Operation Manual

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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

Operation of steering handle lock switch ...................................................................... 7

Operation of seat open switch ....................................................................................... 7

Use of buttons ............................................................................................................... 7

Storage box....................................................................................................................... 9

Safety helmet hook ......................................................................................................... 10

Fuel tank cap ................................................................................................................ 10

Brake ............................................................................................................................ 10

8. Important points and cautions for starting engine ....................................................... 11

9. The best way to drive off ............................................................................................. 12

The control of throttle valve handle ............................................................................. 12

Parking method ........................................................................................................... 12

10.Inspection and maintenance before riding ................................................................... 13

Routine inspection ...................................................................................................... 13

Engine oil inspection and change ............................................................................... 13

Fuel inspection .............................................................................................................. 14

Transmission oil inspection and change ....................................................................... 14

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 ....................................................................... 17

Tire inspection ............................................................................................................. 18

Steering handle front shock absorbers inspection ...................................................... 18

Checking and changing fuses ..................................................................................... 19

Checking the turn signal lights and horn ..................................................................... 19

Checking the front and rear lights ............................................................................... 19

Checking the brake light ............................................................................................. 19

Summary of content (26 pages)

PAGE 1
.CONTENTS 1. 2. 3. 4. 5. 6. 7. Contents ........................................................................................................................ Control location ............................................................................................................. Before riding .................................................................................................................. Safe riding .................................................................................
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1.CONTENTS Checking for fuel leakage ........................................................................................... 20 Checking the lubrication of body’s various mechanisms ............................................ 20 Checking the spark plug ............................................................................................. 20 Checking the air cleaner ............................................................................................. 20 11.
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2.
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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. For your benefit, please ask your SANYANG dealer the operating manual and carefully read the following:  Correct use of the motorcycle.  Pre-delivery inspection and maintenance.
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.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.
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7.USE OF EACH COMPONENT (The following is SYM 4 stroke air-cooling scooter’s basic operation, and they could vary from different individual models. Please consult the end of this manual.) §GAUGES § The panel figure for speedometer may vary from model to model, but the location usually are the same. Tachometer Speedometer Turn Left/ Right Signal Indicator Set key Mode key Engine oil warning light Odometer Fuel meter High Beam Indicator CAUTION: Do not wipe plastic components, e.g.
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§OPERATION OF IGNITION SWITCH § IGNITION SWITCH “ON” position:  Engine can be started in this position.  Ignition switch key can not be removed. “OFF” position:  Engine is shut off and can not be started in this position .  Ignition switch key can be removed. §OPERATION OF STEERING HANDLE LOCK SWITCH § “Steering handle lock” position  Turn the steering handle to left and insert the key into, press ignition switch key clockwise and then lightly turn it to left to the “lock” position.
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 Engine stop switch When the ignition switch key is turned to this position, press the electrical starter button, the engine can be started. When the ignition switch key is turned to this position, press the electrical starter button , the engine can not be started.  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.
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 Engine start control switch The switch button position is under seat. “ON” position: Engine is locked and can not be started engine in this position. “OFF” position: When the ignition switch is “on” position, the start control switch is “off” position, press electrical starter button while holding the front or rear brake lever will start the engine. Engine start control switch  Horn Switch Press this button down when ignition switch is in the “ON” position, the horn will sound.
