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Sym Maxsym TL TL 500, Owner'S Manual

The Sym Maxsym TL TL 500 Owner's Manual is essential for new owners. This comprehensive manual provides detailed instructions on operating, maintaining, and troubleshooting the impressive Maxsym TL TL 500 model. Download your free copy from manualshive.com and unleash the full potential of your scooter with ease.

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50 

13. Periodic Maintenance

 

 

Item 

Odometer Reading 

Annual 
service 

Page 

1,000km  10,000km  20,000km  30,000km  40,000km 

1 

☆

 

Engine air cleaner 
element* 

 

R 

R 

R 

R 

 

44 

2 

☆

 

V-belt case air cleaner 
elements* 

 

 

R 

 

R 

 

44 

3 

☆

 

Engine oil*

#

 

R 

Second at first 5,000km, every 5,000km 

thereafter 

R 

33 

4 

 

Engine oil filter screen*

#

 

C 

Second at first 5,000km, every 5,000km 

thereafter 

C 

35 

5 

☆

 

Engine oil filter 
cartridge*

#

 

R 

R 

R 

R 

R 

 

34 

6 

 

Engine oil level 

I: every 1,000km 

 

33 

7 

☆

 

V-belt* 

R: every 20,000km 

 

 

8 

 

Drive chain lubrication 
condition*

#

 

I: every 500km 

I 

43 

9 

 

Drive chain slack 

I: every 1,000km 

 

42 

10 

 

Drive chain/sprockets 
wear 

 

I 

I 

I 

I 

 

43 

11 

 

Drive chain 

R: every 15,000km 

 

- 

12 

 

Drive chain slider 

 

- 

13 

☆

 

Spark plugs 

 

I/R 

I/R 

I/R 

I/R 

 

44 

14 

☆

 

Idle speed 

I 

I 

I 

I 

I 

 

- 

15 

 

Cooling system

#

 

 

I 

I 

I 

I 

I 

- 

16 

 

Coolant level 

I 

I 

I 

I 

I 

 

36 

17 

☆

 

Coolant, water hoses 
and O-rings

#

 

R: every 3 years 

I 

- 

18 

 

Throttle control system

#

 

I 

I 

I 

I 

I 

I 

38 

19 

☆

 

CVT system 
(rollers/shafts/ drive 
pulley cushion) 

 

 

I/L 

 

I/L 

 

- 

20 

☆

 

Brake system

#

 

I 

I 

I 

I 

I 

I 

- 

21 

 

Brake operation 

I 

I 

I 

I 

I 

I 

 

22 

☆

 

Brake fluid 

R: every 2 years or every 30,000km 

I 

 

23    Brake fluid level 

I 

I 

I 

I 

I 

I 

37 

24 

☆

 Brake hoses 

R: every 4 years or every 60,000km 

I 

- 

25    Brake pad wear* 

 

I 

I 

I 

I 

 

38 

26   

Brake light switch 
operation

#

 

I 

I 

I 

I 

I 

I 

- 

27    Suspension system

#

 

 

I 

I 

I 

I 

I 

- 

28    Wheels and tires

#

 

I 

I 

I 

I 

I 

I 

39 

29    Tire pressure

#

 

I 

I 

I 

I 

I 

I 

39 

30 

☆

 Wheel bearings 

 

I 

I 

I 

I 

 

- 

 
 
 

Summary of Contents for Maxsym TL TL 500

Page 1: ...SANYANG MOTOR CO LTD NO 3 Chung Hua Road Hukou Hsinchu Taiwan R O C T 886 3 598 1911 F 886 3 597 1981 W http www sym global com Owner s Manual TL47W1 EU ...

Page 2: ...tank cap 24 Front compartment 26 Luggage box tool kit helmet hook 26 Side stand parking brake 27 Main stand 28 Rear view mirror 28 Passenger footrest 29 8 How to Start the Engine 29 To start the engine 29 To stop the engine 29 9 How to Ride the Scooter 30 Break in 30 Tips of fuel economy 30 Throttle control 30 Moving off 31 Breaking 31 Anti lock Brake System 31 Park the scooter 32 10 Maintenance a...

Page 3: ... 42 Spark plug inspection 44 Air cleaner V belt case air cleaner inspection 44 Headlight adjustment 46 Rear shock absorber adjustment 46 General lubrication 47 Vehicle data recorder 47 11 Taking Care of Your Scooter 47 Washing 47 Storage 48 12 Trouble Shooting 48 Diagnosis when engine does not start 48 Overheating 48 EFi warning indicator light on 49 ABS indicator light on 49 Low oil pressure indi...

