Sym Tonik 50, Tonik 125 Instruction Manual

Page 1

1.CONTENTS

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

2. Control location ............................................................................................................. 3

3. Before riding .................................................................................................................. 4

4. Safe riding ..................................................................................................................... 4

5. Driving ........................................................................................................................... 5

6. Use genuine spare parts ............................................................................................... 5

7. Use of each component ................................................................................................ 6

Gauges .......................................................................................................................... 6

Operation of ignition switch ........................................................................................... 7

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

Operation of fuel tank cover switch ............................................................................... 7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Inspection and adjustment of brake free play .............................................................. 15

Disc brake inspection (depending on models) ............................................................. 16

Throttle valve handle clearance adjustment ................................................................ 17

Inspection and maintenance of battery ........................................................................ 17

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

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

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

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

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

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

1. CONTENTS

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1.CONTENTS

Checking for fuel leakage ............................................................................................ 20

Checking the lubrication of body’s various mechanisms ............................................. 20

Checking the spark plug .............................................................................................. 20

Checking the air cleaner ............................................................................................. 20

11. When ther e is an abno rm al condition or a trouble ....................................................... 21

Diagnosis when engine does not start ........................................................................ 21

12. C.D.I. electrical ignition system ................................................................................... 21

13. Suggestions on engine fuel ......................................................................................... 21

14. Transmission oil .......................................................................................................... 21

15. Cautions for ri ding motorcycle ..................................................................................... 22

16. Periodical maintenance schedule ...................................................................................23

17. Specification ................................................................................................................ 24

1. CONTENTS

Page 3

2.CONTROL LOCATION

MODEL: Tonik 125/Tonik 50cc

Position light

Front turn signal light

Side stand

Front brake level

Rear brake level

Fuel tank cap

Frame number

Engine number

Main stand

Storage box

Air Cleaner

Kick starter pedal

Light/Starter switch

High& Low beam/

Turn signal/Horn

switch Fuse /CDI

&Battery

Exhaust Muffler

Tail/brake light

Rear turn

signal light

Helmet hook

Front light

Ignition switch

Oil level

2. CONTROL LOCATION

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3.BEFORE RIDING

This manual describes the correct usage of this motorcy cle including safety riding, simple inspection methods and so on. For a more comfortable and safety riding, please read this manual carefully.

For your benefit, please ask your SANYANG dealer the operating manual and carefully read the following:

y Correct use of the motorcycle. y Pre-delivery inspection and maintenance.

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.

y 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.

 To remind you:

y Please wear a safety helmet, and properly tighten the chin belt when riding a motorcycle. y 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.

y So, put on clothes with tight sleeves . y Hold the steering handle by both hands when riding. Never ride with only one hand. y Observe the speed limit. y Wear suitable low-heel shoes. y Perf orm periodical maintenance and inspection in accordanc e with the schedule.

WARNING!!

y To avoid getting burned by exhaust pipe when taking a passenger. Make sure your passenger has

put his/her feet on the pedal s. 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.

CAUTION:

Modified motorcycle will affect its structure or per formance, and cause poor engine operation or exhaust noise, which will result in shorte ning 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.

3.BEFORE RIDING

4.SAFE RIDING

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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 ridin g sa fe ty. Always keep your body’s gravity in th e 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 un stable 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 an d 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.

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:

y Do not place flammable materials such as rags between the body side cover and engine to avoid

components damaging by fire.

y Do not load objects on areas not specified for loading to avoid damage.

SUGGESTION

To maximize the motorcycle’s performa nce 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 60 km/hr.

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 sop histicated 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.

Always use SYM Genuine Spare Parts to keep your motorcycles pure blood and to ensure its long

service life.

5. DRIVING

6.USE GENUINE SPARE PARTS

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7.USE OF EACH COMPONENT

(The following is SYM 4 stroke air-cooling 125 c.c./50 c.c. scooter’s basic operation, and they

could vary from different individual models. Please consult the end of this manual.)

§GAUGES §

The panel figure for speedometer may vary from model to model, but the location usually are the same.

