517170

Sym MAGIC 110RR Handleiding

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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
Use of buttons ............................................................................................................... 7
Safety helmet hook ........................................................................................................ 9
Fuel tank cap ..................................................................................................................9
Fuel coke ........................................................................................................................ 9
Brake............................................................................................................................. 10
Seat lock........................................................................................................................ 10
8. Important points and cautions for starting engine ........................................................ 11
9. Riding the motorcycle .................................................................................................. 13
Set up riding ................................................................................................................ 13
Driving in grade ............................................................................................................ 14
Transmission operation ............................................................................................... 14
Correct riding ............................................................................................................... 14
The control of throttle valve handle .............................................................................. 15
Parking method ............................................................................................................ 16
10.Inspection and maintenance before riding .................................................................... 17
Routine inspection ....................................................................................................... 17
Fuel inspection ............................................................................................................. 17
Engine oil inspection and change ................................................................................ 18
Inspection and adjustment of brake free play .............................................................. 19
Disk brake inspection ................................................................................................... 20
Clutch adjustment ........................................................................................................ 21
Throttle grip free play adjustment ................................................................................ 21
Drive chain ................................................................................................................... 22
Cam chain adjustment ................................................................................................. 22
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1. CONTENTS
Carburetor adjustment ................................................................................................. 22
Tire inspection ............................................................................................................. 23
Steering handle front shock absorbers inspection ....................................................... 23
Checking the lubrication of body’s various mechanisms .............................................. 24
Inspection and maintenance of battery ........................................................................ 24
Checking and changing fuses ...................................................................................... 25
Checking the turn signal lights and horn ...................................................................... 26
Checking the headlight and tail light ............................................................................ 26
Checking the brake light .............................................................................................. 26
Checking the spark plug .............................................................................................. 27
Checking the air cleaner .............................................................................................. 27
Wiring rubber cap .......................................................................................................... 28
Back mirror .................................................................................................................. 28
License plate ................................................................................................................ 28
CDI. ignition system ..................................................................................................... 28
Tool kit ......................................................................................................................... 28
11. When there is an abnormal condition or a trouble ....................................................... 29
Diagnosis when engine does not start ......................................................................... 29
12. CDI. electrical ignition system ...................................................................................... 29
13. Suggestions on engine fuel .......................................................................................... 29
14. Cautions for riding motorcycle ..................................................................................... 30
15. Periodical maintenance schedule................................................................................... 31
16. Specification ................................................................................................................ 32
3
2. CONTROL LOCATION
MODEL:XS110-5
Fuel tank cap
Front brake lever
Side stand
Main stand
Kick starter Arm
Muffler
Oil level gauge
Light/Starter Switch
High(low)beam/Turn
signal / Horn switch
Front turn
signal light
Rear turn
signal light
Ignition switch
Front light
Tail light
Shift pedal
Choke level
Rear brake pedal
Air Cleaner
Fuses & Battery
& Tool bag
Helmet hook
4
3. BEFORE RIDING
This manual describes the correct usage of this motorcycle including safety riding, simple inspection
methods and so on.
For a more comfortable and safety riding, please read this manual carefully.
In case the motorcycle’s specifications and construction are modified and different from the
photos and diagrams on the owner’s manual / catalogues, the specifications and construction of
the actual motorcycle shall prevail.
4. SAFE RIDING
It is very important to be relax and clothe properly when driving, observe traffic regulations, do not rush,
always drive carefully and relaxed.
Usually, most people would ride their newly bought motorcycle very carefully, but after they became
familiar with their motorcycles, they tended to become reckless which may result in an accident.
WARNING!!
To avoid getting burned by exhaust pipe when taking a passenger. Make sure your passenger
has put his/her feet on the pedals.
After running, the exhaust pipe is very hot, be careful not to get burned when conducting an
inspection or maintenance.
After running, the exhaust pipe is very hot, select a suitable location to park your motorcycle to
avoid others getting burned by the exhaust pipe.
Thank you very much for your patronage
In order to maximize your motorcycle’s performance, a periodical inspection and maintenance
should be completely carried out.
We recommend that after riding your new motorcycle for the first 300 kilometers, you should
take your motorcycle to the original dealer for an initial inspection, and to have your motorcycle
inspected periodically every 1000 kilometers thereafter.
To remind you:
Please wear a safety helmet, and properly tighten the chin belt when riding a motorcycle.
Clothes with open or loose cuffs may be blown by wind and cause the cuffs to get caught on the
steering handle and thus affects riding safety.
So, put on clothes with tight sleeves.
Hold the steering handle by both hands when riding. Never ride with only one hand.
Observe the speed limit.
Wear suitable low-heel shoes.
Perform periodical maintenance and inspection in accordance with the schedule.
For your benefit, please ask your SANYANG dealer the operating manual and carefully read the
following:
Correct use of the motorcycle.
Pre-delivery inspection and maintenance.
CAUTION:
Modified motorcycle will affect its structure or performance, and cause poor engine operation or
exhaust noise, which will result in shortening the motorcycle’s service life.
Besides, modification is illegal and does not conform to the original design and specifications.
A modified motorcycle will not be covered by warranty, therefore, do not modify your motorcycle at
will.
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5.
DRIVING
Keep the related parts of your body such as arms, palms, lumbar, and toes relax and ride
with the most comfortable posture in order to be able to react quickly whenever it is
necessary.
