Sym HD 200 EVO Owner's Manual

OWNER’S MANUAL

THE ARTICLES MENTIONED BELOW ARE APPLICABLE ONLY
FOR THE UNITED STATES AND CANADA.

1. NOISE EMISSION WARRANTY

SANYANG INDUSTRY CO.,LTD. warrants that this exhaust system, at the time of sale,
meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first
person who buys this exhaust system for purposes other than resale, and to all subsequent
buyers. Warranty claims should be directed to:
3,chung-Hua Road, Hukou, Hsin-Chu Taiwan, R.O.C
Tel:[phone] Fax:[phone]

2. TAMPERING WARNING

Tampering with noise control system prohibited. Federal law prohibits the following acts or

causing thereof:

(1) The removal or rendering inoperative by any person other than for purposes of

maintenance, repair, or replacement, of any device or element of design incorporated
into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or

(2) The use of the vehicle after such device or element of design has been removed or

rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

(1) Removal of, or puncturing the muffler, baffles, header pipes or any other component

which conducts exhaust gases.
(2) Removal or puncturing of any part of the intake system.
(3) Lack of proper maintenance.

Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts
other than those specified by the manufacturer .

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3. SAFETY INFORMATION

! Always wear your helmet (dot approved) correctly fastened. Do not carry loose items and

always wear suitable protective clothes, and protective eyewear.

! Good psychophysical conditions are very important for safe operation.
! Do not operate under the influence of drugs and/or alcohol.
! Do not operate in state of physical fatigue or drowsiness.
! Slow down on slippery surfaces , unfamiliar terrain and when visibility is reduced.
! Be alert when operating this vehicle.
! Do not exceed weight capacity.
! The safety, stability and handling of this motorcycle may be adversely affected by the

addition of accessories or luggage.

! Do not install accessory or replacement parts not approved by sym.
! Failure to follow these warnings could lead to an accident, serious injuries or death.
! Use unleaded fuel octane rating (R+M)/2 method of between 87&92.
! Read owners manual carefully before operating this scooter.
! Obey posted speed limit and other traffic signs and signals.

4. SAFETY DEFECT REPORT

SANYANG INDUSTRY CO., Ltd.

NO. 3,chung-Hua Road

Hukou Shiang

Hsin-Chu County, 303

Taiwan, R.O.C

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury
or death, you should immediately inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying Sanyang Industry Co., Ltd.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in and individual problems between you, your
dealer, or Sanyang Industry Co., Ltd.

To contact NHTSA you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236
(TTY：1-800-424-9153)；go to http://www.safercar.gov; or write to ：

Administrator, NHTSA

400 Seventh Street SW.,

Washington, DC 20590

You can also obtain other information about motor vehicle safety from
http://www.safercar.gov.

1. Contents

1

1. Contents ......................................................................................................................... 1

2. Control Location ............................................................................................................... 3

3. Before Riding .................................................................................................................. 4

4. Safe Riding ..................................................................................................................... 5

5. Riding ............................................................................................................................. 6

6. Use Genuine Spare Parts ............................................................................................... 6

7. Use of Each Component ................................................................................................ 7

Gauges ............................................................................................................................ 7

Operation of Ignition Switch ................................................................................................ 9

Use of Buttons ................................................................................................................. 10

Safety Helmet Hook ......................................................................................................... 11

Seat Lock ......................................................................................................................... 11

Luggage Box ..................................................................................................................... 12

Fuel Tank Cap ................................................................................................................. 12

Brake ............................................................................................................................. 12

8. Important Points and Cautions for Starting Engine ...................................................... 13

9. The Best Way to Ride off .............................................................................................. 14

The Control of Throttle Valve Handle .................................................................................. 14

Parking Method ............................................................................................................... 14

10. Inspection and Maintenance before Riding .................................................................. 15

Routine Inspection ........................................................................................................... 15

Engine Oil Inspection and Change ..................................................................................... 15

Inspection of Fuel level ....................................................................................................... 16

Transmission Oil Inspection and Change ............................................................................ 16

Inspection and Adjustment of Brake Free Play .................................................................... 17

Disk Brake Inspection ....................................................................................................... 18

Throttle Valve Handle Clearance Adjustment ........................................................................ 19

Tire Inspection ................................................................................................................. 19

Steering Handle Front Shock Absorbers Inspection .............................................................. 20

Rear cushion hardness setting .......................................................................................... 20

Checking for Fuel Leakage ............................................................................................... 20

Checking the Lubrication of Body’s Various Mechanisms ...................................................... 20

