Manual de Serviço SYM 250 (FYM 250)

www.ClassicCycles.
org
Edited by Foxit Reader
Copyright(C) by Foxit Software Company,2005-2008
For Evaluation Only.
PREFACE
PREFACE
This shop manual describes the technical feature and

servicing procedures for the SANYANG NCA250.
All information, illustrations, directions and
specifications included in this publication are base on
SANYANG NCA250.
SANYANG reserves the right to make changes at any
time without notice and without incurring any
obligation whatever.
Este manual da loja descreve o recurso técnico e
procedimentos de manutenção para o SANYANG NCA250.
Todas as informações, ilustrações, instruções e
As especificações incluídas nesta publicação são baseadas em
SANYANG NCA250.
A SANYANG reserva-se o direito de fazer alterações a qualquer
tempo sem aviso prévio e sem incorrer em
obrigação o que for.
SANYANG INDUSTRY CO.,LTD.

SERVICE DIVISION
www.ClassicCycles.org
CONTENTS
CONTENTS
GENERAL INFORMATION ..........................................................................1

INSPECTION/ADJUSTMENT.......................................................................2
LUBRICATION SYSTEM..............................................................................3
ENGINE REMOVAL/INSTALLATION ..........................................................4
CYLINDER HEAD/VALVE............................................................................5
CYLINDER/PISTON......................................................................................6
CLUTCH/OIL PUMP/GEAR SHIFT ..............................................................7
A.C. GENERATOR .......................................................................................8
CRANK SHAFT/CRANK CASE/TRANSMISSION .......................................9
CARBURETOR.............................................................................................10
HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ..........................11
REAR WHEEL/REAR SUSPENSION ..........................................................12
BATTERY/CHARGING SYSTEM .................................................................13
IGNITION SYSTEM.......................................................................................14
SWITCHES/HORN........................................................................................15
WIRING DIAGRAM.......................................................................................16
INFORMAÇÃO GERAL ................................................ .......................... 1

INSPECÇÃO / AJUSTE ............................................... ........................ 2
SISTEMA DE LUBRIFICAÇÃO................................................ .............................. 3
DESMONTAGEM / INSTALAÇÃO DO MOTOR .............................................. ............ 4
CABEÇA / VÁLVULA DO CILINDRO .............................................. .............................. 5
CYLINDER / PISTON ............................................... ........................................ 6
EMBREAGEM / BOMBA DE ÓLEO / SHIFT DE GEAR ........................................... ................... 7
GERADOR DE CA ................................................ .......................................... 8
CRANK SHAFT / CRANK CASE / TRANSMISSION ....................................... 9
CARBURADOR................................................. ............................................ 10
FARO / DIRECÇÃO / RODA FRONTAL / FORQUILHA FRONTAL .......................... 11
RODA TRASEIRA / SUSPENSÃO TRASEIRA ............................................. ............ 12
BATERIA / SISTEMA DE CARREGAMENTO .............................................. ................... 13
SISTEMA DE IGNIÇÃO................................................ ....................................... 14
SWITCHES / HORN ............................................... ......................................... 15
DIAGRAMA DE TELEFONE ................................................ ........................................ 16
1.GENERAL INFORMATION
SERVICE RULES ...............................1-1 TORQUE VALUES ............................. 1-3
SPECIFICATIONS..............................1-2 TROUBLE SHOOTING ...................... 1-4
REGRAS DE SERVIÇO ........................ 1-1 VALORES DO TORQUE ............................. 1-3
ESPECIFICAÇÕES
SERVICE RULES: ............................. 1-2 TIRO DE PROBLEMAS ..................... 1-4
(1)Use new packings, gaskets,O-rings and cotter (5)Clean all removed parts in or with solvent, and
pins space and clipes whenever reassembling. lubricate their sliding surfaces upon disassembly.
(1) Use novas embalagens, juntas, juntas tóricas e chaveiras
(5) Limpe todas as partes removidas em ou com solvente, e
pinos espaçam e se agravam sempre que voltarem a montar.
lubrificar as superfícies deslizantes após a desmontagem.
(2)When tightening bolts or nuts, begin on center or (6)Coat or fill parts with specified grease where
larger diameter bolts and tighten them in criss- specified.
cross pattern in two or more steps if necessary. (6) Revestir ou preencher peças com graxa especificada onde
Especificadas.
(2) Ao apertar parafusos ou porcas, comece no centro ou
parafusos de maior diâmetro e aperte-os em criss-
padrão cruzado em duas ou mais etapas, se necessário.
(3)Use genuine SANYANG parts and lubricants or (7)Upon assembling, check every possible part for
those equivalent. When parts are to be reused, proper installation and movement or operation.
they must be inspected carefully to make sure they (7) Ao montar, verifique todas as partes possíveis para
are not damaged or deteriorated and in good Instalação e movimento ou operação adequados.
usable condition.
(3) Use peças e lubrificantes SANYANG genuínas ou
esses equivalentes. Quando as peças devem ser reutilizadas,
eles devem ser inspecionados cuidadosamente para garantir que
elesnão estão danificados ou deteriorados e em bom estado
condição utilizável.
(4)Use special tool when use of such a tool is (8)Work safely and give your work your undivided
specified. attention. Exchange signals as frequently as possi-
(4) Use uma ferramenta especial quando o uso dessa ble when a work involves two or more workers. Do
ferramenta for Especificadas. n. not run the engine unless the shop or working area
is well ventilated.
(8) Trabalhe com segurança e dê ao seu trabalho o seu indivíduo
atenção. Trocar sinais com a frequência
quando um trabalho envolve dois ou mais trabalhadores. Faz
não execute o motor a menos que a loja ou área de trabalho
está bem ventilado.
Symbol Marks:
:Apply engine oil. NOTE: Things must be noticed.
: Aplique óleo do motor.
CAUTION: Things that could cause damage to the
engine parts.
WARNING: Things that could cause damage to
:Apply grease.
the person or partner.
: Aplique graxa.
1-1
SPECIFICATIONS
ITEM NCA250
Overall length Comprimento total 2180mm
Overall width Largura total 960mm
Overall height Altura Geral 1130mm
DIMENSIONS Wheel base Base de roda 1480mm
Ground clearance Solha no solo 160mm
Dry weight Peso seco 175kg
Tipo Type Double pipe
Suspensão dianteira e viagem
Suspensão traseira e viagem
Front suspension and travel Telescope 165mm
Rear
Tamanho do pneu dianteiro e pressão dossuspension
pneus and travel Swing arm 63mm
Front
Tamanho do pneu traseiro e pressão tire size and tire pressure
dos pneus 90/90-18 2.25Kg/C ㎡
Travão dianteiro Rear tire size and tire pressure
Travão traseiro 130/90-15 2.50Kg/C ㎡
Capacidade de combustível Front brake Disk
FRAME Rear brake
Capacidade de reserva de combustível Drum
Ângulo de rodízio Fuel capacity
Capacidade de óleo da forquilha dianteira
14 liter
Fuel reserve capacity 2.0 liter
Caster angle 26 °
Front fork oil capacity 160c.c
Type Air cooled 4 stroke O.H.C. engine

Cylinder arrangement Double cylinders 15~ inclinde from vertical
Bore & stroke 53 x53mm
Displacement 233.9c.c.
Compression ratio 9.5:1
Oil capacity 1.1 ~1.5 liter (1.3 liter for change)
Intake valve opens 0° BTDC
ENGINE
closes 30 ° ABDC
Exhaust valve opens 35° BBDC
closes -5 ° ATDC
Valve clearance IN. 0.08mm
EX. 0.10mm
Idle speed 1500 rpm
Clutch Wet muti-plate type

Transmission 5-speed internationl
Primary reduction ratio 3.83
Gear ratio I 2.46
II 1.777
DRIVE TRAIN III 1.333
IV 1.083
V 0.913
Final reduction ratio 2.285
Gearshift pattern 1→N→2→3→4→5
Ignition system C.D.I. unit

