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1999 mercruiser 230 hp manual

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1999 mercruiser 230 hp manualIf you have a dirty old paper copy of this manual or a PDF copy of this manual on your computer and it crashed we can help! Your SYM Jet 100 Scooter Service Manual will come to you in pdf format and is compressed for a lightning fast download. After downloading your SYM Jet 100 Scooter Service Manual you can view it on your computer or print one or all of the pages needed. You can pay for your SYM Jet 100 Scooter Service Manual with Paypal or Visa, MasterCard or Discover. Immediately upon payment you will automatically be forwarded to our secure download page. We will also send you an email with a copy of your SYM Jet 100 Scooter Service Manual download link. SYM Jet 100 Service Manual Vault - the easy way! All Rights Reserved. Oil tank cap Frame number Tail light Storage box Air cleaner Ignition switch. For a more comfortable and safety riding, please read this manual carefully. Thank you very much for your patronage In order to maximize your scooter’s performance, a periodical inspection and maintenance should be completely carried out. When the switch is turned to this position, rear light, instrument panel light, and position Horn Switch light will go on. Press this switch to switch between high and low beams. This is for high beam.Take out valuables before washing to avoid wetting these objects. Replenishment: 1. Using the main stand to support the vehicle on a level ground, lift up the saddle, and remove the oil tank cover. Authorized Dealer or Franchised Dealer for a Recommended Brake Fluid: WELL RUN check or repair. Have your scooter checked by SYM Authorized Dealer or Franchised Dealer should any abnormality is found. Remove the battery terminals and clean if there are dirt and corrosion on them. Remove battery from scooter, store it in a well- ventilated and dimly lighted place after the battery has been fully charged. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.http://moiabolgaria.ru/fckeditorfiles/drager-carina-user-manual.xml

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Run your engine in an open area, if you strictly prohibited. Using non-designed parts oil. Check these parts before installation to for SANYANG scooter may damage the make sure that they are in good condition, scooter. In go to their connections so that there is enough case of confusion, Insert the bolt into the hole room below the enlarged ends for tightening. Have your scooter checked, adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition.Recommended engine oil: MAX-2 serial oils. Squeeze out remaining oil Squeeze oil out. Remove the fuel line from the fuel filter. Replace the fuel filter with new one. Install the fuel filter. The arrow indicates the fuel flowing direction. Check the fuel line for leaking. Fuel filter Engine Oil Line Remove the body cover. Remove the luggage box. Wide open the throttle valve, and check if the calibration point aligns on the oil pump lever with the mark of pump body. Check tire for cracks, damage, nail, or other object stuck in tread.Brake Fluid: Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid DOT-3 to UPPER limit. Front brake Remove the front wheel shaft bolt. Take out the front wheel. Lining guide bolts Remove brake caliper mounting bolt and then remove the brake caliper. Caution Caliper bolt Do not operate the brake lever after the clipper removed to avoid clipping the brake lining. Lift the front wheel out of ground, and check if the steering handle turning is smoothly. If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut. Draining bolt Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt. Belt width Driver Belt Remove left crankcase cover. Check if the belt is crack or worn out.http://reddonbo.com/userfiles/drager-bg4-service-manual.xml Replace the belt if necessary. Idle speed check and adjustment have to be done after engine is being warned up. Caution Higher Lower Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance. Headlight adjustment bolt 2-13. SYM-1120100-G5 No. SYM-1130000-L No. SYM-1130000-R L. Crankshaft install bush Name R. Crankshaft install bush Name Extension bush SYM-1130031(long) No. SYM-9121600 No. SYM-9120200 No. SYM-9125500 2-15. SYM-9620000 No. SYM-9110400 Name Inner bearing puller Name Inner bearing puller Name Outer bearing puller SYM-6204020 No. SYM-6204022 No. SYM-6204001. If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control Control cable cable, and remove the control cable. Thus, always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Care must be taken when dealing with gasoline, and always work in a well-ventilated place and strictly prohibit flame. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Inspection Sealed cap Throttle valve spring. Auto by-starter coupler Disconnect the auto by-starter coupler. Carburetor Fuel hose Loosen draining screw and then drain out fuel upper part inside the carburetor. Loosen carburetor upper part and remove 2 bolts carburetor upper part. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper and air screws, record their original turns for close to their original set up position as installation. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Fuel hose Carburetor Installation. Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper. Hose clamp Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner. Install in the reverse order of removal procedures. 2 bolts. Remove the spark plug cap from the spark plug. Remove the fuel output and the vacuum tubes from fuel pump. Vacuum tube Control cable Remove the oil control cable from oil pump. Remove brake cable from cable clamp. Rear brake cable Disc type rear brake Remove rear brake caliper (2 bolts) from engine rear-upper side. Remove brake hose from hose clamp. Connection nut Remove two bolts beside fan cover and exhaust pipe. 3 bolts Support the engine and then remove cushion Rear cushion lower mounting bolt lower mounting bolt. Remove engine mounting nut and bolt. It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. Remove all washes from the interfaces of cylinder head, cylinder and crankcase. Remove fuel pump tubes. Fuel inlet tube 2 nuts Remove spark plug cap. Remove fuel pump bracket (2 nuts). Plug cap Remove vacuum tube and oil pump control cable from engine shield. Remove the 4 cylinder head bolts and then remove the cylinder head. Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging it. Cleaning Carbon in Combustion Chamber Clean carbon deposit in which built up in combustion chamber with shown chisel. Remove fan cover. Remove engine shield. Remove two connection nuts of the exhaust pipe. Remove exhaust muffle mounting bolt, and then remove the exhaust muffler.http://intrasservices.com/images/contraindications-for-manual-hyperinflation.pdf 3 bolts Cylinder Removal Remove cylinder head. Caution Do not scratch both the cylinder and the piston. Use a straight edge and a feeler gauge to measure the cylinder head for warp. Service limit: 12.030mm The ID of piston pinhole Measure the OD of piston pin. The OD of piston pin Service limit: 11.970 mm Piston Ring Inspection Measure the end gap of each piston ring. Service limit: 0.40 mm Caution With the piston, push each piston ring into. Align the ring end with the lock pin in the ring groove. Install the top ring and the 2 ring onto the ring groove respective. Hold the piston and then install it into cylinder. Caution To avoid to damaging the piston and the cylinder sliding surface. Lock pin 4 bolts Install the cylinder head.Please refer to Chapter 15 for the relative A.C. generator inspection.Support the flywheel and the remove the 10 mm nut on the flywheel. Special tool: Universal holder SYM-2210100 Universal holder Remove the flywheel with flywheel puller. Special tool: Flywheel puller SYM-3110A01 Flywheel puller. Pulse coil coupler Remove the pulse coil and generator coil bolts (4 bolts), and then take out the generator assembly. Caution Care to be taken for not damaging the generator coil. Remove air cleaner (2 bolts). Remove kick-start arm (1 bolt). Remove left crankcase cover (9 bolts). 9 bolts Return spring Disassembly of Kick Starter Remove snap clip and thrust washer from left. Install thrust washer and snap clip onto starter spindle. Return spring Width-tooth Driven gear Install kick-starter lever temporary. Hold clutch outer with universal holder, and remove nut and clutch outer. Special tool: Universal holder SYM-2210100 Caution Using special tools for tightening or loosening the nut. Universal holder Fixed rear wheel or rear brake will damage reduction gear system. Remove left crankcase cover. Crankshaft Ramp plate Remove ramp plate. Movable drive face Remove weight rollers from movable face. Weight roller Weight roller Inspection. Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit. Crankshaft Drive belt Drive Face Installation Press down Press drive belt into pulley groove, and then pull the belt on to crankshaft. Universal holder Install drive face, washer and nut. Special tool: Clutch spring compressor SYM-2301000 Clutch nut wrench SYM-9020200 Clutch spring Caution compressor Do not press the compressor too much. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 82.5 mm Free length Driven pulley. Caution Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient elasticity. Snap clip Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clip Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. Special tool: Clutch spring compressor SYM-2301000 Clutch nut wrench SYM-9020200 Remove the clutch spring compressor.Drain gear oil out from gearbox. Oil draining hole Remove muffler and rear wheel. Rear wheel nut 7 bolts Remove gearbox cover mounting bolts from the clutch side (7 bolts). Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010 Remove drive shaft oil seal and bearing from left crankcase. Oil seal. Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010 Remove drive shaft oil seal and bearing from left crankcase. Oil seal. Caution If remove the drive shaft from the gear box upper side, then its bearing has to be replaced. Special tool: Inner bearing puller SYM-6204020 or SYM-6204021 Caution Never install used bearings. Once bearing removed, it has to be replaced with new one. With the special service tools to install drive shaft by through the bearing. Special tool: R. Crank shaft puller SYM-1130000-R L. Crank shaft install bush SYM-1130010 Extension bush SYM-1130031 (long) Extension bush SYM-1130032 (short) R. Crank shaft puller Apply with grease onto drive shaft oil seal. Disassemble the right crankcase. Special Tools: Crankcase disassemble tool SYM-1120100-G5 Right crankcase Crankcase Crankshaft Removal disassemble tool As the diagram show with 2 special bolts to install the specified service tool onto the left crankcase. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge. Dowel pin 10-5. Special Tools: R. Crank shaft puller SYM-1130000-R R. Crank shaft install bush SYM-1130020 Install the bolts and tighten them.Body Cover Steering Handle Cover 4 screws Removal Remove 4 screws from the handle rear cover upper. Remove 2 screws from the handle rear cover under. Each side 1 screws 3 screws Remove 3 screws from the handle front cover under. Body Cover Remove 1 screw from the handle rear cover inner. 1 screw Remove handle upper cover. Remove 1 screw from rear by handle rear cover. 1 screw Remove 2 inner screws. Disconnect each switch connectors. 2 Screws Remove speedometer electric cord coupler. Body Cover Front Cover Removal Remove 10 screws from the front inner box and front cover. Each side 5 screws Remove 1 screw from the front cover. Screws Headlight coupler Remove electric cord coupler from the headlight. Remove the front cover. Body Cover Luggage Box Removal Lift up seat cushion. Hold the luggage box in both front and rear sides by two hands, and then lift up the box to remove it. Body Cover Side Covers Removal Remove 2 screws under side cover front end. 2 screws Remove 2 screws, and then slide the side cover backward so that their hooks are out of slots. Take out the side cover end part and then remove the cover. Body Cover Center Cover Removal Remove 2 screws from center cover. Slide the center cover frontward so that their hooks are out of slots. Take out the center cover end part and then remove the cover. Installation Install in reverse order of removal procedures. Remove front wheel and front fender. Remove 6 screws from the front inner box. Each side 3 screws Remove 2 screws from the front upper part of the front spoiler and the front inner box. Body Cover Front Inner Box Removal Remove the front cover. Remove main switch cover.Body Cover Front Fender 1 Bolt Speedometer cable Removal Ramoval 1 bolt from left front cushion, and then remove speedometer cable clamp and front brake hose clamp. Front brake hose Ramoval 4 screws form front fender right and left side. Body Cover Rear Inner Fender Removal Ramoval luggage box, rear carrier, body covers and rear fender. Ramoval 2 screws from rear inner fender upper. Each side 1 screw Pull out rear fender front hanger with frame, and then removal rear inner fender. Body Cover Under Cover Removal Remove right and left side cover. Remove 1 bolt and 1 nut from the under cover right side. 1 nut 1 bolt Remove 1 bolt and 1 nut from the under cover left side, and then remove under cover. Brake System Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. Brake System Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. Caution Do not release the brake lever before the drain valve is closed. Brake System Disc Brake - Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the Caliper bolt brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Brake System Install the new brake pads onto brake caliper. Locking spring Install the brake pad guide pin bolts.Brake System Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: Front brake disc 3.5mm Rear brake disc. Brake System Install the rubber pad into groove properly. Remove the rubber pad. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Brake System Place the master cylinder onto handlebar, and install the bolts. 2 bolts Install the brake lever, and connect leads to brake Master cylinder light switch. Brake hose Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified Washers torque value. Brake System Rear Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts. Brake System Installation Bolt Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin. Brake System Notes: 12-16. The rim is bent. The steering shaft bearing are damaged. Remove front brake master cylinder (disc brake) after 2 bolts removed. Remove throttle grip and right handle switch after right handle switch mounting screws removed. Installation Installs handle and align with bolt hole. Install bolt and nut and then tighten it.Remove speedometer cable from speedometer gear box (1 screw). Speedometer cable Remove front wheel axle nut, and then pull out the axle and remove the wheel. Remove left side dust seal, bearing and dist. collar. Special tools Inner bearing puller (SYM-6204020) Dust seal Dist.Drive the left bearing, dust seal into wheel rim and Bearing install the dist. Align the flange part on the speedometer gear with the slot of wheel hub. Remove the caliper mounting bolt and the caliper. Take out the hose from hose clamp. 2 bolts Brake caliper 4 bolts Remove the front cushion upper bolts and the. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing. Top cone race 13-11. Shaft nut Remove rear wheel shaft nut and then remove the rear wheel. Check item refer chapter 12. Install by reverse order of removal procedures. Shaft nut Installation Install the rear wheel and tighten the nut.Remove rear cushion. Installation Install the rear cushion.Electrical Equipment Maintenance Information Precautions in Operation When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing. Electrical Equipment Troubleshooting Charging system does not operate No voltage properly Battery discharged The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor AC.G. Open seat, remove 2 screws and then open battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal. Electrical Equipment Charging Voltage Inspection Connect a tachometer. Digital voltmeter Turn on the headlight to high beam and start the engine. Ammeter Accelerate the engine to the specified revolution per minute and measure the charging voltage.Electrical Equipment Charging System Fuse 15A Black Green Main switch REG. REC. Yellow Pink Fuse 15A Battery Auto by- starter AC. Generator Regulator rectifier Inspection Regulator rectifier coupler Check the each pins of coupler on the regulator rectifier. Yellow Caution If the probe is touched by finger, then the. Electrical Equipment Ignition System DC. CDI. Unit To tachometer Main switch Fuse 15A Ignition Coil AC. Generator Pulse Generator ENG. Stop switch Battery Ignition Coil Inspection Remove lower side cover. Remove ignition coil wire pins. Ignition Coil Measure the primary coil resistance. Electrical Equipment Remove the plug cap, and measure its negative (-) terminal for the secondary coil resistance. Disconnect pulse generator coil coupler. Electrical Equipment Starting System Brake light Main switch Stop switch Starter relay Start switch Starter motor Battery Starter Relay Inspection Starter relay Remove battery box and then remove starter relay.Remove starter motor pinion holder, and then remove starter motor pinion. Install the starter motor pinion in reverse order of removal. Remove bolt and oil pump control cable. Disconnect starter motor harness coupler. Remove 2 bolts for separation starter motor and gasket. Remove 2 bolts for disassembly the starter motor. 2 bolts Armature Inspection Check the armature for discoloration or other. Electrical Equipment Oil Level Switch Troubleshooting Fuse Main switch If the oil level in oil tank is in specified level, but the oil level indicator still goes on. 1. Remove luggage box. 2. Disconnect oil level switch wire, and turn the main switch to ON position. Electrical Equipment Carburetor Heater Power filter Thermo switch Main switch Fuse 15A To REG. REC. Carburetor heater Battery AC. Remove carburetor heater wire pins. Remove carburetor heater. Remove floor plate (2 nuts). Remove fuel tank heat guard. Heat guard Disconnect fuel unit coupler from front wheel side. Turns the fuel unit retain plate in counter-clockwise direction and then remove the fuel unit retain plate. Check continuity on each switch. Main switch cap The connected circles with a line are that they should be in continuity. Main Switch Wire color Black LOCK Replacement of main switch. Electrical Equipment Left handle switch Passing switch Remove the front cover. Disconnect the coupler of left handle switch.Headlight Remove the headlight bulb set coupler. Headlight coupler Turn the set in counter-clockwise direction, and then remove the bulb. Replace with new bulb if necessary. Specification: Headlight bulb 12V 35W (H8) Electrical Equipment Front winker light Remove 9 screws and then remove handle front cover (refer to chapter 11). Turn the front winker light set in counter-clockwise direction, and then remove the front winker light bulb seat. Push and turn the bulb in counter-clockwise direction, and then remove the bulb. Remove body cover, rear carrier, rear fender and taillight assembly. (Refer chapter 11) 1 screw Remove 1 screw from taillight upper side. Remove 4 screws and then remove taillight 4 Screws assembly. Electrical Equipment Meter indicator light Rubbers Remove steering handle front cover. Remove winker and hi-beam indicator light rubber. Winker indicator light bulb Turn the bulb seat in counter-clockwise direction and then remove, and then take out the bulb seat from the bottom of instrument panel. Electrical Diagram 16-1. Electrical Diagram Notes: 16-2. 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Found an error? Please let us know. Go to form The specifications of models sold in other countries may differ. Louis does not accept any responsibility for the accuracy of the information provided.If so, Louis will provide you with all the information you need. What type of engine oil and which brake fluid should you use. Which are the right spark plugs. What are the correct tyre pressures and valve clearances. We give you the answers to all the important questions about your motorcycle. In addition, we offer a carefully compiled list of all the wearing parts, add-ons and accessories available in our range specifically for your SYM JET 100 (G100-P2). So we are a one-stop shop where you can get all the information you need and the right product quickly and easily.Our data privacy page provides more information about our external service providers, as well as the ability to opt out. 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