Page 4: ...pletely carried out We recommend that after riding your new scooter for the first 300 kilometers you should take your scooter to the original dealer for an initial inspection and to have your scooter inspected periodically every 1000 kilometers thereafter In case the scooter s specifications and construction are modified and different from the photos and diagrams on the owner s manual catalogues t...

Page 5: ...orm periodical maintenance and inspection in accordance with the schedule 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...

Page 6: ... 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 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 maximi...

Page 7: ...ront brake calipers 7 Front brake discs 8 Side stand 9 Oil level inspection window 10 Oil drain bolt 11 Oil filler cap 12 Passenger footrests 13 Rear shock absorber 14 Tail brake light 15 Seat 16 Helmet hook 17 V belt case air cleaner left 18 Fuel tank cap MAXSYM TL TL47W1 EU TL 500 TL47W1 EU 1 2 3 4 5 6 8 9 10 11 13 14 15 16 17 18 7 12 ...

Page 8: ... Main stand 7 V belt case air cleaner right 8 Oil Filter screen 9 Oil Filter cartridge 10 Coolant level inspection window 11 Coolant reserve tank 12 Front fork 13 Battery 14 Diagnostic tool connector 15 Fuse box 16 Tool kit 17 Luggage box 18 Passenger handlebar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 16 18 15 ...

Page 9: ...ches 4 Rear brake fluid reservoir 5 Combination instrument 6 Front brake fluid reservoir 7 Right handlebar switches 8 Front brake lever 9 Throttle grip 10 Right compartment 11 USB power outlet 12 Ignition switch 13 Left compartment 1 2 3 4 6 7 2 5 8 13 12 10 11 9 ...

Page 10: ...and digits in the multi function meter is lit up as marquee for function test then the whole combination instrument turns to operational mode NOTE Do not wipe plastic components such as the instrument panel the headlight body covers etc with solvents such as gasoline Wiping plastic components with solvents can damage these components WARNING Never operate the instrument buttons while riding the sc...

Page 11: ...r The oil check indicator shows how long the engine oil is used The oil check indicator light turns on at every 1 000km riding distance according to the oil distance meter page 17 When this indicator comes on please check the oil level in the oil level inspection window page 33 In oil meter mode quickly press the S button twice to reset the oil check indicator D ABS Indicator The ABS Anti lock Bra...

Page 12: ...te this parking brake page 27 This indicator goes on when the side stand is kicked down The rear wheel will be locked when the parking brake is activated The engine will be stopped if the side stand is kicked down while the engine is running This indicator goes off when the side stand is up Setting Buttons A S Button Push this button to reset the trip meter oil mileage meter in the multifunction m...

Page 13: ...the display for seconds and the selected function screen displays after the animation Themes and function screens This combination instrument is built in three display themes and each theme contains five function screens Every function screen in different themes shares the same items RPM Speedometer Clock Trip computer Vehicle info Theme 1 Theme 2 Theme 3 A ...

Page 14: ...ng synchronizes with the multi function meter s speedometer The current fuel consumption level is shown in kilometers liters km l the light bar varies with the current fuel consumption Your style of riding can be adapted to the desired fuel consumption If the scooter is stationary 0 0 will be shown in the display area Clock This function screen displays one digital and one alternative style This c...

Page 15: ...the maximum limit 999 9 Travelled time The travelled time is the total driving distance since the last travelled time reset The travelled time is reset automatically when the ignition switch is turned off over 30 minutes Max RPM This function records the maximum engine revolution of this scooter since the last max rpm reset The max rpm is reset automatically when the ignition switch is turned off ...

Page 16: ...l is displayed Display range 40 130 C NOTE If the battery voltage is below 12 0V when the ignition switch is turned on and the engine is hard to start or cannot be started have your scooter checked by an authorized SYM dealer If the battery voltage is below 12 0V or above 15 5V when the engine is running have your scooter checked by an authorized SYM dealer A B C A Clock B Battery voltage gauge C ...

Page 17: ... 3 Push the select button to finish selecting theme NOTE The TFT display only shows the last selected function screen every time you turn the ignition switch on The function screen select can be operated while riding do not distract from your current drive A B C D A Up button B Down button C Sequence when pushing up button D Sequence when pushing down button A B C F E A Up button B Select button C...