Ignition timing "F" mark BTDC 15°±20° /1500rpm
Full advance BTDC 29.5°±2° /4000rpm
Starting system Electrical motor starter
Alternator A.C. generator
ELECTRICAL Battery capacity 12V 9AH
Fuse 20A×2/15A×2/10A×4
Spark plug A6RTC
Spark plug gap 0.6~0.7mm
1-2
ENGINE
TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf・cm)
Oil plate pan screw Parafuso de panela de placa
3 de óleo 6 80~120
Crank shaft bolt 5
Parafuso do eixo de manivela 8 180~220
Crank shaft nut Porca do eixo da manivela1 7 70~110
Cylinder head nut Porca de cabeça de cilindro 3 6 80~120
Cylinder head cover Tampa da cabeça do cilindro
2 6 80~120
Cam shaft sprocket bolt
Parafuso de roda de eixo2de came 7 80~120
Crank case bolt 10
Parafuso da caixa de manivela 6 80~120
L crank case cover bolt 7
L parafuso da tampa da caixa da manivela 6 80~120
Fly wheel bolt Perna da roda da mosca1 10 400~500
A.C.G. scocket bolt A.C.G. parafuso de estrangulamento
3 5 50~70
Start motor bolt 4
Inicie o parafuso do motor 6 80~120
R crank case cove bolt 10 manivela
R parafuso da anca da caixa 6 80~120
Cam shaft holder nutPorca de suporte de eixo8de came 8 180~220
Porca de engrenagem de1transmissão primária 16
Primary drive gear nut 400~500
Oil pump flat bolt Parafuso plano da bomba3 de óleo 6 80~120
Clutch lock nut Porca de bloqueio da embreagem
1 16 400~500
Shift durm stopper Shift Durm Stopper 1 6 80~120
Shift cam bolt Shift parafuso de câmera1 6 80~120
Parafuso ajustador de corrente
Cam chain adjuster screw 1 de came 6 80~120
Drain oil bolt Escorrer o parafuso de óleo
1 12 150~250
Parafuso do fuso de mudança
Gear shift spindle bolt 1 de marchas 8 100~150
FRAME
TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf・cm)
Front wheel nut Porca da roda dianteira1 14 600~800
Rear wheel nut Porca da roda traseira 1 14 1000~1200
Rear fork pivot nut 1
Porca giratória da forquilha traseira 14 800~1000
Engine hanger nut 3
Porca de suspensão do motor 10 450~550
Handle pipe upper holder
Pega 4
bolto parafuso do suporte superior do tubo 8 180~ 250
Steering stem nut 1
Porca de haste de direção 22 600~900
Front fork nut 1
Porca de forquilha dianteira 22 400~500
Rear shock absorber Amortecedor traseiro 4 10 300~400
1
Rear brake torque link Ligação de torque do freio traseiro 8 150~200
Front fork top bridge Ponte dianteira topo da 2 forquilha 7 100~140
2 traseira
Rear fork bottom bridgePonte inferior da forquilha 8 240~300
Final drive sprocket Pneu de transmissão final
4 10 270~330
Seat bolt Parafuso de assento 2 8 200~250
Drive sprocket bolt Pino de transmissão 2 6 100~140
STANDARD TORQUE
TYPE TORQUE(kgf·cm) TYPE TORQUE(kgf·cm)
5 mm bolt, nut 45~60 5 mm bolt 35~50
6 mm bolt, nut 80~120 6 mm bolt 70~110
8 mm bolt, nut 180~250 6 mm flange bolt, nut 100~140
1-3
Torque specifications listed below for respective locations.
TROUBLE SHOOTING
A. HARD START OR CANNOT START
symptom inspection adjustment cause
loosen carburetor drain

screw, check inner side for no gasoline in the tank
gasoline
fuel tube between gasoline tank and
carburetor clogged.
enough gasoline supplied no gasoline supplied float chamber fuel tube clogged
for carbuertor for carburetor gasoline cover air hole clogged
fuel filter clogged
remova a vela de ignição, insira-a remove spark plug,insert it
na tampa do plugue, verifique into plug cap, check the fuel filter screen clogged
faísca ao tocar o motor grade spark by touching engine gasoline auto fuel cup faulty
grid
spark plug faulty Bujão defeituoso
fouled spark plug vela de ignição
CDI unit fualty Unidade CDI defeituosa
spark plug jump spark weak or no spark
Saída da vela de ignição faísca fraca ou nenhuma faísca pulse coil faulty Bobina de pulso com defeito
high voltage coil cable open or
Cabo de bobina de
test cylinder short alta tensão aberto oucurto
compression high voltage coil open or shortBobina de alta tensão
main switch faulty aberta ou curta
A.C.G. faulty interruptor principal com defeito
A.C.G. defeituoso
Battery faulty Bateria defeituosa
normal compression pressure too low or no
valve too tight, no gap
pressure
valve seat faulty
cylinder, piston, piston ring
follow the starter faulty
keypoints to re-start
cylinder gasket leak
valve burnt out
valve timing faulty
crankcase leak when wmpress
engine dose not fire engine knocks, but no
starting
Fuel tube clogged
muffler clogged
remove and check the auto air cut poor action
spark plug again inlet duct has air in
ignition timing incorrect
carburetor fuel adjusting
screw set faulty
air cleaner clogged
spark plug dry spark plug wet
carburetor fuel level too high
auto air cut poor action
throttle excessively
start engine with choke closed
1-4
B. ROTATION ROUGH (LACKS POWER)
start engine and slightly

apply fuel air cleaner clogged
fuel tube clogged
air hole on the fuel tank cap blocked
engine speed up engine speed can't up exhaust tube clogged
auto air cut faulty
adjust ignition timing use carburetor vacuum diaphragm worn
timing tester auto fuel cup faulty
ignition timing faulty CDI unit

ignition timing
correct incorrect faulty A.C.Generator
valve adjuster poor
valve clearance valve coearance valve clearance misadjustment

correct incorrect valve seat worn
compression pressure check
fualty valve seat
cylinder, piston worn
compression normal pressure to low gasket leak
valve timing incorrect
carburetor block check piston ring worn
no clogged block remove and clean
remove spark plug
remove dirt
no fouled dirt and color change spark plug improper heat range
discolored spark plug clearance misadjustment
check crankcase oil level
for too much or dirt
too much oil
oil lever normal oil too much too little oil
oil no replacement
check cylinder head
lubrication
oil tube clogged
normal abnormal lean projection from oil pump
engine too hot piston, cylinder worn

lean mixture
poor gasoline
no overheating overheated carbon in burning chamber too much
ignition timing too early (C.D.I. faulty)
high speed
clutch slip
continue working
carbon in burning chamber too much
poor gasoline
no knock shock knocks
clutch slip
lean mixture
ignition timing too early(C.D.I.faulty)
1-5
C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED)
ignition timing
adjustment
faulty CDI unit

normal abnormal faulty A.C.Generator
valve gap adjust faulty
adjust carburetor fuel

adjusting screw
adjust OK lean mixture(loosen screw)

adjust faulty
rich mixture(tighten screw)
carburetor gasket
has air inlet
insulator plate gasket poor

no air inlet has air inlet carburetor locking nut loose
insulator plate gasket torn
vacuum tube crack
remove spark plug,
insert to the plug
cap, check spark by
toucning engine iron
grid.
poor or dirty spark plug

faulty CDI unit
sparking well poor sparking faulty A.C.Genertor
poor ignition coil
spark plug cable open or short
poor main switch
vacuum tube damaged

good no good
air inlet duct clogged, damaged
1-6
D. ROTATION ROUGH (HIGH SPEED)
ignition timing
adjustment
faulty CDI unit

normal abnormal
faulty pulse generator
valve clearance
adjustment
poor adjustment
normal abnormal valve seat faulty
check auto fuel

cup for fuel
supplied.
too little fuel in the fuel tank

normal abnormal fuel tube, fuel filter clogged
air hole on the fuel tank colgs
auto fuel cup faulty
carburetor blocked
no blocked blocked clean
valve timing
adjusting
inspection
timing correct timing incorrect cam sprocket aligning marks incorrect
check valve spring
good spring broken faulty spring

loose elasticity
1-7
E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE)
measure battery voltage.

and then start engine
battery voltage battery voltage rise to reach battery life

can't rise normal value,after faulty battery
engine stops, the voltage
return to original.
check voltage regulator
rectifier coupler
normal coupler poor contact

abnormal
red wire open
check the voltage between

voltage red wire
and frame body(grounding)
with mult-meter(+).(-)
terminals.
voltage adjuster
hsa voltage no voltage
white wire open
measure the resistance of

AC generator coil
coil faulty
normal abnormal connector.poor contact
AC generator white wire open
faulty battery
poor charge (over charge)
after engine starter, measure the
voltage between voltage regulaton
/rectifier red (+) wire and
green (-) wire connected with
frame body.
voltage over voltage normal
normal
check voltage regulator/

rectifier coupler for poor
contact.
normal poor contact Coupler poor contact.

green wire poor
grounding
measure the resistance of
voltage adjuster unit
can't meet faulty voltage

specification regulator/rectifier
1-8
F.SPARK PLUG NO SPARK
Inspection adjustment cause
symptom
replace with new spark plug

and test again.
spark wear of spark strong

no spark original spark
plug faulty
Check spark cap and high

voltage cable for slack
no slack slack spark plug cap

slack
check CDI unit plug for slack
normal abnormal plug poor contact
Check the resistance

between the wires.
terminals of CDI unit.
normal abnormal
Check related portions
fualty main switch.