Speedometer

Odometer

Fuel meter

Turn Left/Right Signal Indicator

High Beam Indicator

Engine oil replacement indicator

CAUTION:

Do not wipe plastic components, e.g. instrument panel, headlight, with organic solvents such as gasoline…etc to avoid damaging these components.

y Speedometer：

Indicates driving speed.

y Odometer：

Indicates total accumulated distance traveled.

y High Beam Indicator：

This indicator comes on with high beam headlight is turned on.

y 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.

y Fuel Met er:

The pointer in this meter shows how much fuel remains in the tank. When the pointer stays position "①" , it means full of gasoline in the fuel tank. The pointer stays position "②" , it means 50% of gasoline in the fuel tank. When the pointer stays position "③" , it means residual about 1.0 liters in the fuel tank. That is the reserved gasoline. It can continue to ride about 30 ~ 50km. When the pointer stays position "④" , it means empty in the fuel tank.

7. USE OF EACH COMPONENT

y Engine oil replacement indicator:

Engine oil replacement indicator is used to indicate the time tables of engine oil replacement, the color is expressed as green as usual. When the vehicle traveling about 1,000 kilometers, the indicator light turns red. It means that it need to supply or replace engine oil. After adding engine oil, insert the key in to the relieve hole as shown, the indicator will change from red to green.

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§OPERATION OF IGNITION SWITCH §

“ON” position:

y Engine can be started in this position. y Ignition switch key can not be removed.

“OFF” position:

y Engine is shut off and can not be started in this position . y Ignition switch key can be removed.

§OPERATION OF STEERING HANDLE LOCK SWITCH §

“Steering handle lock” position

y Turn the steering handle to left and insert the key in to,

press ignition switch key clockwise and then lightly turn it to left to the “lock” position.

y The steering handle is locked in this position. y Ignition switch key can be removed. y When unlocking, simply turn the key from the “LOCK”

position to the “OFF” position.

§OPERATION OF FUEL TANK COVER SWITCH§

“Fill gasoline lock” position

y Inserted the ignition switch key in the main switch lock. y Turn the ignition switch key to the“ fill gasoline” position counter-clockwise.

y Then, the fuel tank cover can be open. You can fill gasoline in the fuel tank.

CAUTION:

y Make sure to take the key

away with you before you lock your seat.

CAUTION:

y Never operate the ignition switch key when the motorcycle is running. To turn the ignition switch

to “OFF” and “LOCK” 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.

y Always remove the key and be sure to take the key away with you after locking the steering handle

before leaving your motorcycle.

y If ignition switch remains in the “ON” position for a prolonged period after the engine has been

stopped, the battery’s capacity w ill be reduced and this may affect the engine’s start ability.

y Make sure to take the key away with you before you lock your seat.

§USE OF BUTTONS §

High/low

beam switch

Hazard warning

switch

Turn Signal

Switch

Horn Switch

Electrical starter button

7. USE OF EACH COMPONENT

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Insert the key into the mai n sw itch to be “ON” position, and the engine is being started, the speed meter light, position light, tail light, license plate light are always come on.

y Hazard warning switch

When the switch is turned to this position as the engine is being started, the front and rear turn signal lights will flash.

Switch to this position to turn of the front and rear signal hlghts.

y Electrical starter button

This is a starting motor button (switch) for engine starting. With the main switch “on”, press this button while holding the front or rear brake lever will start the engine.

CAUTION:

y Release this button immediately after engine has been starter, and never pre ss the button again to

avoid damaging the engine.

y This mechanism is a safety design. The engine can only be started after the front or rear brake

lever (pedal) has been applied.

y Do not use light system. Turn headlight and turn signal light to the “off” position when the engine is

being started.

y High/low beam switch

This is the high and low beam of headlight switching switch. Press this switch to switch between high and beams.

This is for high beam. This is for low beam.(please turn to low beam riding in city.)

7. USE OF EACH COMPONENT

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y Horn Switch

Press this button down when ignition switch is in the “ON” position, the horn will sound.

y 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 signa l swit ch to left or right . Then, the turn signal lights will flash. To release, simply return the turn signal light button to the original position.

Left -side turn signal light flashing means you intend to make a right turn.

Right-side turn signal light flashing means you intend to make a left turn.

§STORAGE BOX§

y This box is located under the seat. y Maximum load capacity:5kg. y Do not store valuables in the box. y Make sure that the seat has been locked completely after it

was pressed down.

y Take out valuables before washing to avoid wetting these

objects.

y Do not place thermal sensitive objects in the box because of

engine’s heat and high temperature.

Storage box

7. USE OF EACH COMPONENT

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§SAFETY HELMET HOOK§

y Stop the motorcycle, and hook the safety helmet

chin belt the hook.