Rider’s posture will greatly affect riding safety. Always keep your body’s gravity in the center of
the saddle, if your body’s gravity is on the rear part of saddle, the front wheel load will be reduced,
and this will cause the steering handle shaking. It is dangerous to ride a motorcycle with an
unstable handle.
It will be much easier to make a turn if rider inclines his body inward when turning. On the other
hand, the rider will feel unstable if his body and the motorcycle do not incline.
The motorcycle is hard to control on a bumpy, unleveled, unpaved road, try to know the road
conditions in advance, slow down and use your shoulder’s force to control the handle.
Suggestion: Do not load objects on the front pedals unnecessarily, to avoid affecting the riding
safety and the operation of steering handle.
6.
USE GENUINE SPARE PARTS
In order to maintain the motorcycle’s best performance, each part’s quality, material, and machined
precision must conform with the design requirements. “SYM Genuine Spare Parts” were made from
the same high quality materials used for the original motorcycle. No parts would be sold to the market
until they could meet the designed specifications through sophisticated engineering and stringent quality
control. Therefore, it is necessary to purchase “SYM Genuine Spare Parts” from “Authorized
Dealers or Franchised Dealers” when replacing spare parts. If you buy cheap, or fake substitute parts
from the market, no guarantee can be provided either for the quality or durability. Also, it may result in
unexpected troubles and lower the motorcycle’s performance.
Always use Genuine Spare Parts to keep your motorcycles pure blood and to ensure its long
service life.
CAUTION:
The rider’s feeling on the handle is slightly different with a load or without a load.
Overload may cause the handle to swing and affects the riding safety.
Therefore, do not overload your motorcycle.
CAUTION:
Do not place flammable materials such as rags between the body side cover and engine to
avoid components damaging by fire.
Do not load objects on areas not specified for loading to avoid damage.
SUGGESTION
To maximize the motorcycle’s performance and prolong its service life:
The first month or first 1000km is the wear- in period for the engine and components.
Avoid rapid acceleration, and keep the speed below 60km/hr.
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CAUTION:
Do not wipe plastic components, e.g. instrument panel, headlight, with organic solvents such as
gasoline…etc to avoid damaging these components.
The panel figure for speedometer may vary from model to model, but the location usually are the
same.
7.
USE OF EACH COMPONENT
(The following is 4 stroke air cooling 110 c.c. Cub’s basic operation, and they could vary
from different individual models. Please consult the end of this manual.)
§GAUGES §
Speedometer：
Indicates driving speed（km/h）.
Odometer：
Indicates total accumulated distance traveled.
High Beam Indicator：
This indicator comes on with high beam
headlight is turned on.
Turn (left/right) 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.
Transmission Neutral Indicator：
This indicator shows transmission neutral.
Gear Position Indicator：
This indicator comes on with gear position.
Fuel Meter:
The pointer in this meter shows how much
fuel remains in the tank.
The pointer stays in “E” position when key
switch is turned to “OFF”.
When the meter needle reaches “E” with the
ignition switch on, refill the tank as soon as
possible.
High Beam Indicator
Odomete
r
Speedometer
Turn Signal
Indicator
Transmission
neutral Indicator
Gear position
indicator
Turn Signal Indicator
Fuel meter
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§OPERATION OF IGNITION SWITCH §
“ON” position:
Engine can be started and lights can be operated in this
position.
Ignition switch key can not be removed.
“OFF” position:
Engine and lights are shut off and can not be started
in this position .
Ignition switch key can be removed.
“STOP” position:
Engine is shut off when the ignition switch turn to this
position .
The position light and the rail light will come on.
Ignition switch key can be removed.
§OPERATION OF STEERING HANDLE LOCK SWITCH §
“Steering handle lock” position
Turn the steering handle to left and press ignition switch
key into. Push the key and turn to “LOCK” position.
The steering handle is locked in this position.
Ignition switch key can be removed.
When unlocking, simply turn the key from “LOCK”
to “OFF” position.
§USE OF BUTTONS §
IGNITION SWITCH
CAUTION:
Never operate the ignition switch key when the motorcycle is running. To turn the ignition
switch to the “OFF” position, 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.
To prevent the motorcycle from be stolen, lock the steering when parking.
Always remove the key and be sure to take the key away with you after locking the steering
handle before leaving your motorcycle.
If ignition switch remains in the “ON” position for a prolonged period after the engine has been
stopped, the battery’s capacity will be reduced and this may affect the engine’s start ability.
Light Switch
Electrical starter
button
Horn Switch
Turn Signal
Switch
High/Low Beam Switch
P
LOCK
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Light Switch
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. This is the high beam of headlight
switching switch.
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. This is the low beam of headlight switching switch.
(Please turn to low beam when riding in city)
When the switch is turned to this position, all lights will go off.
Electrical Starter Button
This is a starting motor button (switch) for engine starting.
Check the gear position before starting the engine.The gear must be at neutral.
With the main switch “ON”,press this button slightly to start the engine.
High/Low Beam Switch
This is the high and low beam of headlight switching switch. Press this switch to switch between
high and low beams.
This is for high beam.
This is for low beam. (Please turn to low beam when riding in city)
Horn Switch
Press this button down when ignition switch is in the “ON” position, the horn will sound.
Turn Signal Switch
Turn signal lights are used when turning left/right or changing lane.
Turn ignition switch to the “ON” position, 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.
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 except squeezing the clutch
lever or the gear must be at neutral.