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§SAFETY HELMET HOOK§  Stop the motorcycle, and hook the safety helmet chin belt the hook. Hook CAUTION:  Do not hang the safety helmet onto this hook when riding to avoid damaging motorcycle and loosing safety helmet’s function. §FUEL TANK CAP§ 1.Insert the key into the main switch and open the seat, and turn the fuel cap anticlockwise, then the cap can be removed. 2. Do not fill above the fuel upper limit when refueling. 3.
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8.IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE CAUTION:   Please check the oil and fuel volume are adequate or not before starting the engine. To start the engine the main parking stand must be firmly on the ground and the brake is applied on the rear wheel to prevent the motorcycle from moving forward suddenly. 1.Turn ignition switch key to the ”ON” position. 2.Apply hand(foot) rear wheel brake. 3.Do not accelerate, press starter button when the brake is applied.
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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. Deceleration Acceleration §PARKING METHOD §  when approaching the parking lot: 1.
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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 Brake Tires Front Braking condition? (Brake lever free play: 10~20mm) Rear Braking condition? (Brake lever free play: 10~20mm) Front Is tire pressure normal? (Standard: 1.75kg/cm2) Rear Is tire pressure normal? (Standard: 2.
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OIL CHANGE:  Change engine oil after the first 300km, and change the engine oil every 1000km thereafter.  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 SL/CFSAE 10W-30 grade or better engine oil. Otherwise, damage will not be covered by warranty.  Use SAE 5W-40 when outside temperature is below 0℃.
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§INSPECTION AND ADJUSTMENT OF BRAKE FREE PLAY§ INSPECTION: (Brake lever free play must checked with the engine shut off.)  Brake lever and pedal free play for front and rear wheels. ◆If checking the hand-braking lever for front wheels, its free play (the stroke of hand-braking lever from no braking to initial braking) should be 10~20mm. It is abnormal if the feel is spongy when holding the hand-braking lever forcefully.
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§DISK BRAKE INSPECTION§  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.
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§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. 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.
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§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 Foreign materials (nails or small stones) Crack and damage     Tread wear indicator Visual check tires for frontal and lateral side walls for crack or damage.
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§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 (10A). Using a fuse of more than 10 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 holder near battery.  Open the fuse box cover, and pull out the fuse. Check it for damage or broken.
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§CHECKING FOR FUEL LEAKAGE§  Check fuel tank, fuel cup, fuel hose, and carburetor for leakage. §CHECKING 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.
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11.WHEN THERE IS AN ABNORMAL CONDITION OR A TROUBLE §DIAGNOSIS WHEN ENGINE DOES NOT START § For rear wheel (1). Has the ignition switch key been turned to the “ON” position? 1/4 For front wheel (2). Is there enough fuel in the fuel (3). Is the rear or front wheel brakes applied when tank? pressing starting button? 1/8 Turn Signal Switch Horn Switch (5). Turn the ignition switch key to the “ON” position, and press horn button down, if the horn does not sound, the fuse may have been blown.
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15.CAUTIONS FOR RIDING MOTORCYCLE 1. Raise the motorcycle with the main stand, and sit on the seat. Push the motorcycle 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 motorcycle from the left side, and sit on the saddle properly, keep your right feet firmly on the ground to prevent the motorcycle from falling. CAUTION:  Apply brake on the rear wheel before driving off. 3.
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16.
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17.SPECIFICATION Item Model Specification AE05W6-RU(CROX 50) Length 1895mm Width 775mm Height 1095mm Wheel base 1335mm Net Weight 98kg Type 4- stroke single cylinders engine Fuel UNLEADED (OCTANE 90 OR HIGHER) Cooling type Air-cooled Displacement 49.5c.c. Compression ratio 12.6 :1 Maximum 2.3kw/7500 rpm(Apply to model: Speed 1.84kw/8500 rpm(Apply to model: Speed HP limited:45km/h) limited:25 km/h) Maximum 2.5 N.m/6500 rpm(Apply to model: Speed 2.0N.
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Item Model Specification Length Width Height Wheel base Net Weight Type Fuel Cooling type Displacement Compression ratio Maximum HP Maximum torque Starting methods Front shock absorber Rear shock absorber Clutch Transmission Front tire Rear tire Wheel Tire pressure Front brake Rear brake Front light bulb (high, low) Brake light bulb (tail light) License light bulb Turn signal light bulb Speedometer light bulb Engine oil capacity Transmission oil capacity Fuel tank capacity Fuse Spark plug Battery capacity
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Model Item Length Specification AE15W1-COC/AE15W1-DZ/AE15W1-SA(CROX 150) 1905mm Width 690mm Height 1238mm Wheel base 1325mm Net Weight 109kg(Front:41kg Rear:68kg) Type 4- stroke single cylinders engine Fuel Unleaded (Octane 90 or higher) Cooling type Air-cooled Displacement 151 cm3 Compression ratio 10.4±0.2 :1 Max. HP 7.7kw/7500 rpm Max. torque 10.8N.m/6000 rpm Idling speed 1700±100 rpm Valve clearance: IN/EX 0.12±0.02/0.12±0.