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Sym ComBiz 125 Manual

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1
1. Contents
1. Contents ........................................................................................................................ 1
2. Control Location ............................................................................................................ 3
3. Before Riding ................................................................................................................ 4
4. Safe Riding .................................................................................................................... 4
5. Driving ........................................................................................................................... 5
6. Use Genuine Spare Parts ............................................................................................. 5
7. Use of Each Component ............................................................................................... 6
Gauges ........................................................................................................................... 6
Operation of Ignition Switch ............................................................................................... 7
Use of Buttons ................................................................................................................. 8
Fuel Tank Cap ............................................................................................................... 10
Set Lock ........................................................................................................................ 10
Storage Box .................................................................................................................... 11
Safety Helmet Hook.......................................................................................................... 11
Rear Seat -Carrier............................................................................................................ 11
Brake ............................................................................................................................ 12
Rear Cushion Hardness Setting ........................................................................................ 12
8. Important Points and Cautions for Starting Engine ..................................................... 13
9. The Best Way to Drive off ........................................................................................... 14
The Control of Throttle Valve Handle ................................................................................. 14
Parking Method .............................................................................................................. 14
10. Inspection and Maintenance before Riding ................................................................. 15
Routine Inspection .......................................................................................................... 15
Engine Oil Inspection and Change .................................................................................... 15
Fuel Inspection .............................................................................................................. 16
Transmission Oil Inspection and Change ........................................................................... 16
Inspection and Adjustment of Brake Free Play ................................................................... 17
Disc Brake Inspection ...................................................................................................... 17
Throttle Valve Handle Clearance Adjustment ..................................................................... 18
Inspection and Maintenance of Battery .............................................................................. 19
Tire Inspection ............................................................................................................... 20
Steering Handle Front Shock Absorbers Inspection ............................................................. 20
Checking and Changing Fuses ......................................................................................... 21
Checking the Turn Signal Lights and Horn ......................................................................... 21
2
1. Contents
Checking the Front and Rear Lights .................................................................................. 22
Checking the Brake Light ................................................................................................. 22
Checking for Fuel Leakage .............................................................................................. 22
Checking the Lubrication of Body’s Various Mechanisms ..................................................... 22
Checking the Spark Plug ................................................................................................. 22
Checking the Air Cleaner ................................................................................................. 23
Checking the Left Crankcase Cover Air Cleaner ................................................................. 23
11. When there is an Abnormal Condition or a Trouble .................................................... 24
Diagnosis when Engine does not Start .............................................................................. 24
12. C.D.I. Electrical Ignition System .................................................................................. 24
13. Suggestions on Engine Fuel ....................................................................................... 24
14. Transmission Oil ......................................................................................................... 24
15. Cautions for Riding Scooter ........................................................................................ 25
16. Periodical Maintenance Schedule ............................................................................... 26
17. Specification ................................................................................................................ 27
3
2. Control location
Tail light/
Turn signal light
Fuel tank cap
Muffler
Rear brake lever
Front brake lever
Turn signal light /
Horn switch /
High & Low beam/
Passing
Light / Starter switch / seat open
Ignition
Seat lock
Storage Box
Fuses& Battery
Engine number
Turn signal light
Headlight
Oil level
Frame
number
4
3. Before riding
4. Safe 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:
• Correct use of the scooter.
• Pre-delivery inspection and maintenance.
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.
We recommend that after riding your new scooter for the first 300 kilometers, you should take your
scooter to the original dealer for an initial inspection, and to have your scooter inspected periodically
every 1,000 kilometers thereafter.
• In case 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 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.
To remind you:
• Please wear a safety helmet, and properly tighten the chin belt when riding a scooter.
• 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!!
• 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.
CAUTION:
Modified scooter will affect its structure or performance, and cause poor engine operation or exhaust
noise, which will result in shortening the scooter’s service life.
Besides, modification is illegal and does not conform to the original design and specifications.
