation of the muffler and exhaust pipe, including torque values for lock bolts and nuts.

Rear Wheel

Details the removal and inspection procedures for the rear wheel, including brake disc thickness and wheel bearing checks.

Rear Cushion

Explains the removal and installation of the rear shock absorbers and related components, including torque values.

18. Electrical System

Mechanism Diagram

Illustrates the motorcycle's electrical system components, including battery, ECU, lights, and switches.

Precautions in Operation

Outlines general precautions for battery handling, spark plug torque, ignition timing, and AC generator removal.

Troubleshooting

Provides a diagnostic guide for electrical system issues such as no voltage, low voltage, no spark, and starter motor problems.

Battery

Details the procedure for battery removal, voltage inspection, and charging, including safety warnings and specifications.

Charging System

Explains the charging system circuit, regulator rectifier inspection, and charging circuit checks with standard values.

Ignition System

Details the ignition system circuit and procedures for inspecting the ignition coil and CPS sensor resistance.

Starting System

Explains the starting circuit, starter relay inspection, and starter motor removal/installation procedures.

Switch / Horn

Explains the inspection and replacement of main switches, handlebar switches, and horn, including circuit checks.

Fuel Unit

Details the removal and inspection of the fuel unit, including float resistance and fuel gauge function checks.

Thermo Switch

Explains how to test the thermo switch's operation by checking its continuity at different coolant temperatures.

19. SPECIAL TOOLS

Special tools list

Lists various special tools required for motorcycle maintenance and repair, with part numbers and prices.

How to use special tools

Provides visual guides on the correct usage of specific tools like crank case tools for disassembly and installation.

Bearing driver

Illustrates the use of bearing drivers for installing and removing bearings in various engine components.

Water pump bearing / seal driver

Shows how to use specialized drivers for installing water pump bearings and oil seals correctly.

AC.G. flywheel puller

Explains the procedure for using an ACG flywheel puller to safely remove the flywheel.

Outer / inner bearing puller

Illustrates the use of bearing pullers for removing outer and inner bearings from various components.

20. WIRING DIAGRAM

EFi Model Joyride 200i / Super Joyride 200i / Joyride 200i EVO

Presents the wiring diagram specific to the EFI models of Joyride 200i, Super Joyride 200i, and Joyride 200i EVO.

EFi Model X`Pro RV125 / 200 EFi

Provides the wiring diagram for the EFI models of X'Pro RV125 and 200 EFi scooters.

Carburetor Model RV200

Displays the wiring diagram for the RV200 model, which utilizes a carburetor system.

Carburetor Model Joyride 125 / 200EVO

Shows the wiring diagram for the Joyride 125 / 200EVO models with carburetor systems.