faulty trigger
normal abnormal magntic coil
poor pulse coil
poor IGN coil
control cable open
connector.socket
poor contact
use CDI tester for CDI unit
normal abnormal faulty CDI unit
use CDI tester to check

ignition voltage coil
abnormal faulty IGN coil
1-9
2.INSPECTION/ADJUSTMENT
ENGINE FRAME
MAINTENANCE SCHEDULE .............2-2 AIR CLEANER................................... 2-12
SERVICE INFORMATION ..................2-3 CLUTCH ADJUSTMENT ................... 2-12
ENGINE OIL/OIL FILTER ...................2-4 BRAKE ADJUSTMENT ..................... 2-13
SPARK PLUG.....................................2-5 DRIVE CHAIN ADJUSTMENT .......... 2-14
COMPRESSION TEST.......................2-6 WHEELS/RIM.................................... 2-15
VALVE CLEARANCE .........................2-7 SUSPENSION ................................... 2-16
IGNITION TIMING ..............................2-8 STEERING ........................................ 2-17
CAM CHAIN TENSION ADJUSTMENT .......2-9 BATTERY .......................................... 2-17
THROTTLE GRIP ADJUSTMENT ......2-10 HEAD LIGHT AIM.............................. 2-18
IDLING SPEED ADJUSTMENT..........2-11 STOPLIGHT SWITCH ....................... 2-18
2-1
MAINTENANCE SCHEDULE
Maintenance Every Every Every Every
300KM
kilometer 1000KM 3000KM 6000KM 12000KM
Item Maintenance
NEW 1 Month 3 Months 6 Months 1 Year
Check Items Interval
1 Air cleaner I C R
2 Gasoline filter I C R
3 Oil filter C Replacement for every 5000KM R
4 Oil filter screen C Cleaning for every 5000km C
5 Engine Oil R Replacement for every 1000KM R
6 Wheels tires I I
7 Battery I I
8 Brake and operation free play I I
9 Steering stem bearing I
10 FR./RR. Cushion I I
11 Screws/nuts I I
12 Spark plug I R
13 Clutch I I
14 Frame of lubrication L
15 Exhaust muffler I I
16 Carburetor I I
17 Ignition timing I I
18 Emission I I
19 Idle speed I I
20 Gasoline system I I
21 Throttle cable I I
22 Engine bolt torque I I
23 Deposit of exhaust outlet I
Cylinder head/cylinder
24 I
Piston exhaust system deposit
25 Cam chain I I
26 Valve clearance I I
27 Light/electrical appliance/Meter I I
28 Side stand﹠Spring I I
The table is refered to the driving distance about 1000km per month
I-inspection, cleaning, adjustment or replacement (if necessary)R-replacement C-leaning L-lubrication
REMARK: Ridden in unusually dusty areas, require more frequently air filter element cleaning.
2-2
SERVICE INFORMATION
SPECIFICATLON
ENGINE Clutch lever free play 10-20mm
Oil capacity 1.1～1.5 liter Drive chain stack 10-20mm
Spark plug gap A6RTC Front brake lever free play 10-20mm
Spark plug gap 0.6-0.7mm Rear brake pedal free play 20-30mm
Valve clearance IN 0.08mm Throttle grip free play 2-6mm
EX 0.10mm
Cylinder compression 12.5kg/c ㎡±2kg/c ㎡
FRAME
SPECIAL TOOL
Valve clearance adjuster
TORQUE VALVES
Right crankcase cover 80-120 kgf・cm
Front fork top bridge bolt 100-140 kgf・cm
Front fork bottom bridge bolt 200-250 kgf・cm
Rear wheel axle nut 400-550 kgf・cm
Rear shock absorber nut 300-400 kgf・cm
Rear fork pivot bolt 350-450 kgf・cm
2-3
OIL/OIL FILTER
OIL LEVEL CHECK
Start and warm up the engine for few minutes,then
stop the engine.
Check the oil level with oil level gauge after a few
minutes.
If the oil level is near the lower mark,fill the
crankcase to the upper level mark with the
recommended grade oil.
OIL REPLACEMENT DRAIN BOLT
NOTE:
Drain the engine oil while the engine is warm.
Remove the drain bolt, and drain the engine oil.

NOTE :
Make sure that the drain bolt washer is in good
condition.
Fill the crankcase up to the upper level mark on the
oil level gauge with the recommended oil:15W-40
API:SH/CD
2-4
OIL FILTER SCREEN CLEANING
Remove the drain bolt, and drain the engine oil.
Remove the right crankcase cover.
Remove the pump.
Clean the oil filter screen with compressed air.
Assemble the filter screen in reverse order of
disassemble.
OIL FILTER
SPARK PLUG
Disconnect the spark plug cap and remove the spark
plug .
Visually inspect the spark plug electrodes for wear.
The center electrode should have square edges and
side electrode should have a constant thickness.
Discard the spark plug if there is apparent wear or if
the insulator is cracked and/or chipped .If the spark
plug deposits can be removed by sandblasting or wire
brushing,the spark plug can be reused.
Inspect the gap with a feeler gauge and adjust by
bending the side electrode.
Standard gap:0.6-0.7mm
NOTE:
To install turn finger tight then tighten with a spark
plug wrench.
2-5
COMPRESSION TEST
Warm up the engine.
Stop the engine .Remove spark plug .Insert the
compression gauge. ELECTRICAL
Push in the choke lever .Open the throttle grip fully. START ENGINE
Electrical start engine several times.
NOTE:
Watch for compression leaking at the gauge
connection.
Crank the engine until the gauge reading stops
rising .The maximum reading is usually reached
in several times.
Compression:9.5kg/c ㎡±1kg/c ㎡
Low compression can be caused by:
Improper calve adjustment.
Valve leakage .
Blown cylinder head gasket.
Worn piston rings or cylinder.
Worn piston.
High compression can be caused by:
Carbon deposits in combustion chamber or on
piston head.
2-6
VALVE CLEARANCE ALIGN
MARK
NOTE:
Inspect and adjust the valve clearance while the
engine is cold.
Remove the timing inspection hole cap and crankshaft

hole cap.
Rotate the generator rotor counterclockwise and align
the “T”mark on the generator rotor with the index mark
in the left crankcase
(piston must be at T.D.C.of the compression ALIGN
MARK
stroke).
Inspect the intake and exhaust valve clearance by LOCK NUT

inserting a feeler gauge between the adjusting screw
and valve stem,valve clearance:
Intake: 0.08mm
Exhaust: 0.10mm
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag in the feeler
gauge.
NOTE:
Inspect the valve clearance again after tightened the
ADJUSTING
lock nut. SCREW
2-7
Install the valve adjuster caps and generator cap.
NOTE:
Check the O-ring for damage and spread oil before
installing the caps.
O-RING
IGNITION TIMING
The C.D.I.ignition timing is not adjustable.
If the ignition timing is not correct ,check the C.D.I.unit
and A.C.generator and replace any faulty parts.
Use the standard tester to check the ignition timing.

Spark plug inspection and adjustment.
Replace the coil if there is no sparks at plug.
IGNITION TIMING INSPECTION

Remove the generator cover and check the ignition
timing with a timing light.
Timing is correct if the index mark aligns with the
“F”mark within ±3°at 1500rpm.
Ignition timing :10°BTDC/1500rpm.
Ignition coil continuity test :
Check the resistance of the primary coil
and secondary coil.
1.Primary coil 0.31±0.03Ω

2.Secondary coil 4.0±0.4kΩ
2-8
Inspect the C.D.I unit with C.D.I tester.
Replace the faulty C.D.I unit.
SWITCH C.D.I. normal C.D.I faulty

1. OFF no sparks -------
2. P no sparks -------
3. EXT no sparks sparks
4. ONI sparks no sparks
5. ONZ sparks no sparks
CAM CHAIN TENSIONER

ADJUESTER
The cam chain tension is kept by the tensioner
push rod that is compressed by the spring.
CAUTION:
If remove any parts that is related with the cam
chain ,remove the cam chain tensioner adjuester
first.
CAM CHAIN TENSIONER ADJUESTER
2-9
CARBURETOR
THROTTLE GRIP FREE PLAY
Check throttle grip free play.
Free play:2-6mm
ADJUSTER NUT
THROTTLE GRIP ADJUSTMENT
Loosen the lock nut and turn the adjuster to adjust.
2-10
IDLING SPEED ADJUSTMENT

Warm up the engine.
Turn the stop screw to obtain the idling speed of
1100rpm.
Turn the air screw to the maximum speed,then turn
the stop screw to obtain the specified idling speed.
Idling speed:1500±100 rpm
NOTE:
Turn the air screw clockwise for making fuel –air
mixture lean.
Turn counterclockwise for rich. STOP
SCREW
AIR SCREW
2-11
AIR CLEANER
Remove the left side cover.
Remove the air cleaner cover.
Remove the air cleaner element.
NOTE:
Clean the cleaner element periodically.(Refer to
maintenance schedule.)
SCREWS
Assemble air cleaner element in reverse order of AIR CLEANER ELEMENT

disassemble.
CLUTCH ADJUSTMENT
CLUTCH LEVER FREE PLAY
Measure the clutch free play at the tip of the clutch
lever.
Free play :10-20mm
2-12
FREE PLAY ADJUSTMENT ADJUSTER
NUT
Loosen the lock nut and turn the adjuster.

