517155

Sym JET EUROX 100 Handleiding

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◎ CONTENTS
1. Contents ........................................................................................................................................ 1
2. Control location ............................................................................................................................ 3
3. Before riding ................................................................................................................................. 7
4. Safety riding .................................................................................................................................. 7
5. Driving........................................................................................................................................... 8
6. Use genuine spare parts ................................................................................................................ 8
7. Use of each component ................................................................................................................. 9
Gauges .......................................................................................................................................... 9
Operation of ignition switch ....................................................................................................... 10
Use of buttons ............................................................................................................................. 11
Saddle lock .................................................................................................................................. 12
Safety helmet hook ...................................................................................................................... 13
Storage box................................................................................................................................... 13
Fuel tank cap ............................................................................................................................... 13
Brake ........................................................................................................................................... 13
Parking method ........................................................................................................................... 14
8. Important points and cautions for starting engine ....................................................................... 14
9. The best way to drive off ............................................................................................................ 15
The control of throttle valve handle ............................................................................................ 15
10. Inspection and maintenance before riding ................................................................................... 16
Routine inspection ...................................................................................................................... 16
Inspection and replenishment of engine oil ................................................................................. 16
Inspection of fuel level ................................................................................................................ 17
Transmission oil inspection and change ...................................................................................... 17
Inspection and adjustment of brake free play .............................................................................. 17
Disc brake inspection [Depending on models] ............................................................................ 18
Throttle valve handle clearance adjustment................................................................................. 19
Inspection and maintenance of battery ........................................................................................ 19
Tire inspection ............................................................................................................................ 20
Steering handle front shock absorbers inspection ....................................................................... 21
Checking and changing fuses ...................................................................................................... 21
Checking the turn signal lights and horn ..................................................................................... 22
Checking the front and rear lights ............................................................................................... 22
2
Checking the brake light ............................................................................................................. 22
Checking for fuel leakage ........................................................................................................... 22
Checking the lubrication of body’s various mechanisms ............................................................ 22
Checking the spark plug .............................................................................................................. 23
Checking the air cleaner .............................................................................................................. 23
11. When there is an abnormal condition or a trouble ...................................................................... 24
Diagnosis when engine does not start ......................................................................................... 24
12. Periodical Maintenance Schedule ............................................................................................... 25
13. Specification ............................................................................................................................... 26
14. Wiring diagram............................................................................................................................. 27
JET 50 series wiring diagram........................................................................................................ 27
JUNGLE 50 series wiring diagram ............................................................................................... 28
MASK 50 series wiring diagram................................................................................................... 29
BS05W series wiring diagram....................................................................................................... 30
JET 100 series wiring diagram...................................................................................................... 31
3
◎ CONTROL LOCATION
MODE：JET 50/100 SERIES (G5J/G100P)
Head light
Front brake lever Rear brake lever
Tail light
Helmet hook
Fuel tank cap
Engine number
Stora
g
e box
Muffler
Fuses / C.D.I. /
Eng. Oil tank cap
Li
g
ht / Starter switch
High & Low beam /
Turn signal / Horn switch
Air cleaner
Frame number
Front turn signal
Ignition switch
Rear turn signal
Seat lock
Rear turn signal
4
MODE：JUNGLE SERIES (BM05W)
Head light
Tail light
Fuel tank cap
Engine number
Stora
g
e box
Fuses / C.D.I. /
Eng. Oil tank cap
Li
g
ht / Starter switch
High & Low beam /
Turn signal / Horn switch
Helmet hook
Air cleaner
Front turn signal
Ignition switch
Muffler
Rear brake leverFront brake lever
Rear turn signal
Seat lock
5
MODE：MASK SERIES (BF05W)
Head light
Tail light
Rear turn signal
Fuel tank cap
Engine number
Stora
g
e box
Muffler
Li
g
ht / Starter switch
High & Low beam /
Turn signal / Horn switch
Helmet hook
Fuses / C.D.I. /
Eng. Oil tank cap
Air cleaner
Front turn signal
Ignition switch
Rear brake leverFront brake lever
Seat lock
6
MODE：BS05W SERIES
Head light
Fuel tank cap
Engine number
Stora
g
e box
Li
g
ht / Starter switch
Tail light
High & Low beam /
Turn signal / Horn switch
Helmet hook
Fuses / C.D.I. /
Eng. Oil tank cap
Front turn signal
Ignition switch
Muffler
Rear brake leverFront brake lever
Rear turn signal
Air cleaner
Seat lock
7
◎ 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.
