This document is an Owner's Manual for a Sanyang Motor Co., Ltd. scooter, covering several models: XE05W2-EU, XE05W2-IT, XE05W2-NL, XE12W2-EU, and XE12W2-IT. Sanyang Motor Co., Ltd. is located at 3 Chung Hua Road Hukou Hsinchu Taiwan, R.O.C. Contact information includes TEL: 886-3-598-1911, FAX: 886-3-598-1844, E-mail: SERVICE@sym.com.tw, and website: http://www.sym.com.tw. The manual emphasizes safe riding, proper use of components, and periodical maintenance.
Function Description
The scooter is a 4-stroke single-cylinder engine vehicle designed for personal transportation. It features an electrical starter for convenience. Key components include a speedometer, odometer, fuel meter, high beam indicator, turn signal indicators (left/right), and a fault indicator light. The ignition switch has "ON" and "OFF" positions, with a "Steering handle lock" position for security. A "Fuel tank cap open" switch allows access to the fuel tank. The scooter is equipped with a magnetite key system for enhanced security, where the keyhole baffle can be opened or closed using the magnetite key.
Control features include a high/low beam switch, passing switch, horn switch, and an electrical starter button. The electrical starter requires the main switch to be "on" and either the front or rear brake lever to be held to start the engine. The throttle valve handle controls acceleration and deceleration. The scooter also includes a storage box located under the seat, with a maximum load capacity of 5kg. A safety helmet hook is provided for convenience.
Braking is managed by a front brake lever and a left brake lever that operates both front and rear brakes simultaneously in CBS models. Engine braking is achieved by returning the throttle valve handle to its original position.
Important Technical Specifications
The manual provides detailed specifications for different models. Here's a summary of common and model-specific features:
General Dimensions:
- Length: 1915±20 mm (XE05W2 models), 1900±20mm (XE12W2 models)
- Width: 680±10 mm (XE05W2 models), 682±10mm (XE12W2 models)
- Height: 1125±20 mm (XE05W2 models), 1120±20mm (XE12W2 models)
- Wheel base: 1290±20 mm (XE05W2 models), 1320±20mm (XE12W2 models)
- Net Weight: 107±5kg (XE05W2 models), 115±5kg (XE12W2 models)
Engine and Fuel:
- Type: 4-stroke single cylinders engine
- Fuel: UNLEADED (OCTANE 90 OR HIGHER)
- Compression ratio: 11.0±0.2:1 (XE05W2 models), 10.68±0.2:1 (XE12W2 models)
- Maximum HP:
- XE05W2 models: 2.2kw/8000 rpm (EU/IT), 2.2kw/6000 rpm (NL, speed limited to 25km/h)
- XE12W2 models: 8.4kw/8500 rpm
- Maximum torque:
- XE05W2 models: 3.0N.m/6000 rpm (EU/IT), 3.2N.m/5500 rpm (NL, speed limited to 25km/h)
- XE12W2 models: 10.3N.m/6500 rpm
- Starting methods: Electrical starter
- Engine oil capacity: 0.8L (0.7 L for change) (XE05W2 models), 0.95 L (0.70 L for change) (XE12W2 models)
- Fuel tank capacity: 6.2±0.2 L
Chassis and Brakes:
- Front shock absorber: TELESCOPE
- Rear shock absorber: UNIT SWING
- Clutch: Centrifugal type
- Transmission: CVT
- Front tire: 110/70-12 47J
- Rear tire: 120/70-12 51J
- Wheel: Aluminum
- Tire pressure (Front): STD 2.00 kg/cm²
- Tire pressure (Rear): STD 2.00kg/cm² for 1 person, 2.25kg/cm² for 2 persons
- Front brake: Disk type (Ø 226 mm)
- Rear brake: Drum type (Ø 110 mm) (XE05W2 models), Drum type (Ø 130 mm) (XE12W2 models)
Electrical System:
- Headlight deep/main beam: 12V 35W/35W *1
- Position Lamps: 12V 5W *1
- Taillight/Stoplight: 12V 5W/21W *1
- Turn Signal Light front/rear: 12V 10W *2 / 12V 10W *2
- Fuse:
- XE05W2 models: 20A1&15A2&10A*1
- XE12W2 models: 10A1&15A2&20A*1
- Spark plug: CR6HSA (XE05W2 models), CR7HSA (XE12W2 models)
- Battery capacity: 12V 6Ah
- Air cleaner: Paper type
Usage Features
Safe Riding:
- Always wear a safety helmet and properly tighten the chin belt.
- Wear clothes with tight sleeves to avoid interference with the steering handle.
- Hold the steering handle with both hands.
- Observe the speed limit and wear suitable low-heel shoes.
- Perform periodical maintenance and inspection.
- Avoid getting burned by the hot exhaust pipe; ensure passengers place feet on pedals and park in a suitable location.
