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    Sym 3. Lubrication System: Mechanism Diagram

    Uploaded by

    Luis Carlos Barrera Idarraga
    The document discusses the lubrication system of an engine, including an operational precautions section that lists engine oil and gear oil specifications. It describes cleaning the engine oil strainer, replacing the engine oil, inspecting and reassembling the oil pump, and replacing the gear oil. Diagrams show the engine's lubrication passages and the oil pump components.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Sym 3. Lubrication System: Mechanism Diagram

    Uploaded by

    Luis Carlos Barrera Idarraga
    487 views7 pages
    The document discusses the lubrication system of an engine, including an operational precautions section that lists engine oil and gear oil specifications. It describes cleaning the engine oil strainer, replacing the engine oil, inspecting and reassembling the oil pump, and replacing the gear oil. Diagrams show the engine's lubrication passages and the oil pump components.

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    3 lubrication system

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    The document discusses the lubrication system of an engine, including an operational precautions section that lists engine oil and gear oil specifications. It describes cleaning the engine oil strainer, replacing the engine oil, inspecting and reassembling the oil pump, and replacing the gear oil. Diagrams show the engine's lubrication passages and the oil pump components.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    487 views7 pages

    Sym 3. Lubrication System: Mechanism Diagram

    Uploaded by

    Luis Carlos Barrera Idarraga
    The document discusses the lubrication system of an engine, including an operational precautions section that lists engine oil and gear oil specifications. It describes cleaning the engine oil strainer, replacing the engine oil, inspecting and reassembling the oil pump, and replacing the gear oil. Diagrams show the engine's lubrication passages and the oil pump components.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    SYM 3.

    LUBRICATION SYSTEM

    MECHANISM DIAGRAM ....................3-1 CLEANING ENGINE OIL STRAINER... 3-3


    OPERATIONAL PRECAUTIONS .......3-2 OIL PUMP ............................................ 3-4
    TROUBLE DIAGNOSIS......................3-2 GEAR OIL ............................................ 3-7
    ENGINE OIL .......................................3-3

    MECHANISM DIAGRAM

    Valve rocker
    arm Forcedly lubrication

    Camshaft

    Scoop lubrication

    Inner passage
    Connecting rod

    Forcedly
    lubrication

    Crankshaft

    Oil strainer
    Oil pump

    3-1
    3. LUBRICATION SYSTEM SYM
    OPERATIONAL PRECAUTIONS
    General Information
    This chapter contains maintenance operations for the engine oil pump, engine oil and
    gear oil.
    Oil viscosity
    Specifications
    Engine oil quantity Disassembly 850 c.c.
    Replacement 750 c.c.
    Oil viscosity SAE 10W-30 or equivalent
    (Recommended King-Mate
    serial oils)
    Gear Oil Disassembly 110 c.c.
    Replacement 100 c.c.
    Oil viscosity of gear oil SAE 85W-140
    (Recommended King-Mate
    gear oil series SYM
    HYPOID GEAR OIL)

    unit : mm
    Items Standard Limit

    Inner rotor clearance - 0.12


    Clearance between outer
    Oil pump rotor and body - 0.12
    Clearance between rotor
    side and body 0.05~0.10 0.20

    Torque value
    Engine oil drain plug 3.5~4.5kgf-m
    Engine oil screen cover 1.3~1.7kgf-m
    Gear oil drain bolt 0.8~1.2kgf-m
    Gear oil filling bolt 1.0~1.4kgf-m
    Oil pump connection screw 0.1~0.3kgf-m
    TROUBLE DIAGNOSIS
    Low engine oil level Dirty oil
    Oil leaking No oil change in periodical
    Valve guide or seat worn out Cylinder head gasket damage
    Piston ring worn out Piston ring worn out
    Low Oil Pressure
    Low engine oil level
    Clogged in oil strainer, circuits or pipes
    Oil pump damage

    3-2
    SYM 3. LUBRICATION SYSTEM
    ENGINE OIL
    Turn off engine, and park the motorcycle in
    flat ground with main stand.
    Check oil level with oil dipstick after 3-5
    minutes.
    Do not rotate the dipstick into engine as
    checking.
    If oil level is nearly low level, fill out
    recommended oil to upper level.