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.
z 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.
◎ SAFE RIDING
It is very important to be relax and clothe properly when driving, observe traffic regulations, do not rush, always drive
carefully and relaxedly.
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.
To remind you:
z Please wear a safety helmet, and properly tighten the chin belt when riding a motorcycle.
z 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.
z Hold the steering handle by both hands when riding. Never ride with only one hand.
z Observe the speed limit.
z Perform periodical maintenance and inspection in accordance with the schedule.
WARNING!!
z To avoid getting burned by exhaust pipe when taking a passenger. Make sure your passenger has put his/her feet
on the pedals.
z After running, the exhaust pipe is very hot, be careful not to get burned when conducting an inspection or
maintenance.
z 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.
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.
8
◎ DRIVING
z 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.
z Rider’s posture will great influent riding safety. As for the riding position, please always keep your body’s
gravity on the center of seat. If your body’s gravity is placed on the rear of seat, the front wheel load will be
reduced, this can cause steering handles shaking. Riding in this way is dangerous.
z 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.
z On bumpy, unleveled and slope road, the road condition may change often, driving on these roads may become
very unstable. To drive safely and smoothly, know your road condition before hand, slow down, and hold the
handle firmly with aid of your shoulder.
z Suggestion: Do not load objects on the front pedals unnecessarily, to avoid affecting the riding safety and the
operation of steering handle.
CAUTION:
Feeling on the handle is different when the vehicle is with load or without load. Over-load will make steering
handle swing and then influent riding safety. Thus, please be ware of load weight.
CAUTION:
z Please do not load cargo or luggage on places where are not designed for loading to prevent danger and
damage.
z Do not place rags or similar objects between the storage compartment and engine to avoid engine seizure
because of inadequate engine oil supply.
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.
◎ 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.
z Always use SYM Genuine Spare Parts to keep your motorcycles pure blood and to ensure its long service life.
9
◎ USE OF EACH COMPONENT
§Gauges §
CAUTION:
Do not wipe plastic components, e.g. instrument panel, headlight, with organic solvents such as gasoline…etc to
avoid damaging these components.
1. 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.”
When key switch is turned to “ON”, and the “pointer” also in “E” position (red area). Refuel immediately.
2. 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.
3. High Beam Indicator
This indicator comes on with high beam headlight is turned on.
4. Engine Oil Warning Light
Turn the main switch to the “ON” position, if the oil warning light comes on continuously, this indicates the
engine oil level is too low, add oil as required.
Model : JET SERIES
Model : MASK SERIES
Model : JUNGLE SERIES
Time indicator
Model : BS05W SERIES
10
WARNING:
z To continue drive the vehicle under low oil level condition will result in an engine seizure due to lack of
lubrication of engine parts. It is therefore very important to bring your vehicle to your dealer for an oil
replenishment immediately whenever the warning light comes on continuously.
z Use only 2-cycle engine oil meeting Japanese Automobile Standard Organization FC specifications.
Otherwise, this company will not assume any responsibility for damages resulted from using substandard
engine oil.
※ Recommended oil: SYM EXTRA 2X oil.
5. Speedometer
This shows your speed in kilometers per hour (km/h)
and in mileage per hour(mph).
6. Odometer
This odometer shows the total kilometers this motor
has been driven.
§OPERATION OF IGNITION SWITCH §
“ON” position
z Engine can be started in this position.
z Ignition switch key can not be removed.