Page 18: ...previous selected theme function screen The theme select can be operated while riding do not distract from your current drive NOTE The multi function display always shows the previously selected display modes every time you turn the ignition switch on The multi function display shows in odometer mode after the battery is reconnected NOTE The data is maintained in the combination instrument even wh...

Page 19: ...nge 8 16 V NOTE When the figures come to 999 9 they will return to 0 and the trip meter starts working again This trip meter only shows in kilometers NOTE If the oil distance meter is not reset the oil check indicator will go on permanently until it is reset If the oil distance meter is not reset when the oil distance exceed the maximum limit 9999 9 km the meter will return to 0 km and continue ad...

Page 20: ...e low fuel level indicator page 10 goes on when there s only the first sector b remains go refuel the fuel tank immediately If the fuel level signal is in fault all 5 bars blink c have your scooter checked by an authorized SYM dealer C Speedometer This digital speedometer displays the current vehicle speed only in km h Display range 0 199 km h a b c ...

Page 21: ...l return to Off position automatically E Lock Position The handlebar can be locked in this position Turn the ignition key to Off position to stop the engine Turn the handlebar fully to the left Push the ignition key anti clockwise to lock the handlebar The ignition key can be removed in this position To unlock the handlebar turn the ignition key clockwise to Off position F Shutter Opener This shut...

Page 22: ...ey when the scooter is running Turning the ignition switch to Off position will shut off the electrical system and that may result in a dangerous accident The ignition switch can only be turned off after the scooter is completely stopped If the ignition switch remains in the On position for a prolonged period after the engine is stopped the battery voltage will be reduced and this may affect engin...

Page 23: ...Switches NOTE Even though the engine stop switch can stop the engine it does not turn off all the electrical circuits Normally the engine stop switch should be used to stop the engine NOTE Do not use the hazard lights for a long period of time or the battery may become totally discharged If you turn the ignition switch off without deactivating the hazard lights the hazard lights cannot be deactiva...

Page 24: ...trument Please refer to page 11 D Turn Signal Switch When the turn signal switch is turned to the left or right the corresponding turn signals blink on and off To stop blinking push the switch in E Horn Button When the horn button is pushed when the ignition switch is turned on the horn sounds Front Rear Brake Lever This scooter is equipped with four position adjustable front rear brake levers for...

Page 25: ...r and mount the windscreen Tightening torque Windscreen bolt 1 2 kgf m Fuel Tank Cap Turn the ignition key to Fuel Lid position page 20 to release the fuel lid and open it To open the fuel tank cap flip up a the fuel tank cap cover A hold the cover and turn it anticlockwise b NOTE If you lack proper experience or doubt your ability please contact your authorized SYM dealer for adjustment A A B A A...

Page 26: ... conditions Do not smoke and turn the ignition switch off when fueling Make sure the area is well ventilated and free of any flammable source Never fill the fuel tank to the top If the tank is filled to the top heat may cause the fuel to overflow Make sure the fuel tank cap is closed securely after refueling Wipe off the gasoline immediately if it is spilled out on the scooter CAUTION Use only unl...

Page 27: ...stored in the luggage box Some helmets may not fit in the space due to the size or design Please refer to the below picture for recommendation This scooter is equipped with a luggage box light B The luggage box light goes on when the seat is opened Maximum load 10 kg NOTE Do not use the USB power outlet when the engine is not running To prevent the fuse to melt down do not charge devices exceed 24...

Page 28: ... kicking down the side stand This scooter is equipped with a side stand switch B When the side stand is kicked down the parking brake indicator goes on page 11 The engine cannot be started when the side stand is kicked down The engine will be stopped when kicking down the side stand while the engine is running NOTE Do not exceed the maximum weight limit The luggage box may affected by engine heat ...

Page 29: ...or storing the scooter To fold the mirrors do the below steps Hold the stem securely and turn it forward a or backward b until it is positioned Return the rear view mirrors to the neutral position A before riding NOTE Turn the handlebar fully to the left when using the side stand Do not sit on the scooter when it is on its side stand If it is necessary to park the scooter on a slope do not let the...

Page 30: ...d rear view mirrors NOTE Fold up the passenger footrests when there is no passenger sit on the scooter CAUTION Check the oil and the fuel volume before starting the engine To prevent unexpected movement fully pull the clutch lever before starting the engine Release the starter button immediately after starting the engine If the engine cannot be started after activating the starter 3 5 seconds plea...

