USER MANUAL - we are moto

USER MANUAL - we are moto
ENG
mod.# B 55
USER MANUAL
INTRODUCTION
Thanks for your purchasing of this vehicle. This model is designed for safety, built for durability, and
perfected for daily street use. The unique vehicle design, enrich of stylish and peronality, represents your
outstanding taste and favor to pursue the state of the art living attitude.
This manual describes the correct usage of this motorcycle including safety riding, simple inspection methods
and so on. For a more comfortable and safety riding, please read this manual carefully. If any questions concerning
the operation or maintenance of your vehicle, please consult a dealer.
1
IMPORTANT MANUAL INFORMATION
In this manual with some important information is distinguished by the following notations:
!
WARNING
CAUTION
It is WARNING instructions that need to follow, failure of follow coulnd be end in result
severe injuiry or lead to death to the operator.
A CAUTION indicates with special precautions to avoid damage to the vehicle.
CAUTION
• Please always put this manual with vehicle for rider maintenance/ dealer tracking of service records even if vehicle is
being sold.
• This manual contains the most of the vehicle information, however, the maker will continually imrprove it’s product
design and quality that lead to difference between the manual and vehicle . If you have any questions concerning this
manual, please consult your dealer.
!
WARNING
FOR YOUR OWN SAFETY, PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION THIS Vehicle. ONLY OPERATE
THE Vehicle UNTIL YOU HAVE COMPLETELY AWARE OF ADEQUATE KNOWLEDGE OF CONTROLS AND OPERATION FEATURE AND YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. PERIODIC INSPECTIONS, WELL MAINTENANCE AND GOOD RIDING SKILLS, WILL ENSURE YOUR SAFETY RIDING AND INCEASE THE PRODUCT RELIABILITY OF
THIS VEHICLE.
*Product and specifications are subject to change without notice.
2
IMPORTANT MANUAL INFORMATION
Dealer label here
3
TABLE OF CONTENTS
SAFETY INFORMATION
5
Other safetyriding points
7
Location of labels
8
DESCRIPTION
9
Left views9
Right view 10
Controls and instruments
11
INSTRUMENT AND CONTROL
FUNCTIONS 12
Main switch/steering lock
12
Indicator and warning lights
13
Dashboard unit
13
Fuel gauge 14
Handlebar switches
14
Front brake lever
15
Rear brake lever
15
Fuel tank cap
15
Fuel16
2-stroke engine oil tank cap
17
Catalytic converter
18
Kickstarter 18
Seat18
Storage luggage box 19
Front hook,helmet
19
Front storage luggage box
19
Rear carrier 20
Sidestand20
PRE-OPERATION CHECKS
21
Pre-operation check list 22
OPERATION AND IMPORTANT
RIDING POINTS 23
Starting the engine
23
Starting off 24
Acceleration and deceleration
24
Braking24
Engine break-in
25
Parking25
PERIODIC MAINTENANCE AND
MINOR REPAIR
26
Owner’s tool kit
27
Battery cover 27
Spark plug 27
Final transmission oil 29
Air filter28
Carburator 31
Checking the throttle cable free
play31
Tires31
Rims33
Adjusting the rear brake lever free
play33
Brake pads 34
Brake fluid 35
Cables35
Throttle grip and cable 36
Lubricating the front and rear brake
levers36
Main stand 36
4
Front fork37
Steering37
Wheel bearings
38
Battery38
Fuse39
Headlight bulbs
39
Front indicator
40
Rear indicator40
Tail/brake and licenes plate light
40
TROUBLESHOOTING 41
Troubleshooting chart 42
CLEAN AND STORAGE
43
Clean the vehicle
43
Storage44
SPECIFICATIONS
45
CONSUMER INFORMATION
47
Identification numbers 47
WARRANTY INFORMATION
48
MAINTENANCE SCHEDULE
49
SERVICE PLAN
50
WIRING DIAGRAM
51
SPACE FOR NOTES 52
SAFETY INFORMATION
THIS VEHICLE ARE TWO WHEEL
SINGLE TRACK VEHICLES. THE
USE OF SAVETY AND OPERATION
MAY IN DIFFERENT RESULT BY THE
USE OF PROPER RIDING TECHNIQUES OF THE OPERATOR.
TO REMIND OF OPERATOR, WHO
SHOULD KNOW THE FOLLOWING
REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
• WELL TRAINED AND FIMILIAR
TO ALL THE ASPECTS OF Vehicle
OPERATION.
• FULLY READ AND AWARE OF
MAINTENANCE REQUIREMENTS
THAT NOTED IN THIS OWNER’S
MANUAL.
• OBTAIN QUALIFIED TRAINING &
LEGAL LICENSE FOR OPERATION OF THIS VEHICLE.
• WELL
AND
PROFESSIONAL
MAINTENANCE SERVICE FOR
OPERATOR AND CERTIFICATED REPAIR SHOP/DEALER TO
ACQUIRE GOOD MECHANICAL
CONDITIONS OF VEHICLE.
Safe riding
• Always pre-check your vehicle before riding is key point to prevent an
accident.
• Please follow the maxium loads limited of operator and passenger.
• Most of accident on the motorists is
cased by automobile driver who “failure to recognize out the vehicle” and
caused mobile/vehicle accidents.
Therefore, to make yourself conspicuous apprear to public will be very
effective in reducing the change of
this kind of accidents.
Therefore:
• Wear a brightly colored and protective clothes/Jacket
• Operate the turning signals before
turning and slow down the Speed
when approaching and passthrough
the intersection
• Keep proper distance with other Motorists, and let them aware of your
location
• Know your skills and limits
• Never lend your vehicle to oththers
5
who not qualified for riding
• Always follow the legal speed limit
on the vehicle and traffic law
• The posture of the operator and
passenger is important for proper
control. properly riding posture can
Keep vehicle in balance while riding.
• Operator should sit up-right with
two hand hold on handle bar, foot
on floorboard while driving.
• Passenger should make sure that
he/she can firmly hold on grip or
operator with foot step on footrest.
• Drving after Acohol drink or other illegal drugs is strickly prohibited.
• This vehicle is designed for onroad
use only. It is not suitable for off-road
use.
Protective clothing
Properly clothing yourself will keep you
safety from potential accidents:
• Always wear an approved helmet.
• With face shield to protect your eye
from dust and rain drop.
• The wear of proper jacket, shoes,
groves etc., can be better protection,
SAFETY INFORMATION
reducing the degree of injuiry from
un-expected accident.
• Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.
• Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective
clothing that covers your legs, ankles, and feet.
Modifications
Modifications made to this vehicle that
not approved by maker, or the removal
of original equipment, may let vehicle
unsafe for use and cause severe personal injury. Modifications may also
make your vehicle illegal touse.
Loading and accessories
Adding accessories or cargo to your
vehicle may cause the different on the
weight distribution of vehicle and influence on the steering & balance. It
may cause possibility of an accident,
please extremely caution and follow
below limitation when you equipped
with accessories. Below are some general or accessories. Here are some
guidelines to follow if loading cargo or
adding accessories to your vehicle.
Loading
The total weight of the operator, passenger, accessories and cargo must
not exceed the maximum load limit.
Maximum load
(not include the vehicle): 150kg
When loading within this weight limit,
keep the following in mind:
• Cargo and accessory weight should
be kept as low and close to the vehicle as possible. Make sure to distribute the weight as evenly as possible on both sides of the vehicle to
minimize imbalance or instability.
• Make sure that accessories and
cargo are securely attached to vehicle before riding
• Never attach any large or heavy
items to the handlebar, front fork, or
front fender. Such items can create
unstable handling or a slow steering
response.
6
Accessorries
Genuine accessories have been specifically designed for use on this vehicle.
If need, please contact with dealer for
detail. Since the maker can not test all
other accessories , you must personally be responble for the proper selection, installation and use of non-OEM
accessories.
Keep the following guidelines in mind,
when mounting accessories.
• Never install accessories or carry
cargo that would influence on the
ground clearance, limit suspension
travel, steering,or obscure lights or
turning lights, reflectors.
• Accessories on the handle bar/front
suspension area will cause bad influence on steering the vehicle. if
you will install accessories, please
keep it as light in weight and not interfere on steering the vehicle. This
vehicle is for On-Road transportation purpose only, please do not install any of extended cargo carrier as
sulky, that will make vehicle unstable in cross winds and vehicle turns.
• While equip with electrical acces-
SAFETY INFORMATION
sories, please consult with qualifiled
stores, to make sure such items
will not exceed the capacity of the
vehicle’s electrical system. Unproper install of such items may cause
a dangerous loss of lights, lower engine power or even damage the vehicle.
king the vehicle, please note the following:
• The engine and exhaust system
remain hot, therefore, park the vehicle in a place where pedestrians
or children are not likely to touch
these hot areas.
• Do not park the vehicle on a slope
or soft ground, otherwise it may
fall over.
• Do not lay your vehicle to near
flammable place.
Gasoline and exhaust gas
• GASOLINE IS HIGHLY FLAMMABLE:
• Always turn the engine off when
refueling.
• In case of swallow any gasoline, or
• Take care not to spill any gasoligasoline get into your eyes, please
ne on the engine (hot) or exhaust
see your doctor immeidately. Keep
system when refueling.
away the gasoline to your skin and
• Do not smoke or use Mobile phowater.
ne while re-fueling.
Other safe-riding points
• Never start the engine or let it run for • Turn the signal before making turns.
any length of time in a closed area. • When raining or across on run on
the wet road, Iron Plates, keep your
The exhaust fumes are poisonous
speed low, slightly using braking to
and may cause loss of consciousavoid slipping or even fall down.
ness and death within a short time.
• Be careful when passing parked
cars. A driver might not see you and
• Always turn the engine off before
leaving the vehicle and remove the
open a door in your path.
key from the main switch. When par7
SAFETY INFORMATION
LOCATION OF LABEL
1. Label, anti-tampering
1
Symbol image
8
DESCRIPTION OF THE VEHICLE
LEFT VIEW
1. Front wheel
2. Front brake caliper
3. Front turn signal light
4. Helmet holder
5. Storage compartment
6. Battery
7. Rear turn signal light
8. Rear wheel
9. Adjusting nut
10. Air filter element
11. Kickstarter
12. Pedal
13. Sidestand
4
5
7
3
6
1
8
2
13
9
12
10
11
9
DESCRIPTION OF THE VEHICLE
RIGHT VIEW
14. Tail/brake light
15. Carrier
16. 2-stroke engine oil tank cap
17. Seat
18. Fuel tank cap
19. Headlight
20. Spark plug
21. Mainstand
22. Muffler
15
18
17
16
20
14
20
22
21
10
DESCRIPTION OF THE VEHICLE
CONTROLS AND INSTRUMENTS
23. Rear brake lever
24. Left handlebar switches
25. Speedometer unit
26. Fuel gauge
27. Right handlebar switches
28. Front brake lever
29. Throttle grip
30. Main switch/steering lock
25
26
24
27
23
28
29
30
11
INSTRUMENT AND CONTROL FUNCTIONS
MAIN SWITCH/STEERING LOCK
CHECK
The 2-stroke engine oil level warning
light should come on.
LOCK
The steering is locked, and all electrical systems are off. The key can be
removed.
The main switch/steering lock controls
the ignition and lighting systems, and
also used to lock the steering. The various positions are described as below.
ON
All electrical circuits are supplied with
power, the engine can be started. The
key cannot be removed.
Lenker verriegeln
1.Turn the handlebars all the way to
the left.
2.Push the key in and turn it to the
position while still pushing it.
3.Remove the key.
To unlock the steering
Push the key in and then turn it to
position while still pushing it.
OFF
All electrical systems are off . The key
can be removed.
12
! WARNING
Never turn the key to
or , while
the vehicle is moving, otherwise the
electrical systems will be switched
off, which may result in loss of control or an accident. Make sure that
the vehicle is stopped before turning the key.
INSTRUMENT AND CONTROL FUNCTIONS
INDICATOR AND WARNING LIGHTS
1
2
3
1.High beam indicator light
2.Turn signal indicator light
3.2-stroke engine oil level warning
light
HIGH BEAM INDICATOR LIGHT
This indicator light comes on when the
high beam of the headlight is switched
on.
HIGH BEAM INDICATOR LIGHT
This indicator light comes on when the
high beam of the headlight is switched
on.
2-STROKE ENGINE OIL LEVEL
WARNING LIGHT
The warning light comes on when the
key is in the
position or when the
when the engine oil level in the 2-stroke engine oil tank is low during operation. If the warning light comes on during operation, check the oil level and
fill the oil tank with an 2- stroke engine
oil. The warning light should go off after
the 2-stroke engine oil tank has been
refilled.
CAUTION
Do not operate the vehicle until you
know that the 2-stroke engine oil level
is sufficient. Lack of engine oil will damage the engine.