“OFF” position
z Engine is shut off and can not be started in this position.
z Ignition switch key can be removed.
“LOCK” position
z Turn the handle all the way to left, then press down the key and
turn the key to the “LOCK” position on the left.
z In this position, the handle is locked and the key can be
removed.
z To unlock, simply turn the key from “LOCK” to “OFF”.
CAUTION:
z 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.
z Always remove the key and be sure to take the key away with you after locking the steering handle before
leaving your motorcycle.
z 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 startability.
CAUTION:
Observe the speed limit to ensure drive safety.
IGNITION SWITCH
11
§USE OF BUTTONS §
z Light Switches
When the switch is turned to this position, headlight, rear light, instrument panel light, and position light will
go on.
When the switch is turned to this position, rear light, instrument panel light, and position light will go on.
When the switch is turned to this position, all lights will go off. (Depending on Models)
z Electrical Starter Button
This is the electrical starter button, it is used for starting the engine.
When the ignition switch key turns to “ON” and brake lever hold, and then press this button down to start
engine.
《This mechanism is designed for safety. Thus, the front or rear brake lever must be hold before using this
button so that engine can be started.》
Horn Switch
Head light
switch
High / Low
Beam Switch
Turn Signal
Switch
Electrical
Starter Button
This type is only on JUNGLE.
Warning
signal switch
Head light
switch
Electrical
Starter Button
12
CAUTION:
z Release this button immediately after engine has been started, and never press the button again to avoid
damaging the engine.
z Do not use light system. Turn headlight and turn signal lights to the “OFF” position when the engine is being
started.
z 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)
z 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.
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.
z Horn Switch
Press this button down when ignition switch is in the “ON” position, the horn will sound.
CAUTION:
z Do not press this button when you are in the no horn area.
§SADDLE LOCK §
z Unlock:
Insert your ignition switch key into the lock on
the lower left of the saddle, and turn the key to
the right. Then, the saddle can be lifted up.
z Lock:
Press the saddle down and push it locks
automatically.
CAUTION:
z Please do not put the key into the storage compartment
after saddle is unlocked to prevent the key from being
locked inside and can not be removed when the saddle is
locked.
z Be sure to remove the key after the saddle has been locked.
13
§SAFETY HELMET HOOK §
z Open the saddle, and hook the safety helmet chin belt onto the hook, and then lock the saddle.
CAUTION:
z Please do not hang your safety helmet as usual on the hook when driving, to prevent it from damaging the
vehicle and affecting your driving safety.
§STORAGE BOX §
This box is located under the saddle.
Maximum load capacity: 10kg.
Do not store valuables in the box.
Please make sure that seat cushion had been locked
completely after it was 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.
§FUEL TANK CAP §
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
4. on the cap with the “△” mark on the body, and press down the cap in parallel until a “click” sound is heard.
That means the cap is locked (the ignition key now turns back to the left slightly). To remove the ignition key,
simply turn the key to the left and then remove it.
WARNING:
z 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.
z 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.
z Make sure the cap has been tighten properly.
§BRAKE §
Use front and rear wheel brakes simultaneously when
braking.
Avoid unnecessary sudden braking.
Using only the front brake or the rear brake increases
the risk of falling because the motorcycle is tend to
pulled to one side.
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.
For Rear Wheel For Front Wheel
14
§PARKING METHOD §
z 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.)
z When stop completely:
1. Press the turn signal switch back to its original position, and turn the ignition switch key to “OFF” position to shut
off the engine.
2. 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.
3. 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.
4. 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:
z Park your motorcycle at a safe place where it will not interfere with traffic.
◎ IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE
CAUTION:
z Please check the engine oil and fuel volume are adequate or not before starting engine.
z To start engine the main parking stand must be firmly on the ground and the brake is applied on the rear wheel to
prevent the motorcycle from moving forward suddenly.
1. Turn ignition switch key to the “ON” position.
2. Apply hand (foot) rear wheel brake.
3. 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.]