A modified scooter will not be covered by warranty, therefore, do not modify your scooter at will.
5
5. Driving
6. Use genuine spare parts
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.
•
Rider’s 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.
•
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.
•
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.
•
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.
CAUTION:
• Do not place flammable materials such as rags between the body side cover and engine to avoid
components damaging by fire.
•
Do not load objects on areas not specified for loading to avoid damage.
SUGGESTION
To maximize the scooter’s performance and prolong its service life:
The first month or first 1,000km 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.
6
7. Use of each component
(The following is SYM 4 stroke air cooling ComBiz. scooter’s basic operation, and they could vary from
different individual models. Please consult the end of this manual.)
Gauges
CAUTION :
• Before battery installation, please do not use the kick starter to start the engine, in prevention.
• Not to have trouble on electrical meter working, or damage the electrical meter.
• Do not wipe plastic components, e.g. instrument panel, headlight, with organic solvents such.
• As gasoline…etc. to avoid damaging these components.
• INFORMATION OF THE GAUGE BOTTON
Speedometer
This shows your speed in kilometers per hour (km/h) and in mileage per hour (mph).
Odometer
This odometer shows the total kilometers this motor has been driven.
High Beam Indicator
This indicator comes on with high beam headlight is turned on.
Turn 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.
Fuel Gauge：
The fuel gauge doesn’t come on when the main switch is at “OFF” position.
When key switch is turned to “ON”, and the “pointer” also in “E” position (red area). Refuel octane
92/95/98 unleaded gasoline immediately.
High Bean
Indicator
Oil change
indicator
Speedometer
Fuel Gauge
Turn Signal
Indicator
Odometer
7
7. Use of each component
OPERATION OF IGNITION SWITCH
IGNITION SWITCH IGNITION SWITCH KEY
MAGNETITE KEY
：
：：
：
Insert your magnetite key into the magnetite keyhole, and turn it to right ignition keyhole block board
can be to open.
When close ignition keyhole. You just push the Ignition keyhole block board push rod, and ignition
keyhole can be to close.
"Start" position
• Engine can be started in this position.
• Ignition switch key can not be removed.
"Stop" position
• Engine is shut off and can not be started in
this position .
• Ignition switch key can be removed.
"Steering handle lock" position
• Turn the steering handle to left and press
ignition switch key down and then lightly turn it
to left to the “LOCK” position.
• The steering handle is locked in this position.
• Ignition switch key can be removed.
• When unlocking, simply turn the key from
“LOCK” to “OFF.”
"OPEN" position (fuel tank cap open)
：
• How to open：Insert your key into the ignition switch, and turn it to the left.
• How to lock：Push the fuel tank cap and it locks automatically.
CAUTION:
• Never operate the ignition switch key when the scooter is running. To turn the ignition switch to
“OFF” and “LOCK,” 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 scooter has been
completely stopped.
• Always remove the key and be sure to take the key away with you after locking the steering
handle before leaving your scooter.
•
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.
8
7. Use of each component
USE OF BUTTONS
• Light Switches
When the switch is turned to this position as the engine is being started, headlight, rear light,
instrument panel light, and position light will come on.
Note:
Position Light Function:
This light can indicate the scooter position when the scooter is running in dim, rainy, or foggy weather.
When the switch is turned to this position as the engine is being started, rear light, instrument
panel light, and position light will come on.
When the switch is turned to this position, all lights will go off.
• 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.
CAUTION:
• Release this button immediately after engine has been started, 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 lights to the “OFF” position when the
engine is being started.
High/Low Beam
Switch
Turn signal
switch
Horn switch
Electrical starter
button
Light switch
9
7. Use of each component
• High/Low Beam Switch
This is the high and low beam of headlight switching switch. Press this switch to switch between high
and low beams.
This is for high beam.