CAUTION:

y Do not hang the safety helmet onto this hook

when riding to avoid damaging motorcycle and loosing safety helmet’s function.

Hook

§FUEL TANK CAP§

1.Insert the key into the main switch, and turn the ignition switch key to the“ fill gasoline” position counter-clockwise, then the fuel tank cap can be removed.

2. Do not fill above the fuel upper limit when refueling.

3. Align the “△ ”mark on the cap with the “△ ”mark on the fuel tank, then close the fuel tank cap .

Fuel tank cover

CAUTION:

y Main stand should be put down on the ground, engine should be shut off and flames shou ld be

strictly prohibited to ensure safety when refueling.

y 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.

y Make sure the cap has been tighten properly.

§BRAKE§

y Avoid unnecessary sudden braking. y Use front and rear wheel brakes simultaneo usly when braking. y Avoid brake continuously for a long period of time because that may overheat the brakes and reduce

its braking efficiency.

y Slow down and brake early when riding in rainy days on slippery roads. Never apply the brakes

suddenly to prevent skidding and falling.

y 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 interm ittently when riding on a long or stiff slope.

For Front Wheel For Rear Wheel

7. USE OF EACH COMPONENT

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8.IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE

CAUTION:

y Please check the oil and fuel volume are adequate or not before starting the engine. y To start the engine the main parking stand must be firmly on the ground and the brake is applied

on the rear wheel to prevent the motorcycle from moving forward suddenly.

1.Turn ignition switch key to the ”ON” position.

2.Apply hand(foot) rear wheel brake.

3.Do not accelerate, press starter button when the brake is applied.

［We care for you! Before drive off, keep the hand brake applied on the rear wheel.］

1/8

1/4

CAUTION:

y If engine can not be starte d after press the kick starter arm for 3~5 times, turn the throttle valve

handle 1/8~1/4 turns, and then press the kick starter arm again for an ease start.

y In order to avoid damaging the starter motor, please do not press the starter button continuously

over 15 seconds.

y If engine still can not be started after pressing starter button over 15 times, stop and wait for 10

seconds before start it again.

y 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.

y It may need several minute s to warm up engine if it is a cold start. y Exhaust contains harmful gases (CO), therefore please start the engine at a well ventilated place.

【When starting engine with starting lever.】

y After step 1~5 is comp leted, press the kick starter forcefully by foot with the throttle valve handle at

the close position.

y 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 eas ier.

y Put the kick starter back to its original position after the engine has been started.

CAUTION:

y Firmly support the motorcycle with the main parking stand before starting the engine with the kick

starter arm.

y Starter engine with the kick starter arm occasionally to prevent it from loosing its function because

of unused for a long time.

8. IMPORTANT POINTS AND CAUTIONS FOR STARTING ENGINE

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9.THE BEST WAY TO DRIVE OFF

y turn on the turn signal light before moving, and make sure no vehicle is coming from behind. Then,

drive off.

§THE CONTROL OF THROTTLE VALVE HANDLE §

Acceleration : To increase speed. When riding on an inclined road, turn the throttle valve handle

slowly to allow the engine to output its power.

Deceleration : To decrease speed.

Deceleration

Acceleration

§PARKING METHOD §

y 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 ve hicles behind.)

y 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 y our 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:

y Park your motorcycle at a safe place where it will not interfere with traffic.

9. THE BEST WAY TO DRIVE OFF

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10.INSPECTION AND MAINTENANCE BEFORE RIDING

(Please refer to the components location diagram for the following components.)

§ROUTINE INSPECTION §

Check Items Check Key Points

Engine Oil Is there enough engine oil? Fuel Is it enough? Is it Octane 90 or above

Front

Brake

Rear

Front

Tires

Rear

Steering Handle Does the handle vibrate abnormally or is difficult to turn? Speedometer, lights, and

rearview mirror Tightness of Main Components Are screws, nuts loosen?

Abnormal Points Do the previous troubles still exist?

Braking condition? (Brake lever free play: 10~20mm)

Braking condition? (Brake

Is tire pressure normal? (Standard: 1.75kg/cm

Is tire pressure normal? (Standard: 2.0 kg/cm

Is it operated properly? Do lights come on? Can it be seen clearly from behind?

lever free play: 10~20mm)

)

for 1 person, 2. 25 kg/cm2 for 2 persons)

CAUTION:

y If any problem founded during routine inspection, correct the problem before using the motorcycle

again, have your motorcycle checked and repaired by the “SANYANG dealer or authorized service personnel” if necessary.