1/4
1/8
15
CAUTION:
z 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.
z In order to avoid damaging the starter motor, please do not press the starter button continuously over 15
seconds.
z 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.
z It may need several minutes to warm up engine if it is a cold start.
z Exhaust contains harmful gases (CO), therefore please start the engine at a well ventilated place.
【When starting engine with starting lever】
z Turn the main switch to ON, press the starting lever forcefully by foot with the throttle valve handle at the close
position.
z 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.
z Put the starting lever back to its original position after the engine has been started.
CAUTION:
z Firmly support the motorcycle with the main parking stand before starting the engine with the starting lever.
z Start engine with the starting lever occasionally to prevent it from loosing its function because of unused for a
long time.
◎ THE BEST WAY TO DRIVE OFF
§THE CONTROL OF THROTTLE VALVE HANDLE §
z Turn on the turn signal light before moving, and
make sure no vehicle is coming from behind.
Then, drive off.
z During driving, attention should be paid to vehicles
ahead and behind and keep highly alert at all
times.
Deceleration
Acceleration
16
◎ INSPECTION AND MAINTENANCE BEFORE RIDING
§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: 1.75g/cm
2]
Tires
Rear Is tire pressure normal? [Standard: 2kg/cm
2
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?
§INSPECTION AND REPLENISHMENT OF ENGINE OIL §
Inspection:
z Turn the main switch to the “ON” position, if the oil warning light comes on continuously, this indicates the
engine oil level is too low, add oil as required.
z Check oil tank and oil lines for leakage.
WARNING:
z To continue drive the vehicle under low oil level condition will result in an engine seizure due to lack of
lubrication of engine parts. It is therefore very important to bring your vehicle to your dealer for an oil
replenishment immediately whenever the warning light comes on continuously.
z Use only 2-cycle engine oil meeting Japanese Automobile Standard Organization FC specifications.
Otherwise, this company will not assume any responsibility for damages resulted from using substandard
engine oil.
※Recommended oil: SYM EXTRA 2X oil.
Replenishment:
1. Using the main stand to support the vehicle on a level ground, lift up the saddle, and remove the oil tank cover.
2. Turn the oil tank cap to the left to remove. Add oil until reaches to the standard level.
3. Screw in the oil tank cap until properly tightened, then reinstall the tank cover and lower the saddle and press it
down until locked.
Add oil note:
z Use only 2-cycle engine oil meeting Japanese Automobile Standard Organization FC specifications. Otherwise,
this company will not assume any responsibility for damages resulted from using substandard engine oil.
z When adding oil, do not let foreign materials, dust, dirt enter into the oil system, do not use different brands
mixed oil, because this will affect the engine’s performance.
z Do not add oil above the standard level. Clean spilled oil around the oil tank cap.
z Be sure to tighten the oil tank cap properly after adding oil.
CAUTION:
z 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.
17
§INSPECTION OF FUEL LEVEL §
z Firmly support the motorcycle with its main stand on a leveled ground, turn the main switch to “ON” position,
check if the fuel meter needle moves.
z Fuel gauge may be defective or electric circuit disconnected if there is some fuel in the tank, but the needle does not
move. Please drive slowly to an authorized service station to have your motorcycle checked.
Note: It is not necessary to start engine to check the fuel level.
§TRANSMISSION OIL INSPECTION AND CHANGE §
INSPECTION:
z 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: 120 c.c. / at change:
100~110 c.c.).
OIL REPLACEMENT:
z 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.
z Install the drain bolt and tighten it. Fill new transmission oil (100~110 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.)
z 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.
Adjustment:
z The indentation of brake adjustment nut must be aligned
with the pin. (see right figure)
CAUTION:
z 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.
z Turn the adjustment nut on brake arm of front and rear wheels to adjust the free play of hand-brake lever.
z Hold the hand-brake levers after adjusting with both hands until there is effective brake feeling.
z Measure the free play with a rule.