This is for low beam. (Please turn to low beam when riding in city)
• Passing Switch
Turn ignition switch “ON” and press this button down. Then, the high beam of headlight will
come on immediately to warn the driver of the vehicle ahead that you intend to overtake
him/her. (For overtaking, high beam indicator will come on at this time) This button will return
to original position after releasing.
• Horn Switch
Press this button down when ignition switch is in the “ON” position, the horn will sound.
CAUTION:
Do not press this button when you are in the area where there’s no honking.
• Turn Signal Switch
Turn signal lights are used when turning left/right or changing lane.
Turn ignition switch to “ON”, 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.
Right-side turn signal light flashing means you intend to make a right turn.
Left-side turn signal light flashing means you intend to make a left turn.
10
7. Use of each component
FUEL TANK CAP
Insert ignition switch key into the ignition switch,
and turn the key to the left, then the cap can be
removed.
Do not fill above the fuel upper limit when
refueling.
Turn the fuel tank cap right, and simply push the
fuel tank cap. Fuel tank cap can be locked.
CAUTION：
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 may cause a fire to burn down the scooter.
Make sure the cap has been tighten properly.
This model has a reserve tank device. The fuel indicator will not move before the fuel in the reserve tank
running out. After the fuel in the reserve tank running out, it is normal that the indicator drops
down a little faster.
SEAT LOCK
Unlock： Insert the ignition switch key into lock located under seat left (front) and turn to right to unlock.
Lock：Press the saddle down and it will be locked automatically.
```````````````
CAUTION！！
！！！！
！！
Be sure to remove the key after the seat has been locked.
Do not put the key inside the storage box after unlocking to avoid the key being locked inside the storage
box when the saddle is pressed down automatically.
Fuel tank cap
STORAGE BOX
This box is located under the seat.
Maximum load capacity: 10kg.
Make sure that the seat has been locked
completely after it was pressed down.
Do not place thermal sensitive objects in the box
because of engine’
Do not store valuables in the box.
Take out valuables before washing to avoid wetting
these objects.
SAFETY HELMET HOOK
Open the seat, and hook the safety helmet chin belt
onto the hook, and then lock the seat.
CAUTION！！
！！！！
！！
Do not hang the safety helmet onto this hook
when riding to avoid damaging scooter and
loosing safety helmet’s function.
REAR SEAT-CARRIER
For carrying goods:
1. Put the hands on the both sides of the rear seat (A
points) and pull the rear seat up. When the hook on the
seat is released from the spring holder on the carrier, the
rear seat can stand vertically.
2. Release the rear seat when it stands vertically.
Meanwhile, the rear seat will be pulled to the fixing
position by the spring.
Caution！！
！！！！
！！
Pay attention while riding with carrying goods.
Standing rear seat is designed for carrying goods. Do
not use the standing rear seat as the back seat.
Obey the weight limit of the carrying goods (maximum
30kg).
BRAKE
Avoid unnecessary sudden braking.
Use front and rear wheel brakes simultaneously
when braking.
Slow down and brake early when riding in rainy
days on slippery roads. Never apply the brakes
suddenly to prevent skidding and falling.
Avoid brake continuously for a long period of time
because that may overheat the brakes and reduce
its braking efficiency.
CAUTION！！
！！！！
！！
Using only the front brake or the rear brake increases the risk of falling because the scooter is tend to
pulled to one side.
13
8. Important point and cautions for starting engine
CAUTION！！
！！！！
！！
Please check the engine oil and fuel volume are adequate or not before starting engine.
To start 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 rear wheel brake.
3. Do not accelerate, press starter button when the brake is applied.
CAUTION！！
！！！！
！！
If engine can not be started after starter motor running for 3~5 seconds, turn the throttle valve handle
1/8~1/4 turns, and then press starter button again for an ease start.
In order to avoid damaging the starter motor, please do not press the starter button continuously over
15 seconds.
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 necessary 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】
】】
】
After step 1 is completed, press the starting lever forcefully by foot with the throttle valve handle at the
close position.
