Sym AK12W Series User manual

1
1. CONTENTS
1. Contents ....................................................................................................................... 1
2. Control Location............................................................................................................ 3
3. Before Riding ............................................................................................................... 5
4. Safe Riding ................................................................................................................... 5
5. Driving .......................................................................................................................... 6
6. Use Genuine Spare Parts ............................................................................................ 6
7. Use of Each Component ............................................................................................. 7
Gauges ......................................................................................................................... 7
Operation of Ignition Switch ....................................................................................... 8
Use of Buttons ............................................................................................................. 9
Safety Helmet Hook ................................................................................................... 10
Saddle Lock...................................................................................................................10
Storage Box...................................................................................................................10
Fuel Tank Cap ............................................................................................................ 11
Brake .......................................................................................................................... 11
8. Important Points and Cautions for Starting Engine ............................................... 12
9. The Best Way to Drive off ......................................................................................... 13
The Control of Throttle Valve Handle ...................................................................... 13
Parking Method .......................................................................................................... 13
10.Inspection and Maintenance before Riding ............................................................ 14
Routine Inspection .................................................................................................... 14
Engine Oil Inspection and Change .......................................................................... 14
Fuel Inspection .......................................................................................................... 15
Transmission Oil Inspection and Change ............................................................... 15
Inspection and Adjustment of Brake Free Play ...................................................... 15
Disc Brake Inspection (Depending on Models) ....................................................... 16
Throttle Valve Handle Clearance Adjustment........................................................... 18
Inspection and Maintenance of Battery ................................................................... 18
Tire Inspection ........................................................................................................... 19
Steering Handle Front Shock Absorbers Inspection .............................................. 19
Checking and Changing Fuses ................................................................................ 20
Checking the Turn Signal Lights and Horn ............................................................. 20
Checking the Front and Rear Lights ........................................................................ 20
Checking the Brake Light ......................................................................................... 21
Checking for Fuel Leakage ....................................................................................... 21
Checking the Lubrication of Body’s Various Mechanisms .................................... 21

2
1. CONTENTS
Checking the Spark Plug .......................................................................................... 21
Checking the Air Cleaner .......................................................................................... 21
11.When there is an Abnormal Condition or a Trouble .............................................. 22
Diagnosis when Engine does not Start ................................................................... 22
12.C.D.I. Electrical Ignition System .............................................................................. 22
13.Suggestions on Engine Fuel .................................................................................... 22
14.Transmission Oil ....................................................................................................... 22
15.Cautions for Riding Motorcycle ............................................................................... 23
16.Periodical Maintenance Schedule...............................................................................24
17.Specification .............................................................................................................. 25

3
2. CONTROL LOCATION
AK12W / U
Oil level
Front brake lever
Rear brake lever
Fuel tank ca
p
Helmet hook
Side stand Main stand
Kick starter
pedal
Li
g
ht / Starter switch
Seat open / High & Low beam /
Turn signal / Horn switch
Stora
g
e box
Muffler
Fuses & C.D.I.
& Batter
y
Front turn
si
g
nal li
g
ht
Front light
Tail / rear turn
si
g
nal li
g
ht
Air cleaner
I
g
nition switch
Seat lock

4
2. CONTROL LOCATION
AK12V1-3
Oil level
Li
g
ht / Starter switch
Seat open / High & Low beam /
Turn signal / Horn switch
Stora
g
e box
Front turn
si
g
nal li
g
ht
Front light
Seat lock
Fuel tank ca
p
Helmet hook
Side stand Main stand Kick starter
pedal
Tail / rear turn
si
g
nal li
g
ht
Air cleaner
Front brake lever
Rear brake lever
Muffler
Fuses & C.D.I.
& Batter
y
I
g
nition switch

5
3. BEFORE RIDING
This manual describes the correct usage of this motorcycle including safety riding, simple inspection
methods and so on.
For a more comfortable and safety riding, please read this manual carefully.
In case the motorcycle’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
motorcycle 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 motorcycle very carefully, but after they became
familiar with their motorcycles, they tended to become reckless which may result in an accident.
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 motorcycle to avoid
others getting burned by the exhaust pipe.
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.
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.
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.
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, therefore, do not modify your motorcycle
at will.

6
5. DRIVING
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 motorcycle 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 motorcycle do not incline.