§ENGINE OIL INSPECTION AND CHANGE §

y INSPECTION:

1. Use the main parking stand to support the motorcycle on a level ground, remove the dipstick after engine stoppe d for 3~5 minutes. Wipe oil off the dipstick and then insert it into the guide tube again (Do not rotate it.)

2. Remove the dipstick an d c he c k whethe r oil level is in between the upper and lower marks.

y Add oil to upper limit if oil is under the lower limit. (Check

cylinder, crankcase…etc for leakage.)

10. INSPECTION AND MAINTENANCE BEFORE RIDING

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OIL CHANGE:

y Change engine oil after the first 300km, and change the engine oil

every 1000km thereafter.

y In order to maintain the engine’s maximum performance, check

whether the engine oil is enough eve ry 500km. Add oil to upper limit if the engine oil has been found to be inadequate.

y Engine Oil : Use (API) SL/CFSAE 10W-30 grade or better engine

oil. Otherwise, damage will not be covered by warranty.

y Use SAE 5W-40 engine oil when outside temperature is below 0℃

※Recommended Oil: SYM Genuine 4X OIL.

y Oil Capacity :

TONIK 125CC : 0.75 Liter (0.60 liter for routine change). TONIK 50CC: 0.80 Liter (0.65 liter for routine change).

oil filter change: 0.60～0.65 liters.

【Oil Filter Cleaning】

The oil filter nut assembly of the element, and remov e the element. Remove the foreign materials from the element by using a gasoline or air spraying gun.

WARNING:

y Oil level will not be correct when checking the oil leve l with

the motorcycle parked on an unleveled ground or immediately after the engine stopp ed.

y Engine and exhaust pipe are hot right after engine stopped.

Pay special attention not to get burned when checking or replacing engine oil.

y If the oil lever approach lower limit again after refilled, check

the engine for leaks and refill it again.

y Keep away from spark and flames when refilling the oil.

Upper limit

Lower limit

Oil filter

Filter nut

§FUEL INSPECTION§

y Turn main switch key to “ON” position, and check fuel gauge’s needle range to make sure there is

enough amount of fuel in the fuel tank.

y This motorcycle’s engine is designed for using the unle aded fuel of Octane 90 or above. y Firmly secure the main stand on the gr ound, shut off the engine and keep flames away from the

motorcycle when refueling.

y Do not fill above fuel upper limit lever when refueling. y Make sure the fuel tank cap had been tighten properly.

§TRANSMISSION OIL INSPECTION AND CHANGE§

INSPECTION:

y 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:110c.c/at change:100c.c.).

OIL REPLACEMENT:

y Stop the engine and use the main stand to support your motorcycle on a lever ground. Remove the

infusion bolt and drain bolt, drain out the oil.

y Install the drain bolt and tighten it. Fill new transmission oil (90~100c.c.), and install the infusion bolt

and tighten it. (make sure that bolts are tightened and check that there’s no leakage.)

y Recommend Oil: Genuine SYM HYPOLD GEAR OIL (SAE 85W-140).

10. INSPECTION AND MAINTENANCE BEFORE RIDING

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§INSPECTION AND ADJUSTMENT OF BRAKE FREE PLAY§

INSPECTION: (Brake lever free play must checked with the engine shut off.)

y Brake lever and pedal free play for front and r ear wheels.

◆ If checking the hand-braking lever for front wheels, its free play (the stroke of hand-braking lever from no braking to initial braking) should be 10~20mm. It is abnormal if the feel is spongy when holding the

hand-braking lever forcefully.

◆ If 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 forcef ully.

Rear Wheel hand-brake type

10~20 mm

Adjustment:﹙ Drum type﹚

y The indentation of brake adjustment nut must be aligned with the pin. (see below figure)

Adjustment nut

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.

y Turn the adjustment nut on brake arm of fr ont and rear wheels to adjust the free play of hand-brake

lever.

y Hold the hand-brake levers after adjusting with both hands until there is effective brake feeling. y Measure the free play with a ruler.