If 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.
Put the starting lever back to its original position after the engine has been started.
1/4
1/8
14
9. The best way to drive off
• Turn on the turn signal light before moving, and make sure no vehicle is coming from behind.
Then, drive off.
THE 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.
PARKING METHOD
• When approaching the parking lot:
1. Turn on the turn signal 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.)
• When stop completely:
3. Press the turn signal switch back to its original position, and turn the ignition switch key to “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.
CAUTION:
• Park your scooter at a safe place where it will not interfere with traffic.
Deceleration
Acceleration
15
10. Inspection and maintenance before riding
(Please refer to the components location diagram for the following components.)
ROUTINE INSPECTION
Check Items Check Key Points
Engine Oil Is there enough engine oil?
Fuel Is it enough? Is it Octane 90 or above
Front
Braking condition?
(Brake lever free play: 10~20mm)
Brake
Rear
Braking condition?
(Brake lever free play: 10~20mm)
Front
Is tire pressure normal?
(Standard: 1.75kg/cm
2
)
tires
Rear
Is tire pressure normal?
(Standard: 2.0 kg/cm
2
for 1 person, 2.25 kg/cm
2
for 2 persons)
Steering Handle
Does the handle vibrate abnormally or is difficult to turn?
Speedometer, lights,
and rearview mirror
Is it operated properly?
Do lights come on? Can it be seen clearly from behind?
Tightness of Main
Components
Are screws, nuts loosen?
Abnormal Points Do the previous troubles still exist?
CAUTION:
• If any problem founded during routine inspection, correct the problem before using the scooter again,
have your scooter checked and repaired by the “SYM dealer or authorized service personnel” if
necessary.
ENGINE OIL INSPECTION AND CHANGE
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.
Add oil to upper limit if oil is under the lower limit. (Check cylinder, crankcase…etc for leakage.)
OIL CHANGE:
• Change engine oil after the first 300km, and change the engine oil
every 3,000km thereafter. Clean oil filter after the first 300km, and
clean oil filter every 6,000km.
• In order to maintain the engine’s maximum performance, check
whether the engine oil is enough every 500km. Add oil to upper
limit if the engine oil has been found to be inadequate.
• Engine Oil : Use API SJ, SAE 10w-40 grade or better engine oil.
Otherwise, damage will not be covered by warranty.
※ Recommended Oil: SYM Genuine EXTRA 4X OIL.
• Oil Capacity :1.0 Liter (0.8 liters for routine change),
oil filter change: 0.8 liters.
Upper
Lower
16
10. Inspection and maintenance before riding
【Oil Filter Cleaning】
Open the filter nut assembly of the element, and
remove the element. Remove the foreign materials
from the element by using a gasoline or air spraying
gun.
WARNING:
• Oil level will not be correct when checking the oil level with the scooter parked on an unleveled
ground or immediately after the engine stopped.
• Engine and exhaust pipe are hot right after engine stopped. Pay special attention not to get burned
when checking or replacing engine oil.
FUEL INSPECTION
• 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.
• This scooter’s engine is designed for using the unleaded fuel of Octane
90 or above.
• Firmly secure the main stand on the ground, shut off the engine and
keep flames away from the scooter when refueling.
• Do not fill above fuel upper limit level when refueling.
• Make sure the fuel tank cap had been tighten properly.
TRANSMISSION OIL INSPECTION AND CHANGE
INSPECTION:
• Use the main stand to support the motorcycle 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: 110 cc. / at change: 90~100 cc.).
OIL REPLACEMENT:
Stop the engine and use the main stand to support your motorcycle on a level ground. Remove the
infusion bolt and drain bolt, drain out the oil.
Install the drain bolt and tighten it. Fill new transmission oil (90~100 cc.), and install the infusion
bolt and tighten it. (make sure that bolts are tightened and check that there’s no leakage.)
※ Recommend Oil: Genuine SYM HYPOID GEAR OIL (SAE 85W-140).