10~20 mm
Pin
Adjustment nut
18
§DISK BRAKE INSPECTION §[Applicable for model equipped with disc brake.]
z Visual Inspection for leakage or damage. If
there is any, take your motorcycle to SYM
Authorized Dealer or Franchised Dealer for a
check or repair.
z 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).
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.
Viewing window
Lower limit
Front wheel drum type
Rear wheel drum type
Adjustment nut
To increase
free play
To decrease
free
p
la
y
To increase
free play
To decrease
free
p
la
y
Hose connection
Brake caliper
Brake disk
Brake pad wear limit grooves
【ADDING BRAKE FLUID】
Upper
Screw
M
as
t
er cy
li
n
d
er
cover
Diaphragm
Brake fluid
19
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.
§THROTTLE VALVE HANDLE CLEARANCE ADJUSTMENT §
z Correct clearance allows throttle vale handle to rotate 2~6mm.
z To adjust, first loosen the fixing nut, then turn the adjusting nut to
the proper position and securely tighten the fixing nut.
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 §
z 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.
CAUTION:
z Clean the battery posts with warm water if the posts are eroded and have some white powders on them.
z 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.
z Install battery cable after cleaning and apply a thin coat of grease on the terminals.
z Install battery in reverse order of removal.
CAUTION:
Do not fill above the upper limit when
adding brake fluid and avoid dropping on
p
ainting or plastic components to preven
t
damage.
Negative
Positive
Remove the battery terminals and clean if there are dirt and
corrosion on them.
Battery removal procedures are as follows:
Turn ignition switch “OFF,” and remove negative cable
screw firstly and disconnect the negative cable. Then,
remove positive cable screw and positive cable.
Adjust nut
Lock nut
2~6 mm
20
CAUTION:
z This is a closed type battery. Never remove the caps.
z 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.
z If the battery needs to be replaced, replace with a same closed-type battery (Maintenance-Free).
§TIRE INSPECTION §
z Tires should be checked and inflated with the engine shut off.
z If a tire’s ground contacting curve is abnormal, check it with an air pressure gauge and inflate it to the specified
pressure.
z Tires pressure must be checked with an air pressure gauge when cold.
z Visual check tires for frontal and lateral side walls for crack
or damage.
z Visual check tires for any nails or small stones wedged in the
tread.
z Check the “tread wear indicator” condition to see if tread
groove depth is insufficient.
z A tire with a wear bar showing is worn out and should be
replaced immediately.
CAUTION:
Abnormal tire pressure, wear, or crack is the most important cause that
results in the loss control of the steering handle and a punctured tire(s).
PLEASE REFER TO SPECIFICATIONS FOR STANDARD TIRE PRESSURE
Forei
g
n materials
(
nails or small stones
)
Tread wear
indicator
Crack and
damage
21
§STEERING HANDLE FRONT SHOCK ABSORBERS INSPECTION §
z Perform this check with engine shut off and ignition switch key removed.
z Visual check front shock absorbers for damage.
z Operate steering handle up and down, and check front shock absorbers for noises due to bends.
z Check the bolts and nuts of front shock absorbers with wrenches for tightness.
z 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.
z Check steering handle if it is being pulled too tight by the brake cables.
z Take your motorcycle to SYM Authorized Dealer or Franchised Dealer for a check or adjustment if any abnormal
conditions are found.
【Figures on the right are for operation checks only】
§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.
z Remove the battery cover screws, and open the battery cover. Fuses are installed in the fuse box located by the
battery.
z Fuses must be firmly secured with wire connectors when replacing.
z 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.
z Avoid spraying water directly on or around fuse box when washing the motorcycle.
z Take your motorcycle to your dealer for an inspection if a fuse is blown by unknown causes.
【REMOVE】【INSTALLATION】
Wire
Fuse connectors
Fuse
Press in from above
22
§CHECKING THE TURN SIGNAL LIGHTS AND HORN §
z Turn the ignition switch key to “ON” position.
z Turn on the turn signal light switch, and make sure that the front & rear and left & right signal lights flashes and
also check if the warning buzzer sounds.
z Check turn signal light covers if they are dirty, crack, or loosen.
z Press horn button to check if it works.