Do not use light system. Turn headlight and turn signal lights to the “●” position when the
engine is being started.
CAUTION:
Do not press this button when you are in “No Horn” area.
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§SAFETY HELMET HOOK §
Insert ignition switch key into the lock on the rear of
the left body side cover, and turn the key clockwise
then the lock can be opened, and hook the safety
helmet chin belt onto the hook, Press the seat down
and the lock will be locked automatically.
§FUEL TANK CAP §
1. Insert ignition switch key into the lock on the rear of the left body side cover, and turn the key
clockwise, then the lock can be opened, the turn the fuel tank cap counter-clockwise, so the cap
can be removed.
2. Do not fill above the fuel upper limit when refueling.
3. Align the “△” mark on the cap ,turn the fuel tank clockwise to close the fuel cap. press the seat
down and the lock will be locked automatically.
§FUEL COKE §
The fuel cock is at the left side of the carburetor.
Cut off the fuel supply.
Normal fuel supply.
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 of the fuel tank that may
damage the fuel tank’s painting, in serious cases, it
may cause a fire to burn down the motorcycle.
Make sure the cap has been tighten properly.
CAUTION:
Set the cock in “ ’’ position when the fuel tank is
full.
Set the cock in ”
●” position when cleaning the fuel
cup or disassembling the carburetor.
●
CAUTION:
Do not hang the safety helmet onto this hook
when riding to avoid damaging motorcycle and
loosing safety helmet’s function.
Helmet hook
10
§BRAKE §
Avoid unnecessary sudden braking.
Use front and rear wheel brakes simultaneously when braking.
Avoid brake continuously for a long period of time because that may overheat the brakes and
reduce its braking efficiency.
Slow down and brake early when riding in rainy days on slippery roads. Never apply the brakes
suddenly to prevent skidding and falling.
Using only the front brake or the rear brake increases the risk of falling because the motorcycle is
tend to pulled to one side.
《Engine Brake》
Return the throttle valve handle back to its original position, and apply engine brake.
It is necessary to apply brake both for front wheel and for rear wheel intermittently when riding on a
long or stiff slope.
§SEAT LOCK §
Unlock
Insert the ignition key into the seat lock and turn it clock wise to unlock.
Lock
Press down on the rear of the seat until the
seat lock engages securely.
Life the seat when using the luggage box,
or refilling the fuel tank.
For Front Wheel
For Rear Wheel
CAUTION:
Do not put the key in the bottom of the seat. The key can not be put out if the set has been
locked.
Make sure that the seat is locked securely pulling the seat up.
Seat lock
Ignition key
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8. IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE
Method of Starting the Engine
1. Turn the fuel cock to ” ”
position.
2. Turn the ignition switch to the
“ON” position with ignition key.
3. Shift the transmission into
neutral. The neutral indicator
(green) lights.
4. Pull the choke lever up (choke valve closed
position).
5. Don’t turn the throttle grip, press the starter
button.
CAUTION:
Release the starter button immediately after starting the engine.
Don’t press the starter button when the engine is running.
If the engine fails to start after 3~4 attempts with the starter button, open the throttle.
Allow the engine to warm up 2~3 minutes after started, then push the choke lever close
(Apposition).
CAUTION:
Please check the oil and fuel volume before starting the engine. Start the engine in a ventilative
area.
Closed
Open
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【When starting engine with kick starter】
After step 1~5 is completed, press the kick starter forcefully by foot with the throttle valve handle
at the close position.
If engine is difficult to start with the kick starter when the engine is cold, rotating the throttle valve
1/8~1/4 turns will make the start easier.
Put the kick starter back to its original position after the engine has been started.
CAUTION:
If engine can not be started after starter motor running for 3~5 seconds, turn the throttle valve
handle 1/8~1/4 turns, and then press starter button again for an ease start.
In order to avoid damaging the starter motor, please do not press the starter button continuously
over 15 seconds.
If engine still can not be started after pressing starter button over 15 seconds, stop and wait for
10 seconds before start it again.
It is harder to get the engine started after the motorcycle has been left idle for a long time or
after refueling only after the fuel has been depleted. Then, it is necessary to press starting
lever or starter button several times, and keep the throttle valve handle at the close position to
start the engine.
It may need several minutes to warm up engine if it is a cold start.
Exhaust contains harmful gases (CO), therefore please start the engine at a well ventilated
place.
CAUTION:
Firmly support the motorcycle with the main parking stand before starting the engine with the
kick starter arm.
Start engine with the kick starter arm occasionally to prevent it from loosing its function because
of unused for a long time.
1/4
1/8
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9. RIDING THE MOTORCYCLE
§SET UP RIDING §
Check the brakes and tire pressure before riding.
Ride the motorcycle from left side, put the foot on the
ground to prevent it from falling over.
Start and warm up the engine.
1. Shift the transmission into neutral. Warm up the engine
2~3 minutes after be started, then push shift pedal
down to engage the 1st gear.
2. Open the throttle gradually, then the
motorcycle will move slowly. Push shift pedal
down to engage the 2
nd
gear.
Change the gear position according to the driving
speed.
The relationship between speed and gear
position is on the right table.
Change the gear position according with the
table can get the good performance and fuel
economy of the motorcycle.
CAUTION:
After the engine was started and before
riding, don’t operate the throttle grip rapidly to
rise up the engine speed.