! WARNING
Please note that the engine oil warning light is model dependent. If
your vehicle has no engine oil warning you must check the oil level
before each ride.
13
DASHBOARD UNIT
1
2
1. Odmeter
2. Speedmeter
The dashboard unit is equipped with
a speedometer and an odometer. The
speedometer shows the riding speed.
The odometer shows the total distance traveled.
INSTRUMENT AND CONTROL FUNCTIONS
FUEL GAUGE
HANDLEBAR SWITCHES - LEFT
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
“E”, refuel as soon as possible.
HANDLEBAR SWITCHES - RIGHT
1
2
1
1.Dimmer switch
/
2.Turn signal switch
3.Horn switch
3
1
2
1.Light switch
2.Start switch
HIGH/LOW BEAN SWITCH
/
Set this switch tof
for the high
beam and to
for the low beam.
CAUTION
Be take care not let the fuel tank to fully
empty it-self, that cause engine can not
run it-self anymore.
HORN SWITCH
Press this
14
switch to sound the horn.
INSTRUMENT AND CONTROL FUNCTIONS
TURN SIGNAL SWITCH
To signal a right-hand turn, push this
switch to
. To signal a left-hand turn,
push this switch to
. When released,
the switch returns to the center position. To cancel the turn signal lights,
push the switch in after it has returned
to the center position.
BRAKE LEVER RIGHT - FRONT
BRAKE
BRAKE LEVER LEFT - FRONT BRAKE
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handlebar grip.
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebargrip.
LIGHTSWITCH
Turning the light switch to
turns
on the position light,mater light
and taillight.Tur ning the light switch to
,turns the headlight on also.
START SWITCH
Push this switch
(pull the brake lever at same time) to the start the engine.
FUEL TANK CAP
To remove the fuel tank cap (1)
Turn it 1/4 turn counterclockwise. The
lock will be released and the fuel tank
cap can be removed.
CAUTION
Before starting the vehicle check the
notes in the user manual.
15
INSTRUMENT AND CONTROL FUNCTIONS
To install the fuel tank cap (1)
Push the fuel tank cap into position.
Turn the cap clockwise to the original
position.
FUEL
a clean, dry, soft cloth, since fuel may
damage the painted surfaces or plastic parts.
1
1
2
Regular unleaded gasoline only.
Recommended fuel: 95 oct
5.5l +/- 0.2l
!!CAUTION!!
BIOETHANOL E10 IS NOT SUITABLE
1.Fuel tank filler tube
2.Fuel level
CAUTION
Make sure that the fuel tank cap is properly closed and locked before riding.
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
! WARNING
• Do not overfill the fuel tank, otherwise it may overflow when the fuel
warms up and expands.
• Avoid spilling fuel on the hot engine.
CAUTION
Immediately wipe off spilled fuel with
16
2-STROKE ENGINE OIL TANK CAP
1.Remove the 2-stroke engine oil tank
cap (1) by pulling it off.
2.Install the 2-stroke engine oil tank
cap (1) by pushing it into the oil tank
opening.
INSTRUMENT AND CONTROL FUNCTIONS
! WARNING
1
At each refuelling you have to controll
the engine oil.
Capacity: 0.85 l
Recommendation:
Castrol Actevo X-Tra Vehicle
or
Castrol Power 1 Racing 2T
CAUTION
Make sure that the 2-stroke engine oil
tank cap is properly installed before riding the vehicle.
1
served to prevent a fire hazard or other
damages.
• Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the catalytic
converter.
• Never park the vehicle near possible
fire hazards such as grass or other
materials that easily burn.
• Do not allow the engine to idle too
long.
CATALYTIC CONVERTER
KICKSTARTER
This model is equipped with a catalytic
converter in the exhaust system.
To start the engine,move it down lightly
with your foot until the gears engage,
and then push it down smoothly but
forcefully.
! WARNING
The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any
maintenance work.
CAUTION
The following precautions must be ob17
CAUTION
At the same time you have to pull the
right brake lever to start the vehicle.
INSTRUMENT AND CONTROL FUNCTIONS
To close the seat
1
1.Fold the seat down, and then push it
down to lock it in place.
2.Remove the key from the main
switch if the vehicle will be left unattended.
1
CAUTION
•
CAUTION
SEAT
To open the seat
1.Place the vehicle on the centerstand.
2.Insert the key into the rear lock, and
then turn the key anticlockwise to
“OPEN” the seat.
Do not push inward when turning the
key.
3.Fold the seat up.
18
•
When you close the seat by force
or strike, parts can be damaged.
Make sure that the seat is locked
before driving or when you park
the vehicle.
INSTRUMENT AND CONTROL FUNCTIONS
STORAGE LUGGAGE BOX
FRONT HOOK, HELMET
FRONT STORAGE LUGGAGE BOX
There storage luggage box (1) is under
the seat.
1
CAUTION
1
1
CAUTION
CAUTION
Do not exceed the load limit of 1
kg for the front Hook (1).
Do not exceed the load limit of 0.5 kg
for front storage luggage box (1).
• Do not exceed the load limit of 2.5
kg for storage luggage box (1).
• Since the storage luggage box will
accumulates heat by the heat of sun
and engine, please do not put any
thing that sentitive to the heat.
• Do not put anything valuable or
breakable objects in the storage luggage box.
19
INSTRUMENT AND CONTROL FUNCTIONS
REAR CARRIER
SIDESTAND
1
1
CAUTION
Do not exceed the load limit of 5kg for
the carrier (1).
The side stand (1) is located on the left
side of the Vehicle. Release the sidestand by using your feet to step on the
bracket of side stand to up-right position to stand the vehicle.
CAUTION
• The side stand with auto-rebound
system. Make sure your vehicle have been park well are stable
enough to stand the vehicle.
• Please avoid to use side stand to
park the vehicle on the slope, soft
land or un-flat ground.
20
PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. The operator should check the vehicle by simple but thorough
inspection,to make sure of vehicle condition, quick inspect some key and important parts, to prevent the vehicle from serious consquence/accident. Please carefully check the following points before each ride.
CAUTION
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
! WARNING
If any item in the Pre-operation check list is not working properly , have it inspected and repaired before operating
the vehicle. If failed to be corrected by yourself, please turn to repair shop immediately.
If failed to be corrected by yourself, please turn to repair shop immediately.
21
PRE-OPERATION CHECKS
PRE-OPERATION CHECK LIST
CHECKPOINT
TO VERIFY
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
2-stroke engine oil
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
Final transmission oil
• Check vehicle for oil leakage.