CAUTION:
z Specified specification bulbs should be used for turn signal lights. Otherwise, the normal operation of turn
signal lights will be affected.
z Turn on the turn signal light before turning or switching lane to warn driver of vehicles behind.
z Turn off the turn signal light immediately by pressing its button down after using. Otherwise, the flashing of
twin signal lights may confuse the drivers of vehicles behind.
§CHECKING THE FRONT AND REAR LIGHTS §
z Turn the ignition switch key to “ON” position, start the engine and then turn on the front light switch. Check if
front and rear lights come on.
z Check the brightness and direction of front light by projecting the light on the wall to see if it is correct.
z Check the front light cover if it is dirty, crack, or loosen.
§CHECKING THE BRAKE LIGHT §
z Turn the ignition switch key to “ON” position, hold the hand-braking levers for front and rear wheels. Check if
the brake lights come on.
z Check the brake light cover if it is dirty, crack, or loosen.
CAUTION:
z Use only specified specification bulbs, do not use bulbs with different specifications to avoid damaging
electrical system, burning out bulbs, and discharging the battery.
z Do not modify or add other electrical components to prevent over load or short circuit which may result in a fire
and burn down the motorcycle in serious cases.
§CHECKING FOR FUEL LEAKAGE §
z Check fuel tank, fuel hoses, and carburetor…etc. for leakage.
§CHECING THE LUBRICATION OF BODY’S VARIOUS MECHANISMS §
z 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.)
23
§CHECKING THE SPARK PLUG §
z Remove the cap of high tension cable. (Use a plug wrench in tool box to remove
the spark plug by turning it counterclockwise.)
z Check the electrode if it is dirty or fouled by carbon deposits.
z Remove the carbon deposits on the electrode with steel wire, and clean the spark
plug with gasoline, then, wipe dry with a rag.
z Check the electrode, and adjust its gap to 0.6~0.7mm. (Check it with a feeler
gauge)
z Hand tight the spark plug as far as it can go and then tighten it another 1/2~3/4
turns with a wrench.
WARNING: The engine is very hot after running. Pay attention not to get
burned.
※Use only spark plugs suitable for the engine specifications of this motorcycle
recommended by the manufacturer. (Refer to specifications.)
§CHECKING THE AIR CLEANER §
《DISASSEMBLE PRCEDURE》
1. Remove the screw of air cleaner cover.
2. Remove the air cleaner cover and then the cleaner’s element.
3. Clean or replace the element.
(For checking interval please refer to maintenance
schedule.)
4. Refer to figures shown on the right for air cleaner element
cleaning steps.
《ASSEMBLE PRCEDURE》
z Assemble the air cleaner in reverse order of disassemble.
CAUTION:
z Dust deposit is one of the major causes of reducing output horsepower and increasing fuel consumption.
z Change the air cleaner element more frequently to prolong the engine’s service life if the motorcycle is driven
on dusty roads very often.
z If air cleaner is installed improperly, dust will be absorbed into cylinders, which may cause a premature wear
and reducing output power and engine life.
z Be careful not to soak the air cleaner when washing the motorcycle. Otherwise, it will cause engine hard to
start.
Procedures for cleaning air cleaner
element:
1.cleam. 2.squeeze dry.
3.soak in engine oil. 4.squeeze dry
0.6~0.7mm
24
◎ WHEN THERE IS AN ABNORMAL CONDITION OR A TROUBLE
§DIAGNOSIS WHEN ENGINE DOES NOT START §
【Please go to SYM authorized dealer or franchised dealer immediately if there are no problems on above
conditions and engine still can not be started.】
1. Does the ignition switch key
turn to “ON” position?
2. Is there fuel in the fuel tank?
3. Is the rear or front wheel brakes being hold
when pressing starting button?
For Front Wheel
For Rear Wheel
4. Turn the ignition switch key “ON”, and press
horn button. The fuse may blow if horn no
t
sounding.
