"user manual"
Contents
1. 1 CONTENTS Bs SONG es anne E A E A deste ates aaa ase ta neo ee eats TEA 1 Ze MOP OWN OC AMOI sarsie a r easiest evade a teldn alee lees e E 3 is NESTOR ICM teat a st a sr we chet apts east op Deleted eee aca ea eaied Maciaeh apace ata et ese cent 4 A OU AN ayers 00 cts ete since a a Resets ae ed ate e ese Re lesb ener eeeneenae 4 o SEIU etctaedtee ach N Sv otasccta sat siesta atu en aueanasts ch Sp esioste T clots eaten ates 5 6 Use genuine spare parts ce cceccccecc ccc ecceecseeeeceeceeceeceeceeeeeseeeeeeeseegeeeseeseeseeseeseeseesees 5 t YJseol CACN COMPONEIN araa a a a S ae 6 GGO a E ee E A A a 6 Operation Of ignition SWICK sissit a a a A A a T Operation of steering handle lock switch annsnennnnsnnensrerrrenrrsrerrsrrrrsrrrrsrrrrerrrrsres rne 7 Operation of seat open switch ccss eclacsncekcs ric Sosa sew ew a acne ace ew ae ae ede eee 7 Bis Jl a 8 8 earn ee te Partie a eee a near eee ee tare 7 DIO LAGS DOK ee ake he as eels ak een aioe acs onthe a ase oie 9 Sately helmet NOOK aen canst ace tent an ATE tou sige aes Ea cloud AE A aE EE se 10 FUSAK Ca Dad 5 oes cas a A an cede e adem eee doen ee 10 ESE AIC S EE nas sist coe sien escola me sate A AA tae OA EA A A 10 8 Important points and cautions for Starting engine cccecceeesecceeeeeeeeeeeeeeeeneeseeenes 11 9 The best way to drive off cccccccccecceeceecceeceeseeeceeseeceeecueceeseuecseeeesseeceesenseeecenseesaes 12 The control of throttle valve2. 21 15 CAUTIONS FOR RIDING SCOOTER 1 Raise the scooter with the main stand and sit on the saddle Push the scooter forwarding to raise the main parking stand Z CAUTION e Never rotate the throttle valve handle at will to increase the engine RPM before driving off 2 Get on the scooter from the left side and sit on the saddle properly keep your right feet firmly on the ground to prevent the scooter from falling A CAUTION e Apply brake on the rear wheel before driving off 3 Rotate the throttle valve handle slowly and then the scooter will begin to move Z CAUTION e Rapidly rotate the throttle valve handle or release the clutch lever may cause the motorcycle moving forward suddenly and it is very dangerous e Make sure the side parking stand is spring back completely before driving off Do not use the brake suddenly and make a sharp turn e Rapid braking and sharp turning will cause slip and fall e Rapid braking or sharp turning will cause slipping lateral slipping or fall especially in rainy days when the road is wet and slippery Drive with extreme caution during rainy days e The brake distance in rain day or on wet road will longer than that on a dry road Therefore slow down and prepare to apply the brake earlier e The throttle valve handle should be released and the brakes should be properly applied as it is needed while reducing the speed when going down a slope 22 16 PERI
3. 20 11 WHEN THERE IS AN ABNORMAL CONDITION OR A TROUBLE DIAGNOSIS WHEN ENGINE DOES NOT START For rear wheel For front wheel 1 Has the ignition switch key 2 Is there enough fuel in the fuel 3 Is the rear or front wheel been turned to the ON tank brakes applied when position pressing starting button Turn Signal Switch Horn Switch 5 Turn the ignition switch key to the ON position and press horn button down if the horn does not sound the fuse may have been blown Have your scooter checked by SYM authorized dealer or franchised dealer immediately if there are no problems with the above items and engine still can not be started 12 C D I ELECTRICL IGNITION SYSTEM 4 Do you rotate the throttle valve handle while pressing starting the button The charge and discharge principle of a condenser is adopted for the C D I system to supply electrical energy created by generator s coil to the ignition coil in accordance with specified ignition timing so that the spark plug may generate sparks as required 13 SUGGESTIONS ON ENGINE FUEL e This scooter is designed to use UNLEADED gasoline of Octane No 90 or higher e f the scooter is operated in high attitude where the atmosphere pressure is lower it is suggested that the air fuel ratio should be readjusted to maximize the engine performance 14 TRANSMISSION OIL e Recommended OIL GENUINE SYM HYPOID GEAR OIL SAE 85W 140
4. Fuel tank cap control switch Frame number Ignition switch Tail Stop light Fuses amp C D 1 Battery High amp Low beam Turn signal Seat open Horn Switch Front brake level Light Starter switch Rear turn signal light Rear brake level Exhaust muffler 3 BEFORE RIDING This manual describes the correct usage of this scooter including safety riding simple inspection methods and so on For a more comfortable and safety riding please read this manual carefully For your benefit please ask your SANYANG dealer the operating manual and carefully read the following e Correct use of the motorcycle e Pre delivery inspection and maintenance Thank you very much for your patronage In order to maximize your motorcycle s performance a periodical inspection and maintenance should be completely carried out We recommend that after riding your new motorcycle for the first 300 kilometers you should take your motorcycle to the original dealer for an initial inspection and to have your motorcycle inspected periodically every 1000 kilometers thereafter e Incase the scooter s specifications and construction are modified and different from the photos and diagrams on the owner s manual catalogues the specifications and construction of the actual scooter shall prevail 4 SAFE RIDING It is very important to be relax and clothe properly when driving observe traffic regulations do not rush always drive carefully and
