Sym Fiddle II 125 Factory Service Repair Manual

SERVICE MANUAL Fiddle II 125 – AW12W

SYM FORWARD This service manual contains the technical data of each component inspection and repair for the SYM series motorcycle. The manual is shown with illustrations and focused on 「Service Procedures」, 「Operation Key Points」 , and 「Inspection Adjustment」 so that provides technician with service guidelines. If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. This manual that contains all data, illustration, indication and specifications is based on current production information. SYM reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this manual can be duplicated by any means without written permission of SANYANG. SERVICE DEPARTMENT SAN YANG INDUSTRY CO., LTD.

HOW TO USE THIS MANUAL SYM This service manual describes basic information of different system parts and system inspection & service for SYM series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance. The third to the eleventh chapters cover engine and driving systems. The twelfth to fifteenth chapters are contained the parts set of assembly body. The sixteenth chapter is electrical equipment. The seventh chapter is for wiring diagram. Please see index of content for quick having the special parts and system information.

SYM CONTENTS CONTENTS GENERAL INFORMATION/TROUBLE DIAGNOSIS ................................... 1 MAINTENANCE INFORMATION ................................................................. 2 LUBRICATION SYSTEM .............................................................................. 3 FUEL SYSTEM ............................................................................................. 4 ENGINE REMOVAL...................................................................................... 5 CYLINDER HEAD/VALVE ............................................................................ 6 CYLINDER/PISTON...................................................................................... 7 "V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM ....................... 8 FINAL DRIVING MECHANISM..................................................................... 9 A.C. GENERATOR/STARTING CLUTCH .................................................... 10 CRANKCASE/CRANKSHAFT ..................................................................... 11 BODY COVER .............................................................................................. 12 BRAKE SYSTEM .......................................................................................... 13 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER ........................ 14 REAR WHEEL/SUSPENSION...................................................................... 15 ELECTRICAL EQUIPMENT ......................................................................... 16 ELECTRICAL DIAGRAM ............................................................................. 17

MECHANISM ILLUSTRATIONS SYM Light/starter switch Front disk brake Exhaust muffler Ignition switch Gear oil draining bolt Battery/Fuse/CDI Front brake lever Rear brake lever Air cleaner Gear oil filling bolt Oil level Tail light Front turn signal light Fuel tank / Fuel unit High&Low beam/Seat open/turn signal/horn Head light/ Position light Rear turn signal light Engine number/engine oil draining bolt Ignition coil Frame number Meter A.C. Generator Start magnetic switch Horn/REG.REC RR. turning signal light Tail light Front turn signal light Winker relay Engine control switch

SPECIAL TOOL 1 ITEM: R/L CRANKCASE DISASSEMBLE TOOL NO：SYM-1120100 PURPOSE: DISASSEMBLE CRANKCASE ITEM: CRANK PULLER NO：SYM-1130000 PURPOSE: INSTALL CRANKCASE ITEM: OUTER BEARING PULLER NO：SYM-6204010 PURPOSE: REMOVE THE BEARING ITEM: ACG FLYWHEEL PULLER NO：SYM-3110A00 PURPOSE: REMOVE ACG FLYWHEEL ITEM: LOCK NUT PULLER NO：SYM-9020100 PURPOSE: REMOVE THE LOCK NUT ITEM: UNIVERSAL HOLDER NO：SYM-2210100 PURPOSE:HOLD THE MDF/CLUTCH OUTER

SPECIAL TOOL 2 ITEM: CLUTCHSPRING COMPRESSOR NO：SYM-2301000 PURPOSE:DISASSEMBLE THE CLUTCH ITEM: CLUTCH NUT WRENCH NO：SYM-9020200 PURPOSE:LOOSE THE CLUTCH NUT ITEM: GY6 STARTER GEAR PULLER NO：SYM-2822100-GY6 PURPOSE:REMOVE THE STARTER GEAR

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS 1-1 SYMBOLS AND MARKS .................... 1-1 GENERAL SAFETY............................ 1-2 SERVICE PRECAUTIONS ................. 1-3 SPECIFICATIONS .............................. 1-9 TORQUE VALUES (ENGINE) .............. 1-10 TORQUE VALUES (FRAME) ............... 1-11 TROUBLES DIAGNOSIS ..................... 1-12 LUBRICATION POINTS ....................... 1-16 SYMBOLS AND MARKS Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks. Warning Means that serious injury or even death may result if procedures are not followed. Caution Means that equipment damages may result if procedures are not followed. Engine oil Limits to use SAE 10W-30 API SH/CD class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. Grease King Mate G-3 is recommended. Locking sealant Apply sealant, medium strength sealant should be used unless otherwise specified. Oil seal Apply with lubricant. Renew Replace with a new part before installation. Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid. Special tools Special service tools. Correct Meaning correct installation. Wrong Meaning wrong installation. Indication Indication of components. Directions Indicates position and operation directions. Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility).

1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYM 1-2 GENERAL SAFETY Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Used engine oil Caution Hot components Caution Battery Caution Brake shoe Do not use an compressed air or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid asbestos dust flying. Caution Brake fluid Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. y Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. y Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water, then go to hospital to see an ophthalmologist. y If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil, and then go to see a doctor. y Keep electrolyte beyond reach of children. Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verdict. Inhaling asbestos dust may cause disorders and cancer of the breathing system. Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep brake fluid beyond reach of children. Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.

SYM 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS 1-3 SERVICE PRECAUTIONS y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG motorcycle may damage the motorcycle. y Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged. y When servicing this motorcycle, use only metric tools. Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle. y Clean the outside of the parts or the cover before removing it from the motorcycle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause a damage. y Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them. y Never bend or twist a control cable to prevent stiff control and premature worn out. y Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary. y When loosening a component which has different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress. y Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later. y Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position). y Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

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Sym Fiddle II 125 Factory Service Repair Manual

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