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 ............................................ 3-6
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
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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 950 c.c.
Replacement 700 c.c.
Oil viscosity SAE 10W-30 or equivalent
Gear Oil Capacity Disassembly 180 c.c.
Replacement 170 c.c.
Oil viscosity of gear oil SAE 85W-140
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 1.0~2.0kgf-m
Gear oil drain bolt 1.0~1.5kgf-m
Gear oil filling bolt 1.0~1.5kgf-m
Oil pump drive sprocket nut 0.8~1.2kgf-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
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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
Oil drain plug
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 oil drain plug and tighten it.
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: 1.0~2.0 kgf-m
Fill out oil to the oil filler (Oil viscosity SAE
10W-30).
Engine oil quantity: Replacement 700 c.c.
3-3
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3. LUBRICATION SYSTEM SYM
OIL PUMP
bolts
Oil Pump Removal
Remove the alternator (refer to chapter10).
Remove the engine right crankcase cover.
Remove the one-way clutch and starting
drive gear (1 nut).
Make sure that the pump axle can be rotated
freely.
Remove the oil pump cover (2 bolts),
Remove the oil pump fixing flat screw .
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 body
Oil pump shaft
Outer rotor
Inner rotor
Oil pump cover
3-4
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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
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3. LUBRICATION SYSTEM SYM
Oil Pump Installation
Install the oil pump (2 bolts).
2 bolts
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)
GEAR OIL Draining bolt Gear oil refilling 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.
3-6
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SYM 3. LUBRICATION SYSTEM
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: 180cc.
Replacement:170 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：1.0~1.5 kgf-m
Add new gear oil (170 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: 1.0~1.5 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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