Adjustment nut

Rear Wheel drum type Front wheel drum type

10. INSPECTION AND MAINTENANCE BEFORE RIDING

Wear limit mark

To decrease free play

To increase free play

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§DISK BRAKE INSPECTION§(applicable for model equipped with disc brake.)

y Visual check brake lines for leakage, or damage, check brake lines connections for looseness using a wrench or similar tool, and check whether steering handle vibration in driving, or any parts’ interference may have damage the brake lines. If so, bring your motorcycle to your SANYANG dealer for repairing or service.

（leak, damaged, looseness of brake line）

（Checking front brake lining）

y 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.

calipe

（Replenishment of front wheel brake fluid）

1.Loosen the screws and remove the master cylinder cover.

2.Wipe clean foreign materials, dirt around the reservoir, being careful not to let foreign materials fall into the reservoir.

3. Remove the diap hragm plate and the diaphragm.

4. 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.

Brake

Brake pad wear

limit grooves

Brake disk

CAUTION:

y 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. .

（Checking oil quantity in brake oil reservoir）

y Park the motorcycle on a lever ground, and

check if fluid lever is under the “LOWER” mark. Recommended Brake Fluid: WELL RUN BRAKE OIL (DOT3 or DOT4 ).

Screw

Maste

cylinder cove

Diaphragm

Upper

Brake fluid

CAUTION:

y TO prevent chemical reaction, please do not use brake fluids other than those recommended. y Do not fill above the upper limit when adding brake fluid and avoid dropping on painting or plastic

components to prevent damage.

10. INSPECTION AND MAINTENANCE BEFORE RIDING

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§THROTTLE VALVE HANDLE CLEARANCE ADJUSTMENT §

y Correct clearance allows throttle vale handle to rotate

2~6mm.

y Loosen the lock nut first, then turn the adjust nut to adjust.

Tighten the lock nut securel y when finis h ed .

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 preventi n g it fro m being operated smoothl y.

2~6 mm

Adjust nut

Lock nut

§INSPECTION AND MAINTENANCE OF BATTERY §

y The 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.

﹙ Cleaning of battery terminals﹚

y Remove the battery terminals and clean if there are

dirt and corrosion on them.

y Battery removal procedure s 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.

Negative

Positive

CAUTION:

y Clean the battery posts with warm water if the posts are eroded and have some white powders on

them.

y If there is an obvious erosion on the terminals, disconnect the cables, and then clean the erosion

off with a steel brush or a piece of sandpaper.

y Install battery cable after cleaning and apply a thin coat of grease on the terminals. y Install battery in reverse order of removal.

y The 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:

y This is a closed type battery. Never remove the caps. y In order to prevent electric leakage and self-discha rge when the battery sits idle for long periods.

Remove battery from motorcycle, store it in 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.

y If the battery needs to be replaced, replace with a same closed-type battery (Maintenance-F ree).

10. INSPECTION AND MAINTENANCE BEFORE RIDING

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§TIRE INSPECTION §

y Tires should be checked and inflated with the engine shut off. y If a tire’s ground contacting curve is abnor mal, check it with an air pressure gauge and inflate it to the

specified pressure.

y Tires pressure must be checked with an air pressure gauge when cold.

PLEASE REFER TO SPECIFICATIONS FOR STANDARD TIRE PRESSURE

Foreign materials (nails or small stones)

Crack and dama

Tread wear indicator

y Visual check tires for frontal and lateral side walls for

crack or damage.

y Visual check tires for any n a ils or small stones

wedged in the tread.

y Check the “tread wear indicator” condition to see if

tread groove depth is insufficient.

y A tire with a wear bar showing is worn out and should

be replaced immediately.

CAUTION:

y 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).

§STEERING HANDLE FRONT SHOCK ABSORBERS INSPECTION §

y Perform this check with engine shut off and ignition switch key

removed.

y Visual check front shock absorbers for damage. y Operate steering handle up and down, and check front shock

absorbers for noises due to bends.

y Check the bolts and nuts of front shock absorbers with wrenches for

tightness.

y 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.

y Check steering handle if it is being pulled too tight by the brake

cables.

y Take your motorcycle to SYM Authorized Dealer or Franchised

Dealer for a check or adjustment if any abnormal conditions are found.

10. INSPECTION AND MAINTENANCE BEFORE RIDING

Page 19

§CHECKING AND CHANGING FUSES §

Turn off ignition switch , and check fuses if they ar e intact. Replace the blown fuse with a new one having the same specified amperage rating (10A&15A). Using a fuse of more than 10A&15A amperes, a brass or iron wire to replace a blown fuse is strictly prohibited to avoid damaging the electrical system and the circuit.

y Remove the storage box, and you’ll find the fuse holder near battery. y Open the fuse box cover , and pull out the fuse. Check it for damage or broken. y Fuses must be firmly secured with wire connectors when replacing. Loose connections w i ll result in

overhead and damage.

y 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.

y Avoid spraying water directly on or around fuse box when washing the motorcycle. y 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.