The motorcycle 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.
6. USE GENUINE SPARE PARTS
In order to maintain the motorcycle’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 motorcycle. 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 motorcycle’s performance.

Always use “SYM Genuine Spare Parts” to keep your motorcycles pure blood and to ensure its
long service life.
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 motorcycle.
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 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.

7
CAUTION:
Do not wipe plastic components, e.g. instrument panel, headlight, with organic solvents such as
gasoline…etc to avoid damaging these components.
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.)
Gauges
AK12W / U
AK12V1-3

Speedometer：
Indicates driving speed.

Odometer：
Indicates total accumulated distance traveled.

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.
High Beam
Indicator
Fuel Gauge
Turn Signal
Indicator Turn Signal Indicator
Odometer
Speedometer
Oil zero reset button
Odometer
Speedometer
Oil zero reset button
Turn Signal
Indicator
Fuel Gauge
High Beam
Indicator
Turn Signal
Indicator

8

Fuel Gauge：
The pointer in this gauge shows how much fuel remains in the tank.
The pointer stays in “E” position when key switch is turned to “OFF.”

Engine Oil Change Indicator：
This indicator shows when to change engine oil by colors. Usually, the indicator will be in green. But it
will be in red color when the motorcycle has been driven approximately 1,000 km. Then, it means you
should add or change the engine oil. After replacing the engine oil, please insert the key into the relief
hole as shown on the right. The indicator will then turn from red to green.

Zero reset button
1. Operate the zero reset button regularly.
2. To reset to zero, simply press the button.
The button will spring back to its original
position when released.
OPERATION OF IGNITION SWITCH
“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.”
IGNITION SWITCH
ON
OFF
LOCK
CAUTION:
 Never operate the ignition switch key when the motorcycle 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 motorcycle
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 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.
 Make sure to take the key away with you before you lock your seat.
Key

9
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.
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.

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.
Light Switches
Electrical
Starter Button
High/Low
Beam Switch
Turn Signal
Switch Horn Switch
Passing switch
Note:
Position Light Function:
This light can indicate the motorcycle’s
position when the motorcycle is
running in dim, rainy, or foggy
weather.
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.
PASSING

10
 Horn Switch
Press this button down when ignition switch
is in the “ON” position, the horn will sound.
 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.
SAFETY HELMET HOOK
 Open the saddle, and hook the safety helmet
chin belt onto the hook, and then lock the
saddle.
SADDLE LOCK
 Unlock:
Insert the ignition switch key into lock located
under saddle left (front) and turn to right to
unlock.
 Lock:
Press the saddle down and it will be locked
automatically.
After the saddle has been locked, check to
make sure it has been locked properly by
lightly lifting the saddle.
STORAGE BOX
 This box is located under the saddle.
 Maximum load capacity: 10kg.
 Do not store valuables in the box.
 Make sure that the saddle has been locked completely after it was pressed down.
 Take out valuables before washing to avoid wetting these objects.
 Do not place thermal sensitive objects in the box because of engine’s heat and high temperature.
CAUTION:
Do not press this button when you are in
the area where there’s no honking.
CAUTION:
 Be sure to remove the key after the saddle 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.
CAUTION:
 DO not hang the safety helmet onto this hook
when riding to avoid damaging motorcycle and
loosing safety helmet’s function.
Helmet hook
Storage box

11
FUEL TANK CAP 【Fuel refilling】
1. Insert ignition switch key into the lock on the fuel tank
cap, and turn the key to the right, then the cap can be
removed.
2. Do not fill above the fuel upper limit when refueling.
3. Align the “△” mark on the cap with the “△” mark on
the body, and turn the key and the fuel cap right to lock
the fuel cap. To remove the ignition key, simply turn
the key to the left and then remove it.
BRAKE
 Avoid unnecessary sudden braking.
 Use front and rear wheel brakes
simultaneously when braking.
 Avoid brake continuously for a long period
of time because that may overheat the
brakes and reduce its braking efficiency.
 Slow down and brake early when riding in
rainy days on slippery roads. Never
apply the brakes suddenly to prevent
skidding and falling.
 Using only the front brake or the rear
brake increases the risk of falling because
the motorcycle 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 both brake and engine brake intermittently when riding on a long or stiff slope.
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 motorcycle.
 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 (fuel tank
capacity : 4 liter, sub tank capacity :1.5 liter).
For Rear Wheel For Front Wheel
“△”mark
Fuel tank cap
Fuel tank cap
Sub fuel tank
Fuel tank
Fuel unit