CAUTION:
During the first 1000km, it is better to drive in low speed for running the engine in good condition and
long life.
Change the engine oil and clean the oil filter screen after first 300km.
It is better to drive in low speed after have just replaced the engine oil.
Warm up the engine before start riding.
Speed
1
st
gear
2
nd
gear
3
rd
gear
4
th
gear
20 40 60 80 100 120 140
CAUTION:
Do not operate the transmission when the
engine is not running.
Do not push the shift pedal rudely to
prevent the transmission from be damaged.
Control the driving speed for passing other
vehicles.
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§DRIVING IN GRADE §
Up Grade
Driving up a slightly grade can drive with high position gear.
Under heavy loading or steep grade driving condition, It
must drive with low gear.
Down Grade
Close the throttle and operate the brakes when driving
down a slight grade. Shift the gear to low gear in case of
heavy loading or driving down steep grade condition.
§TRANSMISSION OPERATION §
The change pedal is located on the left side of the
engine. Shift transmission to the lower gear when
driving hard or down grade.
Don’t operate the transmission when the engine is not
running.
Don’t operate change pedal rudely, or the
transmission will be damaged.
Shift the gear to the next lower position for overtaking
other vehicles.
This limit speed for shift to lower gear.
4
th
→ 3
rd
Below 50~40km/h
3
rd
→ 2
nd
Below 40~30km/h
2
nd
→ 1
st
Below 30~20km/h
§CORRECT RIDING §
Optimum Start Riding
Turn on the turn signal and make sure of no vehicle
coming behind before start riding.
CAUTION:
Braking must apply both the front and rear brakes.
15
§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.
Maintenance Performance-During The
Initial Period, It Is Better To Drive In Low
Speed For Running The Engine In good
condition and long life.
During the first month or first 1000 km, never excess
40km/h.
Avoid abrupt acceleration.
Avoid engine running in RPM (over 6000RPM) while
under no load.
Do not operate throttle full open from idle running of
engine.
Never Making Abrupt Braking Or Making A
Full Turn.
Extreme braking or making a full turn may cause
wheel slip.
When riding in wet or rainy conditions, making
abrupt braking or making a turn may cause wheel
slip, may lose control of the motorcycle.
Extreme Caution When Riding In Rainy
Condition.
When riding in wet or rainy. Conditions needs longer
distance to stopping the motorcycle. Slow the
motorcycle down early to brake.
When descending a grade, close the throttle fully
and use both brakes to slow the motorcycle.
Deceleration
Acceleration
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§PARKING METHOD §
Brake-Apply both The Front And Rear Brakes.
Close the throttle then squeeze the brake control lever.
“Brake slightly in beginning, then squeeze tightly”, it is the best way to brake.
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 the
“OFF” position to shut off the engine.
4. Get off the motorcycle from left side after the
engine has been stopped, and select a parking
place where the motorcycle will not interfere
with traffic and the ground is level, then put
down motorcycle’s main parking stand.
5. Hold the steering handle with your left hand,
and hold down the front end of saddle or hold
the parking handle on the lower-left side of
saddle with your right hand.
6. Press the main parking stand with your right
foot, put down the main parking stand firmly on
the ground.
To remind you: Lock the steering handle and
remove the key after parking to
prevent the motorcycle from
being stolen.
CAUTION:
Park your motorcycle at a safe place where it will not interfere with traffic.
CAUTION:
Use of only the front brake or rear brake may cause wheel slip.
17
10. INSPECTION AND MAINTENANCE BEFORE RIDING
(Please refer to the components location diagram for the following components.)
§ROUTINE INSPECTION §
Check Items Check Key Points
Engine Oil Is there enough engine oil?
Fuel Is it enough? Is it Octane 90 or above
Front
Braking condition?
(Brake lever free play: 10~20mm)
Brake
Rear
Braking condition?
(Brake
pedal free play: 20~30mm)
Front
Is tire pressure normal?
(Standard: 1.75kg/cm
2
)
Tires
Rear
Is tire pressure normal?
(Standard: 2.0 kg/cm
2
for 1 person, 2. 25 kg/cm
2
for 2 persons)
Steering Handle Does the handle vibrate abnormally or is difficult to turn?
Speedometer, lights, and
rearview mirror
Is it operated properly?
Do lights come on? Can it be seen clearly from behind?
Tightness of Main Components Are screws, nuts loosen?
Abnormal Points Do the previous troubles still exist?
§FUEL INSPECTION §
Check fuel quantity, see if it is enough for your destination.
When the indicator of the fuel unit turn to ”E” position, please refill
the tank at once.
This motorcycle’s engine is designed for using the unleaded fuel
of Octane 90 or above.
Firmly secure the main stand on the ground, shut off the engine
and keep flames away from the motorcycle when refueling.
Turn and open the fuel tank cap, then refill the gasoline.
Do not fill above fuel upper limit level when refueling.
Turn the fuel cock to the ”
” position after refilling the gasoline.
Leakage
Check fuel cup, tank, tube and carburetor for leaks.
CAUTION:
If any problem founded during routine inspection, correct the problem before using the motorcycle
again, have your motorcycle checked and repaired by the “Dealer or Authorized service
personnel” if necessary.
CAUTION:
Stop the engine and keep away from spark and flames when refilling the fuel.
Make sure that the fuel tank cap has been locked tightly after refilled.