    Dipstick

    Oil Replacement
    Caution
    Drain oil as engine warmed up so that
    make sure oil can be drained smoothly
    and completely.
    Place an oil pan under the motorcycle, and
    remove oil strainer cap.
    Make sure if the aluminum washer of the
    draining bolt is damaged. If so, replace it
    with new one.
    Install the drain bolt and tighten it. Oil drain plug
    Torque value: 3.5~4.5 kgf-m

    CLEANING ENGINE OIL STRAINER


    Remove the oil strainer cap.
    Remove oil strainer and spring.
    Clean oil strainer (recommended using
    compressed air to clean dirty foreign).
    Check if the strainer and O-ring of the oil
    strainer are broken. Replace with new one if
    found.
    Install the oil strainer and spring.
    Install the oil strainer cap and tighten it. Oil strainer cap
    Torque value: 1.3~1.7 kgf-m
    Fill out oil to the oil filler (Oil viscosity SAE
    10W-30) (Recommended King-Mate serial
    oils).
    Engine oil quantity: Replacement 750 c.c.

    3-3
    3. LUBRICATION SYSTEM SYM
    OIL PUMP
    bolts
    Oil Pump Removal
    Remove the alternator (refer to chapter10).
    Remove the engine right cover.
    Remove the one-way clutch and starting
    gear (1 nut).

    Make sure that the pump axle can be rotated


    freely.
    Remove the oil pump cover (2 bolts), and
    then the oil pump driving gear nut and the
    gear and oil pump driver chain.
    Remove oil pump body bolts (2 bolts).

    Oil Pump Disassembly


    Remove the screw on oil pump cover.
    Disassemble the oil pump as illustration shown.

    Right crankcase cover

    Starting gear

    Oil pump driving gear

    Starting clutch

    Oil strainer

    Right crankcase

    Oil pump outer cover

    Oil pump driving chain

    Oil pump body

    Oil pump shaft

    Outer rotor

    Inner rotor

    Oil pump cover

    3-4
    SYM 3. LUBRICATION SYSTEM
    Oil Pump Inspection
    Check the clearance between oil pump body
    and outer rotor.
    Limit: below 0.12 mm

    Check clearance between inner and outer


    rotors.
    Limit: below 0.12 mm

    Check clearance between rotor side face


    and pump body.
    Limit: below 2.0 mm

    Oil Pump Re-assembly


    Install inner and outer rotors into the pump
    body.
    Align the indent on driving shaft with that of
    inner rotor. Install the driving shaft.
    Install the oil pump cover and fixing pin
    properly and then tighten screw. (1 screw)

    3-5
    3. LUBRICATION SYSTEM SYM
    Oil Pump Installation
    Install the oil pump (2 bolts).

    2 bolts

    Install oil pump driver chain and drive gear. oil pump driver
    chain

    drive gear

    Install oil pump outer cover (2 bolts). oil pump outer cover

    2 bolts

    Install the starting gear and the alternator. Start drive gear
    (Refer to chapter 10)

    3-6
    SYM 3. LUBRICATION SYSTEM
    GEAR OIL
    Filling bolt
    Oil Level Inspection
    Park the motorcycle on flat ground with main
    stand.
    Turn off engine and remove both engine oil
    filling bolt and oil draining bolt.

    Draining bolt

    Remove gear oil filling hole bolt and place a


    measurement cup under the draining plug.
    Remove the oil draining plug and the pour
    gear oil into the measurement cup.
    Measure the gear oil quantity if within
    standard value.
    Add specified gear oil if the oil level too low.
    Standard quantity: 110cc.
    Replacement: 100 cc.

    Gear Oil Replacement


    Remove the gear oil filling hole bolt and its
    draining plug and then drain oil completely.
    Install the draining plug and tighten it. (Make
    sure if the plug washer is damaged. If so,
    replace it with new one.)
    Torque Value：0.8~1.2 kgf-m
    Add new gear oil (100 c.c.) from the gear oil
    filling hole and then install the gear oil filling
    hole bolt after added oil. And then, tighten
    the bolt.
    Torque Value: 1.0~1.4 kgf-m
    ※Recommended to apply with SYM
    HYPOID GEAR OIL (SAE 85W-140)
    Start engine and run it for 2~3 minutes.
    Turn off engine and check if oil leaking.

    3-7

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