Sym Joyride 200 EFi User manual

THE ARTICLES MENTIONED BELOW ARE APPLICABLE ONLY FOR
THE UNITED STATES AND CANADA.
1. NOISE EMISSION WARRANTY
SANYANG INDUSTRY CO.,LTD. warrants that this exhaust system, at the time of sale,
meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first
person who buys this exhaust system for purposes other than resale, and to all subsequent
buyers. Warranty claims should be directed to:
3,chung-Hua Road, Hukou, Hsin-Chu Taiwan, R.O.C
Tel:[phone] Fax:[phone]
2. TAMPERING WARNING
Tampering with noise control system prohibited. Federal law prohibits the following acts or
causing thereof:
(1) The removal or rendering inoperative by any person other than for purposes of
maintenance, repair, or replacement, of any device or element of design incorporated
into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or
(2) The use of the vehicle after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
(1) Removal of, or puncturing the muffler, baffles, header pipes or any other component
which conducts exhaust gases.
(2) Removal or puncturing of any part of the intake system.
(3) Lack of proper maintenance.
Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts
other than those specified by the manufacturer .t80
3. SAFETY INFORMATION
yAlways wear your helmet (dot approved) correctly fastened. Do not carry loose items and
always wear suitable protective clothes, and protective eyewear.
yGood psychophysical conditions are very important for safe operation.
yDo not operate under the influence of drugs and/or alcohol.
yDo not operate in state of physical fatigue or drowsiness.
ySlow down on slippery surfaces , unfamiliar terrain and when visibility is reduced.
yBe alert when operating this vehicle.
yDo not exceed weight capacity.
yThe safety, stability and handling of this motorcycle may be adversely affected by the
addition of accessories or luggage.
yDo not install accessory or replacement parts not approved by sym.
yFailure to follow these warnings could lead to an accident, serious injuries or death.
yUse unleaded fuel octane rating (R+M)/2 method of between 87&92.
yRead owners manual carefully before operating this scooter.
yObey posted speed limit and other traffic signs and signals.

4. SAFETY DEFECT REPORT
SANYANG INDUSTRY CO., Ltd.
NO. 3,chung-Hua Road
Hukou Shiang
Hsin-Chu County, 303
Taiwan, R.O.C
Reporting Safety Defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury
or death, you should immediately inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying Sanyang Industry Co., Ltd.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in and individual problems between you, your
dealer, or Sanyang Industry Co., Ltd.
To contact NHTSA you may call the Auto Safety Hotline toll-free within the United
States on 1-800-424-9393 or write to:
NHTSA, 1200 New Jersey Avenue SE W43-488, Washington, DC 20590
You can also obtain other information about motor vehicle safety from
http://www.safercar.gov.

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 ............................................................................................... 8
Use of Buttons ................................................................................................................. 8
Safety Helmet Hook ........................................................................................................ 10
Saddle Lock ......................................................................................................................10
Storage Box ......................................................................................................................10
Enging Control Switch.........................................................................................................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 ....................................................................... 17
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 .................................................................................. 21

2 1.Contents
Checking the Brake Light ................................................................................................. 21
Checking for Fuel Leakage .............................................................................................. 21
Checking the Lubrication of Body’s Various Mechanisms ..................................................... 21
Checking the Spark Plug ................................................................................................. 21
Cooling system inspection...................................................................................................21
Replenishment of coolant....................................................................................................22
A reference table for anti-freeze concentration percentages under different temperatures............22
Checking the 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 .................................................................................. 25
13.Suggestions on Engine Fuel ....................................................................................... 25
14.Transmission Oil ......................................................................................................... 25
15.Cautions for Riding Scooter ........................................................................................ 25
16.Periodical Maintenance Schedule...................................................................................26
17.Specification ................................................................................................................ 27

ENG. Stop / Light / Starter switch
Turn signal light
seat open / High & Low
beam / Turn signal / Horn
switch
Fuel tank cap
Fuses
Helmet hook
Head light Tail light/
Turn signal light
Frame number
Side stand Main stand
Rear brake
Fuel tank cap Ignition switch
Front brake lever
Coolant filler cap
Muffler
Engine number
3
2.Control Location

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.
4 3.Before Riding
4.Safe Riding

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 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.
5
5.Driving
6. Use Genuine Spare Parts

(The following is SYM 4 stroke liquid cooling scooter’s basic operation, and they could vary from different
individual models. Please consult the end of this manual.)
Gauges
Water temperature
gauge
S
p
eedomete
r
Turn Signal Indicator Turn Signal Indicator
High Beam
Indicator
Fuel Gauge
Oil check
Indicator
Odometer/Clock Set Button
Oil reset
EFi Indicator
button
CAUTION :
•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.
ySpeedometer:
This shows your speed in kilometers and miles per hour (Outer ring for Km/h, inner ring for MPH).
•Odometer：
This odometer shows the total kilometers this scooter has been driven.
•High Beam Indicator( blue)：This indicator comes on with high beam headlight is turned on.
•Turn Signal Indicator(green)：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” indicates above “E” position, it shows how much fuel
in the tank, and also the fuel indicator light keeps coming on. When the “pointer” is below “E” position, the
fuel indicator flashes, and the fuel warning indicator(orange) will come on. It means there is only
approximately 1.72 liter of fuel left in the tank. Refuel octane 92/95/98 unleaded gasoline immediately.
6 7.Use of Each Component