18
§ENGINE OIL INSPECTION AND CHANGE §
INSPECTION:
1. Engine oil is very important to good effect and
long life of operating engine. So, it should be
checked carefully and usually.
2. Use the main parking stand to support the
motorcycle on a level ground, remove the
dipstick after engine stopped for 3~5 minutes.
Wipe oil off the dipstick and then insert it into
the guide tube again (Do not rotate it.)
3. Remove the dipstick and check whether oil
level is in between the upper and lower marks.
Add oil to upper limit if oil is under the lower limit.
(Check cylinder, crankcase…etc for leakage).
OIL CHANGE:
Change period: First 300km for new motorcycle, and
the engine oil has been just renewed every 1000km
thereafter.
Service more frequently when riding in dusty or cold
area.
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 SYM SUPER 4X SH/CD SAE
10W-30 grade or better engine oil. Otherwise,
damage will not be covered by warranty.
Oil Capacity : 0.9 Liter (0.8 liters for routine change),
oil filter change: 0.8 liters.
WARNING:
Oil level will not be correct when checking the oil
level with the motorcycle parked on an unleveled
ground or immediately after the engine stopped.
Engine and exhaust pipe are hot right after engine
stopped. Pay special attention not to get burned
when checking or replacing engine oil.
If the oil lever approach lower limit again after
refilled, check the engine for leaks and refill it
again.
Keep away from spark and flames when refilling
the oil.
Screw in the drain bolt and the oil gauge tightly
after refilled.
Drain bolt
Upper limit
Lower limit
Oil in
Oil gauge
19
§INSPECTION AND ADJUSTMENT OF BRAKE FREE PLAY §
INSPECTION: (Brake lever and pedal free play must be checked with the engine shut off.)
Brake lever and pedal free play for front and rear wheels.
When 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.
When checking the foot-braking pedal for rear wheels, its free play (the stroke of foot-braking pedal
from no braking to initial braking) should be 20~30mm. It is abnormal if the feel is spongy when
press the foot-braking pedal forcefully.
Adjustment:﹙Drum type﹚
The indentation of brake adjustment nut must be aligned with the pin. (see below figure)
Turn the adjustment nut on brake arm of front and rear wheels to adjust the free play of
hand-brake lever.
Hold the hand-brake levers after adjusting with both hands until there is effective brake feeling.
Measure the free play with a ruler.
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.
Pin
A
djustment nut
A
djustment nut
To increase free
To decrease free play
20~30 mm
10~20 mm
20
§DISK BRAKE INSPECTION§(Applicable for model equipped with disc brake.)
Visual check brake lines for leakage, or damage, check
brake lines connections for looseness using a wrench or
similar tool, and check whether steering handle vibration in
driving, or any parts’ interference may have damage the
brake lines. If so, bring your motorcycle to your dealer for
repairing or service.
（leak, damaged, looseness of brake line）
（Checking front brake lining）
check the brake from behind the brake
caliper. The brake pad must be replaced
with new lining when the brake pad wear
limit reaches the brake disk.
（Checking oil quantity in brake oil reservoir）
Park the motorcycle on a lever ground, and
check if fluid lever is under the “LOWER”
mark. Recommended Brake Fluid: WELL
RUN BRAKE OIL (DOT 3).
（Replenishment of front wheel brake fluid）
1.Loosen the screws and remove the master cylinder
cover.
2.Wipe clean foreign materials, dirt around the
reservoir, being careful not to let foreign materials
fall into the reservoir.
4. Remove the diaphragm plate and the diaphragm.
5. Add brake fluid to upper lever.
5.Install the diaphragm plate and the diaphragm, and
install the master cylinder cover.
6.please note the diaphragm direction, and do not let
foreign materials fall into the reservoir. And tighten
the master cylinder cover securely.
CAUTION:
Please drive your motorcycle on a dry road
surface slowly and operate front and rear brakes
in order to find out if there is any malfunction so
as to ensure the motorcycle is at optimum
condition and safe ride. .
Brake
disk
Brake calipe
r
Brake pad wear
limit grooves
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.
Screw
Master cylinder
cover
Diaphragm
Uppe
r
Brake
fluid
Hose connection
Lower leve
r
21
§CLUTCH ADJUSTMENT§
The function of the clutch is translating the engine
power to the rear wheel, if the clutch adjustment is
incorrect, it will be hard to shift or make the clutch
plates slip.
Adjustment:
Loosen the lock nut first.
Rotating the clutch adjust nut counter-clockwise
1turn.
Rotating the clutch adjust nut clockwise 3/4 turn
slowly until feel the pressure appreciably.
Tighten the lock nut securely when finished.
§THROTTLE GRIP FREE PLAY ADJUSTMENT §
Correct free play allows throttle grip 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 grip 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 grip cable is interfered.
3. Check to see if the throttle grip cable is
obstructed by other cables preventing it
from being operated smoothly.
Lock nut
A
djust nut
CAUTION:
Make sure the shift is easy to be done after
adjustment.
Clutch adjust
nut
Lock nut
22
§DRIVE CHAIN §
The drive chain will be elongated and slackened as the
using time passed. So it is necessary to be inspected
and adjusted periodically.
<Drive Chain Inspection>
The drive chain check lie under drive chain center,
the slack of the chain should be 10~20mm.
Stand the motorcycle with main stand upright.
Turning the rear wheel, check the drive chain for
free operation and noise.
Adjust the drive chain if there is any abnormality.