Page 31: ...tively Tips of Fuel Economy Your riding style is one of the major factors of fuel consumption Please refer to the below tips to reduce fuel consumption Avoid high engine speeds when accelerating Avoid high engine speeds without engine load Turn the ignition switch off rather than keeping it idle for a long period of time Throttle Control To accelerate slowly open the throttle A To decelerate close...

Page 32: ...ile stopping by preventing wheel lock up remember the following characteristics ABS cannot compensate for adverse road conditions misjudgment or improper application of brakes You must take the same care as with scooters not equipped with ABS ABS is not designed to shorten the braking distance On loose uneven or downhill surfaces the stopping distance of a scooter s with ABS may be longer than tha...

Page 33: ...r pollution Maintenance is the owner s responsibility Be sure to inspect your scooter before every ride and perform the routine checks The first maintenance is extremely important and must be performed SYM cannot warn you of every conceivable hazard that can arise in performance Only you can decide whether or not you should perform a given task If you lack proper experience or doubt your ability p...

Page 34: ...ase warm up the engine several minutes at idle speed Stop the engine and wait for several minutes to allow the oil to settle Set the scooter upright with the main stand and lower the side stand check the engine oil level through the oil level inspection window A the oil level should be between the upper a and lower b marks Top up the oil to the upper mark with the same oil when it is at the lower ...

Page 35: ...moved 2 7 L When oil filter cartridge is removed 2 9 L Engine oil recommendation SYMOIL S6800 API SM JASO MA2 synthetic Tightening torque Engine oil filter cartridge A 1 8 kgf m Engine oil drain bolt B 4 2 kgf m Although SAE 10W40 oil is recommended for most conditions the oil viscosity may need to be changed to accommodate climate conditions in your riding area NOTE Oil level will not be correct ...

Page 36: ...e When the low fuel indicator comes on page 10 it shows the fuel remains approximately 2 2 liter reserve fuel please fill up the tank immediately Do not add too much fuel to the fuel tank Make sure the fuel tank cap is securely closed Recommended fuel Unleaded 95 RON gasoline or greater NOTE If the fuel level signal is in fault the whole fuel gauge blinks have your scooter checked by an authorized...

Page 37: ...and L b marks Top up the coolant carefully when the level is at the L mark Pull up the tip of the right front floor panel mat A and remove the maintenance cap B from its tip Open the reserve tank cap A to fill in coolant Reverse the above steps to restore NOTE You can add soft water to the coolant reserve tank in an emergency it must be restored to the correct mixture ratio afterwards If you have ...

Page 38: ...ction This scooter is equipped with a disk brake system on the front wheel and the rear wheel If there is something wrong when applying the brakes have the brake system checked by an authorized SYM dealer Front Rear Brake Fluid Level Inspection Set the scooter upright To inspect the right brake fluid reservoir turn the handlebar to the left To inspect the left brake reservoir turn the handlebar to...

Page 39: ...rip moves smoothly from full open to close Check that there is 5 10 A of throttle free play when turning the throttle grip back and forth Have the throttle free play checked by an authorized SYM dealer WARNING Use only DOT 4 brake fluid Brake fluid is easy to absorb moisture from the air any absorbed moisture will reduce the braking efficiency greatly Never let water or dirt enter the reservoirs w...

Page 40: ... and cuts A before riding replace the tires when necessary Measure the depth of the tread with a depth gauge A replace the tire that has worn down to the minimum allowable tread depth WARNING Insufficient tire tread depth can make the scooter difficult to control Please refer to the local regulations about tire tread depth New tires are slippery and may cause loss of control Smoothly operate the s...

Page 41: ... Check that the steering axle locknut is tightened If any irregularity is found on the handlebar front fork contact your authorized SYM dealer Fuse Inspection Fuses are arranged in the fuse box located behind the front right cover A To remove the front right cover follow the below steps Turn ignition switch off and set the scooter up right Open the right storage compartment cover and remove the 2 ...

Page 42: ...d SYM dealer Do not replace it with any material other than the specified fuse Have the scooter checked by an authorized SYM dealer if the fuse fails repeatedly Battery Inspection Battery Inspection This scooter is equipped with a sealed type battery There is no need to check the electrolyte level or add distilled water The battery is located behind the front right cover To take out the battery do...

Page 43: ...tery chargers Drive Chain Inspection Drive Chain Slack Inspection Inspect the chain slack before riding Turn ignition switch off and set the scooter upright with its main stand Remove the 2 screws A and the 2 bolts B to remove the outer lower chain guard Rotate the rear wheel to find the tightest position of the chain and measure the chain slack A by pushing up and pulling down the chain midway be...