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
Rear brake
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have dealer adjust cable free play and lubricate cable and grip housing.
Wheels and tires
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
Brake levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
Main stand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
Instruments, lights, signals and switches
• Check operation
• Correct if necessary
22
OPERATION AND IMPORTANT RIDING POINTS
! WARNING
• Before riding the vehicle, please
make sure that you are fully fimiliar with all operating controls &
their functions before riding. To
consult a dealer shop if you not
thoroughly understand.
• Please do not start the engine in
a closed area, the exhaust air are
poisonous, and inhaling them can
cause loss of consciousness and
even death in short time.
STARTING THE ENGINE
CAUTION
Note the point „Engine break in“ before you start to riding the vehicle.
Starting with the kickstarter
• Turn the key to ON .
• Pull the right brake lever otherwise
the vehicle will not start.
• Unfold the kickstart lever (1) and
push with your foot down until you
see a noticeable resistance.
• Then kick the kickstarter evenly and
powerfully downwards.
1
Starting with the electric starter
• Turn the key to ON .
• Pull the right brake lever otherwise
the vehicle will not start.
• Push the start swich button
(1)
for a few seconds.
CAUTION
Do not crank the engine more than 5
seconds on any one attempt.
23
1
CAUTION
• The engine starts immediately upon
actuation of the starter, then wait a
few seconds before you try to start it
again. Each starting process should
be as short as possible in order to
save battery and the starter.
OPERATION AND IMPORTANT RIDING POINTS
• The vehicle must periodically (recommended weekly) start with the
kick starter, otherwise the grease
can gum up the kick starter gear and
the kick starter not to operate. den
Anlasser zu schonen.
STARTING OFF
CAUTION
Before starting off, allow the engine to
warm up to avoid damages.
1.While pulling the rear brake lever
with your left hand and holding the
carrier with your right hand, push the
vehicle off the main stand.
2.Sit astride the seat, and then adjust
the rear view mirrors.
3.Switch the turn signal on to the direction you wish to turn.
4.Check for oncoming traffic, and then
slowly turn the throttle grip (on the
right) in order to take off.
5.Switch the turn signal off
ACCELERATION AND DECELERATION
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throttle grip in direction (b).
24
BRAKING
1.Close the throttle completely.
2.Apply both front and rear brakes simultaneously while gradually increasing the pressure.
OPERATION AND IMPORTANT RIDING POINTS
FRONT
REAR
avoided.
! WARNING
Avoid braking hard or suddenly,
otherwise the vehicle may skid
• Railroad crossings, streetcar
rails, iron plates on road construction sites, and manhole covers
become extremely slippery when
wet. Therefore, slow down when
approaching such areas and
cross them with caution.
• Keep in mind that braking on a
wet road is much more difficult.
• Ride slowly down a hill, as braking downhill can be very difficult.
ENGINE BREAK IN
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km. The various parts in the engine wear and polish themselves to the
correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
25
CAUTION
If any engine trouble should occur during the engine break-in period, immediately have a dealer check the vehicle.
PARKING
When parking, stop the engine, and
then remove the key from the main
switch.
! WARNING
Since the engine and exhaust system
can become very hot, park in a place
where pedestrians or children are not
likely to touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle may
overturn. beim Parken einen sicheren
Stand hat.
PERIODIC MAINTENANCE AND MINOR REPAIR
CAUTION
Most of the Safety and condition of vehicle depend on how you do the correct maintenance , periodic inspection,
adjustment and lubrication. The following are contents that help the operator to do such skills on the following pages.
! WARNING
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair shop or
individual that is certified and must follow the local law regulations.
If you are not familiar with maintenance work, have a dealer do it for you.
26
PERIODIC MAINTENANCE AND MINOR REPAIR
OWNER’S TOOL KIT
! WARNING
The owner’s tool kit (1) is located inside the rear storage luggage box.
1
Modifications not approved by maker
may cause loss of performance, excessive emissions, and render the vehicle
unsafe for use. Consult a dealer before
attempting any changes.
Modifications without authorization of
the manufacturer cause void the warranty.
CAUTION
If you do not have the tools or experience required for a particular job, have
a dealer perform it for you.
1
The covers (1) shown needs to be removed to perform some of the maintenance jobs described in this chapter.
27
To install the cover
Place the cover in the original position,
and then install the screws.
SPARK PLUG
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can
reveal the condition of the engine.
BATTERY COVER
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
To remove the cover
Remove the screws, and then take the
cover off.
REMOVE THE SPARK PLUG
1.Remove cover
2.Remove the spark plug cap (1)
PERIODIC MAINTENANCE AND MINOR REPAIR
tan (the ideal color when the vehicle
is ridden normally).
4
1
3
3.Remove the spark plug as shown,
with the spark plug wrench (2) included in the owner’s tool kit.
2
4.Check that the porcelain insulator
(3) around the center electrode of
the spark plug is a medium-to-light
Specified spark plug:
NGK - BR8HSA
CAUTION
If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead,
have a dealer check the vehicle.
5.Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if necessary.
28
! WARNING
Please note that no other spark plug
model is allowed. Using a different
spark plug model can immediately lead
to engine damage.
6.Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
PERIODIC MAINTENANCE AND MINOR REPAIR
spark plug threads.
7.Install the spark plug with the spark
plug wrench, and then tighten it to
the specified torque.
0,6-0,7 mm
Spark plug gap: 0,6 - 0,7 mm
! WARNING
Please note the max. torque when inserting the plug. If you do not have the
ability to control you leave control of
the spark plug to the dealer. .
Tightening torque: 12 Nm
FINAL TRANSMISSION OIL
The final transmission case (1) must
be checked for oil leakage before each
ride. If any leakage is found, have a
dealer check and repair the vehicle. In
addition, the final transmission oil must
be changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
CAUTION
As long as the vehicle is within the warranty period the dealer is responsible
to change the gear oil.
CHANGE THE FINAL TRANSMISSION OIL
1.Start the engine, warm up the final
transmission oil by riding the vehicle
for several minutes, and then stop
the engine.
2.Place the vehicle on the main stand.
3.Place an oil pan under the final transmission case to collect the used oil.
29
4.Remove the oil filler cap (2) and
drain bolt (3) to drain the oil from the
final transmission case.
2
1
3
5.Install the final transmission oil drain
bolt, and then tighten it to the specified torque.