<Drive Chain Adjustment>
1. Loose the rear wheel axle nut.
2. Turn the adjusting nut for adjustment. Tighten the
axle nut after adjusted.
3. Check the rear brake pedal free play and adjust if
necessary.
§CAM CHAIN ADJUSTMENT§
The cam chain auto pensioner need not adjustment. If
there are any problem, please see the authorized SYM
dealer or the service centers for inspection as soon as
possible.
§CARBURETOR ADJUSTMENT§
Start and warm up the engine to normal operating
temperature.
Set the engine idle speed to 1200 rpm by adjusting the
stop screw. Turning the stop screw clockwise will increase
the rpm, and turning in the stop screw counter- clockwise
will result in a decrease.
Turn the pilot screw clockwise until the engine misses or
decrease in speed again. Set the pilot screw exactly
between these two extreme positions to adjust fuel mixture.
Usually the correct setting will be found to be 1~1/2 turns
open from a fully closed position.
CAUTION:
The right and left adjuster must be adjusted to
the same scale.
Clean and lubricate the drive chain frequently.
A
xle nut
A
djuster
Scale
The stop screw
The pilot
screw
Cam chain
adjustment
23
§TIRE INSPECTION §
Tires should be checked and inflated with the engine shut off.
If a tire’s ground contacting curve is abnormal, check it with an air pressure gauge and inflate it
to the specified pressure.
Tires pressure must be checked with an air pressure gauge when cold.
Visual check tires for frontal and lateral side walls
for crack or damage.
Visual check tires for any nails or small stones
wedged in the tread.
Check the “tread wear indicator” condition to see if
tread groove depth is insufficient.
A tire with a wear bar showing is worn out and
should be replaced immediately.
§STEERING HANDLE FRONT SHOCK
ABSORBERS INSPECTION §
Perform this check with engine shut off and ignition
switch key removed.
Visual check front shock absorbers for damage.
Operate steering handle up and down, and check front
shock absorbers for noises due to bends.
Check the bolts and nuts of front shock absorbers with
wrenches for tightness.
Shake steering handle up & down, left & right, and
front & rear to check if it is loosen, has too much
resistance and pulls to one side.
Check steering handle if it is being pulled too tight by
the brake cables.
Take your motorcycle to Authorized Dealer or
Franchised Dealer for a check or adjustment if any
abnormal conditions are found.
PLEASE REFER TO SPECIFICATIONS FOR STANDARD TIRE PRESSURE
CAUTION:
Abnormal tire pressure, wear, or crack is the most important cause that results in the loss
control of the steering handle and a punctured tire(s).
Tread wear
indicato
r
Crack and
dama
g
e
Foreign materials
(nails or small
stones)
24
§CHECING THE LUBRICATION OF BODY’S VARIOUS MECHANISMS §
Check the body’s pivot points if they have enough lubrication.
(For example, the pivot points on the main stand, the side stand, and the brake lever…etc.)
§INSPECTION AND MAINTENANCE OF BATTERY §
The electrolyte will vaporize so it is necessary to
inspect and refill if necessary. Have your
motorcycle checked by SYM Authorized Dealer or
Franchised Dealer should any abnormality is found.
Open up the seat, the electrolyte level should be
between the upper and lower limit.
If the electrolyte level is lower than the lower
limit, remove the battery, then remove the cap
from each cell and refill the distilled water to the
upper limit.
﹙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 to the “OFF” position, then
remove negative cable screw firstly and disconnect
the negative cable. Then, remove positive cable
screw and positive cable.
CAUTION:
Clean the battery posts with warm water if the
posts are eroded and have some white powders
on them.
If there is an obvious erosion on the terminals,
disconnect the cables, then clean the erosion
off with a steel brush or a piece of sandpaper.
Install battery cable after cleaning and apply a
thin coat of grease on the terminals.
Install battery in reverse order of removal.
Negative
Positive
A
ssembly position for
brake control lever
Distilled water
Breather tube
Upper
Lower
25
§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 right side cover, 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.
Fuses must be firmly secured with wire connectors when replacing. Loose connections will result
in overhead and damage.
Use only parts having the specified specification to replace electrical components such as light
bulbs. Using parts not having the specified specifications for replacement may cause the fuse to
blow and over-discharge the battery.
Avoid spraying water directly on or around fuse box when washing the motorcycle.
If the new fuse burn out quickly again, please check the faulty reason before replace it again.
Take your motorcycle to your dealer for an inspection if a fuse is blown by unknown causes.
CAUTION:
In order to prevent electric leakage and self-discharge when the battery sits idle for long
periods. Remove battery from motorcycle, store it in a well- ventilated and dimly lighted place
after the battery has been fully charged. Disconnect battery’s negative cable if the battery is still
kept on the motorcycle.
If the battery needs to be replaced, replace with a same type battery.
The electrolyte level is incorrect if the motorcycle is not standee on level ground.
Don’t over fill the distilled water other wise the over flay acid fluid will corrode parts.
Keep away from sparks and flames when dealing with the battery.
Don’t clog the breather tube.
The breather tube clogged will break the battery because the inner pressure will be up.
Keep your eyes and skin away from the electrolyte, if touched by the electrolyte, clean with
water immediately or see the doctor.
Notice the polarity of the cables when removing and assembling.
Fuse
Battery
Wire
【REMOVE】
【INSTALLATION】
Press in from above
Fuse
connectors
26
§CHECKING THE TURN SIGNAL LIGHTS AND HORN §
Turn the ignition switch key to the “ON” position.