The turn signal light switch
Horn button
25
◎PERIODICAL MAINTENANCE SCHEDULE
Maintenance
kilometer
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
Item
Check Items
Maintenance
Interval
NEW 1 Month 3 Months 6 Months 1 Year
Remarks
1 Air cleaner element(Remark) ICCR
2 Fuel filter IIR
3Tire, pressure II
4Battery II
5 Brake and brake clearance checking II I I I
6 Spark plug II R
7 Carburetor(idle speed) II
8 Ignition timing II I I I
9 Steering bearing and handles II
10 Check Transmission for leakage II
11 Check crankcase for leakage II
12 Transmission Oil R Replacement for every 5000KM(5 Months)
13 Drive Belt/roller IR
14 Light / electrical / meters II I I I
15 Fuel tank switch and lines II
16 Throttle valve operation and cable II
17 Engine bolts and nuts II
18 Cylinder head, cylinder, and piston I
19 Exhaust system/cleaning carbon I
20 Greasing on chassis LL
21 Front/rear suspension II
22 Main/side stands II/L
23 Clutch disk I
24 Operation of oil pump rod II
25 Brake mechanism/brake lining (pad) II
26 Bolts/nuts for each components II
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
Have your motorcycle checked and adjusted periodically by your SYM Authorized Dealer or Franchised Dealer to maintain the
motorcycle at the optimum condition.
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Remark: 1. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily-
polluted environment.
2. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
26
◎SPECIFICATION
Model
Item Specification
JET 50
JET 50-
α
RED
DEVIL 50
JUNGLE
50
MASK 50 BS05W JET 100
Length ( mm) 1785 1845 1835 1870 1785
Width ( mm) 630 670 650 700 630
Height ( mm) 1115 1075 1110 1130 1115
Wheel base ( mm) 1275 1280 1280 1335 1275
Net Weight 94 kg 94 kg 94 kg 108 kg 94 kg
Type 2- stroke single cylinders engine
Fuel Unleaded gasoline(octane 90 or higher)
Cooling type Air-cooled
Bore
Ø 39 mm Ø 51 mm
Stroke
41.4 mm 49.6 mm
Displacement
49.4 c.c. 101.3 c.c.
Compression ratio 7.2:1 6.3:1
Max. HP
3.2 kW / 7000 rpm
2.8 kW/
7000rpm
3.2 kW/
6500rpm
2.8 kW/
6000rpm
7.0 ps/
6500rpm
Max. torque
4.6 Nm / 6500 rpm
5.1 Nm
/6000rpm
4.58 Nm
/5000rpm
0.89 kg-m
/5500rpm
Starting methods Electrical & kick type
shock absorber Front :Telescope / Rear : Unit swing
Clutch Dry/auto centrifugal clutch
Transmission C.V.T., auto speed change
Front tire 120/70–12 120/90-10
120/70–
12
100/90-
12(59J)
130/70-
12
Rear tire 130/70-12 130/90-10
130/70-
12
130/70-
12(59J)
130/70-
12
Tire pressure Front: STD 1.75kg/cm
2
/ Rear: STD 2.0 kg/cm
2
Front brake (Disc type) (Ø 190 mm)
(Ø 273
mm)
(Ø 190
mm)
Rear brake (drum type) (Ø 110 mm)
Front light bulb(high, low)
12V15W
X 2
12V35W/
35W X 1
12V15W X 2 12V35W/35W X 1
12V18W/
18W X 2
Brake light bulb(tail light) 12V5W / 21W X 2 12V5W / 21W X 1
12V10W
X 2
Turn signal light bulb 12V 10W
Engine oil tank capacity 1.2 L
Transmission oil capacity 120 c. c. (100~110 c. c. for change)
Fuel tank capacity 6.3 L 7.5 L 6.3 L
Fuse 7A
Spark plug BR 8HSA BR 6HSA
Battery capacity(MF battery) 12V 4Ah 12V 3Ah 12V 4Ah
Air cleaner Sponge type
… 6 …

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