- Do not modify the motorcycle, as it can affect structure, performance, and warranty.
Driving:
- Maintain a relaxed posture with body gravity centered on the saddle for stability.
- Incline the body inward when turning for better control.
- Be cautious on bumpy, unleveled, or unpaved roads; slow down and use shoulder force to control the handle.
- Avoid overloading the front pedals, as it can affect riding safety and steering.
- Do not place flammable materials near the engine.
Starting the Engine:
- Ensure adequate oil and fuel.
- The main parking stand must be firmly on the ground, and the rear wheel brake applied.
- Turn the ignition switch to "ON."
- Apply the hand rear wheel brake and press the starter button without accelerating.
- If the engine doesn't start after 3-5 kick starter arm presses, turn the throttle 1/8~1/4 turns and try again.
- Avoid continuous pressing of the starter button for over 15 seconds to prevent damage.
- If the engine is cold or has been idle, it may require several attempts and warming up.
- Start the engine in a well-ventilated area due to harmful exhaust gases.
Driving Off:
- Turn on the turn signal light before moving and check for oncoming vehicles.
- Increase speed by slowly turning the throttle valve handle.
- Decrease speed by returning the throttle valve handle.
Parking:
- Approach slowly, using turn signals and checking traffic.
- Return the throttle to the original position and apply brakes in advance.
- Turn off the engine by setting the ignition key to "OFF."
- Park on a level ground where the motorcycle won't interfere with traffic.
- Use the main parking stand firmly.
- Lock the steering handle and remove the key to prevent theft.
Maintenance Features
Routine Inspection (Before Riding):
- Engine Oil: Check for adequate level.
- Fuel: Ensure sufficient Octane 90 or above fuel.
- Brakes: Check braking condition and lever free play (10~20mm).
- Tires: Check pressure (Front: 1.75kg/cm², Rear: 2.0 kg/cm² for 1 person, 2.25 kg/cm² for 2 persons) and for damage/wear.
- Steering Handle: Check for abnormal vibration or difficulty in turning.
- Speedometer, Lights, Mirror: Ensure proper operation and visibility.
- Main Components: Check for loose screws and nuts.
- Abnormal Points: Address any existing troubles.
Engine Oil Inspection and Change:
- Inspection: Support the motorcycle on level ground, remove dipstick after 3-5 minutes, wipe clean, reinsert (without rotating), then remove and check oil level between marks. Add oil to the upper limit if needed.
- Change: Change engine oil after the first 300km, then every 1000km. Check every 500km. Use (API)SJ MA 10W-30 grade or better engine oil (suggest SM 10W-50). Capacity: 0.8 Liter (0.70 liters for routine change). Use SAE 5W-40 below 0℃.
- Oil Filter Cleaning: Remove and clean the oil filter element with gasoline or an air spraying gun.
- Cautions: Check oil level on level ground after engine has stopped. Be careful of hot engine/exhaust. Refill if oil level drops. Keep away from sparks/flames.
Fuel Inspection:
- Check fuel gauge. Use unleaded fuel of Octane 90 or above.
- Ensure main stand is secure, engine off, and no flames during refueling.
- Do not fill above the upper limit. Tighten fuel tank cap properly.
Transmission Oil Inspection and Change:
- Inspection: Support on main stand, wait 3-5 minutes after engine stops. Remove infusion and drain bolts to check oil volume.
- Replacement: Stop engine, support on main stand. Remove infusion and drain bolts to drain oil. Install drain bolt, fill with new transmission oil (170c.c. for XE12W2 models, 90c.c. for XE05W2 models), install infusion bolt. Recommend Genuine SYM HYPOLD GEAR OIL (SAE 85W-140).
Brake Free Play Inspection and Adjustment:
- Inspection: Check brake lever and pedal free play (10~20mm). If spongy, it's abnormal. If brake lining wear indicator aligns with the mark, replace lining immediately.
- Adjustment: Turn the adjustment nut on the brake arm until the free play is correct. Hold levers and measure with a ruler.
Disc Brake Inspection:
- Visually check brake lines for leakage, damage, or looseness.
- Front Brake Lining: Check brake caliper. Replace pad when wear limit reaches the brake disk.
- Brake Oil Reservoir: Park on level ground, check fluid level is not below "LOWER" mark. Use WELL RUN BRAKE OIL (DOT 3).
- Replenishment: Loosen screws, remove master cylinder cover, clean around reservoir, remove diaphragm plate/diaphragm, add fluid to upper level, reinstall components, tighten securely. Do not use other fluids or overfill.
Throttle Valve Handle Clearance Adjustment:
- Correct clearance is 2~6mm. Loosen lock nut, turn adjust nut, then tighten lock nut.
- Check cable for smooth movement, interference, and obstruction.
Battery Inspection and Maintenance:
- Maintenance-free battery; no need to check/add electrolyte.