Turn on the turn signal light switch, and
make sure that the front & rear and left &
right signal lights flashes and also check if
the warning buzzer sounds.
Check turn signal light covers if they are
dirty, crack, or loosen.
Press horn button to check if it sound.
§CHECKING THE HEADLIGHT AND TAIL LIGHT §
Turn the ignition switch to “on” position.
Turn on the headlight and taillight switch.
Check if the headlight and taillight come
on.
Check the brightness and light angle of the
front light by wall to see if it is correct.
Check the light cover if it is dirty, crack, or
loosen.
§CHECKING THE BRAKE LIGHT §
Turn the ignition switch key to the “ON”
position, hold the hand-braking levers for
front and rear wheels. Check if the brake
lights come on.
Check the brake light cover if it is dirty, crack,
or loosen.
CAUTION:
Specified specification bulbs should be used for
turn signal lights. Otherwise, the normal
operation of turn signal lights will be affected.
Turn on the turn signal light before turning or
switching lane to warn driver of vehicles behind.
Turn off the turn signal light immediately by
pressing its button down after using. Otherwise,
the flashing of twin signal lights may confuse the
drivers of vehicles behind.
CAUTION:
Use only specified specification bulbs, do not use bulbs with different specifications to avoid
damaging electrical system, burning out bulbs, and discharging the battery.
Do not modify or add other electrical components to prevent over load or short circuit which may
result in a fire and burn down the motorcycle in serious cases.
27
§CHECKING THE SPARK PLUG §
The electrodes too dirty or excessive air gap will cause hard or fail starting,
so it will be inspect and adjusted periodically.
Remove the cap of spark plug cable (remove the spark plug using the spark
plug wrench in the tool kit.
Check the electrode if it is dirty or fouled by carbon deposits.
Remove the carbon deposits on the electrode with steel wire, and clean the
spark plug with gasoline, then, wipe dry with a rag.
Check the electrode, and adjust its gap to 0.6~0.7 mm. (Check it with a
feeler gauge)
Hand tight the spark plug as far as it can go and then tighten it another
1/2~3/4 turns with a wrench.
§CHECKING THE AIR CLEANER §
If air cleaner is clogged by dust, engine performance and fuel
economy will be affected, so, it’s important to do periodic
maintenance.
1. Remove the front body side cover.
2. Remove the air cleaner cover by removing the four screws.
3. Remove the air cleaner element. Wash the element in clean
solvent and wrap it in dry cloth to try thoroughly.
4. Soak the element in clean gear oil (SAE 30W) then squeeze
out excess oil and install it back.
Procedures for cleaning air cleaner element:
Gasoline or low flash point solvents are highly flammable and must
not be used to clean the element.
Don’t keep too much oil in the element, or the engine performance
will be affected.
1.clean. 2.squeeze dry. 3.soak in engine oil. 4.squeeze dry
CAUTION:
Dust deposit is one of the major causes of reducing output horsepower and increasing fuel
consumption.
Change the air cleaner element or clean it more frequently to prolong the engine’s service life if
the motorcycle is driven on dusty roads very often.
If air cleaner is installed improperly, dust will be absorbed into cylinders, which may cause a
premature wear and reducing output power and engine life.
Be careful not to soak the air cleaner when washing the motorcycle. Otherwise, it will cause
engine hard to start.
Water enters the air cleaner will cause the engine fails to start ,so do not allow water to enter the
air cleaner when washing the motorcycle.
WARNING:
The engine is very hot after running. Pay attention not to get burned.
※Use only spark plugs suitable for the engine specifications of this motorcycle recommended by the
manufacturer. (Refer to specifications.)
0.6~0.7 mm
28
§WIRING RUBBER CAP §
The rubber caps are used for protecting the wires of
the wiring. Check the caps frequently for settling at
right position.
Do not direct water under pressure against the wiring
or use brush when washing motorcycle. If the wiring
is very dirty，use cloth to scrape it.
§BACK MIRROR §
Sit on seat, check and make sure the image of the back mirrors is suitable.
§LICENSE PLATE §
Check the license plate for dirt ,injury and damage. Make sure it is secure.
Check The Exhaust for unusual.
Make Sure All The Previous Abnormalities Have Been Solved.
§CDI IGNITION SYSTEM §
The condenser discharge ignition system uses the electric energy that is stored in the “A.C. generator
exciting coil” to supply the ignition coil and make the spark plug generating spark at the right time.
The advantage of CDI system:
1. Correct ignition timing, no deviation, and need not adjust the
timing.
2. No contact wearing, waterproof, vibration proof.
3. Generate high voltage in short time, reduce the pollution of the spark plug.
4. Easy to start, high ignition energy, excellent combustion efficiency, high power and reducing fuel
consumption.
§TOOL KIT §
The tool bag is stored below the battery. The tools in the tool bag can support general maintenance or
repair.
Rubber cap
Rubber cap
Check points
Tools box
29
11. WHEN THERE IS AN ABNORMAL CONDITION OR A TROUBLE
§DIAGNOSIS WHEN ENGINE DOES NOT START §
(1). Has the ignition switch key
been turned to the “ON”
position?
(2). Is there enough fuel in the fuel
tank?
(3). Do Shift the transmission
into neutral ? The neutral
indicator (green) must
light.
(4). Do you rotate the throttle valve handle while
pressing starting the button?