Inspection and Maintenance of Battery ............................................................................... 21

Checking and Changing Fuses .......................................................................................... 22

1. Contents

2

Checking the Turn Signal Lights and Horn

.......................................................................... 22

Checking the Headlight and Tail Lights ............................................................................... 22

Checking the Brake Light .................................................................................................. 23

Checking the Spark Plug ................................................................................................ 23

A reference table for anti-freeze concentration percentages under different temperatures ........... 23

Cooling system inspection .................................................................................................. 24

Replenishment of coolant ................................................................................................... 24

Checking the Air Cleaner .................................................................................................. 25

11. When there is an Abnormal Condition or a Trouble ..................................................... 26

Diagnosis when Engine does not Start ............................................................................... 26

12. C.D.I. Electrical Ignition System ................................................................................... 27

13. Suggestions on Engine Fuel ......................................................................................... 27

14. Transmission Oil ........................................................................................................... 27

15. Cautions for Riding Motorcycle ..................................................................................... 27

16. Periodical Maintenance Schedule .................................................................................. 28

17. Specification ................................................................................................................. 29

2. Control location

3

Fuel tank cap

Passing / High & Low beam /
Turn signal / Horn switch

Front brake lever

Rear brake lever

Side stand

Main stand

Light / Starter switch

Storage box

Muffler

Reserved
tank cap

Coolant filler cap

Ignition switch

C.D.I. / Battery

Helmet hook

Turn signal light

Headlight

Tail light/
Turn signal light

Air cleaner

Fuses box

Engine number
Frame number

4

3. Before Riding

This manual describes the correct usage of this scooter including safety precautions to ensure your personal

safety while operating this scooter.

Please read this manual carefully and completely before operating this scooter. Familiar yourself with

these precautionary measures before you start riding. Do not attempt to operate this scooter until you have

attained adequate knowledge of its controls and operating features and have received adequate training in

safety and proper riding techniques.

Thank you very much for choosing a SANYANG scooter:

! In order to maximize your scooter’s performance, a periodic inspections and regular maintenance

should be performed. We recommend that after riding your new scooter for the first 300 kilometers that
you take your scooter to an Authorized SANYANG scooter dealer for an inspection. Thereafter, we
recommend that you take your scooter to an Authorized SANYANG scooter dealer for an inspection
every 1,000 kilometers.

! In case the scooter’s specifications and construction are modified and different from the photos and

diagrams on the owner’s manual/catalogues, the specifications and construction of the actual scooter

shall prevail.

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4. Safe Riding

It is very important to be alert and wear proper clothing when operating this scooter. Observe all traffic
regulations and signs, do not rush, and always ride carefully and obey all traffic signs and signals.
Usually, most people would ride their newly bought scooter very carefully, but after they became familiar
with their scooter, they tended to become reckless which may result in an accident.

To remind you:

! Always wear a helmet when riding your scooter. Use care to properly tighten the chin strap. Never

operate this scooter with a helmet hanging from the scooter. It may get caught on something causing
you to lose your balance. Protective clothing, gloves and goggles or other protective eye wear is highly
recommended.

! Wear close fitting clothes. Open or loose clothing may be blown by the wind and cause clothing to get

caught on the steering handle or other scooter parts and could affect riding safety.

! Hold the steering handle with both hands when riding. Never ride with only one hand. Keep both feet on

the foot rests.

! Always observe the speed limit and obey all other traffic signs and signals.
! Check to see that your scooter is road worthy before operating.
! If you notice any irregularities with the scooter before driving, make all necessary repairs before resuming

its operation.

WARNING!!

! While riding, the exhaust muffler is extremely hot. A passenger must use care and place his/her feet on

the foot pegs to avoid being burned by the exhaust muffler. Do not touch any part of the exhaust
system while it is hot. Failure to follow this instruction could result in being burned.

! After riding, the exhaust muffler is extremely hot and remains hot for a while even after the engine has

been switched off. Be careful not to get burned when conducting an inspection or maintenance of the
scooter. Do not touch any part of the exhaust system while the same is hot. Touching any part of the
exhaust system while hot could result in being burned.

! After riding, the exhaust muffler is extremely hot. Select a suitable location to park your scooter to help

others avoid getting burned by the exhaust muffler.

! Only wear clothing that fully covers your legs, ankles and feet to avoid having your legs from being

burned by any part of the exhaust system, including the exhaust muffler. The same applies to any
passenger riding with you.

WARNING:

! Do not modify your scooter! Modification to this scooter, removal of original parts, or fitting of

non-authorized part from SANYANG and/or accessories may render the scooter unsafe and illegal to
operate. Modifying the scooter will void the warranty. Modifying the scooter may be illegal. Modification
will affect the performance of the scooter. Engine modification could cause poor engine performance,
engine damage, excessive exhaust noise, and could shorten the life of the scooter. The installation of any
performance increasing components results in the loss of this warranty.

! Tire and rim modifications will make it unsafe to ride and may cause severe injury or death.

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5. Riding

6. Use Genuine Spare Parts

! Operation of the scooter must be only by a person with a valid license to operate the same.
! Your safety on the road relates to the way you drive. Never operate this scooter when tired, under the

influence of alcohol, drugs or medication.

! Rider’s posture will greatly affect riding safety. Always keep your body’s gravity in the center of the seat, 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. 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. It is dangerous to ride a scooter with an unstable handle.

! It will be much easier to make a turn if rider inclines his body inward when turning. On the other hand, the

rider will feel unstable if his body and the scooter do not incline.

! The scooter is hard to control on a bumpy, unleveled, unpaved road, try to know the road conditions in

advance, slow down and use your shoulder’s force to control the handle. Always adjust your speed to the
road and traffic condition.

! Suggestion: Do not load objects on the front pedals unnecessarily, to avoid affecting the riding safety and

the operation of steering handle.

WARNING:

! Be aware of the weight load on the scooter. The scooter will handle different depending on its load.

Over loading the scooter will cause the scooter to become unstable and hard to maneuver, as it may
change the center of gravity, which could result in an accident that could cause injury or death. Do not
exceed the maximum authorized load.

! Overloading the scooter will cause the scooter to become unstable and hard to maneuver, it may cause

serious damage to the tires and rims, as well as it may change the center of gravity, which could result in
an accident that could cause injury or death. Do not exceed the maximum authorized load.

WARNING:

! Only carry cargo or luggage in/on places that are specifically designed for carrying cargo or luggage.
! Do not place flammable objects, such as rags, paper, plastic, etc. or other objects between body covers

and the engine. Placing objects in these areas could cause a fire or other damage to the scooter, and
serious injury as a result there from.

Suggestion:

To maximize the scooter’s performance and prolong its life:
! The first month or first 1000km is the wear- in period for the engine and components. Avoid rapid

acceleration, and keep the speed below 60km/hr.

6. USE GENUINE SPARE PARTS

In order to maintain the scooter’s best performance, each part’s quality, material, and machined precision
must conform with the design requirements. “SYM Genuine Spare Parts” were made from the same high
quality materials used for the original scooter. No parts would be sold to the market until they could meet
the designed specifications through sophisticated engineering and stringent quality control. Therefore, it is
necessary to purchase “SYM Genuine Spare Parts” from “SYM Authorized Dealers or Franchised
Dealers” when replacing spare parts. If you buy cheap, or fake substitute parts from the market, no
guarantee can be provided either for the quality or durability thereof. Also, it may result in unexpected
troubles and lower the scooter's performance.

! Always use SYM Genuine Spare Parts to keep your scooter pure blood and to ensure its long service life.

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7. Use of Each Component

Gauges

CAUTION:

! Do not wipe plastic components, such as the instrument panel, the headlight, body covers, etc. with

solvents, such as gasoline, etc. Wiping plastic components with solvents can damage these
components.

! Speedometer:

This shows your speed in kilometers per hour (km/h)
and in mileage per hour(mph).

! Odometer:

This odometer shows the total kilometers this motor has been driven.

! Turn Signal Indicator:

The left or right Indicator will be flashing according to the operated directions of turn signal light switch
when it is turned on.

! High Beam Indicator:

This indicator comes on when the high beam headlight switch is turned on.

! 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.

! Water temperature gauge:

To indicate engine coolant temperature.
When the main switch turns to “ON”, the pointer indicator should be below the (H) position when the
scooter is operating.
If the pointer indicator stays above (H) position. Please check the coolant level of spare coolant tank
and check cooling fan for proper operation.

! EFi Indicator

It displays the condition of the EFi system. If there is any problem in the EFi system, the warning
indicator will blink or light up all the time.

CAUTION:
The indicator will stay above (H) position when engine is run under high temperature for a long period
of time. In this case, the only way to cool the engine is to stop the engine.

Fuel Gauge

Turn Signal Indicator

Speedometer

Odometer

Oil change
indicator

Water temperature
gauge

Clock / Voltage

High Beam Indicator

Turn Signal Indicator

WARNING:
To ensure safe riding always observe the
speed limit and other road signs.

EFi Indicator