•Water temperature gauge
To indicate engine coolant temperature.
When the main switch turns to “ON”, the pointer indicator should be below the (H) position when the
scooter is operating.
If the pointer indicator stays above (H) position. Please check the coolant level of spare coolant tank and
heck cooling fan for proper operation.c
CAUTION:
The indicator will stay above (H) position when engine is run under high temperature for a long period
f time. In this case, the only way to cool the engine is to stop the engine.o
•Function setting
There are two buttons on the speedometer, explanation as below :
1. SET button :
a. Under normal mode, press SET button shortly to change between ODO & TRIP displays.
b. Under TRIP display mode, press SET for 2 seconds to reset the trip readings.
c. Under ODO mode and the vehicle is standing still, press SET for above 2 seconds to enter CLOCK
mode. Press SET button shortly to increase the hour readings, once per one time. Then press SET for
2 seconds to enter tenth minute setting. Increase the tenth minute readings by pressing SET button
once per one time. Again press SET for 2 seconds to enter unit minute setting. Increase the unit
minute readings by pressing SET button once per one time. Press SET button for above 2 seconds to
exit CLOCK mode.
2. OIL button :
a. The oil indicator will be on every 1,000 km, to warn the user to check (change) engine oil. Every 1,000
km when the oil indicator is on, press OIL button for above 2 seconds to put it out.
7
7.Use of Each Component

OPERATION OF IGNITION SWITCH IGNITION SWITCH
"Start" position
ON
•Engine can be started in this position.
8 7.Use of Each Component
•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.
OFF
LOCK
•The steering handle is locked in this position.
•Ignition switch key can be removed.
•When unlocking, simply turn the key from “LOCK” to “OFF.”
"fuel tank cap open " position
•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.
USE OF BUTTONS
Light Switches Electrical
Starter Button
High/Low
Beam Switch
Turn Si
g
nal Switch
Hazard Switch
Seat Open switch
Horn Switch

•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.
Note:
Position Light Function:
T
his light can indicate the scooter’s position when the scooter is running in dim, rainy, or foggy weather.
When the switch is turned to this position, all lights will go off.
The main switch in the〝ON 〞position, cuts according to this switch, four directions lantern festivals
dodge extinguish do move, also can simultaneously dodge on the display board direction indicating
lamp extinguishes does moves. If stops the vehicle has when the transportation frequent dangerous
position or the vehicle the breakdown, may use the dangerous police to show the switch.
The main switch in the〝ON 〞position, hazard switch only then may close.
•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
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)
•Seat open Switch
Turn ignition switch “ON” and press this button down. Then, the seat will unlock immediately.
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:
D
o not press this button when you are in the area where there’s no honking.
9
7.Use of Each Component

•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
•Hook the safety helmet chin belt onto the hook.
CAUTION:
•Do not hang the safety helmet onto this hook when riding to avoid damaging scooter and loosing
safety helmet’s function.
SADDLE LOCK
•Unlock:
Insert the ignition switch key and turn to left to unlock.
•Unlock:
Press this button down when ignition switch is in the “ON” position, the seat can be 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.
CAUTION:
•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.
•
Be sure to remove the key after the saddle has been locked.
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:
Make sure to take the key away with you before you lock your seat.
ENGING CONTROL SWITCH
•This switch is located in the luggage box, under the seat.
•To set on the ENG. control switch, switch it to〝ON〞or〝〞.
•Switch to〝OFF〞or〝〞，before start the engine.
•Be sure the seat locked preperly after set on the switch.
7.Use of Each Component
10

FUEL TANK CAP
1. Insert ignition switch key into the ignition switch,
and turn the key to the left, then the cap can be
removed.
2. Do not fill above the fuel upper limit when refueling.
3. 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.
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 scooter is tend to
pulled to one side.
For Rear Wheel For Front Wheel
《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.
7.Use of Each Component 11

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 scooter from moving forward suddenly.
Turn ignition switch key to the “ON” position. 1/41/8
1. Apply 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 brake applied on the rear wheel.]
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 scooter 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.
CAUTION:
•Firmly support the scooter 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.
8. Important points and cautions for starting engine
12

•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.
9.The best way to drive off 13
Deceleration : To decrease speed.
Deceleration
Acceleration
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.

(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: 2.25 kg/cm2for 1 person, 2.5 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?
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:
Lower
Upper
•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 1,000km. 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 change: 0.8 liters.
10.Inspection and Maintenance before Riding
14

【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.
•Ethanol in gasoline can not be more than 10%.
TRANSMISSION OIL INSPECTION AND CHANGE
INSPECTION:
•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: 110
cc. / at change: 90~100 cc.).
OIL REPLACEMENT:
•Stop the engine and use the main stand to support your scooter 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 SAE85-90 when outside temperature is below 0℃.
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.
10~20 mm
10.Inspection and Maintenance before Riding 15

Adjustment:﹙Drum type﹚
•The indentation of brake adjustment nut must be aligned with the pin. (see below figure)
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.
Adjustment
Pin
•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.
To decrease
free play
To increase
free play
To decrease
free play
To increase
free play
Rear wheel drum type
Adjustment nut
Front wheel drum type
DISK BRAKE INSPECTION (Applicable for model equipped with disc brake.)
(Leak, damaged, looseness of brake line) Hose connection
•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.Inspection and Maintenance before Riding
16

﹙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).
Brake pad wear
limit grooves
Br
a
k
e
d
i
s
k
Br
a
k
e
ca
li
per
10.Inspection and Maintenance before Riding 17
﹙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.
Upper
Brake fluid
Diaphragm
Master
cylinder cover
Screw
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 2~6 mm
Lock nut
Adjust nut
•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.

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.
18 10.Inspection and Maintenance before Riding
﹙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.
Negative
Positive
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).