Tightening torque: 18 Nm
6.Add the requested amount of the
recommended final transmission oil,
and then install and tighten the oil
filler cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
REPLACE THE AIR FILTER
Empfohlenes Getriebeöl:
Castrol MTX Part Synth. 80W
or EP 80W-90
Oil quantity:
Full: 0,13 l/ Change: 0,11 l
5.Remove air filter case by removing
the screws (3) on the crankcase
side.
1
! WARNING
• Make sure that no foreign material
enters the final transmission case.
• Make sure that no oil gets on the tire
or wheel.
7.Check the final transmission case
for oil leakage. If oil is leaking, check
for the cause.
1.Open the seat (1)
2.Remove the fuel tank cap and oil
tank cap
3.Remove the seat (1) and storage
luggage box by removing the bolt.
4.Remove the air filter band (2)
3
6.Remove the air filter case cove (4)
by removing the screws.
AIR FILTER
2
The air filter should be replaced according to the maintenance schedule.
Replace the air filter more often if you
drive in unusually wet or dusty areas
.
4
30
PERIODIC MAINTENANCE AND MINOR REPAIR
7.Pull the air filter element (5) out.
5
8.Replace the filter with a new one.
9.Coat the mating surfaces of the air
filter case and air filter case cover
lightly with grease for an airtight
seal.
CARBURETOR
TIRES
The carburetor is an important part of
the engine and its emission control system, which requires very sophisticated
adjustment. Therefore, carburetor adjustments should be left to dealer, who
has the necessary professional knowledge and experience.
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specifed tires.
CHECKING THE THROTTLE CABLE
FREE PLAY
The tire air pressure should be checked and, if necessary, adjusted before
each ride.
! WARNING
CAUTION
• Make sure that the air lter element is
properly seated in the air filter case.
• The engine should never be operated without the air lter element installed, otherwise the piston and/or
cylinder may become excessively
worn.
TIRE AIR PRESSURE
1
The throttle cable free play (1) should
measure 1.5 ~ 3.5 mm at the throttle grip. Periodically check the throttle
cable free play and, if necessary, have
a dealer adjust it.
31
The tire air pressure must be checked
and adjusted on cold tires (i.e., when
the temperature of the tires equals the
ambient temperature).
The tire air pressure must be adjusted
in accordance with the riding condition.
If you are not familiar to this, please
have dealer for help.
PERIODIC MAINTENANCE AND MINOR REPAIR
Tire air pressure:
Front: 2.1 bar - 2.5 bar
Rear: 2.1 bar - 2.5 bar
Total weight of rider, passenger,
cargo and accessories!
! WARNING
Do not over load your vehicle, since
it will increase pressure on the tire,
braking, steering than original design,
and may could cause damge or even
lead to accident.
Allocation of your cargo and weight of
your vehicle is very important for your
own safety and vehicle performance.
Load your cargo rmly on vehicle and put
the heaviest cargo to the center of vehicle, then distribute the weight evenly from
side to side. It will keep you to have good
steering after load.
Maximum load*: 150 kg
* Total weight of rider, passenger,
cargo and accessories
TIRE INSPECTION
1
3
2
1.Tire tread depth
2.Tire sidewall
3.Tire wear indicator
! WARNING
The tires must be checked before each
ride. If a tire tread shows crosswise li32
nes (minimum tread depth), if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a dealer
replace the tire immediately.
CAUTION
The tread depth may vary depending
on country. Observe local regulations.
The values ​​listed here are technical values and
​​
may differ from the legal values ​​of your region.
Minimum tire tread depth:
Front and rear: > 1,6 mm
! WARNING
• Drive with worn tire is illegal, reduces stability and can lead to loss of
control over the vehicle.
• Let worn or damaged tires replaced
immediately by your dealer.
• Working tires and the dealer is responsible.
PERIODIC MAINTENANCE AND MINOR REPAIR
DIMENSIONS TIRES/
RIMS
Front: Rim: 16x1.6
Tire: 2.5-16 or 80/80-16
Rear: Rim: 16x1.85
Tire: 2.75-16 or 90/80-16
TYRE TYPE: tubless
RIMS
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
• The wheel rims should be checked
for cracks, bends or warpage before
each ride. If any damage is found,
have a dealer replace the wheel. Do
not attempt even the smallest repair
to the wheel. A deformed or cracked
wheel must be replaced.
• The wheel should be balanced whenever either the tire or wheel has
been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.
• Ride at moderate speeds after changing a tire since the tire surface must
first be “broken in” for it to develop its
optimal characteristics.
in the hydraulic system. If there is air
in the hydraulic system, have a dealer
bleed the system before operating the
motorcycle. Air in the hydraulic system
will diminish the braking performance,
which may result in loss of control and
an accident.
Rear brake
CAUTION
Unlike the front brake lever needs to
have the rear brake a game of about 10
mm. The rear brake is actuated cable.
ADJUSTING THE REAR BRAKE LE- If there is no play, it may be that the
VER FREE PLAY
brake linings drag permanently in the
brake drum.
Front brake
CAUTION
There should be no free play at the brake lever end. If there is free play, have a
dealer inspect the brake system.
! WARNING
A soft or spongy feeling in the brake
lever can indicate the presence of air
33
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodically check the brake lever free
play and, if necessary, adjust it as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (A). To decrease the
brake lever free play, turn the adjusting
nut in direction (B).
BRAKE PADS
the brake. If a brake pad has worn to
the point that a wear indicator almost
The front brake pads and the rear brake touches the brake disc, have a dealer
shoes must be checked for wear at the replace the brake pads as a set.
intervals specified in the periodic maintenance and lubrication chart.
Rear brake Shoes
Always check and adjust the break
lever before riding. To check the brake, check the position of the adjustab1
le nut if the nut position reach to the
end, have a dealer to replace the brake
shoes as a set.
A
1
B
! WARNING
If proper adjustment cannot be obtained as described, have a dealer make
this adjustment.
2
3
1.Wear indicator
2.Brake disc
3.Brake pad
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without having to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
34
PERIODIC MAINTENANCE AND MINOR REPAIR
BRAKE FLUID
! WARNING
Insufficient brake fluid may allow air to
enter the brake system, possibly
causing it to become ineffective. Before riding, check that the break fluid is
above the minimum level mark (1) and
refill it if necessary.
1
Low position brake fluid level may indicate worn brake pads and/or brake
system leakage. If the brake fluid level is low, be sure to check the brake
pads for wear and the brake system for
leakage. When checking the fluid level,
make sure that the top of the master
cylinder is level by turning the handlelevel goes down suddenly, have a
bars.
dealer check.