5. panel light and position light will come on When the switch is turned to this position all lights will go off e Electrical starter button this is a starting motor button switch for engine starting With the main switch on press this button while holding the front or rear brake lever will start the engine Z CAUTION Release this button immediately after engine has been starter and never press the button again to avoid damaging the engine This mechanism is a safety design The engine can only be started after the front or rear brake lever pedal has been applied Do not use light system Turn headlight and turn signal light to the off position when the engine is being started e High low beam switch This is the high and low beam of headlight switching switch Press this switch to switch between high and beams This is for high beam D This is for low beam please turn to low beam riding in city e Seat open Turn ignition switch to the ON position and press this button down Then the seat will be Seat open Sa This button will return to original position after releasing A CAUTION Press the seat down and it will be locked automatically e Be sure to remove the key after the seat After the seat catch has been locked check to make has been locked sure it has locked properly by lightly lifting the seat Do not put the key inside the storage box after unlocking to avoid the
6. therefore do not modify your motorcycle at will 5 DRIVING e Keep the related parts of your body such as arms palms lumbar and toes relax and ride with the most comfortable posture in order to be able to react quickly whenever it is necessary e Riders posture will greatly affect riding safety Always keep your body s gravity in the center of the saddle if your body s gravity is on the rear part of saddle the front wheel load will be reduced and this will cause the steering handle shaking It is dangerous to ride a scooter with an unstable handle e It will be much easier to make a turn if rider inclines his body inward when turning On the other hand the rider will feel unstable if his body and the scooter do not incline e The scooter is hard to control on a bumpy unleveled unpaved road try to know the road conditions in advance slow down and use your shoulder s force to control the handle e Suggestion Do not load objects on the front pedals unnecessarily to avoid affecting the riding safety and the operation of steering handle CAUTION The rider s feeling on the handle is slightly different with a load or without a load Overload may cause the handle to swing and affects the riding safety Therefore do not overload your scooter Z CAUTION e Do not place flammable materials such as rags between the body side cover and engine to avoid components damaging by fire e Do not load objects on areas not s
7. handle ccc ccccceccecceeeceeceeceeeceeceeceeecueceeseeeeeesseseeees 12 FAKING MEMO arana eea renin r seh Om semuhedesseust a a a a a 12 10 Inspection and maintenance before riding s nsssnsnnensnrersrrsrrrrsrerrererrernrrererrsrerrerne 13 ROUNE ITSO CU ON 2 cis oleh cig oat lec sh gpa E a a a dostodes 13 Engine oil inspection ANd CHANGE ccceccecceeceeceeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeseeaeegees 13 FUCA S DCC ON asa nan a oeaaetonmenena A ann deine sanaat sean T 14 Transmission Oil inspection ANd change ccceccecceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeseeseeseeaes 14 Inspection and adjustment of brake free play cc ececcsecceeeeeeneeceeeeeeseeeeeeneeneeeeeees 15 Disc brake inspection depending ON models ccceeceecceeeeeeeeeeeeeeeeneeseeeeseeeeeeaes 16 Throttle valve handle clearance adjustment ccccccccecceceeeeeeeeeeeeeeeeeeeseeseeseeseeees 17 Inspection and maintenance of battery cc ccccccceeceeeseeeeeeeeeeeeeeeeeeeseeseeeaeeneeea tees 17 UES MINS SCC LIOMM sete east k Gta ol ih cd le dA ee ee AN od aah 18 Steering handle front shock absorbers INSPECTION cece cece eee eec seca eceeceeeeeseeseeeeees 18 Checking and Changing TUSES 222 06 iina a a E 19 Checking the turn signal lights and horn assenannennnnensnnensnneneenrnsrrensrrnrsrrersrrersrrersnene 19 Checking the front and rear lights cccecceeccecceeeceeceeceeseeeceeseeseeeceeseeseessees