Turn the adjuster ,clockwise for decreasing the free
play ,counterclockwise for increasing the free play.
LOCK
NUT
LEVER ADJUSTER NUT
Or adjust clutch lever adjuster nut.
BRAKE ADJUSTMENT
FRONT BRAKE LEVER FREE PLAY
Measure the brake free play at the tip of the brake 10~20mm
lever.
Free play:10-20mm
BRAKE PAD WEAR INSPECTION

Check for brake pad wear by operating the bake lever.
Check the brake pads for wear by looking through the
slot indicated by the arrow cast on the caliper
assembly.
Replace the brake pads if the wear line on the pads
reaches the edge of the brake disc.
2-13
REAR BRAKE PEDAL FREE PLAY

Measure the brake pedal free play before the brake
start to engage.
20~30mm
Free play :20-30mm
REAR BRAKE PEDAL ADJUSTMENT

Turn the adjuster clockwise for decreasing the
clearance ,counterclockwise for increasing the
clearance.
CAUTION:
Keep the adjuster at the right position.
ADJUSTER NUT
DRIVE CHAIN ADJUSTMENT

Place the motorcycle on its side stand and shift the
transmission into neutral.
Remove chain cap and check the drive chain slack by
moving up and down with the fingers.
Chain slack:10-20mm
10~20mm
2-14
Loose the rear wheel axle nut for adjusting.
Turn the adjusting nuts on both adjusters as
necessary.
CAUTION:
Tighten the axle nut.
TORQUE:1000-1200 kgf・cm
Recheck the drive chain slack and free wheel rotation.
Lubricate the drive chain with chain lubricant.
ADJUSTING NUTS
WHEEL/RIM One rider

Front 2.25 kg/c ㎡
Stand the motorcycle,check the tires for Rear 2.50 kg/c ㎡
Cold tire
cuts,imbedded nails,or other sharp objects. Two riders Front 2.50 kg/c ㎡
Check the tire pressure. pressure Rear 2.50 kg/c ㎡
Max.load 120kg
Front 90/90-18
Tire size
Rear 130/90-15
Front 1.5mm
Min. depth of tread
Rear 2.0mm
2-15
SUSPENSION
FRONT SUSPENSION
Check the action of the front forks by compressing
them several times with the front brake applied .
If there are abnormal noises or rattles ,check all the
fasteners and tighten them to the specified torque.
TORQUE:
Front fork top bridge bolt :100-140 kgf・cm
Frint fork bottom bridge bolt :240-300 kgf・cm
Axle nut:600-800 kgf・cm
REAR SUSPENSION
Check for abnormal noises and leaks by compressing
the rear suspension several times.
Check the rear suspension nut for loosing
Torque:300-400 kgf・cm
Move the rear wheel side ways with force to see if the
swing arm bushings are worn.
Rear fork torque:800-1000 kgf・cm
2-16
STEERING
Raise the front wheel off the ground and check that
the handlebar rotates freely.If the handlebar moves
unevenly ,binds or has vertical movement,adjust the
steering head nut.
BATTERY
Inspect the battery fluid level ,if the fluid level nears
the lower level mark,fill with distilled water to the upper
level mark .
Clean the battery terminals with warm water.
Check the specific gravity of the battery
electrolyte.(13-3)
NOTE :
Do not overfill. Add only distilled water.
Tap water will shorten the service life of the
battery.
WARNING:
Keep the electrolyte away from eyes ,skin and
clothes. If touched it ,wash them with clean
water quickly.
2-17
HEADLIGHT AIM
Adjust vertically by turning headlight up and down with
the headlight bolts loosening.
Fasten the bolts after adjustment.
NUTS
ADJUSTING NUT
STOPLIGHT SWITCH
The stoplight should come on when the brake pedal is
depressed 20mm from the standard pedal position.If
the action is abmormal, adjust by turning the stoplight
switch adjusting nut.
STOPLIGHT SWITCH
2-18
3.LUBRICATION SYSTEM
CAM SHAFT
OIL LINE OF
CAM SHAFT
MAIN SHAFT PISTON
OIL ORIFICE OF
CRANKSHAFT
OIL PUMP
OIL FILTER
COUNTER SHAFT
3-0
3.LUBRICATION SYSTEM
TROUBLE SHOOTING ...................... 3-1 SERVICE INFORMATION ................. 3-1
TROUBLE SHOOTING
OIL LEVEL TOO LOW
1. Natural consumption
2. Oil leaks
3. Worn piston rings
OIL CONTAMINATION
1. Oil not changed often enough
2. Faulty cylinder head gasket
OIL PRESSURE TOO LOW
1. Oil filter clogged
2. Oil pump damaged
OIL PRESSURE TOO HIGH
1. Oil filter or line clogged
2. Oil not recommended
NO OIL PRESSURE
1. Oil level too Iow
2. Oil pump damaged
SERVICE INFORMATION
NOTICE:
Inspection and service of oil pump can be serviced
with the engine installed on the frame.
Oil pump service --- 7-9
Oil filter cleaning --- 2-4 ~ 2-5
SPECIFICATIONS
Oil capacity 1.1~1.5 liter
Oil recommended SAE 15W-40 API:SH/CD
Oil pump delivery 3.5 liter above / min. / 4600rpm
3-1
4.ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION ..................4-1 ENGINE INSTALLATION .................. 4-5

ENGINE REMOVAL ...........................4-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The following parts can be serviced with the engine installed on the frame:
Generator
Clutch
Oil pump
Cam shaft / Rocker arm
Shift spindle
Cam chain tensioner
The following parts must be serviced with the engine removed off the frame:
Cylinder head
Cylinder
Piston
Crankshaft
Transmission
During removal and installation, jack or adjustable support is required to maneuver the engine.
TORQUE VALUES
Engine hanger 10mm bolt / nut 450-550 kgf・cm
Drain bolt 300-500 kgf・cm
Gearshift pedal bolt 80-120 kgf・cm
4-1
ENGINE REMOVAL
Drain the engine oil.
Disconnect the fuel tubes and all connect tubes.
Remove the right and left side covers.
LEFT CRANKCASE
Remove the gear change pedal and left crank case
RR.COVER
rear cover.
GEAR CHANGE
ARM
Disconnect the A.C. generator wire of the connector

and remove the generator wire.
A.C. GENERATOR
WIRE
4-2
Remove the clutch cable. CLUTCH CABLE
Remove the spark plug cap.
Remove the muffler.
Loosen carburetor clip. CLIP

Separate the carburetor pipe and the cylinder head by
removing the attaching bolts.
Remove the crankcase breather tube.
BREATHER TUBE
Loosen the rear wheel axle nut. ADJUSTING NUT

Loosen the drive chain adjusting nut and push the rear
wheel forward.
Remove the drive chain clip, and remove the drive
chain.
WHEEL AXLE NUT
4-3
Remove the front engine hanger bolt.
NOTE:
Places jack or padded block under the engine before
removing the front engine hanger.
Disconnect the starter motor wire.
FRONT ENGINE HANGER

BOLT
Remove the 10mm bolts of the rear engine hanger. BOLTS
Remove the engine.

NOTE:
Prevent damage to wire harnesses and cables during
operation.
4-4
ENGINE INSTALLATION
Follow the reverse procedure of removal to install the
engine.
Notice the following items during installation:
Route all wire harnesses and cables properly.
Adjust the throttle grip free play (P2-10)
Adjust the clutch lever free play (P2-12)
Adjust the drive chain slack (P2-14)
Fill the crankcase with the recommended grade oil
to the proper level.
SAE 15W-40 APl: SH / CD
4-5
5. CYLINDER HEAD/ VALVE

TROUBLE SHOOTING.......................5-1 VALVE GUIDE REPLACEMENT........ 5-8
SERVICE INFORMATION ..................5-2 VALVE SEAT INSPECTION/REFACING ... 5-9
CAM SHAFT REMOVAL ....................5-3 VALVE SEAT GRINDING................... 5-10
CYLINDER HEAD/ROCKER ARM REMOVAL .....5-4 CYLINDER HEAD ASSEMBLY .......... 5-13
CYLINDER HEAD DISASSEMBLY ....5-6 CYLINDER HEAD INSTALLATION .... 5-14
VALVE/VALVE GUIDE INSPECTION ........5-7 CAM SHAFT INSTALLATION ........... 5-15
TROUBLE SHOOTING
LOW COMPRESSION
1. Valve
Incorrect valve clearance
Burned or bent valves
Incorrect valve timing
Broken valve spring
2. Cylinder head
Leaking or damaged head gasket
Warped or cranked cylinder head
HIGH COMPRESSION
1. Excessive carbon buildup on piston or combustion chamber.
ABNORMAL NOISE
I. Incorrect valve clearance
2. Broken valve spring
3. Worn rocker arm or camshaft
4. Loose or worn cam chain
5. Worn cam chain tensioner
6. Worn cam sprocket teeth
5-1
SERVICE INFORMATION
Camshaft, rocker arm shaft and rocker arm can be serviced with the
engine installed on the frame.
Camshaft lubrication oil is fed to the cylinder head through an oil
control orifice in the engine case.
Be sure this orifice is not clogged and the O-ring and dowel pins are in
place before installing the cylinder head.
During assembly, apply molybdenum disulfide grease to the camshaft
bearings, and pour clean engine oil into the cylinder head.
TORQUE VALUES
Cylinder head bolt 280-300 kgf・cm
Cylinder 6mm bolt 140 -180 kgf・cm
Cam sprocket 80-120 kgf・cm
SPEClFICATIONS
ITEM STANDARD SERVICE LIMIT
IN 32.382mm 31.25mm below
Cam lift
Camshaft EX 31.987mm 30.87mmbelow
Runout 0.02mm
Rocker arm I.D. I.D. 10.000～10.015mm 10.015mm above
Rocker arm shaft O.D. 9.978～9.987 mm 9.978mm below
Outer 35.7～36.3mm 35mm below