Use only the recommended quality brake fluid, otherwise the rubber seals may
deteriorate, causing leakage and poor CHANGING THE BRAKE FLUID
braking performance.
! WARNING
Recommended brake fluid:
Castrol Super Disc Brake Fluid DOT 4
• Refill with the same type of brake fluid.
Mixing fluids may result in a harmful
chemical reaction and lead to poor
braking performance.
• Be careful that water does not enter
the master cylinder when refilling. Water will significantly lower the boiling
point of the fluid and may result in vapor lock.
• Brake fluid may deteriorate painted
surfaces or plastic parts. Always clean
up spilled fluid immediately.
• As the brake pads wear, it is normal
for the brake fluid level to gradually
go down. However, if the brake fluid
35
Have a dealer change the brake fluid
at the intervals specified in the NOTE
after the periodic maintenance and lubrication chart.
CABLES
Checking and lubricating
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the
cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have
a dealer check or replace it.
Recommended lubricant:
Castrol Motorrad DWF oilspray
PERIODIC MAINTENANCE AND MINOR REPAIR
! WARNING
MAIN STAND
Front brake lever
CAUTION
Damage to the outer housing of cables
may result in internal rusting and cause
interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.
The operation of the main stand should
be checked before each ride, and the
pivots and metal-to-metal contact surfaces should be lubricated if necessary.
THROTTLE GRIP AND CABLE
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
Rear brake lever
! WARNING
LUBRICATING THE FRONT AND
REAR BRAKE LEVERS
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart..
If the main stand does not move up and
down smoothly, have a dealer check or
repair it.
Recommended lubricant:
Castrol Motorrad DWF oilspray
36
Recommended lubricant:
Castrol Multi Purpose Grease
PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT FORK
cause danger. Therefore, the operation of the steering must be checked as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Castrol Motorrad DWF oilspray
! WARNING
Securely support the motorcycle so
that there is no danger of it falling over.
1.Place the vehicle flat and upright
from.
2.Check the inner tubes for scratches,
damage and oil leakage.
3.Apply the front brake and push the
handlebars several times down hard
to verify the suspension of the fork.
! WARNING
• When damage to the fork, please
contact your dealer.
• If you treat the telescopic fork with
cleaning agents, make sure that
they get no contact with the tires or
the brakes. This can lead to dangerous accidents.
STEERING
Checking the steering
! WARNING
Worn or loose steering bearings may
37
1.Place the vehicle on the center
stand/suitable motorcycle stand to
raise the front wheel off the ground.
2.Hold the lower ends of the front fork
legs and try to move them forward
and backward.
3.If any free play can be felt, have a
dealer check or repair the steering..
PERIODIC MAINTENANCE AND MINOR REPAIR
WHEEL BEARINGS
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart.
CAUTION
If there is play in the wheel hub or if the
wheel does not turn smoothly, have a
dealer check the wheel bearings.
BATTERY
This model is equipped with a sealedtype (MF) battery, which does not require
any maintenance. There is no need to
check the electrolyte or to add distilled
water.
! WARNING
• Do not remove the battery vent seal,
this can be dangerous, the battery
permanently damaged.
• Battery acid is poisonous and dangerous, it contains sulfuric acid and
leads to dangerous burns.
• Avoid skin, eye and clothing contac.
Protect your eyes always when working near the battery.
• Upon contact with the battery aicd,
make immediate FIRST AID.
• If skin or eye contact with battery
acid, rinse the affected areas with
plenty of water.
• When accidentally swallowed battery
acid drink large amounts of water.
• In both cases, as soon as possible,
see a doctor.
• Batteries develop explosive hydrogen gas. Keep open flames, smoking
materials away from the battery and
make sure there is adequate ventilation when you charge a battery indoors.
• KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHILDREN.
38
TO CHARGE THE BATTERY
Have a dealer charge the battery as
soon as possible if it seems to have discharged. Keep in mind that the battery
tends to discharge more quickly if the
vehicle is equipped with optional electrical accessories.
TO STORE THE BATTERY
• If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
• If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
• Fully charge the battery before installation.
• After installation, make sure that the
battery leads are properly connected
to the battery terminals.
PERIODIC MAINTENANCE AND MINOR REPAIR
! WARNING
• Please contact your dealer if you are
not familiar with handling the battery.
CAUTION
• Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
FUSE
1
The fuse holder is located behind battery cover.
REPLACING THE FUSE
LIGHTING
1.Turn the key to
and turn off all HEADLIGHT BULBS
electrical circuits.
2.Remove the blown fuse, and then install a new fuse of the specified amperage.
Specified fuse:
10 Amp
2
3
1
! WARNING
Do not use a fuse of a higher amperage rating than recommended to CAUTION
avoid causing extensive damage to This model is equipped with halogen
the electrical system and possibly a bulb headlight (1).If a headlight bulb
fire.
burns out,have a dealer replace it and,
if necessary,adjust the headlight beam.
3.Turn the key to
and turn on the
electrical circuits to check if the de- This model has furthermore a LED povices operate.
sition light (2). If the LED position light
4.If the fuse immediately blows again, defective, please contact your dealer.
have a dealer check the electrical
system.
39
PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT INDICATOR
If the turn signal light bulb does not
com on, remove the screw of the indicator lens (3) out and replace the bulb.
TAIL/BRAKE LIGHT AND LICENSE
PLATE LIGHT
5
REAR INDICATOR
6
4
5.Tail/brake light
6.License plate light
If the turn signal light bulb does not
com on, remove the screw of the indicator lens (4) out and replace the bulb.
If the tail/brake light and licenes light
bulb does not come on,have a dealer
check its electrical circuit or replace the
bulb.
40
TROUBLESHOOTING
TROUBLESHOOTING
Although the vehicles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
However, should your vehicle require any repair, take it to a dealer, whose skilled technicians have the necessary tools,
experience, and knowhow to service the vehicle properly.
Use only genuine replacement parts. Imitation parts may look like parts, but they are often inferior have a shorter service
life and can lead to expensive repair bills.
41
TROUBLESHOOTING
TROUBLESHOOTING CHART
! WARNUNG
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in
the fuel tank.
Check the compression.
Operate the electric
starter.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a dealer check the
vehicle.
The engine does not start.
Check the compression.
2.Compression
Operate the electric
starter.
3.Ignition
Remove the spark plug
and check the electrodes.