Page 44: ...in dusty or wet areas Clean and lubricate the drive chain with sealed chain cleaner and lubricant as follows Remove the front lower chain guard page 42 Clean the drive chain with sealed chain cleaner and a soft brush Wipe the chain dry Lubricate the drive chain thoroughly with sealed chain lubricant Wipe off excessive lubricant on the drive chain and the rear tire Mount the lower chain guard to re...

Page 45: ...ap 0 8 0 9 mm Tightening torque 1 2 kgf m WARNING Beware of the engine heat when inspecting the spark plug Engine Air Cleaner V belt Case Air Cleaner Inspection A dirty engine air cleaner element can reduce the engine performance and increase fuel consumption The engine air cleaner is element is located behind the front left cover A Inspect the engine air cleaner by following the below instruction...

Page 46: ... groove A with a wet cloth after removing the air cleaner element If the air cleaner element is damaged or too dirty have it changed by a SYM authorized dealer To install the element do in the reverse order of the above instructions This scooter is equipped with 2 V belt air cleaner elements Have the v belt air cleaner elements inspected or replaced by an authorized SYM dealer A A A B A B C A ...

Page 47: ...r C in the toll kit to increase preload After setting up the spring turn the fixer B clockwise to lock the spring To set the spring softer first turn the fixer anti clockwise to release turn the adjuster anti clockwise b with the C spanner in the tool kit to decrease preload then turn the fixer clockwise to lock the spring NOTE Make sure to keep dust or foreign objects from entering the air cleane...

Page 48: ...that is designed for scooters or automobiles and water in a bucket Use a sponge to wash your scooter Use low pressure water stream to clean the radiator After washing rinse your scooter thoroughly with clean water to remove the residue Use an air gun to blow off the water and use a clean soft cloth to dry your scooter Carefully ride your scooter at a slow speed and apply the brakes several times t...

Page 49: ...tion switch turned to ON position Is there enough fuel in the fuel tank or there is only E mark shown in the fuel gauge Is the rear or front wheel brakes applied when pressing start button Turn the ignition switch to ON position and press the horn button if the horn does not sound the fuse may have been blown Remove the front right cover to check the fuses if the wire is obvious melted replacement...

Page 50: ... brake system problem The indicator light comes on while riding The indicator light does not come on when the ignition switch is turned on The indicator does not go off above 5 km h Although the brake system will continue to work without anti lock function SYM suggest you to have your scooter checked by an authorized SYM dealer if any of the above symptoms occurs Low Oil Pressure Indicator On If t...

Page 51: ...rive chain sprockets wear I I I I 43 11 Drive chain R every 15 000km 12 Drive chain slider 13 Spark plugs I R I R I R I R 44 14 Idle speed I I I I I 15 Cooling system I I I I I 16 Coolant level I I I I I 36 17 Coolant water hoses and O rings R every 3 years I 18 Throttle control system I I I I I I 38 19 CVT system rollers shafts drive pulley cushion I L I L 20 Brake system I I I I I I 21 Brake ope...

Page 52: ...lts nuts and fastener condition I I I I I I Inspect or adjust C Clean R Replace L Lubricate Service more frequently when riding in severe conditions such as dusty wet muddy high speed etc Service annually or at indicated odometer reading intervals whichever comes first Should be performed by an authorized SYM dealer For higher odometer readings repeat at the frequency shown above If any problem ra...

Page 53: ...m 70 mm 71 mm 63 mm 75 mm 63 mm Max horse power 40 7 PS 6750 rpm 21 5PS 7500 rpm 27 3PS 8000 rpm Max torque 4 3 kg m 6250 rpm 2 4kg m 5500 rpm 2 8kg m 5500 rpm Idle speed 1 300 rpm 1 650 rpm 1 550 rpm Starting system Electric starter Fuel system EFi fuel injection Fuel Unleaded 95 RON gasoline or greater Ignition system Battery and coil Spark plug NGK CPR7EA 9 NGK CR8E Coolant capacity 1 3 L Drive...

Page 54: ...ear brake disk 275 mm Front brake caliper 4 piston ABS 2 4 piston ABS Rear brake caliper 1 piston ABS 2 piston ABS Brake fluid DOT 4 Suspension System Front Upside down fork 41 mm Rear Multi link single sided shock absorber preload adjustable Electrical Equipment Head light LED Rear brake light LED Turn indicator LED License plate light 5 W Battery MF TTZ 10S 12V 8 6Ah MF GT12A BS 12V 10Ah Specifi...

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