Free length
Inner 29.7～30.3mm 28mm below
Valve
spring →29.65mm 130.5±6.5N
Outer
→23.45mm 330.0±16N
Stall length
→26.65mm 69.0±5.52N
Inner
→20.45mm 236.0±11.8N
(IN)0.06±0.02mm
Valve clearance
(EX)0.10±0.02mm
IN 5.450～5.465mm 5.42mm
O.D.
EX 5.430～5.455mm 5.40mm
IN 5.475～5.485mm 5.50mm
Valve Guide I.D.
EX 5.475～5.485mm 5.50mm
guide
Stem to guide IN 0.010～0.035mm 0.08mm
Clearance EX 0.03～0.055mm 0.10mm
Valve seat width 1.45～1.15mm 1.6mm
5-2
CAMSHAFT REMOVAL special bolts

NOTE:
The camshaft, rocker arm and rocker arm shaft can
be serviced with the engine installed on the frame.
Remove the 6mm special bolts.
Remove the R/L cylinder head side cover and cylinder
head side.
Remove the cylinder head cover.
Remove the crankshaft hole cap and the timing

inspection hole cap. Rotate the generator rotor
counterclockwise and locate the piston at the T.D.C. of
the compressing stroke.
Remove the cam chain adjuster screw.
nut nut
Remove the four holder nuts.
Remove the holder.
Remove the camshaft.
CAUTION:
Support the cam chain to keep it from falling into the
crankcase.
5-3
CYLINDER HEAD
REMOVAL
Remove the 6mm bolts.
Remove the dowel pins.
Remove cam chain tensioner.
Remove the cylinder head.
CAM CHAIN GUIDE BOLT

Remove the rocker arm shaft.
HOLDER
Remove the rocker arms.
5-4
CAMSHAFT INSPECTION
Inspect the cams of the camshaft for wear.
Service limit:
Inlet: 31.25mm
Exhaust: 30.87mm
ROCKER ARM INSPECTION

Inspect the rocker arm I.D. and the rocker arm for
wear, damage or clogged oil holes.
Rocker arm I.D.
Service limit: φ10.1mm
ROCKER ARM SHAFT INSPECTION

Inspect rocker arm shaft for wear or damage.
Rocker arm shaft O.D.
Service limit :φ10.9mm
5-5
CYLINDER HEAD DISASSEMBIY

Remove carbon deposits from the combustion
chamber. Remove valve spring and valve spring and
valve with a valve spring compressor.
CYLINDER HEAD INSPECTION

Remove gasket from cylinder head with a scraper.
Check the cylinder head for crack.
Check the cylinder head for warpage with a straight
edge and a feeler gauge.
Service limit: 0.10mm
VALVE SPRING INSPECTION

Measure the free length of the inner and outer valve
spring.
Service limit:
Outer: 35mm
Inner : 28mm
5-6
VALVE/VALVE GUIDE
INSPECTION
Inspect valves for scratches, burning or wear.
Check the valve movement in the guide.
Measure the valve stem O.D.
Service limit:
Intake: ∮5.42mm
Exhaust:∮5.40mm
NOTE:
Remove any carbon buildup before checking the valve
guide I.D.
Guide I.D. service limit

Intake: ∮5.50mm
Exhaust : ∮5.50mm
Measure the valve guide I.D. and calculate the stem to

guide clearance.
Service limit:
Intake: 0.08mm
Exhaust: 0.10mm
If the stem to guide clearance exceeds the service
limit, replace the valve or guide to fit.
NOTE:
The guide must be reamed when replacing a new one.
5-7
VALVE GUIDE
REPLACEMENT
Drive out the valve guide from the combustion
chamber side with a 5mm valve guide remover.
NOTE:
When driving out the valve guide, do not damage the
cylinder head.
Install the new valve guide from the top of the cylinder
head, and ream it with a reamer, then clean the
cylinder head.
5-8
VALVE SEAT INSPECTION/ REFACING

Clean intake and exhaust valves to remove carbon
deposits.
Apply a light coating of prussian blue to each valve
face.
Insert each valve into the guide and rotate them two
cycles.
Remove the valve and inspect the face.

CAUTION:
If the valve face is burned or damaged or unevenly,
replace the valve.
CONTACT AREA
VALVE SEAT
Inspect the valve seat.

If the seat is too wide or too narrow, the seat must be
refinished.
SERVICE LIMIT SERVICE LIMIT

1.5mm 1.8mm
5-9
VALVE SEAT GRINDING

NOTE: 60°
Follow the instructions described in the cutter
instruction manual.
32°
45°
Remove any roughness from the seat by applying 4~5

kg pressure, turning the cutter left and right.
NOTE: 4~5kg
Add engine oil to the face when operating. CUTTER

CUTTER HOLDER
TURN RIGHT AND LEFT
Using a 45 degree cutter,remove any roughness from

the seat.
ROUGHNESS
45°
VALVE SEAT
5-10

Using a 32 degree cutter, remove 1/4 of the existing
valve seat material. 32o CUTTER
VALVE SEAT
Remove the bottom 1/4 of the old seat by using a 60

degree cutter.
60o CUTTER
Finish the seat to the proper width by using a 45 45o CUTTER

degree cutter.
5-11
If the contact area is too high on the valve,the seat
must be lowered using a 37.5 degree cutter, then finish
CUT TOP END
with a 45 degree cutter.
CONTACT AREA
TOO HIGH
If the contact area is too low on the valve,the seat must

be raised using a 63.5 degree cutter, then finish with a CONTACT AREA TOO LOW
45 degree cutter.
CUT BOTTOM END
63.5o
After cutting the seat, apply lapping compound to the

valve face, and lap the valve using light pressure.
5-12
CYLINDER HEAD ASSEMBLY

Compress the valve springs with a valve spring
compressor and install the valve cotters into the valve
retainer.
CAUTION:
Do not compress the valve spring more than
necessary.
NOTE:
Install a new valve stem seal when assembling.
Lubricate each valve stem with the engine oil then
insert them into the guides.
Install the valve spring and retainers.
NOTE:
Install the valve springs with the tightly wound coils
facing the cylinder head.
Tap the valve stems gently with a plastic hammer to

firmly seat the cotters.
5-13
CYLINDER HEAD INSTALLATION

CAMSHAFT AND CAMSPROCKET
ASSEMBLY
NOTE:
Rocker arms must be installed at the right position.
CAMSHAFT COMP
Clean the cylinder head gasket surface of any gasket

material.
Install the new gasket, O-ring and dowel pins and
chain guide.
NOTE:
Do not allow dust and dirt to enter the cylinder.
Install the cylinder head.

NOTE:
Support the cam chain to keep it from falling into the
crankcase.
Install the cam chain tensioner set and bolt and
washer.
Install dowel pins.
dowel pin dowel pin
5-14
CAM SPROCKET nut

INSTALLATION
Rotate the generator rotor and align the "T" mark with
the index mark.
Install the camshaft comp.
When intalling camshaft set, please take care that.The nut
line on the camsprocket should be in parallel with the
surface of cylinder head.(The IN/EX cam should be
faced down).
Install the camshaft holder.
Install the cylinder head nuts.
TORQUE:280 ~ 300 kgf・cm
CAUTION:
The cap nut of the four holder nuts must be installed
at the left-front side.
Install the 6mm bolts.
Install the cam chain chain tensioner.

Install the auto-tensioner. (Lock the spring cap bolt
first.)
Release the auto-tensioner lock bolt.
Adjust the valve clearance.(2-7)
Install the cylinder head cover.