※ Use SAE85W-90 when outside temperature is below 0℃.
Fuel tank cap
Fuel tank
17
10. Inspection and maintenance before riding
INSPECTION AND ADJUSTMENT OF BRAKE FREE PLAY
INSPECTION: (Brake lever free play must be checked with the engine shut off.)
• Brake lever free play for front and rear wheels
When checking the hand-braking lever for front and rear 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.
DISK BRAKE INSPECTION (Applicable for model equipped with disc brake.)
(Leak, damaged, looseness of brake line)
• 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
repairing or service.
CAUTION:
• Please drive your scooter 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 scooter is at its optimum condition and safe to ride.
10~20 mm
Hose connection
18
10. Inspection and maintenance before riding
﹙
﹙﹙
﹙Checking front brake lining﹚
﹚﹚
﹚
﹙
﹙﹙
﹙Checking oil quantity in brake oil reservoir﹚
﹚﹚
﹚
• Check the brake from behind the brake
caliper. The brake pad must be replaced with
new lining when the brake pad wear limit
reaches the brake disk.
• Park the scooter on a level ground, and check
if fluid level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN
BRAKE OIL (DOT 3).
﹙
﹙﹙
﹙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 level.
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.
CAUTION:
• To prevent chemical reaction, please do not use brake fluids other than those recommended.
• Do not fill above the upper limit when adding brake fluid and avoid dropping on painting or plastic
components to prevent damage.
THROTTLE VALVE HANDLE CLEARANCE ADJUSTMENT
• Correct clearance allows throttle vale handle to rotate 2~6mm.
• Loosen the lock nut first, then turn the adjust nut to adjust.
Tighten the lock nut securely when finished.
Check Items:
1. Check throttle valve cable to see if it can be moved smoothly
from a closed position to a wide open position.
2. Rotate steering handle from side to side to check if the throttle
valve cable is interfered.
3. Check to see if the throttle valve cable is obstructed by other
cables preventing it from being operated smoothly.
Brake disk
Upper
Brake fluid
Diaphragm
Master
cylinder cover
Screw
Brake caliper
Brake pad wear
limit grooves
2~6mm
Lock nut
Adjust nut
19
10. Inspection and maintenance before riding
INSPECTION AND MAINTENANCE OF BATTERY
• This 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﹚
﹚﹚
﹚
Remove the battery terminals and clean if there are
dirt and corrosion on them.
Battery removal procedures are as follows:
Turn ignition switch “OFF”, then open the battery
cabinet door, and remove negative cable screw
firstly and disconnect the negative cable. Then,
remove positive cable screw and positive cable.
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, then clean the 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.
• This 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.
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 scooter, store it in a 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 scooter.
• If the battery needs to be replaced, replace with a same closed-type battery (Maintenance-Free).
Negative
Positive
20
10. Inspection and maintenance before riding
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.
PLEASE REFER TO SPECIFICATIONS FOR STANDARD TIRE PRESSURE
• Visual check tires for frontal and lateral side
walls for crack or damage.
• Visual check tires for any nails or small stones
wedged in the tread.
• Check the “tread wear indicator” condition to see
if tread groove depth is insufficient.
• A tire with a wear bar showing is worn out and
should be replaced immediately.
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 & down, left & right, and front & 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.
Tread wear
indicator
Crack and
damage
Foreign
materials (nails
or small stones)
21
10. Inspection and maintenance before riding
CHECKING AND CHANGING FUSES
Turn the main switch off and check if the fuse blows. Replace the blown fuse with the specified fuse. Do
not use a fuse of a different capacity. Do not use copper wire or any other substitute for the fuse.
• Remove the storage box, and you’ll find the fuse box near light.
• Open the fuse box cover, and pull out the fuse. Check it for damage or broken.
• Fuses must be firmly secured with wire connectors when replacing. Loose connections will result in
overhead and damage.
• 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.
