2011 Sym Maxsym 400i

MAXSYM 400i SERVICE MANUAL FOREWORD

CONTENTS

HOW TO USE THIS MANUAL

MECHANISM ILLUSTRATION

20120303

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Foreword This service manual contains the technical data of each component inspection and repair for the Sanyang MAXSYM 400i scooter. 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, MAXSYM 400i, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

Service Department Sanyang Industry Co., LTD.

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How to Use This Manual

This service manual describes basic information of different system parts and system inspection & service for Sanyang MAXSYM 400i scooter. 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 information. Th third to the twelfth chapter covers the engine and driving systems. The thirteenth to the sixteenth is contained the parts set of assembly body. The seventeenth chapter is electrical equipment. The eighteenth chapter is wiring diagram. Please see index of content for quick having the special parts and system information.

There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and “Mechanism Illustration” in the PDF version, and can be access to these items by clicking on the buttons. If user wants to look for the content of each chapter, selecting the words of each chapter on the contents can reach to each chapter. There are two buttons, “Homepage and contents, on the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this Chapter Contents” button at the second page of each content so that clicking the button can back to the contents of this chapter.

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Contents Page

Content

Index

1-1 ~ 1-16

General Information

1

2-1 ~ 2-16

Maintenance Information

2

3-1 ~ 3-6

Lubrication System

3

4-1 ~ 4-58

Fuel Injection System

4

5-1 ~ 5-4

Engine Removal

5

6-1 ~ 6-16

Cylinder Head / Valve

6

7-1 ~ 7-8

Cylinder / Piston

7

8-1 ~ 8-14

V-Belt Drive System

8

9-1 ~ 9-8

Final Drive Mechanism

9

10-1 ~ 10-4

AC Generator / Starting Clutch

10

11-1 ~ 11-8

Crankshaft / Crankcase

11

12-1 ~ 12-12

Cooling System

12

13-1 ~ 13-16

Body Cover

13

14-1 ~ 14-12

Brake System

14

15-1 ~ 15-11

Steering / Front Wheel / Front Cushion

15

16-1 ~ 16-6

Muffler / Rear Wheel / Rear Cushion

16

17-1 ~ 17-22

Electrical System

17

18-1 ~ 18-2

Wiring Diagram

18

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Mechanism Illustration Start / engine stop switch

Front winker

Luggage box

Fuel tank / fuel pump

Dimmer / winker / horn seat open / pass switch Main switch

Coolant filler cap

Taillight / rear winker

Headlight

Air cleaner

Reserve tank cap

Main stand Side stand Back mirror

Front brake lever Rear brake lever

Engine number

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Muffler

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1. General Information Symbols and Marks····························1-1

Torque Values ···································· 1-10

General Safety ····································1-2

Troubleshooting································· 1-12

Before Servicing·································1-3

Lubrication Points ····························· 1-16

Specifications ·····································1-9

Symbols and Marks Symbols and marks are used in thi