Install the R/L cylinder head side cover.
Install the 6mm special bolts.
NOTE:
If the cylinder head side cover gasket is damaged or
broken, replace with a new one.
cylinder head cover
5-15
6. CYLINDER/PISTON
TROUBLE SHOOTING.......................6-1 PISTON/PISTON RING INSPECTION ...... 6-5

SERVICE INFORMATION ..................6-2 PISTON RING INSTALLATION..... 6-7
CYLINDER REMOVAL .......................6-3 PISTON INSTALLATION ................. 6-9
PISTON REMOVAL .........................6-4 CYLINDER INSTALLATION ............... 6-10
TROUBLE SHOOTING
LOW COMPRESSION
1. Worn cylinder or piston rings.
EXCESSIVE SMOKE
1. Worn cylinder,piston or piston rings.
2. Improper installation of piston rings.
3. Scored or scratched piston or cylinder wall.
OVERHEATING
1. Excessive carbon build-up on piston or
combustion chamber wall.
KNOCKING OR ABNORMAL NOISE
1. Worn piston or cylinder.
2. Excessive carbon build-up
6-1
6.CYLINDER/PISTON
SERVICE INFORNATION
GENERAL STRUCTIONS
NCA250
ITEM
STANDARD CERVICE LIMIT
Cylinder I.D. 53.005～53.015mm 53.015mm
Cylinder Runout 0.05mm
Taper 0.05mm
Piston ring to Top 0.025～0.055mm 0.13mm
ring groove
clearance Second 0.015～0.040mm 0.12mm
Top 0.10～0.25mm 0.5mm

Piston ring
Second 0.25～0.40mm 0.5mm
End gap
Oil ring 0.20～0.70mm
Piston
rings Piston O.D. 52.55～52.60mm 52.55mm
groove Piston pin bore 15.05mm
15.002～15.008mm
clearance
Connecting rod small end I.D. 15.016～15.034mm 15.07mm
Piston pin O.D. 14.994～15.000mm 14.85mm
Piston ring Top 0.97～0.99mm 1.460mm

thickness Second 1.460mm
0.97～0.99mm
Cylinder to piston clearnace 0.005～0.015mm 0.11mm
6-2
6. CYLINDER/PISTON
CYLINDER REMOVAL CAM CHAIN GUIDE

Remove the cylinder head.
Remove the dowel pins and gasket.
Remove the cam chain guide.
Remove the cylinder.
NOTE: DOWEL PIN
Avoid the chain falling into the crankcase during
removing the cylinder.
CAM CHAIN
Remove the dowel pins and gasket.
Clean the cylinder gasket surface of any gasket

material.
NOTE:
Avoid damaging the cylinder gasket surface during
this operation.
6-3
6.CYLINDER/PISTON
CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D.
NOTE:
According to the right picture measure the cylinder
runout.
TOP
Service limit:
ITEM NCA250 MIDDLE
Runout 0.05mm
BOTTOM
Taper 0.05mm
I.D. 53.015mm
PISTON REMOVAL
Remove the piston pin clip with pliers.
Press the piston pin out of piston, remove the piston.
NOTE:
Avoid the clip falling into the crankcase.
6-4
6. CYLINDER/PISTON
PISTON / PISTON RING

INSPECTION
Measure the piston ring-to-ring groove clearance.
Service limit .
Top ring: 0.13mm
Second ring: 0.12mm
Remove the piston rings.

Inspect the piston for damage or cracks.
Inspect the piston groove for wear.
Insert each piston ring into the cylinder and measure

the ring end gap.
Top / Second ring : -0.5mm
6-5
6.CYLINDER/PISTON
Measure the piston O.D. at the skirt.
NOTE:
Measure the piston O.D. at a point from the bottom.
Calculate the piston-to-cylinder clearance.

Service limit:0.11mm
Measure the piston pin bore I.D.

Measure the piston pin O.D.

6-6
6. CYLINDER/PISTON
Measure the top/second ring thickness.
PISTON RING
INSTALLATION TOP RING
Install the piston rings.
NOTE: SECOND
RING
Avoid piston and piston ring damage during
installation. OIL RING
All rings should be installed with the markings
facing up.
After installation, the piston rings should be free
to rotate in the grooves.
Space the piston ring end gaps 120 degree apart.
6-7
6.CYLINDER/PISTON
TOP RING
SECOND RING
OIL RING
6-8
6. CYLINDER/PISTON
PISTON INSTALLATION
Install the piston, piston pin and piston pin clip.
NOTE:
Position the "IN" mark on the piston to the
carburetor side.
Do not let the piston pin clip fall into the crankcase.
NOTE: PISTON PIN CLIP

Use new piston pin clip whenever disassembling.
Do not align the piston pin clip end gap with the
piston cutout.
END GAP
CUTOUT
6-9
6.CYLINDER/PISTON
CYLINDER INSTALLATION
Install the cylinder gasket and dowel pins.
Clean the cylinder gasket surface of any gasket
material.
NOTE:
Avoid damaging the cylinder gasket surface during
this operation.
CAM CHAIN GUIDE

Install the cylinder.
NOTE:
Avoid piston and piston rings damage during
installation.
DOWEL PIN
Install the cam chain guide plate.

Install the cylinder gasket and dowel pins.
Install the cylinder head.(5-14)
NOTE:
CAM CHAIN
Coat the cylinder and piston with the engine oil before
installing the cylinder.
6-10
7.CLUTCH/OIL PUMP/GEAR SHIFT
TROUBLE SHOOTING.......................7-1 OIL PUMP .......................................... 7-7

SERVICE INFORMATION ..................7-2 GEARSHIFT LINKAGE ...................... 7-10
RIGHT CRANKCASE COVER REMOVAL .7-3 RIGHT CRANKCASE INSTALLATION ...... 7-12
CLUTCH .............................................7-3
TROUBLE SHOOTING
Faulty clutch operation can be corrected by adjusting
the clutch lever free play.
CLUTCH SPINS WHEN ACCELERATING
1. No free play
2. Discs worn
3. Spring weak
CLUTCH DISENGAGED ( MOTORCYCLE CREEPS )
1. Too much free play
2. Plates warped
EXCESSIVE LEVER PRESSURE
1. Clutch cable kicked, damaged or dirty
2. Lifter mechanism damaged
HARD SHIFTING
1. Stopper plate bent
2. Improper clutch adjustment
GEARSHIFT PEDAL WON'T RETURN
1. Return spring broken or weak
2. Shift spindle bent
JUMPS OUT OF GEAR
1. Stopper arm spring broken
LOW OIL PRESSURE
1. Oil pump drive gear worn
2. Faulty oil pump
7-1

SERVICE INFORMATION
GENERAL INSTRUCTION
This section covers removal, installation and servicing
of the clutch, oil pump, filter and gearshift linkage. All
these operations can be accomplished with the engine
in the frame.
COMMON TOOLS
22mm wrench socket
Air wrench
TORQUE VALUES
Right crankcase cover 80 ~ 120 kgf・cm
Clutch lock nut 16mm 500 ~ 600 kgf・cm
Step bar 180 ~ 200 kgf・cm
SPECIFICATIONS
Leve
10~20mm ------------
Free play
Spring free length 30.6mm 27.9mm

Clutch
Friction plate thickness 3.0mm 2.5mm
Clutch plate warpage ------- 0.2mm
Tip clearance 0.30mm 0.35mm
Oil pump Rotor-to-body clearance 0.30~0.36mm 0.40mm
End clearance 0~0.06mm 0.11mm
7-2
RIGHT CRANKCASE COVER

REMOVAL
Drain oil from the engine.
Disconnect the clutch cable.
Remove the right crankcase cover.
CLUTCH BEARING
CLUTCH REMOVAL
Remove the clutch bearing.
LOCK NUT
Remove the 16mm lock nut with the wrench socket
and air wrench.
Remove the clutch and drive gear.
7-3
Remove the clutch center, friction disc.

clutch plate and pressure plate.
CLUTCH CENTER
CLUTCH OUTER
CLUTCH PLATE
CLUTCH PRESSURE PLATE
CLUTCH FRICTION DISC

INSPECTION
Measure the friction discs, replacing them if they are
discolored or worn.
7-4
CLUTCH PLATE INSPECTION

Check the plates for warpage on a surface plate using
a feeler gauge.
CLUTCH SPRING INSPECTION

Measure the clutch springs free length.
CLUTCH OUTER INSPECTION

Check the clutch outer for cracks or indentation.
7-5
CLUTCH OUTER INSTALLATION

Install the clutch outer, 20mm washer.
NOTE:
When installing the washer, it should fit with the main
shaft groove.
WASHER
Install the clutch pressure plate, friction discs, clutch

plates and clutch center.
Install and tighten the 16mm lock nut.

TORQUE: 500～600 kgf・cm
7-6

Install the clutch springs, lifter plate and tighten the
bolts.
Install the bearing.
NOTE:
Tighten the bolts in a crisscross pattern in two or
three steps.
TORQUE :500-700 kgf・cm
BEARING
Install the dowel pins and gasket.

Install the right crankcase cover.
Connect the clutch cable.
Fill the crankcase with the recommended oil.
Adjust the clutch lever free play (2-14) .
OIL PUMP OIL PUMP

OIL PUMP REMOVAL
Remove the right crankcase cover (7-3).
7-7

Remove the 6mm screws, remove the oil
pump.
6mm screws
OIL PUMP DISASSEMBLY

Remove the oil pump drive gear.
Remove the oil pump drive gear and oil
pump plate.
OIL PUMP INSPECTION

Measure the inner-to-outer rotor clearance
of the oil pump.
7-8

Measure the outer rotor to oil pump body clearance.
Measure the oil pump upper clearance.

OIL PUMP ASSEMBLY DRIVE GEAR DRIVE SHAFT

Install the inner and outer rotors into the oil pump body.
Install the oil pump drive shaft.
Install the oil pump drive gear.
Install the oil pump cover.
NOTE:
Align the cutout in inner rotor with the cutout on the
shaft.
OIL PUMP BODY OIL PUMP COVER
7-9

Check the oil pump for rotating freely.
OIL PUMP INSTALLATION

Install a O-rings.
Install the oil pump to the right crankcase.
O-RING
OIL PUMP
GEARSHIFT SPINDLE
GEARSHIFT LINKAGE
GEARSHIFT LINKAGE DISASSEMBLY
Remove the clutch (7-3).
Remove the gearshift pedal.
Remove the gearshift spindle.
7-10

Remove the gearshift drum stopper. GEARSHIFT CAM GEARSHIFT DRUM
Remove the gearshift cam. STOPPER
Check each part for wear or damage.
GEARSHIFT LINKAGE ASSEMBLY ROLLER

Install the four 10mm rollers.
Align the hole of the gearshift cam with the roller, then
install the gearshift cam.
GEARSHIFT CAM
GEARSHIFT DRUM STOPPER

Install the gearshift drum stopper.
NOTE
After installation, check the drum stopper
operation.
7-11

Install the gearshift spindle. DRIVE GEAR
NOTE :
Hook the gearshift return spring on the
crankcase abutment.
Install the clutch.
Install the primary drive gear.
Install the oil pump drive gear.
Install the drive gear.
Install the oil through pin.
Install the oil pump.
CLUTCH OIL PUMP
RIGHT CRANKCASE COVER

INSTALLATION
Install the right crankcase cover.
Connect the clutch cable.
Fill the crankcase with recommended oil.
Adjust the clutch free play.
7-12
8. A.C.GENERATOR
TROUBLE SHOOTING ......................8-1 .... 8-4
LEFT CRANKCASE COVER INSTALLATION
LEFT CRANKCASE COVER REMOVAL ...........8-2 STARTER MOTOR REMOVAL ......... 8-4
GENERATOR ROTOR REMOVAL ....8-2 STARTER MOTOR GEAR SET ......... 8-5
GENERATOR ROTOR INSTALLATION ............8-3
8-1
8. A.C.GENERATOR
LEFT CRANKCASE COVER

REMOVAL
Remove the gearshift pedal.
Remove the left crankcase rear cover.
NOTE:
Generator stator is in the left crankcase cover, it can
be removed by removing the attaching screws.
GENERATOR ROTOR REMOVAL

Remove the left crankcase cover.
Remove the rotor bolt.
ROTOR SETTING BOLT
Remove the generator rotor.

Remove the generator stator.
8-2
8. A.C.GENERATOR
STATOR INSPECTION
Check the stator for continuity.
GENERATOR ROTOR
INSTALLATION
Reverse the procedure of removal to assembly.
NOTE :
Check wire for security in its place.
Do not interfere the wire with the rotor.
Install and tighten the rotor.
TORQUE: 400~500 kgf·・cm
8-3
8. A.C.GENERATOR
LEFT CRANKCASE
COVER INSTALLATION
Install the left crankcase cover (with stator coil)
Connect the generator wire connectors.
Route the neutral switch wire through the groove in the
left crankcase cover.
Install the left crankcase rear cover.
Install the gearshift pedal.
STARTER MOTOR
REMOVAL
Disconnect the starter motor wire connector.
Remove the starter motor attaching bolts.
Remove the starter motor.
ELECTRIC
BOLTS CONNECTOR
STARTER DRIVEN GEAR REMOVAL

Remove the left crankcase cover (8-2).
Remove the generator rotor. (8-2)
Remove the starter driven gear.
STARTER
DRIVEN GEAR
8-4
8. A.C.GENERATOR
STARTER MOTOR GEAR SET

1. Starter driven gear 4 1
2. Washer
3. Starter reduce gear
4. Starter motor
8-5
9.CRANKSHAFT/CRANKCASE/TRANSMISSION
TROUBLE SHOOTING.......................9-1 TRANSMISSION DISASSEMBLY ...... 9-6

SERVICE INFORMATION ..................9-2 TRANSMISSION ASSEMBLY ............ 9-9
CRANKCASE SEPARATION .............9-3 CRANKSHAFT INSTALLATION......... 9-11
CRANKSHAFT REMOVAL .................9-4 CRANKCASE ASSEMBLY ................. 9-11
TROUBLE SHOOTING
HARD TO SHIFT
1. Shift fork bent
2. Shift fork shaft bent
TRANSMISSION JUMPS OUT OF GEAR
1. Gear dogs worn
2. Shift fork bent or damaged
3. Shift fork shaft bent
CRANKSHAFT NOISE
1. Worn connecting rod big end bearing
2. Bent connecting rod
3. Worn crankshaft bearing
GEAR NOISE
1. Worn transmission gears
2. Worn spline shafts
9-1
SERVICE INFORMATION
GENERAL INSTRUCTION
Transmission and crankshaft repairs require crankcase separation.
Remove the following parts before separating the crankcase:
Engine removal 4-2
Cam shaft removal 5-2
Cylinder / Piston removal 6-3
Clutch / oil pump / Gearshift linkage removal 7-3
Left crankcase cover removal 8-2
SPECIAL TOOLS
Bearing driver
Bearing driver pilot
SPECIFICATIONS
I.D. 12.000～12.018mm 12.02mm

Gearshift fork
Claw thickness 4.925～5.000mm 4.8mm
Shift fork shaft O.D. 11.976～11.994mm 11.9mm
Runout 0.01mm
Connecting rod small End I.D. 15.016～15.034mm 15.08mm

Crankshaft
Axial 0.10～0.35mm 0.6mm
Connecting rod big
End side clearance
radial 0.004～0.012mm 0.05mm
9-2
CRANKCASE SEPARATION
Remove the right crankcover and interial parts.
(7-3~ 7-13)
Remove left cover and interial parts.
Remove the left crankcover all 6mm attaching bolts.

Separate the left crankcase from the right crankcase.
Remove the gasket and dowel pins.
9-3
CRANKSHAFT REMOVAL CRANKCASE

Remove the left crankcase.
Remove the crankshaft.
CRANKCASE
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance
with a feeler gauge.
FEELER GAUGE
Follow the arrow indicated direction to measure the

connecting rod big end radial clearance.
9-4
Place the crankshaft on a V-block and measure the
runout using a gauge.
NOTE:
Coat the bearing and connecting rod big end with
engine oil before installation.
Runout
Measure the connecting rod small end I.D.

Connecting rod small end I.D.
Service limit: ∮15.08mm
CRANKSHAFT BEARING FREE PLAY

INSPECTION
Spin the crankshaft bearing by hand and check for
play. The bearing must be replaced if it is noisy or has
FREE PLAY
excessive play.
AXIAL RADIAL
9-5
SHIFT DRUM COUNTER
TRANSMISSION SHAFT
DISASSEMBLY
Remove the crankshaft.
Remove the shift fork shaft.
Remove the shift drum.
Remove the shift forks.
MAIN SHAFT
SHIFT FORK SHIFT FORK

SHAFT
SHIFT DRUM
SHIFT FORK AND SHIFT FORK

SHAFT INSPECTION
Check the shift fork for wear, bending or damage.
Measure the shift fork I.D.
CHECK FOR WEAR
OR DAMAGE
Measure each shift fork claw thickness.

9-6
Measure the shift fork shaft O.D.
SHIFT DRUM INSPECTION

Check the gearshift drum for wear or damage.
Disassemble the transmission gears.

Check each gear for wear or damage and replace if
necessary.
9-7
Check the crankcase oil orifice for clogged, blowing
through with compressing air if necessary.
Check the crankcase bearings, replace them if they

have excessive free play or noisy. FREE PLAY
FREE PLAY
AXIAL RADIAL
BEARING INSTALLATION
Install the bearings into the left, right crankcase with
special tools.
NOTE:
Install the bearing horizontally, to prevent bearing
damage.
9-8
TRANSMISSION ASSEMBLY
NOTE:
Before assembling,coat each gears with engine oil.
C1
C3
C4 Counter shaft
C5
C2
Main shaft Driver sprocket
M3
M4
M5
M2
Assemble the gears of the countershaft and mainshaft.