• Avoid spraying water directly on or around fuse box when washing the scooter.
• Take your scooter to your dealer for an inspection if a fuse is blown by unknown causes.
CHECKING THE TURN SIGNAL LIGHTS AND HORN
• Turn the ignition switch key to “ON” position.
• Turn on the turn signal light switch, and make sure that the front & rear and left & right signal lights flashes
and also check if the warning buzzer sounds.
• Check turn signal light covers if they are dirty, crack, or loosen.
• Press horn button to check if it works.
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
flashing of twin signal lights may confuse the drivers of vehicles behind.
Burned fuse
22
10. Inspection and maintenance before riding
CHECKING THE FRONT AND REAR LIGHTS
• Start engine and turn on the head lamp switch. Check if head lamp and rear lamp come on.
• Check the brightness and direction of front light by wall to see if it is correct.
• Check the head lamp cover if it is dirty, crack, or loosen.
CHECKING THE BRAKE LIGHT
• Turn the ignition switch key to “ON” position, hold the hand-braking levers for front and rear wheels.
Check if the brake lights come on.
• Check the brake light cover if it is dirty, crack, or loosen.
CAUTION:
• 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 scooter in serious cases.
CHECKING FOR FUEL LEAKAGE
• Check fuel tank, fuel cup, fuel hoses, carburetor for leakage.
CHECING THE LUBRICATION OF BODY’S VARIOUS MECHANISMS
• 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.)
CHECKING THE SPARK PLUG
• Remove the cap of spark plug cable (remove the spark plug using the spark plug wrench in the tool kit.
• Check the electrode if it is dirty or fouled by carbon deposits.
• Remove the carbon deposits on the electrode with steel wire, and clean the spark plug with gasoline,
then, wipe dry with a rag.
• Check the electrode, and adjust its gap to 0.8 mm. (Check it with a feeler gauge)
• Hand tight the spark plug as far as it can go and then tighten it another 1/2~3/4 turns with a wrench.
WARNING:
The engine is very hot after running. Pay attention not to get burned.
※Use only spark plugs suitable for the engine specifications of this scooter recommended by the
manufacturer. (Refer to specifications.)
0.6~07mm
23
10. Inspection and maintenance before riding
CHECKING THE AIR CLEANER
《DISASSEMBLE PRCEDURE》
1. Remove mounting screws from air cleaner cover.
2. Remove the air cleaner cover, then remove filter element.
3. Take the element out and clean it. (Refer to maintenance schedule.)
《ASSEMBLE PRCEDURE》
• Assemble the air cleaner in reverse order of disassemble.
CHECKING THE LEFT CRANKCASE COVER AIR CLEANER
《DISASSEMBLE PRCEDURE》
1. Remove mounting screws from left crankcase cover.
2. Remove the left crankcase cover, then remove filter element.
3. Take the element out and clean it. (Refer to maintenance schedule.)
《ASSEMBLE PRCEDURE》
• Assemble the air cleaner in reverse order of disassemble.
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 scooter 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 scooter. Otherwise, it will cause engine
hard to start.
Screw
Element
Screw
24
11. When there is an abnormal condition or a trouble
DIAGNOSIS WHEN ENGINE DOES NOT START
(1). Has the ignition switch
key been turned to “ON”
position?
(2). Is there enough fuel in the
fuel tank?
(3). Is the rear or front wheel
brakes applied when
pressing starting button?
(4). Do you rotate the throttle valve handle while
pressing starting the button?
(5). Turn the ignition switch key “ON”, 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
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
• This scooter is designed to use UNLEADED gasoline of Octane No. 90 or higher.
• If 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
• Recommended Oil: Genuine SYM HYPOID GEAR OIL (SAE 85W-140)
Use SAE85-90 when outside temperature is below 0℃.
Turn signal
light switch
Horn button
For Front Wheel
For Rear Wheel
1/4
1/8
25
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.