4.Battery
Operate the electric
starter.
Wet
Dry
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark
plug.
Have a dealer check the
vehicle.
Operate the electric starter.
The engine does not start.
Check the battery.
The engine turns over quickly.
The battery is good.
The engine turns over slowly.
Check the battery lead connections,
and charge the battery if necessary.
42
The engine does not start.
Have a dealer check the
vehicle.
CLEAN AND STORAGE
CLEAN THE VEHICLE
Clean of the vehicle in proper and suitable way will make it attractive, extend
it’s lfe and optimize the performance.
BEFORE CLEANING
1.Cover the muffler outlet with a plastic bag to prevent water to come . inside. Please do it only after the
2.Closed every caps, covers, electrical connectors that are well install
and water can be avoid to get into,
while you do the clean job.
CAUTION
• Do not use acid-based cleaners. If
such funds used for stubborn stains,
so use this only occasionally, dry it
immediately after and then apply a
corrosion protection spray.
• Always follow the manufacturer‘s
instructions on care and cleaning
agents.
• Use best only water and mild detergent or special cleaner from the dea-
ler to the sensitive components of the
vehicle to prevent damage. Dry the
plastic parts then wipe with a soft, dry
cloth or sponge.
• Protect particularly plastic parts,
paint, headlight glass from harsh
chemicals such as fuel, rust remover,
brake cleaner or similar. The use of
such agents may result in malfunction, damage and affect the security
itself.
• Do not use a high pressure washer
or steam cleaner, causing water
in storage can penetrate electrical
components such as connectors or
switches, lighting, ventilation hoses,
brake shoes and brake linings or
damage, seals, paint and other surfaces.
CLEANING AFTER RIDING IN THE
RAIN, NEAR THE SEA OR ON SALTSPRAYED ROADS
CLEANING AFTER NORMAL USE
AFTER CLEANING
CAUTION
Since sea salt or salt sprayed on the
roads during winter are extremely corrosive in combination with water, carry
out the following steps after each ride.
• Wait until the engine / exhaust have
cooled.
• Clean the vehicle with warm water
and a mild detergent.
• Do not use hot water, which increases the corrosive effect of the salt.
• Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
Remove dirt with warm water, a mild de- • Dry the vehicle.
tergent, and a soft, clean sponge, and • To prevent rust, we recommend apthen rinse thoroughly with clean wapropriate care to use according to
ter. Use a toothbrush or bottlebrush for
manufacturer‘s instructions.
hard-to-reach areas.
• Wax all painted surfaces.
43
CLEAN AND STORAGE
Recommended Castrol care products:
Greentec Bike Reiniger
Bike Politur
Motorrad DWF oilspray
! WARNING
• Make sure that there is no oil or wax
on the brakes or tires.
• If necessary, clean the brake discs
and brake linings with a regular brake disc cleaner and wash the tires
with warm water and a mild detergent.
• Before operating the vehicle, test
the braking performance and tires.
STORAGE
Short-term (for a few days)
• Always store your vehicle in a cool,
dry place and, if necessary, protect
it against dust with a vehicle cover.
! WARNING
! WARNING
Please store the vehicle in a well air
flow room with dry air if possible. A
place with wet humidity will cause rust.
Long-term (for weeks)
• Clean the vehicle.
• Drain the fuel from the carburetor.
• Enter the drained fuel back into the
fuel tank.
• Fill the fuel tank to completely or add
if necessary a fuel stabilizer to protect the fuel tank from rusting and
the fuel from degradation.
Follow the steps below to cylinders,
piston rings, etc. to prevent rusting.
• Remove spark plug cap and the
spark plug.
• Give a teaspoon of engine oil into
the spark plug hole.
• Join the Kickstarter to slow down and
let the engine several times slowly
rotate (thus the cylinder is oiled).
• Put the spark plug back in and put
on the spark plug cap.
44
To prevent damage or injury from sparking, make sure to ground the spark
plug electrodes while turning the engine over.
• Lubricate all control cables and the
pivoting points of all levers and pedals as well as of the side stand/
main stand.
• Check and, if necessary, correct the
tire air pressure, and then lift the vehicle so that both of its wheels are
off the ground. Alternatively, turn the
wheels a little every month in order
to prevent the tires from becoming
degraded in one spot.
• Cover the muffler outlet with a plastic bag to prevent moisture from entering it.
• Remove the battery and fully charge
it. Store it in a cool, dry place and
charge it once a month. Do not store
the battery in an excessively cold or
warm place [less than 0 °C (30 °F) or
more than 30°C (90 °F)].
SPECIFICATIONS
DIMENSIONS
ENGINE
Engine type
Air cooled 2-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
49.2 cm³
Compression ratio
6.9:1
Starting system
Electric starter and kickstarter
Lubrication system
Separate lubrication
2-stroke engine oil
ENGINE OIL
Quantity: 0.85 l
recommended type:
Castrol Power 1 Racing 2T
TRANSMISSION OIL
Typ SAE 80W-90
recommended type:
Castrol MTX Part Snth. 80W or EP 80W-90
AIR FILTER
Wet element
FUEL
Unleaded gasoline only
Capacity
5.5 +/- 0.2l
45
CAUTION
!! BIOETHANOL FUEL E10 IS NOT PERMITTED !!
CARBURETOR
Manufacturer
LEADER
SPARK PLUG
Manufacturer/model
NGK/ BR8HSA
Spark plug gap
0.6-0.7 mm
CLUTCH
Clutch type
Dry, centrifugal automatic
Transmission type
V-belt automatic
CHASSIS
Frame type
Steel tube backbone
FRONT TIRE
Rim: 16x1.6
Tyre: 2.5-16 or 80/80-16
REAR TIRE
Rim: 16x1.85
Tyre: 2.75-16 or 90/80-16
SPECIFICATIONS
TIRE AIR PRESSURE (COLD TIRES)
Front: 2.1 bar - 2.5 bar
Rear: 2.1 bar - 2.5 bar
The selected tire pressure depends on the
load!