【REMOVE】

【INSTALLATION】

Press in from above

Wire

Fuse connectors

§CHECKING THE TURN SIGNAL LIGHTS AND HORN §

y Turn the ignition switch key to the “ON” position. y 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 sound s.

y Check turn signal light cov ers if they are di rty, crack, or loosen. y Press horn button to check if it works.

CAUTION:

y Specified specification bulbs should be used for turn signal lights. Otherwise, the normal

operation of turn signal lights will be affected.

y Turn on the turn signal light before turning or switching lane to warn driver of vehicles behind. y 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 §

y Start engine and turn on the head lamp switch. Check if head lamp and rear lamp come on. y Check the brightness and direction of front light by wall to see if it is correct. y Check the head lamp cover if it is dirty, crack, or loosen.

§CHECKING THE BRAKE LIGHT §

y 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.

y Check the brake light cover if it is dirty, crack, or loosen.

CAUTION:

y Use only specified specification bulbs, do not use bulbs with different specifications to avoid

damaging electrical system, burning out bulbs, and discharging the battery.

y 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.

10. INSPECTION AND MAINTENANCE BEFORE RIDING

Page 20

§CHECKING FOR FUEL LEAKAGE§

y Check fuel tank, fuel cup, fuel hose, carburetor for leakage.

§CHECKING THE LUBRICATION OF BODY’S VARIOUS MECHANISMS§

y Check the body’s pivot points if they have enough lubrication.

(for example, the pivot points on the main stand, the side stand, and the brake lever…etc.).

§CHECKING THE SPARK PLUG§

y Remove the cap of spark plug cable (remove the spark plug using

the spark plug wrench in the tool kit.

y Check the electrode if it is dirty or fouled by carbon deposits. y Remove the carbon deposits on the electrode with steel w i re, and

clean the spark plug with gasoline, then, wipe dry with a rag.

y Check the electrode, and adjust its gap to 0.6~0.7 mm. (Check it

with a feeler gauge)

y Hand tight the spark plug as far as it can go and then tighten it

another 1/2~3/4 turns with a wrench.

y Tighten torque Value:1.2~1.2kmf-m.

0.6~0.7 mm

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 mounting screws from air cleaner cover.

2.Remove the air cleaner cover, then remove filter element.

3.Take the element out and clean it. (Refer to maintenance schedule.)

《DISASSEMBLE PRCEDURE》

y Assemble the air cleaner in reverse order of disassemble.

Screws

Element

CAUTION:

y Dust deposit is one of the major causes of reducing output horsepow er and increasing fuel

consumption.

y Change the air cleaner element more frequen tly to prolong the engine’s service life if the

motorcycle is driven on dusty roads very often.

y If air cleaner is installed improperly, dust will be absorbed into cylinder, which may cause a

premature wear and reducing output power and engine life.

y Be careful not to soak the air cleaner when washing the motorcycle. Otherwise, it will cause

engine hard to start.

10. INSPECTION AND MAINTENANCE BEFORE RIDING

Page 21

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?

(4). Do you rotate the throttle valve handle while

pressing starting the button?

【Have your motorcycle checked by SYM authorized dealer or franchised dealer immediately if there are no

1/8

1/4

(2). Is there enough fuel in the fuel

tank?

Turn Signal Switch

(5). Turn the ignition switch key to the “ON”

For rear wheel

(3). Is the rear or front wheel

brakes applied when pressing starting button?

position, and press horn button down, if the horn does not sound, the fuse may have b een blown.

For front whe e l

Horn Switch

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

y This motorcycle is designed to use UNLEADED gasoline of Octane No. 90 or higher. y If the motorcycle is operate d in high attitude (where the atmosphere pressure is lower), it is

suggested that the air/fuel ratio should be readjusted to max imize the engine performance.

14. TRANSMISSION OIL

y Recommended OIL: GENUINE SYM HYPOID GEAR OIL (SAE 85W-140)

11. WHEN THERE IS AN ABNORMAL CONDITION OR A TROUBLE

Page 22

SYM

15.CAUTIONS FOR RIDING MOTORCYCLE

1. Raise the motorcycle with the main stand, and sit on the seat. Push the motorcycle forwarding to rai se the main parking stand.