- Cleaning Terminals: Remove terminals, clean dirt/corrosion. If eroded, clean with steel brush/sandpaper. Apply thin grease.
- Removal: Turn ignition to "OFF," remove negative cable first, then positive.
- Installation: Reverse order of removal.
- Cautions: Do not remove caps. For long storage, remove and store in a well-ventilated, dimly lit place after full charge, or disconnect negative cable if kept on motorcycle. Replace with same closed-type battery.
Tire Inspection:
- Check and inflate tires with engine off.
- Check ground contacting curve and inflate to specified pressure when cold.
- Visually check for cracks, damage, nails, or stones.
- Check tread wear indicator; replace tire if wear bar shows.
Steering Handle Front Shock Absorbers Inspection:
- Perform with engine off and key removed.
- Visual check for damage.
- Operate handle up/down, check for noises/bends.
- Check bolts/nuts for tightness.
- Shake handle up/down, left/right, front/rear for looseness, resistance, or pulling.
- Check for brake cable interference.
- Take to SYM Authorized Dealer for adjustment if abnormalities found.
Checking and Changing Fuses:
- Turn off ignition, check fuses. Replace blown fuse with new one of same amperage (20A/15A*2/10A). Do not use brass/iron wire.
- Remove storage box to access fuse holder near battery. Open cover, pull out fuse, check for damage. Secure connections.
- Use specified parts for electrical components. Avoid spraying water. If new fuse blows quickly, seek dealer inspection.
Checking Turn Signal Lights and Horn:
- Turn ignition to "ON." Check front/rear, left/right signal lights flash and warning buzzer sounds.
- Check covers for dirt, cracks, looseness.
- Press horn button to check operation.
- Use specified bulbs. Turn on signals before turning/changing lane, turn off immediately after.
Checking Front and Rear Lights:
- Start engine. Check head lamp and rear lamp come on.
- Check brightness and direction of front light.
- Check head lamp cover for dirt, cracks, looseness.
Checking Brake Light:
- Turn ignition to "ON." Hold hand-braking levers. Check brake lights come on.
- Check brake light cover for dirt, cracks, looseness.
- Use specified bulbs. Do not modify or add other electrical components to prevent overload/short circuit.
Checking for Fuel Leakage:
- Check fuel tank, fuel cup, fuel hose, and carburetor for leakage.
Checking Lubrication of Body's Mechanisms:
- Check pivot points (main stand, side stand, brake lever) for lubrication.
Checking Spark Plug:
- Remove cap, spark plug. Check electrode for dirt/carbon. Clean with steel wire/gasoline, wipe dry. Adjust gap to 0.6~0.7 mm. Hand tighten, then 1/2~3/4 turns with wrench.
- Engine is hot after running. Use suitable spark plugs.
Checking Air Cleaner:
- Remove mounting screws, cover, and filter element. Clean element.
- Dust reduces horsepower and increases fuel consumption. Change element more frequently on dusty roads. Improper installation allows dust into cylinders. Avoid soaking during washing.
Periodical Maintenance Schedule:
The manual includes a detailed table for periodical maintenance, with intervals based on kilometers (300KM, 1000KM, 3000KM, 6000KM, 12000KM) or time (1 Month, 3 Months, 6 Months, 1 Year), whichever comes first. Tasks include:
- Air cleaner element: Inspection (I), Cleaning (C), Replacement (R) (paper/sponge).
- Air cleaner: C.
- Oil filter (Screen): C.
- Fuel pump filter: R every 10000KM.
- Engine oil: R, R every 3000KM.
- Tire, pressure: I.
- Battery: I.
- Spark plug: I, R.
- Carburetor (idle speed): I.
- Steering bearing and handles: I.
- Check transmission for leakage: I.
- Check crankcase for leakage: I.
- Transmission oil: R every 5000KM (5 Months).
- Drive belt/roller: I, R.
- Fuel tank switch and lines: I.
- Throttle valve operation and cable: I.
- Engine bolts and nuts: I.
- Cylinder head, cylinder, and piston: I.
- Exhaust system/cleaning carbon: I.
- Cam Chain/ignition time: I.
- Valve clearance: I.
- Shock absorbers: I.
- Shock tension rod: I every 10000KM, R every 30000KM.
- Front/rear suspension: I.
- Main/side stands: I, L.
- Crankcase Blow-by system (PCV): I.
- Clutch disk: I.
- Brake mechanism/brake lining (pad): I.
- Bolts/nuts for each components: I.
Remarks:
- "I" for Inspection, cleaning, and adjustment.
- "C" for Cleaning (replaced if necessary).
- "R" for Replacement.
- "L" for Lubrication.
- Clean or replace air cleaner element more often in dusty or heavily polluted environments.
- Perform maintenance more often if operated frequently at high speed or accumulated higher mileage.
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