8. key being locked inside the storage box when the seat is pressed down automatically e Engine start control switch Engine start control switch The switch button position is under seat ON position Engine is locked and can not be started engine in this position OFF position When the ignition switch is on position the start control switch is off position press electrical starter button while holding the front or rear brake lever will start the engine e Horn Switch Press this button down when ignition switch is in the ON position the horn will sound e Turn Signal Switch Turn signal lights are used when turning left right or changing lane Turn ignition switch to the ON position and slide the turn signal switch to left or right Then the turn signal lights will flash To release simply return the turn signal light button to the original position Left side turn signal light flashing means you intend to make a right turn U gt Right side turn signal light flashing means you intend to make a left turn STORAGE BOX e This boxis located under the saddle Storage box e Maximum load capacity 10kg e Do not store valuables in the box e Make sure that the saddle has been locked completely after it was pressed down e Take out valuables before washing to avoid wetting these objects e Do not place thermal sensitive objects in the box because of engine s heat
9. not fill above fuel upper limit lever when refueling e Make sure the fuel tank cap had been tighten properly STRANSMISSION OIL INSPECTION AND CHANGES INSPECTION e Use the main stand to support the scooter on a level ground after the engine stops wait for 3 5 minutes Remove the transmission oil infusion bolt put a measuring glass under the drain bolt and remove the drain bolt Let the oil flows into measuring glass and check for decreased or not at disassembly 100 105c c at change 90 100c c OIL REPLACEMENT e Stop the engine and use the main stand to support your scooter on a lever ground Remove the infusion bolt and drain bolt drain out the oil e Install the drain bolt and tighten it Fill new transmission oil 90 100c c and install the infusion bolt and tighten it make sure that bolts are tightened and check that there s no leakage e Recommend Oil Genuine SYM HYPOLD GEAR OIL SAE 85W 140 14 e S INSPECTION AND ADJUSTMENT OF BRAKE FREE PLAY INSPECTION Brake lever free play must checked with the engine shut off e Brake lever and pedal free play for front and rear wheels If checking the hand braking lever for front wheels its free play the stroke of hand braking lever from no braking to initial braking should be 10 20mm It is abnormal if the feel is spongy when holding the hand braking lever forcefully If checking the foot braking pedal for rear wheels its free play the stroke of foot b
10. relaxed Usually most people would ride their newly bought scooter very carefully but after they became familiar with their scooters they tended to become reckless which may result in an accident A To remind you Please wear a safety helmet and properly tighten the chin belt when riding a motorcycle Clothes with open or loose cuffs may be blown by wind and cause the cuffs to get caught on the steering handle and thus affects riding safety So put on clothes with tight sleeves Hold the steering handle by both hands when riding Never ride with only one hand Observe the speed limit Wear suitable low heel shoes Perform periodical maintenance and inspection in accordance with the schedule WARNING e To avoid getting burned by exhaust pipe when taking a passenger Make sure your passenger has put his her feet on the pedals After running the exhaust pipe is very hot be careful not to get burned when conducting an inspection or maintenance After running the exhaust pipe is very hot select a suitable location to park your scooter to avoid others getting burned by the exhaust pipe Z CAUTION Modified motorcycle will affect its structure or performance and cause poor engine operation or exhaust noise which will result in shortening the motorcycle s service life Besides modification is illegal and does not conform to the original design and specifications A modified motorcycle will not be covered by warranty
11. upper limit if the engine oil has been found to be inadequate e Engine Oil Use API SH CD SAE 10W 30 grade or better engine oil Otherwise damage will not be covered by p an Upper limit hn Lower limit warranty X Recommended Oil SYM Genuine 4X OIL ED e Oil Capacity 0 8 Liter 0 75 liter for routine change e Use SAE 5W 40 when outside temperature is below OC Oil Filter Cleaning The oil filter nut assembly of the element and remove the Oil filter element Remove the foreign materials from the element by using a gasoline or air spraying gun A WARNING Oil level will not be correct when checking the oil level with the motorcycle parked on an unleveled ground or immediately after the engine stopped Filter nut Engine and exhaust pipe are hot right after engine es eE stopped Pay special attention not to get burned when checking or replacing engine oil If the oil lever approach lower limit again after refilled check the engine for leaks and refill it again Keep away from spark and flames when refilling the oil SFUEL INSPECTIONS e Turn main switch key to ON position and check fuel gauge s needle range to make sure there is enough amount of fuel in the fuel tank e This scooter s engine is designed for using the unleaded fuel of Octane 90 or above e Firmly secure the main stand on the ground shut off the engine and keep flames away from the scooter when refueling e Do
12. 8 33N m 6500 rpm 1650 100 rom 0 12 0 02 0 12 0 02 mm Kick amp electrical starter Telescopic fork Unit swing Auto centrifugal type C V T 90 80 16 51J 90 80 16 51J Aluminum Front STD 2 00 kg cm Rear STD 2 00kg cm for 1 person 2 25kg cm for 2 persons Disk type 226 mm Drum type 130 mm Disk type 226 mm HS1 12V 35 35W 12V 5W 12V 10W 12V 5W 12V 21W 12V 5W 0 95 L 0 70 L for change 180 5c c 170c c for change 4 80L 10AX2 A7RC 12V 6Ah closed type maintenance free battery Paper type 24
13. Front Brake lever free play 10 20mm Brake Siar Braking condition Brake lever free play 10 20mm Front Is tire pressure normal Standard 1 75kg cm Tires Rear Is tire pressure normal Standard 2 0 kg cm for 1 person 2 25 kg cm for 2 persons Steering Handle Does the handle vibrate abnormally or is difficult to turn Speedometer lights and rearview Is it operated properly mirror Do lights come on Can it be seen clearly from behind Abnormal Points Do the previous troubles still exist A CAUTION e f any problem founded during routine inspection correct the problem before using the motorcycle again have your motorcycle checked and repaired by the SYM dealer or authorized service personnel if necessary SENGINE OIL INSPECTION AND CHANGE e INSPECTION 1 Use the main parking stand to support the scooter on a level ground remove the dipstick after engine stopped for 3 5 minutes Wipe oil off the dipstick and then insert it into the guide tube again Do not rotate it 2 Remove the dipstick and check whether oil level is in between the upper and lower marks e Add oil to upper limit if oil is under the lower limit Check cylinder crankcase etc for leakage 13 OIL CHANGE e Change engine oil after the first 300km and change the engine oil every 1000km thereafter e In order to maintain the engine s maximum performance check whether the engine oil is enough every 500km Add oil to
14. ODICAL MAINTENANCE SCHEDULE Maintenance 300KM Every Every Every Every kilometer 1000KM 3000KM prea ae Remake It Sn Malntsnanice 1 Month 3 Months Months Months 1 4Year Check Items Interval ees eee 2 Aircleaner e e e S e 3 foilfiter Screen o TE d oe o f 4 Engneoi R Replacementforevery 1000KM___ 5 Tire pressure orn oe y o S e 6 Battery o o e e e S e 7 sparkpug o y S aR 8 Carburetor idlespeed f tT o o e e Steeringbearinganananaies 1 Et oo So o 10 Checktransmissionforteakage 1 f i ooo Too Soo To 11 Check crankcaseforleakage 1 fo tT Too Too To 12 Transmission oil R Replacement for every 5000KM 5 Months 13 Drivebetwroter o S e o S aR S 14 Fueltankswitchandiines i foo o o S o 15 Throttle valve operation and cabe 1 f tT To o Soo To 16 Engnebotsananus n foo or o S S 17 Cylinder head cylinder and piston J Et 18 Exhaustsystemicleaning carbon J To Too o To 19 CamChainignitiontime 1 fo o Tor o S T 20 Vavectearance o tT o e e 21 Shockabsorbers orn oo o o e e 22 Frontrear suspension o tT Et e e 23 Mainsidestans o tm 24 Crankcase Blow bysystem pov 1 f o or oo Soo To 25 femtonaiss o S S e o e e 26 Brake mechanism brake lining pad 1 f i ooo ooo So o 27 Botsmutstoreachcomponens 1 J i do o So So S o yx The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first X Have your scooter checked and adjusted periodic
15. ally by your SYM Authorized Dealer or Franchised Dealer to maintain the scooter at the optimum condition Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Remark 1 Clean or replace the air cleaner element more often when the scooter is operated on dusty roads or in the Heavily polluted environment 2 Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage Notes in the remarks are used to indicate the applicable models 23 17 SPECIFICATION Specification Length Width Height Wheel base Net Weight Model Fuel required Displacement Compression ratio Maximum HP Maximum torque Idling speed Valve clearance IN EX Starting methods Front shock absorber Rear shock absorber Clutch type Transmission Front tire Rear tire Rim type Tire pressure Front brake Rear brake Head lamp high low Front position lamp Front Rear direction indicator Rear position lamp Stop lamp Licence light Engine oil capacity Transmission oil capacity Fuel tank capacity Fuse Spark plug Battery capacity Air cleaner JET 4 125 AD12W 1 6 1986mm 690mm 1137mm 1340mm if with a replacement of handle visor 1355mm 109kg Front 43kg Rear 66kg Single cylinder 4 stroke forced air cooled engine Unleaded gasoline 124 6 c c 10 5 0 2 1 6 25kw 7500 rpm
16. and high temperature SSAFETY HELMET HOOK e Stop the scooter and hook the safety helmet chin belt the hook Hook Z CAUTION e Do not hang the safety helmet onto this hook when riding to avoid damaging motorcycle and loosing safety helmet s function SFUEL TANK CAP 1 Insert the key into the seat lock and open the seat and turn the fuel cap anticlockwise then the cap can be removed 2 Do not fill above the fuel upper limit when refueling 3 Align the A mark on the cap with the mark on the fuel tank then turn the fuel cap clockwise and lock the seat Z CAUTION e Main stand should be put down on the ground engine should be shut off and flames should be strictly prohibited to ensure safety when refueling Do not fill above fuel upper limit when refueling Otherwise fuel will flow out through a hole on the cap that may damage the body s painting in serious cases it serious cases it may cause a fire to burn down the motorcycle Make sure the fuel cap has been tighten properly SBRAKES e Avoid unnecessary sudden braking e Use front and rear wheel brakes simultaneously when braking e Avoid brake continuously for a long period of time because that may overheat the brakes and reduce its braking efficiency e Slow down and brake early when riding in rainy days on slippery roads Never apply the brakes suddenly to prevent skidding and falling e Using only the front brake or the rear brak
17. ary to press starting lever or starter button several times and keep the throttle valve handle at the close position to start the engine It may need several minutes to warm up engine if it is a cold start Exhaust contains harmful gases CO therefore please start the engine at a well ventilated place When starting engine with starting lever e After step 1 5 is completed press the kick starter forcefully by foot with the throttle valve handle at the close position e f engine is difficult to start with the starting lever when the engine is cold rotating the throttle valve 1 8 1 4 turns will make the start easier e Put the kick starter back to its original position after the engine has been started Z CAUTION Firmly support the motorcycle with the main parking stand before starting the engine with the kick starter arm Starter engine with the kick starter arm occasionally to prevent it from loosing its function because of unused for a long time 11 9 THE BEST WAY TO DRIVE OFF e Turn on the turn signal light before moving and make sure no vehicle is coming from behind Then drive off STHE CONTROL OF THROTTLE VALVE HANDLE Acceleration To increase speed When riding on an inclined road turn the throttle valve handle slowly to allow the engine to output its power Deceleration To decrease speed Deceleration PARKING METHOD e When approaching the parking lot 1 Turn on the turn signal
18. e turn it to left to the lock position key away with you before e The steering handle is locked in this position you lock your seat e Ignition switch key can be removed e When unlocking simply turn the key from the LOCK position to the OFF position CAUTION e Never operate the ignition switch key when the motorcycle is running To turn the ignition switch to OFF and LOCK position will shut off the electrical system and that may result in a dangerous accident Therefore the ignition switch can only be turned off after the motorcycle has been completely stopped e Always remove the key and be sure to take the key away with you after locking the steering handle before leaving your motorcycle If ignition switch remains in the ON position for a prolonged period after the engine has been stopped the battery s capacity will be reduced and this may affect the engine s start ability e Make sure to take the key away with you before you lock your seat SUSE OF BUTTONS High low beam switch Turn Signal Switch Horn Switch Electrical starter button e Light Switches Fea When the switch is turned to this position as the engine is being started headlight rear light e instrument panel light and position light will come on This is the high beam of headlight switching switch When the switch is turned to this position as the engine is being started rear light instrument
19. e increases the risk of falling because the scooter is tend to pulled to one side Engine Brake Return the throttle valve handle back to its original position and apply engine brake It is necessary to apply brake both for front wheel and for rear wheel intermittently when riding on a long or stiff slope For Rear Wheel For Front Wheel 10 8 IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE Z CAUTION e Please check the oil and fuel volume are adequate or not before starting the engine e To start the engine the main parking stand must be firmly on the ground and the brake is applied on the rear wheel to prevent the motorcycle from moving forward suddenly 1 Turn ignition switch key to the ON position 2 Apply hand foot rear wheel brake 3 Do not accelerate press starter button when the brake is applied Z CAUTION If engine can not be started after press the kick starter arm for 3 5 times turn the throttle valve handle 1 8 1 4 turns and then press the kick starter arm again for an ease start In order to avoid damaging the starter motor please do not press the starter button continuously over 15 seconds If engine still can not be started after pressing starter button over 15 times stop and wait for 10 seconds before start it again It is harder to get the engine started after the motorcycle has been left idle for a long time or after refueling only after the fuel has been depleted Then it is necess
20. e location usually are the same Time meter Speedometer Turn Left Signal Indicator Turn Right Signal Indicator ae Jsa Odometer Trip kilometer Fuel meter A CAUTION Do not wipe plastic components e g instrument panel headlight with organic solvents such as gasoline etc to avoid damaging these components e Speedometer Indicates driving speed e Odometer Indicates total accumulated distance traveled e Trip Kilometer The rider can measure the trip kilometers e High Beam Indicator This indicator comes on with high beam headlight is turned on e Turn left right Signal Indicator The left or right Indicator will be flashing according to the operated directions of turn signal light switch when it is turned on e Fuel Meter The pointer in this meter shows how much fuel remains in the tank The pointer stays in E position when key switch is turned to OFF SOPERATION OF IGNITION SWITCH ON position IGNITION SWITCH e Engine can be started in this position e Ignition switch key can not be removed OFF position e Engine is shut off and can not be started in this position e Ignition switch key can be removed SOPERATION OF STEERING HANDLE LOCK SWITCH Steering handle lock position fi e Turn the steering handle to left and insert the key into A CAUTION press ignition switch key clockwise and then lightly Make sure to take th
21. eeseess 19 Checking the pDrakedight aiir Lis ad his a ote Sa ie ae Sole 19 1 CONTENTS Checking for fuel leakage cccceccecceecceecceceeeceeceeceueceeceeseeecsecueeseeceeseeseeeneesanseees 20 Checking the lubrication of body s various mechanisms ccceceeeceeeeeceeeeeeeeeeees 20 CHECKING the Spark PUG araura a cawiea dar cetionctesd ade EE 20 Checking the air cleaner cc cecceecceccecceeeceeceeceeccueceeceueceeseeseuecseseeseeeceeseeseeeceesensaes 20 11 When there is an abnormal Condition or a trouble 00 ec ec cece eee eeeeeeeeeeeeeneeseeeaees 21 Diagnosis when engine does not Start cccceccecceceeceeeeceeeeeeeeeeeeeeeeeeeeeseeeeseeeeenees 21 12 C D I electrical ignition system ccccccceccecceecceeeeeseeeceeceeseeeceeseeseeeceeseeseeeceesensaes 21 13 Suggestions on engine fuel cee cecceecceeeceeceeceeceeeceeseeceeeceeseeseueseeseeseeeceesensass 21 AG Tans mMmiISSionMmOll ssa a a A E E at amen S 21 15 Cautions for iding SC0OtEr sirnana ea a a a a dudes E 22 16 Periodical maintenance SCHEUIE ccccecceececcecceeeceeceeceeeeeecueseeseueseeeuseeeeseeseeees 23 MiP OCCMICAUOMNM sosaren aaa Rath tO oie Meek haat nate A a hatha a aaa ae a 24 2 CONTROL LOCATION MODEL AD12W1 6 Helmet hook Storage box Front turn signal light Front light Air Cleaner Position light Rn Side stand Engine number Kick starter pedal Engine start
22. erosion off with a steel brush or a piece of sandpaper Install battery cable after cleaning and apply a thin coat of grease on the terminals Install battery in reverse order of removal e The scooter is equipped with a maintenance free type battery so it is unnecessary to check and add electrolyte Have your scooter checked by SYM Authorized Dealer or Franchised Dealer should any abnormality is found A CAUTION This is a closed type battery Never remove the caps In order to prevent electric leakage and self discharge when the battery sits idle for long periods Remove battery from motorcycle store it in well ventilated and dimly lighted place after the battery has been fully charged Disconnect battery s negative cable if the battery is still kept on the motorcycle If the battery needs to be replaced replace with a same closed type battery Maintenance Free 17 TIRE INSPECTION Tires should be checked and inflated with the engine shut off If a tire s ground contacting curve is abnormal check it with an air pressure gauge and inflate it to the specified pressure Tires pressure must be checked with an air pressure gauge when cold Foreign materials e Visual check tires for frontal and lateral side walls for nails or small Crack and crack or damage stones damage Visual check tires for any nails or small stones wedged in the tread e Check the tread wear indicator condition to see if
23. he brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk Brake pad wear limit grooves Brake caliper Brake disk Replenishment of front wheel brake fluid 1 Loosen the screws and remove the master cylinder cover 2 Wipe clean foreign materials dirt around the reservoir being careful not to let foreign materials fall into the reservoir 3 Remove the diaphragm plate and the diaphragm 4 Add brake fluid to upper lever 5 Install the diaphragm plate and the diaphragm and install the master cylinder cover 6 please note the diaphragm direction and do not let foreign materials fall into the reservoir And tighten the master cylinder cover securely Z CAUTION repairing or service CAUTION Please drive your motorcycle on a dry road surface slowly and operate front and rear brakes in order to find out if there is any malfunction so as to ensure the motorcycle is at optimum condition and safe ride Checking oil quantity in brake oil reservoir e Park the scooter on a lever ground and check if fluid lever is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 Screw cover Diaphragm rake fluid e TO prevent chemical reaction please do not use brake fluids other than those recommended e Do not fill above the upper limit when adding brake fluid and avoid dropping on painting or plastic components to prevent da
24. ing of twin signal lights may confuse the drivers of vehicles behind SCHECKING THE FRONT AND REAR LIGHTS e Start engine and turn on the head lamp switch Check if head lamp and rear lamp come on e Check the brightness and direction of front light by wall to see if it is correct e Check the head lamp cover if it is dirty crack or loosen CHECKING THE BRAKE LIGHT e Turn the ignition switch key to the ON position hold the hand braking levers for front and rear wheels Check if the brake lights come on e Check the brake light cover if it is dirty crack or loosen Z CAUTION e Use only specified specification bulbs do not use bulbs with different specifications to avoid damaging electrical system burning out bulbs and discharging the battery Do not modify or add other electrical components to prevent over load or short circuit which may result in a fire and burn down the motorcycle in serious cases 19 SCHECKING FOR FUEL LEAKAGE e Check fuel tank fuel cup fuel hose carburetor for leakage SCHECKING THE LUBRICATION OF BODY S VARIOUS MECHANISMSS e Check the body s pivot points if they have enough lubrication for example the pivot points on the main stand the side stand and the brake lever etc S CHECKING THE SPARK PLUG e Remove the cap of spark plug cable remove the spark plug using the spark plug wrench in the tool kit e Check the electrode if it is dirty or fouled by carbon deposit
25. light early and pay attention to the vehicles in front from rear left and right then take the inner lane and approach slowly 2 Return the throttle valve handle back to its original position and apply brakes in advance Brake light comes on when braking to warn drivers of vehicles behind e When stop completely 3 Press the turn signal switch back to its original position and turn the ignition switch key to the OFF position to shut off the engine 4 Get off the scooter from left side after the engine has been stopped and select a parking place where the scooter will not interfere with traffic and the ground is level then put down scooter s main parking stand 5 Hold the steering handle with your left hand and hold down the front end of saddle or hold the parking handle on the lower left side of saddle with your right hand 6 Press the main parking stand with your right foot put down the main parking stand firmly on the ground To remind you Lock the steering handle and remove the key after parking to prevent the scooter from being stolen A CAUTION e Park your motorcycle at a safe place where it will not interfere with traffic 12 10 INSPECTION AND MAINTENANCE BEFORE RIDING Please refer to the components location diagram for the following components SROUTINE INSPECTION Check Items Check Key Points Engine Oil Is there enough engine oil Is it enough Is it Octane 90 or above Braking condition
26. mage 16 STHROTTLE VALVE HANDLE CLEARANCE ADJUSTMENT e Correct clearance allows throttle vale handle to rotate 2 6mm e Loosen the lock nut first then turn the adjust nut to adjust Tighten the lock nut securely when finished Check Items Check throttle valve cable to see if it can be moved smoothly from a closed position to a wide open position Rotate steering handle from side to side to check if the throttle valve cable is interfered Check to see if the throttle valve cable is obstructed by other cables preventing it from being operated smoothly Adjust nut Lock nut SINSPECTION AND MAINTENANCE OF BATTERY e The scooter is equipped with a maintenance free type battery so it is unnecessary to check and add electrolyte Have your scooter checked by SYM Authorized Dealer or Franchised Dealer should any abnormality is found Cleaning of battery terminals e Remove the battery terminals and clean if there are dirt and corrosion on them O e Battery removal procedures are as follows 4 Turn ignition switch to the OFF position then remove if negative cable screw firstly and disconnect the negative Negative cable Then remove positive cable screw and positive UN cable Positive Z CAUTION Clean the battery posts with warm water if the posts are eroded and have some white powders on them If there is an obvious erosion on the terminals disconnect the cables and then clean the
27. pecified for loading to avoid damage SUGGESTION To maximize the motorcycle s performance and prolong its service life The first month or first 1000km is the wear in period for the engine and components Avoid rapid acceleration and keep the speed below 60km hr 6 USE GENUINE SPARE PARTS In order to maintain the scooter s best performance each part s quality material and machined precision must conform with the design requirements SYM Genuine Spare Parts were made from the same high quality materials used for the original scooter No parts would be sold to the market until they could meet the designed specifications through sophisticated engineering and stringent quality control Therefore it is necessary to purchase SYM Genuine Spare Parts from SYM Authorized Dealers or Franchised Dealers when replacing spare parts If you buy cheap or fake substitute parts from the market no guarantee can be provided either for the quality or durability Also it may result in unexpected troubles and lower the scooter s performance Always use SYM Genuine Spare Parts to keep your scooters pure blood and to ensure its long service life 7 USE OF EACH COMPONENT The following is SYM 4 stroke air cooling 125 c c scooter s basic operation and they could vary from different individual models Please consult the end of this manual SGAUGES The panel figure for soeedometer may vary from model to model but th
28. r and pull out the fuse Check it for damage or broken e Fuses must be firmly secured with wire connectors when replacing Loose connections will result in overhead and damage e Use only parts having the specified specification to replace electrical components such as light bulbs Using parts not having the specified specifications for replacement may cause the fuse to blow and over discharge the battery e Avoid spraying water directly on or around fuse box when washing the scooter e Ifthe new fuse burn out quickly again please check the faulty reason before replace it again Take your scooter to your dealer for an inspection if a fuse is blown by unknown causes REMOVE INSTALLATION Press in from above SCHECKING THE TURN SIGNAL LIGHTS AND HORN e Turn the ignition switch key to the ON position e Turn on the turn signal light switch and make sure that the front amp rear and left amp right signal lights flashes and also check if the warning buzzer sounds e Check turn signal light covers if they are dirty crack or loosen e Press horn button to check if it works Z CAUTION Specified specification bulbs should be used for turn signal lights Otherwise the normal operation of turn signal lights will be affected Turn on the turn signal light before turning or switching lane to warn driver of vehicles behind Turn off the turn signal light immediately by pressing its button down after using Otherwise the flash
29. raking pedal from no braking to initial braking should be 20 30mm It is abnormal if the feel is spongy when press the foot braking pedal forcefully 40 20mm Fy FOR REAR BRAKE FOR FRONT BRAKE 10 20mm Adjustment Drum type e The indentation of brake adjustment nut must be aligned with the pin see below figure Adjustment nut CAUTION When free play is between 10 20 mm check brake indicators of front and rear wheels If the arrow on the brake arm aligned with the marked on the brake disk that means the brake lining has been excessively worn and must be replaced immediately e Turn the adjustment nut on brake arm of front and rear wheels to adjust the free play of hand brake lever e Hold the hand brake levers after adjusting with both hands until there is effective brake feeling e Measure the free play with a ruler 2 y To increase tee Adjustment nut Rear Wheel drum brake type 15 DISK BRAKE INSPECTIONS Applicable for model equipped with disc brake e Visual check brake lines for leakage or damage check brake lines connections for looseness using a wrench or similar tool and check whether steering handle vibration in driving or any parts interference may have damage the brake lines If so bring your scooter to your SANYANG dealer for leak damaged looseness of brake line Checking front brake lining e check the brake from behind the brake caliper T
30. s e Remove the carbon deposits on the electrode with steel wire and clean the spark plug with gasoline then wipe dry with a rag e Check the electrode and adjust its gap to 0 6 0 7 mm Check it with a feeler gauge e Hand tight the spark plug as far as it can go and then tighten it another 0 6 0 7 mm 1 2 3 4 turns with a wrench Z WARNING The engine is very hot after running Pay attention not to get burned X Use only spark plugs suitable for the engine specifications of this motorcycle recommended by the manufacturer Refer to specifications SCHECKING THE AIR CLEANER Sorews DISASSEMBLE PRCEDURE 1 Remove tapping screws from air cleaner cover 2 Remove the air cleaner cover remove the element screws then remove filter element 3 Take the element out and clean it Refer to maintenance schedule DISASSEMBLE PRCEDURE e Assemble the air cleaner in reverse order of disassemble A CAUTION Dust deposit is one of the major causes of reducing output horsepower and increasing fuel consumption Change the air cleaner element more frequently to prolong the engine s service life if the motorcycle is driven on dusty roads very often If air cleaner is installed improperly dust will be absorbed into cylinders which may cause a premature wear and reducing output power and engine life Be careful not to soak the air cleaner when washing the motorcycle Otherwise it will cause engine hard to start
31. tread groove depth is insufficient e A tire with a wear bar showing is worn out and should be Tread wear replaced immediately indicator Z CAUTION Abnormal tire pressure wear or crack is the most important cause that results in the loss control of the steering handle and a punctured tire s STEERING HANDLE FRONT SHOCK ABSORBERS INSPECTION Perform this check with engine shut off and ignition switch key removed Visual check front shock absorbers for damage Operate steering handle up and down and check front shock absorbers for noises due to bends Check the bolts and nuts of front shock absorbers with wrenches for tightness Shake steering handle up amp down left amp right and front amp rear to check if it is loosen has too much resistance and pulls to one side Check steering handle if it is being pulled too tight by the brake cables Take your scooter to SYM Authorized Dealer or Franchised Dealer for a check or adjustment if any abnormal conditions are found 18 S CHECKING AND CHANGING FUSES Turn off ignition switch and check fuses if they are intact Replace the blown fuse with a new one having the same specified amperage rating 7A Using a fuse of more than 7A amperes a brass or iron wire to replace a blown fuse is strictly prohibited to avoid damaging the electrical system and the circuit e Remove the storage box and you ll find the fuse holder near battery e Open the fuse box cove
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