CAUTION:

y Never rotate the throttle valve handle at will to increase the engine RPM before dr iving off.

2. Get on the motorcycle from the left side, and sit on the saddle properly, keep your right feet firmly on the ground to prevent the motorcycle from falling.

CAUTION:

y Apply brake on the rear wheel before driving off.

3. Rotate the throttle valve handle slowly, and then the motorcycle will begin to move.

CAUTION:

y Rapidly rotate the throttle valve handle or release the clutch lever may cause the motorcycle

moving forward suddenly and it is very dangerous.

y Make sure the side parking stand is spring back completely before driving off.

【Do not use the brake suddenly and make a sharp turn】

y Rapid braking and sharp turning will cause slip and fall. y 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】

y 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.

y 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.

15. CAUTIONS FOR RIDING MOTORCYCLE

Page 23

16.PERIODICAL MAINTENANCE SCHEDULE

Item

Check Items

1 Air cleaner element (Remark) I C R(paper) R(sponge) 2 Air cleaner I 3 Oil filter (Screen) C C 4 Engine oil R Replacement for every 3000KM 5 Tire, pressure I I 6 Battery I I 7 Spark plug I I R 8 Carburetor (idle speed) I I 9 Steering bearing and handles I I

10 Check transmission for leakage I I

Maintenance kilometer

Maintenance Interval

300KM

NEW 1 Month 3 Months 6 Months 1 Year

Every

1000KM

Every

3000KM

Every

6000KM

Every

12000KM

Remarks

11 Check crankcase for leakage I I 12 Transmission oil R Replacement for every 5000KM(5 Months) 13 Drive belt/roller I R 14 Fuel tank switch and lines I I 15 Throttle valve operation and cable I I 16 Engine bolts and nuts I I 17 Cylinder head, cylinder, and piston I 18 Exhaust system/cleaning carbon I 19 Cam Chain/ignition time I I 20 Valve clearance I I 21 Shock absorbers I I 22 Front/rear suspension I I 23 Main/side stands I I/L 24 Crankcase Blow-by system(PCV) I I 25 Clutch disk I 26 Brake mechanism/brake lining (pad) I I 27 Bolts/nuts for each components I I

☆ The above maintenance schedule is established by taking the monthly 1000 kilometers as a referen ce

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.

【Notes in the remarks are used to indicate the applicable models.】

16. PERIODICAL MAINTENANCE SCHEDULE

Page 24

17.SPECIFICATION

Model

FW05A1-6(Tonik 50)

Item Specification Length 1735mm Width 710mm

Height 1040mm Wheel base 1220mm Net Weight 92kg Type 4- stroke single cylinder engine Fuel Unleaded (Octane 90 or higher) Cooling type Air-cooled Displacement 49.5 c.c. Compression ratio 12.6 :1 Maximum Horsepower 2.3 kw/7500 rpm Maximum torque 3.1 N.m/6500 rpm Maximum Speed 45km/h Idle speed 2100±100 rpm

Valve clearance: IN/EX 0.05±0.02 mm/ 0.10±0.02 mm

Starting methods Electrical & foot type Front shock absorber Telescope Rear shock absorber Single swing Clutch Auto Centrifugal type Transmission C.V.T. Front tire 90/90-10 Rear tire 90/90-10 Wheel Aluminum

Front: STD 2.00 kg/cm

Tire pressure Front brake Disk type (Ø 160 mm)

Rear brake Drum type (Ø 110 mm) Front light bulb (high, low) 12V 35/35W×1 Position light bulb 12V 5W×1 Brake light bulb (tail light) 12V 21W/5W×1 License light bulb 12V 5W Turn signal light bulb Front：12V 10W×2/ Rear：12V 10W×2 Speedometer light bulb 12V 1.7W Engine oil capacity 0.80 L (0.65 L for change) Transmission oil capacity 110c.c (100c.c for change) Fuel tank capacity 5.8L Fuel tank material Steel

Fuse 10A×2&15A×2

Spark plug RC7HSA Battery capacity 12V 6Ah(closed type, maintenance-free battery) Air cleaner Paper type Fuel tank cap Close lock type Rear grab frame Can not load cargo