NOTE:
Seat the snap ring in the ring groove properly.
9-9
OIL PLATE
Install the oil plate comp in the right crankcase.
CRANKSHAFT
Install the crankshaft assemblies in the right
crankcase.
Install the mainshaft and countershaft

MAINSHAFT
assemblies in the right crankcase.
NOTE:
Keep the thrust washers in place during installation.
COUNTERSHAFT
Install the mainshaft, countershaft and shift forks.
SHIFT FORK
9-10
Install the gearshift drum. GEARSHIFT DRUM
Install the shift fork shaft.
NOTE:
Engage the shift fork guide pin with the drum
groove by raising the shift fork.
After assembling, check each part for moving
freely.
SHIFT FORK SHAFT
CRANK CASE ASSEMBLY

Install the gasket and dowel pins.
Install the left crankcase on the right crankcase.
NOTE:
Make sure that the gasket is in place.
9-11
10. CARBURETOR
TROUBLE SHOOTING.......................10-2 FLOAT/FLOAT VALVE/JETS ASSEMBLY .... 10-6

SERVICE INFORMATION ..................10-2 FLOAT/LEVEL ADJUSTMENT........... 10-6
CARBURETOR REMOVAL ................10-3 THROTTLE VALVE ASSEMBLY........ 10-6
THROTTLE VALVE DISASSEMBLY ..10-3 CARBURETOR INSTALLATION ........ 10-7
FLOAT/FLOAT VALVE/JETS DISASSEMBLY 10-4
10-1
10. CARBURETOR
TROUBLE SHOOTING
ENGINE CRANKS BUT NOT START
1. No fuel in the fuel tank
2. No fuel in the carburetor
3. Too much fuel in the combustion chamber
4. No spark at the spark plug ( ignition malfunction )
5. Air cleaner clogged
ENGINE IDLE ROUGHLY
1. Idling speed incorrect
2. Ignition malfunction
3. Low compression
4. Rich mixture
5. Lean mixture
6. Air cleaner clogged
7. Air leaking into intake pipe
8. Fuel contaminated
LEAN MIXTURE
1. Carburetor jets clogged
2. Float chamber vent clogged
3. Fuel filter clogged
4. Fuel line restricted
5. Float level too Iow
6. Float valve faulty
RICH MIXTURE
1. Choke stuck closed
2. Float valve faulty
3. Float level too high
SERVICE INFORMATION
Take cautions when dealing this operation.
Always work in a well-ventilated area and away from
sparks or open flames. When assembling, note the
locations of the jets and place them individually.
SPECIAL TOOL
Float gauge
10-2
10. CARBURETOR
CARBURETOR
CARBURETOR REMOVAL PROTECT
Disconnect the fuel line. COVER
Disconnect the all connect tubes.
Drain fuel from the carburetor.
WARNING:
Keep away from flames or sparks. Wipe up spilled
gasoline at once.
CARBURETOR
Loosen the carburetor band.
BAND
BAND
THROTTLE VALVE
DISASSEMBLY
Disconnect the throttle cable.
THROTTLE CABLE
10-3
10. CARBURETOR
Remove the carburetor assembly.
jet needle spring

VACUUM CHAMBER
DISASSEMBLE
Remove the two screws and remove the vacuum
chamber cover.
Remove the piston spring.
Remove the needle holder, jet needle spring, jet
needle and vacuum piston.
WARNING:
Avoid damage to the vacuum membrane.
vacuum piston jet needle
Needle holder
acuum chamber
INSPECTION vacuum cover
Inspect the jet needle for wear or damage. membrane
Inspect the vacuum piston for damage. Piston spring
Inspect the vacuum membrane for damage.
ASSEMBLY
Install the vacuum piston ,vacuum membrane, jet
needle, needle holder, piston spring on the carburetor
body.
NOTE:
Avoid damage to the vacuum membrane.
10-4
10. CARBURETOR
FLOAT/FLOAT VALVE/JETS
DISASSEMBLE
Remove the float chamber body.
float chamber
WARNING:
Pour the float chamber gasoline into the tank.
Pull out the float pin, remove the float and float valve.
float valve
float
float pin
FLOAT VALVE INSPECTION

Inspect the float valve surface for wear or damage. WEAR OR DAMAGE
10-5
10. CARBURETOR
Remove the main jet, main jet holder and slow jet.
NOTE:
Avoid damage to the jets.
main jet
slow jet
main jet holder main jet
Remove the air screw. air screw

NOTE:
Before removing air screw, record the number of
relations until it rests lightly,so it can be returned to its
original position.
Check each part for damage.

Blow open all body openings with compressed air.
10-6
10. CARBURETOR
FLOAT/FLOAT VALVE/JETS
ASSEMBLY
Install the stop screw, the main jet, main jet holder and
slow jet.
NOTE:
Do not damage jets at the time of assembly.
FLOAT LEVEL ADJUSTMENT

If the float level is too high or too low,bend the float arm
for adjusting.
Float level: 24mm
24mm
10-7
10. CARBURETOR
Connect the throttle cable.
NOTE:
Make sure that the throttle cable is pulled tightly.
throttle cable
CARBURETOR
INSTALLATION
Reverse the procedure of removal to install
the carburetor.
Then adjust the followings:
Throttle grip free play (2-10).
Idling speed (2-11).
10-8
11. IGNITION SYSTEM
TROUBLE SHOOTING.......................14-1 IGNITION COIL .................................. 14-3

SERVICE INFORMATION ..................14-2
TROUBLE SHOOTING
ENGINE CRANKS BUT NOT START
1. No sparks at the spark plug
2. Improper ignition timing
3. Faulty plug
NO SPARKS AT THE SPARK PLUG
Black/white Black/red
1. No current in primary circuit
2. High tension cord broken
3. Faulty ignition coil
4. Faulty A.C. generator
5. Faulty C.D.I. unit Black/yellow
ENGINE RUNS BUT ROUGHLY C.D.I.

1. Primary circuit
-- C.D.I. unit failure
-- Faulty A.C. generator
-- Faulty ignition coil
-- Loose wires
-- Poorly contacted switch terminals Blue/yellow Green
2. Secondary circuit
-- Faulty,spark plug
-- Faulty high tension cord
-- Faulty ignition coil
3. Ignition timing
-- Faulty A.C. generator
-- Faulty C.D.I. unit
11-1
11. IGNITION SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTION
This section contains the ignition system.
Be sure that the battery is fully charged before
diagnosing troubles in the ignition system.
Also refer to the following pages:
Spark plug 2-5
Ignition timing adjustment 2-8
SPECIFICATIONS
Spark plug: A6RTC
Spark plug gap: 0.6~0.7mm(0.024-0.028in)
Ignition timing : 15°±2°/1500rpm
29.5°±2° /4000rpm
11-2
11. IGNITION SYSTEM

IGNITION COIL IGNITION COIL
IGNITION COIL REMOVAL
Remove the seat.
Remove the fuel tank.
Disconnect all wires to the ignition coil.
Remove the ignition coil.
IGNITION COIL TEST

Check the ignition coil output using a tripolar tester.
NOTE:
Follow the instructions described in the user
manual.
Check the primary circuit, it is normal if there is

conductivity when connecting a ohmmeter.
PRIMARY COIL 0.31±0.03KΩ
SECONDARY COIL 4.0±0.4KΩ
11-3
U5FB15E0.book Page 3 Tuesday, May 11, 2004 3:55 AM
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Manual de Serviço SYM 250 (FYM 250)

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This shop manual describes the technical feature and

SANYANG INDUSTRY CO.,LTD.

GENERAL INFORMATION ..........................................................................1

INFORMAÇÃO GERAL ................................................ .......................... 1

Type Air cooled 4 stroke O.H.C. engine

Clutch Wet muti-plate type

Ignition system C.D.I. unit

symptom inspection adjustment cause

loosen carburetor drain

start engine with choke closed

start engine and slightly

ignition timing faulty CDI unit

valve adjuster poor

valve clearance valve coearance valve clearance misadjustment

no clogged block remove and clean

remove spark plug

engine too hot piston, cylinder worn

symptom inspection adjustment cause

faulty CDI unit

adjust carburetor fuel

adjust OK lean mixture(loosen screw)

insulator plate gasket poor

poor or dirty spark plug

vacuum tube damaged

symptom inspection adjustment cause

faulty CDI unit

check auto fuel

too little fuel in the fuel tank

no blocked blocked clean

timing correct timing incorrect cam sprocket aligning marks incorrect

check valve spring

good spring broken faulty spring

measure battery voltage.

battery voltage battery voltage rise to reach battery life

normal coupler poor contact

check the voltage between

measure the resistance of

check voltage regulator/

normal poor contact Coupler poor contact.

can't meet faulty voltage

replace with new spark plug

spark wear of spark strong

Check spark cap and high

no slack slack spark plug cap

check CDI unit plug for slack

normal abnormal plug poor contact

Check the resistance

Check related portions

fualty main switch.

normal abnormal faulty CDI unit

use CDI tester to check

abnormal faulty IGN coil

OIL REPLACEMENT DRAIN BOLT

Remove the drain bolt, and drain the engine oil.

Remove the timing inspection hole cap and crankshaft

Inspect the intake and exhaust valve clearance by LOCK NUT

Use the standard tester to check the ignition timing.

IGNITION TIMING INSPECTION