(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.
【Have your motorcycle checked by authorized dealer or franchised dealer immediately if there are no
problems with the above items and engine still can not be started.】
12. C.D.I. ELECTRICL IGNITION SYSTEM
The charge and discharge principle of a condenser is adopted for the C.D.I system to supply electrical
energy created by generator’s coil, to the ignition coil in accordance with specified ignition timing so that
the spark plug may generate sparks as required.
13. SUGGESTIONS ON ENGINE FUEL
This motorcycle is designed to use UNLEADED gasoline of Octane No. 90 or higher.
If the motorcycle is operated in high attitude (where the atmosphere pressure is lower), it is
suggested that the air/fuel ratio should be readjusted to maximize the engine performance.
1/4
1/8
Turn Signal Switch
Horn Switch
Fuel tank
30
14. CAUTIONS FOR RIDING MOTORCYCLE
1. Raise the motorcycle with the main stand, and to stand on the saddle left side.
Push the motorcycle forwarding to raise the main stand.
2. Get on the motorcycle from the left side, and sit on the saddle properly, keep your right foot firmly
on the ground to prevent the motorcycle from falling.
3. Start engine, squeeze the clutch lever fully, push shift pedal down to engage the 1st gear, release the
clutch lever slowly
, rotate the throttle valve handle slowly, and then the motorcycle will begin to move.
【Do not use the brake suddenly and make a sharp turn】
Rapid braking and sharp turning will cause slip and fall.
Rapid braking or sharp turning will cause slipping, lateral slipping, or fall especially in rainy days
when the road is wet and slippery.
【Drive with extreme caution during rainy days】
The brake distance in rain day or on wet road will longer than that on a dry road. Therefore,
slow down and prepare to apply the brake earlier.
The throttle valve handle should be released, and the brakes should be properly applied as it is
needed while reducing the speed when going down a slope.
VEHICLE ABNORMAL OR BREAKDOWN
Fails to start the engine.
The engine shutting off when riding.
If those conditions happen, first, check the
following items by yourself
1. Is there any gasoline in the tank?
2. Have you operated the starting essential
points correctly?
NOTE:
If there is any abnormal or breakdown of the
motorcycle, go to your dealer for inspection as
soon as possible.
CAUTION:
Never started engine before raise the main stand.
CAUTION:
Apply foot brake on the rear wheel before driving off.
CAUTION:
Rapidly rotate the throttle valve handle or release the clutch lever may cause the motorcycle
moving forward suddenly and it is very dangerous.
Make sure the side parking stand is spring back completely before driving off.
31
15. 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) I C R
2 Oil filter (Screen) C C
3 Engine oil R Replacement for every 1000KM
4 Tire, pressure I I
5 Battery I I
6 Spark plug I I R
7 Carburetor (idle speed) I I
8 Steering bearing and handles I I
9 Check fuel for leakage I I
10 Check crankcase for leakage I I
11 Drive chain I R
12 Fuel tank switch and lines I I
13 Throttle grip operation and cable I I
14 Engine bolts and nuts I I
15 Cylinder head, cylinder, and piston I
16 Exhaust system/cleaning carbon I
17 Valve clearance I I
18 Shock absorbers I I
19 Front/rear suspension I I
20 Main/side stands I I/L
21 Crankcase Blow-by system I I
22 Clutch disk I
23 Clutch free play I I
24 Brake cable/brake lining (pad) I I
25 Bolts/nuts for each components I I
☆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 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.
【Notes in the remarks are used to indicate the applicable models.】
32
16. SPECIFICATION
Model
Item Specification
XS110-5
Len
g
th 1890 mm
Width 680 mm
Hei
g
ht 1090 mm
Wheel base 1205 mm
Net Wei
g
ht 102 k
g
T
yp
e 4- stroke sin
g
le c
y
linder en
g
ine S OHV
Fuel Unleaded
g
asoline
Coolin
g
t
yp
e Ai
r
-cooled
Dis
p
lacement 107.0 c.c.
Com
p
ression ratio 9.0:1
Max. HP 4.5 kw/7500 r
p
m
Max. tor
q
ue 7.2 N.m/6000 r
p
m
En
g
ine idle
1500 ±150 r
p
m
Starting methods Electrical & foot type
Front shock absorber Telescope
Rear shock absorbe
r
Telesco
p
e
Clutch Wet disk t
yp
e
Transmission Gea
r
Front tire 2.50-17
Rear tire 2.75-17
Wheel Aluminum allo
y
Tire pressure
Front: STD 1.75kg/cm
2
,
Rear: STD 2.00kg/cm
2
for 1 person, 2.25kg/cm
2
for 2 person
Front brake Disk type (Ø 220 mm)
Rear brake Drum type (Ø 110 mm)
Front light bulb(high, low) 12V 25/25W
Brake light bulb(tail light) 12V 5W/21W
Turn si
g
nal li
g
ht bulb 12V 10W
S
p
eedometer li
g
ht bulb 12V 1.7W
En
g
ine oil ca
p
acit
y
0.9 L
(
0.85 L for chan
g
e
)
Fuel tank ca
p
acit
y
3.5L
Fuse 10A
S
p
ark
p
lu
g
A7RTC
Batter
y
ca
p
acit
y
12V 5Ah
Air cleaner Sponge type
Fuel tank cap Close lock type
Rear grab frame Can load cargo (Under 5kg)
1 …

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