Rear: STD 2.00kg/cm

for 1 person, 2.25kg/cm2 for 2 persons

17. SPECIFICATION

Page 25

17.SPECIFICATION

Model

FW05A2-6(Tonik 50)

Item Specification Length 1735mm Width 710mm

Height 1040mm Wheel base 1220mm Net Weight 92kg Type 4- stroke single cylinder engine Fuel Unleaded (Octane 90 or higher) Cooling type Air-cooled Displacement 49.5 c.c. Compression ratio 12.6 :1 Max. HP 1.8 kw/6500 rpm Max. torque 2.6 N.m/6500 rpm Maximum Speed 25km/h

Idle speed 2100±100 rpm

Valve clearance: IN/EX 0.05±0.02 mm/ 0.10±0.02 mm

Front: STD 2.00 kg/cm

Tire pressure Front brake Disk type (Ø 160 mm)

Fuse 10A×2&15A×2

Spark plug RC7HSA Battery capacity 12V 6Ah(closed type, maintenance-free battery) Air cleaner Paper type Fuel tank cap Close lock type Rear grab frame Can not load cargo

Rear: STD 2.00kg/cm

for 1 person, 2.25kg/cm2 for 2 persons

17. SPECIFICATION

Page 26

17.SPECIFICATION

Model

FW05A3-D(Tonik 50)

Item Specification Length 1735mm Width 710mm

Height 1040mm Wheel base 1220mm Net Weight 92kg Type 4- stroke single cylinder engine Fuel Unleaded (Octane 90 or higher) Cooling type Air-cooled Displacement 49.5 c.c. Compression ratio 12.6 :1 Max. HP 1.8 kw/6500 rpm Max. torque 2.6 N.m/6500 rpm Maximum Speed 30km/h Idle speed 2100±100 rpm

Valve clearance: IN/EX 0.05±0.02 mm/ 0.10±0.02 mm

Starting methods Electrical & foot type Front shock absorber Telescope Rear shock absorber Unit swing Clutch Centrifugal type Transmission C.V.T. Front tire 90/90-10 Rear tire 90/90-10 Wheel Aluminum

Front: STD 2.00 kg/cm

Tire pressure Front brake Disk type (Ø 160 mm)

Fuse 10A×2&15A×2

Spark plug RC7HSA Battery capacity 12V 6Ah(closed type, maintenance-free battery) Air cleaner Paper type Fuel tank cap Close lock type Rear grab frame Can not load cargo

Rear: STD 2.00kg/cm

for 1 person, 2.25kg/cm2 for 2 persons

17. SPECIFICATION

Page 27

17.SPECIFICATION

Model

FW11A1-6(Tonik 125)

Item Specification Length 1735mm Width 710mm

Height 1040mm Wheel base 1240mm Net Weight 97kg Type 4- stroke single cylinder engine Fuel Unleaded (Octane 90 or higher) Cooling type Air-cooled Displacement 125 c.c. Compression ratio 10.5 :1 Max. HP 5.0 kw/7500 rpm Max. torque 6.8 N.m/6000 rpm Idle speed 1700±100 rpm

Valve clearance: IN/EX 0.12 mm/ 0.12 mm

Starting methods Electrical & foot type Front shock absorber Telescope Rear shock absorber Unit swing Clutch Centrifugal type Transmission C.V.T. Front tire 90/90-10 Rear tire 90/90-10 Wheel Aluminum

Front: STD 2.00 kg/cm

Tire pressure Front brake Disk type (Ø 160 mm)

Rear brake Drum type (Ø 110 mm) Front light bulb (high, low) 12V 35/35W×1 Position light bulb 12V 5W×1 Brake light bulb (tail light) 12V 21W/5W×1 License light bulb 12V 5W Turn signal light bulb Front：12V 10W×2/ Rear：12V 10W×2 Speedometer light bulb 12V 1.7W Engine oil capacity 0.75 L (0.60 L for change) Transmission oil capacity 110c.c (100c.c for change) Fuel tank capacity 5.8L Fuel tank material Steel

Fuse 10A×2&15A×2

Spark plug A7RC Battery capacity 12V 6Ah(closed type, maintenance-free battery) Air cleaner Paper type Fuel tank cap Close lock type Rear grab frame Can not load cargo

Rear: STD 2.00kg/cm

for 1 person, 2.25kg/cm2 for 2 persons

17. SPECIFICATION

Sym Tonik 50, Tonik 125 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual