SYM 5.

REMOVAL OF ENGINE

MECHANISM DIAGRAM ...................... 5-1 REMOVAL OF ENGINE SUSPENSION BUSHING . 5-6

OPERATIONAL PRECAUTIONS ......... 5-2 ENGINE SUSPENSION FRAME.......... 5-7
ENGINE REMOVAL ............................. 5-3 INSTALLATION OF ENGINE ............... 5-8
MECHANISM DIAGRAM

3.5~4.5kgf-m

4.5~5.5kgf-m

2.4~3.0kgf-m

4.5~5.5kgf-m

4.5~5.5 kgf-m

5-1
5. REMOVAL OF ENGINE SYM
OPERATIONAL PRECAUTIONS
General Information
Engine must be supported by a bracket or adjustable tool in height.
The following parts can be serviced with the engine installed on the frame.
1. Carburetor
2. Driving disk, driving belt, clutch, and transporting disk
3. Final reduction gear mechanism

Specification
Specification
Disassemble 850 c.c.
Engine Oil Capacity
Replacement 750 c.c.
Disassemble 110 c.c.
Gear Oil Capacity
Replacement 100 c.c.
Torque Values
Engine suspension bolt (frame side) 4.5~5.5kgf-m
Engine suspension nut (engine side) 4.5~5.5kgf-m
Bolt of rear shock absorber upper connection 3.5~4.5kgf-m
Bolt of rear shock absorber lower connection 2.4~3.0kgf-m

5-2
SYM 5. REMOVAL OF ENGINE
ENGINE REMOVAL Generator connector
Open the seat.
Remove the luggage box assembly (4
bolts ).
Remove the body cover .
Remove the power connector of auto by-
start.
Remove the generator wire and pulse
generator connector.

pulse generator
Auto by-start connector connector

Remove the starter motor wire on the Starter Starter magnetic switch
magnetic switch.

Remove the spark plug.

Spark plug

5-3
5. REMOVAL OF ENGINE SYM

Remove the fuel pipe, vacuum hose, and

throttle valve cable from the carburetor.
Loose the strap screw of the air cleaner
guide, and then the air cleaner guide.

Remove the exhaust muffler (Bolts × Bolts×2

2, Nuts × 2).

Remove the rear wheel (Nut × 1).

Nut ×1

2 bolts
Remove the air cleaner connection bolts (2
bolts).

5-4
SYM 5. REMOVAL OF ENGINE

Remove the rear brake cable nut. Brake cable nut

Remove the rear brake cable.
Remove the rear shock absorber lower bolt.

Rear shock
absorber bolt

Loose the strap screw of engine left guide,

and then remove the engine left guide.

Strap screw of guide

Remove the engine suspension nut and bolt

(engine side), and then remove the engine.
Caution
With a bracket to support the engine
to prevent from it damage by falling
down as removing the engine.

Engine suspension bolt/nut

Check if the engine suspension, rear shock Bushing

absorber bushing, and cushion rubber for
damage. Replace them with new ones if so.

5-5
5. REMOVAL OF ENGINE SYM
REMOVAL OF ENGINE
SUSPENSION BUSHING
If engine suspension frame and the cushion
rubber of rear shock absorber bushing
damaged. Then, with the bushing remover /
presser, Φ28mm &Φ20mm, to press the
bushing out, and replace it with new one.

Engine suspension bushing: Φ28mm

Rear shock absorber bushing: Φ20mm

Pressing out
Place the detent section of the bushing
remover toward the bushing, and drive both
the pressing ring and bolt in to press the
bushing out.

Pressing In
Place the flat section of the remover toward
the bushing, and then drive the bushing,
pressing ring, and bolt in to install the
bushing.

5-6
SYM 5. REMOVAL OF ENGINE
ENGINE SUSPENSION FRAME
Removal
Remove the right side bolt of engine
suspension frame.

Remove the left side bolt of engine

suspension frame.

Bolt of engine suspension

frame (left side)

Check if the engine suspension frame

bushing and cushion rubber for damage. If
so, replace with new ones.

Installation
Tighten the bolts and nuts of engine
suspension frame.

Engine suspension frame nut:

Torque Value: 4.5~5.5 kgf-m

5-7
5. REMOVAL OF ENGINE SYM
INSTALLATION OF ENGINE Engine suspension nut×1
Check if the bushings of engine suspension
frame and shock absorber for damaged. If so,
replace with new ones.
Install the engine according to the reversing
order of removal.

Caution
Notice both feet and hands safety for
squeezing as engine installation.
Do not bent or squeeze each wires or
hose.
Route all cables and wires in
Brake cable nut
accordance with the routine layout.
Engine suspension nut:
Torque Value: 4.5~5.5kgf-m

Rear shock absorber bolt:

Torque Value: Top: 3.5~4.5kgf-m
lower: 2.4~3.0kgf-m

Rear wheel axle nut: Rear shock

Torque Value: 11.0~13.0kgf-m absorber lower bolt

Rear wheel axle nut×1

5-8