CAUTION:
• 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 feet firmly on the
ground to prevent the scooter from falling.
CAUTION:
• Apply brake on the rear wheel before driving off.
3. Rotate the throttle valve handle slowly, and then the scooter will begin to move.
CAUTION:
• Rapidly rotate the throttle valve handle may cause the scooter moving forward suddenly and it is
very dangerous.
• Make sure the side parking stand is spring back completely before driving off.
【
【【
【Do not use the brake suddenly and make a sharp turn】
】】
】
• Rapid braking and sharp turning will cause slip and fall.
• 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】
】】
】
• 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.
• 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.
26
16. Periodical maintenance schedule
Maintenance
Mileage
200mi
600mi
2,000mi 4,000mi 8,000mi
Maintenance
kilometer
300km
Every
1,000km
Every
3,000km
Every
6,000km
Every
12,000km
Item
Check Items
Maintenance Interval
NEW 1 Month
3 Months
6 Months
1 Year
Remarks
1
Air cleaner element (Remark) I C R
2
Oil filter (Screen) C C
3
Engine oil R Replacement for every 3,000km or 2,000mi
4
Tire, pressure I I
5
Battery
I I
6
Spark plug I I R
7
Carburetor (idle speed) I I
8
Steering bearing and handles I I
9
Check Transmission for leakage I I
10
Check crankcase for leakage I I
11
Transmission Oil R Replacement for every 5,000km or 3,000mi(5 Months)
12
Drive Belt/roller I R
13
Fuel tank lines and Fuel filter I I
14
Throttle valve operation and cable I I
15
Engine bolts and nuts I I
16
Cylinder head, cylinder, piston and
ignition time
I
17
Exhaust system/cleaning carbon I
18
Cam Chain I I
19
Valve clearance I I
20
Shock absorbers I I
21
Front/rear suspension I I
22
Main/side stands I I/L
23
Crankcase Blow-by system (PCV) I I
24
Coolant I I R
25
Cooling fan, lines I I
26
Clutch disk I
27
Brake mechanism/brake lining (pad) I I
28
Bolts/nuts for each components I I
☆The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference
which ever comes first.
※Have your scooter checked and adjusted periodically 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.】
SYMEN 2011/08
27
17. Specification
Model
ComBiz
Item Specification
AP12W2 series
length 1,920 mm
width 680 mm
Height 1,080mm
Wheel base 1,380 mm
Net Weight 150 kg
Type 4- stroke single cylinder engine
Fuel
UNLEADED(OCTANE 92 OR HIGHER)
Cooling type
Air - cooled
Displacement
124.6cc
Compression ratio
11.2:1
Max. HP
10.2 ps / 8,000 rpm
Max. torque
1.01 kgf-m / 6,000 rpm
Starting methods
Kick & Electrical
Front shock absorber
TELESCOPE
Rear shock absorber
UNIT SWING
Clutch
Centrifugal type
Transmission
CVT
Front tire
110 / 90-10 56J
Rear tire
110 / 90-10 56J
Wheel
Aluminum alloy
Tire pressure
Front: STD 1.75kg/cm
2
,
Rear: STD 2.0 kg/cm
2
for 1 person,2.25 kg/cm
2
for 2 person
Front brake Disk type (Ø 180 mm)
Rear brake Drum type (Ø 130mm)
Front light bulb(high, low) 12V 35W / 35W ×1
Brake light bulb(tail light) 21W
License light bulb 5W
Turn signal light bulb 12V 10W×4
Engine oil capacity 1.0 L (0.8 L for change)
Transmission oil capacity 110 cc. (100 cc. for change)
Fuel tank capacity 5.5 L
Fuse 15A×1
Spark plug NGK CR7HSA
Battery capacity YTX7A-BS / GT7BS-BS 12V 6Ah
Air cleaner Paper type
Fuel tank cap Open lock type
Front light General type (single)
Rear grab frame Can not load cargo
3 …


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