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8. IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE
Turn ignition switch key to the “ON” position.
1. Apply hand (foot) rear wheel brake.
2. Do not accelerate, press starter button when
the brake is applied.
【We care for you! Before drive off, keep the
hand (foot) brake applied on the rear wheel.】
【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.
CAUTION:
 Firmly support the motorcycle with the main parking stand before starting the engine with the
starting lever.
 Start engine with the starting lever occasionally to prevent it from loosing its function
because of unused for a long time.
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.
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.
 If engine still can not be started after pressing starter button over 15 seconds, 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 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.
1/4
1/8

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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 motorcycle from left side after the engine has been stopped, and select a parking place
where the motorcycle will not interfere with traffic and the ground is level, then put down
motorcycle’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
motorcycle from being stolen.
CAUTION:
 Park your motorcycle at a safe place where it will not interfere with traffic.
Deceleration
Acceleration

14
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/cm2)
Tires Rear Is tire pressure normal?
(Standard: 2.0 kg/cm2for 1 person, 2.25 kg/cm2for 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?
ENGINE OIL INSPECTION AND CHANGE
INSPECTION:
 Use the main parking stand to support the
motorcycle 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.)
 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. Cleaning oil
filter's 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 SH, SAE 10w-30 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 clean or change: 0.85 liters.
CAUTION:
 If 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.
Upper limit
Lower limit

15
【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.
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 motorcycle’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
motorcycle 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 c.c. / at change: 90~100 c.c.).
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 c.c.), 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).
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.
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.
 Engine and exhaust pipe are hot right after engine stopped. Pay special attention not to get
burned when checking or replacing engine oil.
10~20 mm

16
Adjustment:﹙Drum type﹚
 The indentation of brake adjustment nut must be aligned with the pin. (see below figure)
 Turn the adjustment nut on brake arm of front and rear wheels to adjust the free play of hand-brake
lever.
 Hold the hand-brake levers after adjusting with both hands until there is effective brake feeling.
 Measure the free play with a rule.
DISK BRAKE INSPECTION (Applicable for model equipped with disc brake.)
 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
motorcycle to your SANYANG dealer for
repairing or service.
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.
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 its optimum
condition and safe to ride.
Pin
Adjustment nut
Front wheel drum type Rear wheel drum type
Adjustment nut
To increase
free play
To decrease
free play
To increase
free play
To decrease
free play
Hose connection

17
﹙Checking front brake lining﹚
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.
﹙Checking oil quantity in brake oil reservoir﹚
Park the motorcycle 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.
Brake pad wear
limit grooves
Brake disk
Brake caliper
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.
Upper
Brake fluid
Diaphragm
Master cylinder cove
r
Screw

18
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.
INSPECTION AND MAINTENANCE OF BATTERY
 This motorcycle is equipped with a maintenance-free type battery, so it is unnecessary to check and
add electrolyte. Have your motorcycle 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.
 This motorcycle is equipped with a maintenance-free type battery, so it is unnecessary to check and
add electrolyte. Have your motorcycle checked by SYM Authorized Dealer or Franchised Dealer
should any abnormality is found.
Adjust nut
Lock nut
2~6 mm
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.
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.
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 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 motorcycle.
 If the battery needs to be replaced, replace with a same closed-type battery
(Maintenance-Free).
Negative
Positive

19
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.
 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.
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 motorcycle to SYM Authorized Dealer or Franchised Dealer for a check or adjustment if
any abnormal conditions are found.
PLEASE REFER TO SPECIFICATIONS FOR STANDARD TIRE PRESSURE
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).
Tread wear
indicator
Crack and
damage
Foreign materials
(nails or small
stones)

20
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 7 amperes, a brass or iron wire to
replace a blown fuse is strictly prohibited to avoid damaging the electrical system and the circuit.
 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 motorcycle.
 Take your motorcycle to your dealer for an inspection if a fuse is blown by unknown causes.
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 0.6~0.7 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.
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.
Fuse connectors
Wire
Press in from above
【REMOVE】【INSTALLATION】
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 motorcycle recommended
by the manufacturer. (Refer to specifications.)
0.6~0.7 mm