FRONT BRAKE
Type
Single Hydraulic disc brake
220mm
Operation
Right hand
RECOMMENDED FLUID
DOT 4 - CASTROL Super Disc Bremsflüssigkeit DOT 4
REAR BRAKE
Type
Mechanical Drum brake
140 mm
Operation
Left hand
FRONT SUSPENSION
Type
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
REAR SUSPENSION
Type
Unit swing
Spring/shock absorber type
Coil spring/oil damper
ELECTRICAL SYSTEM
Ignition system
CDI
Charging system
CDI magneto
BATTERY
Model
YTX4L-BS
Voltage, capacity
12 V, 4.0 Ah
HEADLIGHT
Halogen bulb
BULB VOLTAGE, WATTAGE X QUANTITY
Headlight
12 V, 35 W/35.0 W
Tail/brake light
12 V, 5.0 W/21.0 W
Front turn signal light
12 V, 10.0 W
46
Rear turn signal light
12 V, 10.0 W
License plate light
12 V, 5.0 W
Meter lighting
12 V, 2 W
Meter lighting (fuel meter)
12 V, 2 W
High beam indicator light
12 V, 2 W
Oil level warning light
12 V, 3 W
Turn signal indicator light
12 V, 3 W
FUSES
Main fuse
10.0 A
CONSUMER INFORMATION
IDENTIFICATION NUMBERS (VIN)
Please write down the VIN (vehicle identification number) to order replacement
parts from your dealer or the vehicle
should be stolen.
The chassis number is stamped into the
frame. To see this, take the cover (1)
from the inner lining in the foot.
1
CAUTION
The vehicle identification number is used
to identify your motorcycle and may be
used to register your vehicle with the
licensing authority in your area.
47
WARRANTY INFORMATION
Please carefully read the instruction manual of your vehicle before operating it in order to make yourself familiar with its handling. We
explicitly point out that the instruction, maintenance, and care instructions given in the operating manual have to be complied with in order
to sustain your claim towards warranty. Only the strict compliance with customer specifications stated in the instruction manual ensures
the prolonging of the natural life of your vehicle. Starting with the date of the invoice a limited warranty of 24 months is granted regarding
the accuracy of the vehicle in terms of material and manufacturing according to latest standards. The legal warranty regulations will not
be restricted by this limited guarantee. Maintenance work has to be exclusively done by authorized workshops entitled by us. Warranty in
general is bound to the region of invoicing and can therefore only be carried out within the country the vehicle was bought. Damages that
can be traced back to inappropriate usage, manipulation, or neglecting of the maintenance/care/operating instructions will not be covered
by warranty. Warranty can only be granted if occurring damages are immediately being reported to the seller or any other authorized
workshop by the buyer. The warranty claim entitles the buyer to remedy deficiencies or to the reparation respectively the exchange of
a damaged part in an authorized workshop after our approval. Compensation for remote or instantaneous damages cannot be granted.
Vehicles in desolate condition will not be covered by warranty. Repair works carried out on warranty do not enlarge the guarantee period.
Only this document entitles you to call on warranty services. Therefore please make sure that you are delivered this fully filled in document by the seller and that he has registered your vehicle correctly in our system. Please also mind the following advices.
Body and panelling of the vehicle have to be kept free of dirt constantly. Do not use high pressure water blasters, strong jets of water,
sharp and corrosive or other aggressive detergents which could harm surfaces and varnish permanently and foster corrosion. It is vital
to use protecting cleansers. Please consult our dealers for the right and appropriate products. Aluminium parts or other refined parts
(chrome parts, anodized parts or other processed surfaces)have to be treated with appropriate maintenance products in order to prevent
oxidation. Frame and metal parts are continuously to be treated with anticorrosive. A vehicle constantly parked outside has to be covered
to avoid weathering and crack formations on seat and plastic parts. Vehicles used off-road and for racing purposes are excluded from
warranty.
Material which is to be used in the context of service and maintenance works are excluded from warranty as well as the following parts:
incandescent bulbs, brake pads, clutch lining, filter elements, spark plugs, drive sprocket, wheel and axle., as well as the tires.
48
MAINTENANCE SCHEDULE
The guarantee can be granted only if the vehicle has been serviced in accordance with this maintenance schedule.
The inspection intervals are required, otherwise, no guarantee can
be granted.
1000 km or
1. month
4.000 km or
6. month
7.000 km or
12. month
10.000 km or
18. month
13.000 km or
24. month
PART
TO DO
Air filter
Clean/ exchange
√
√
Exchange
√
√
Wheels, rims
Control
√
√
√
√
√
Tires
Control/ tire pressure
√
√
√
√
Wheel bearing
Control/ exchange
√
√
√
√
Steering bearing
Control/ clean/ lubricate
√
√
Lubricate
√
Screws Coverparts
Control/ tighten
√
√
√
√
Brake system
Control/ clean/ exchange
√
√
√
√
Main stand
Control/ clean/ lubricate
√
√
√
√
Front forke
Control
√
√
√
√
Rear suspension
Control
√
√
√
√
Oil pump
Control
√
√
√
Transmission oil
Exchange
Variomatic belt
Control/ exchange
√
Exchange
√
Fly wheels
Control/ exchange
√
Exchange
√
Driven chain/ sproket
Control/ clean/ exchange
Clutch
Control
√
√
√
√
√
Cable/ bowden
Control/ clean/ lubricate
√
√
√
√
√
Throttle
Control/ clean/ lubricate
√
√
√
√
Lights/ switches
Control/ adjust
√
√
√
√
Fuel line/ fuel filter
Control/ exchange
Idle speed
Control/ adjust
Exhaust system
Control/ tighten
Coolant
Control
√
√
Exchange
Exchange
√
√
Exchange
Exchange
√
√
√
√
√
√
√
√
√
CAUTION: Variomatic belt, fly wheels, spark pluge, fuel filter and air filter element have to be exchanged every 7000km. Only use duration coolant. Brake lines have to be exchanged at least every 4 years.
From 13.000km or 24th month the inspection should be made every 7000km. The vehicle is constantly checked for rust. The owner is responsible for rust prevention.
49
SERVICE PLAN
The warranty can be granted only if the vehicle has been serviced in accordance with this service plan.
1000 km or 1. month
4000 km or 6. month
Stamp / Signature
Stamp / Signature
7000 km or 12. month
10000 km or 18. month
Stamp / Signature
Stamp / Signature
13000 km or 24. month
16000 km
Stamp / Signature
Stamp / Signature
19000 km
21000 km
Stamp / Signature
Stamp / Signature
VEHICLE IDENTIFICATION NUMBER:
NAME OF THE CUSTOMER:
.........................................................................................................................................................................................................................................
MODEL:
.......................................................................................................................................................................................................................................................................................
SIGNATION OF THE CUSTOMER:
50
.................................................................................................................................................................................................................................................................................................................................................................................................
............................................................................................................................................................................................................................................................
WIRING DIAGRAM
51
SPACE FOR NOTES
52
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