KSR Code User Manual

ENG

USER MANUAL

mod.#

K 69

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

!

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.

CAUTION

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 specications are subject to change without notice.

2

IMPORTANT MANUAL INFORMATION

Dealer label here

3

TABLE OF CONTENTS

INTRODUCTION 1
IMPORTANT MANUAL
INFORMATION 2
TABLE OF CONTENTS 4
SAFETY INFORMATION 5

Other safe-riding points 7
Location of label 8
Side view 9

DESCRIPTION OF THE VEHICLE 9

Controls and instruments 10

INSTRUMENT AND CONTROL
FUNCTIONS 11

Main switch 11
Dashboard unit 11
Handlebar switches - left 12
Handlebar switches - right 13
Brake pedal 14
Shift lever 14
Steering lock 14
Fuel Cock 15
Fuel tank cap 15
Fuel 16
Catalytic converter 16
Side stand 17
Main stand 17
Tools 17

PRE-OPERATION CHECKS 18

Pre-operation check list 19

OPERA TION AND IMPORT ANT
RIDING POINTS 20

Starting the engine 20
Stop the Engine 20
Starting off 20
Shifting and riding 21
Acceleration and deceleration 21
Braking 21
Engine break in 22
Parking 22

PERIODIC MAINTENANCE AND
MINOR REPAIR 23

Owner’s tool kit 24
Spark plug 24
Engine oil 25
Petrol lter 26
Air cleaner 26
Carburetor 27
Idling speed 27
Throttle cable free play 27
Clutch adjustment 27
Tires 28
Rims 29
Brake free play 29
Brake pads 30
Brake uid 31
Cables 31

4

Side stand 31
Main stand 32
Front fork 32
Steering 32
Wheel bearings 33
Drive chain 33
Shock absorber 34
Battery 34
Fuse 35
Lighting 36

TROUBLESHOOTING 37

Troubleshooting 37
Troubleshooting chart 38

CLEAN AND STORAGE 39

Clean the vehicle 39
Storage 40

SPECIFICATIONS 41
CONSUMER INFORMATION 43
WARRANTY INFORMATION 44
MAINTENANCE SCHEDULE 45
SERVICE PLAN 46
WIRING DIAGRAM 47
SPACE FOR NOTES 48

SAFETY INFORMATION

THIS VEHICLE ARE TWO WHEEL
SINGLE TRACK VEHICLES. THE
USE OF SAVETY AND OPERATION
MA Y 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 qualied for riding

• Always follow the legal speed limit

on the vehicle and trafc 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 oorboard while driving.

• Passenger should make sure that

he/she can rmly 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-tting 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.

Modications

Modications made to this vehicle that

not approved by maker, or the removal
of original equipment, may let vehicle
unsafe for use and cause severe per-

sonal injury. Modications 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 in-

uence on the steering & balance.

may cause possibility of an accident,
please extremely caution and follow
below limitation when you equipped

It

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 speci-

cally 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 inuence on the

ground clearance, limit suspension
travel, steering,or obscure lights or

turning lights, reectors.

• Accessories on the handle bar/front
suspension area will cause bad in-

uence on steering the vehicle. if

you will install accessories, please
keep it as light in weight and not in­terfere on steering the vehicle.
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-

This

SAFETY INFORMATION

sories, please consult with qualiled

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.

Gasoline and exhaust gas

• GASOLINE IS HIGHLY FLAMMAB­LE:

• Always turn the engine off when

refueling.

• Take care not to spill any gasoli-

ne on the engine (hot) or exhaust
system when refueling.

• Do not smoke or use Mobile pho-

ne while re-fueling.

• Never start the engine or let it run for
any length of time in a closed area.
The exhaust fumes are poisonous
and may cause loss of conscious­ness and death within a short time.

• Always turn the engine off before
leaving the vehicle and remove the
key from the main switch. When par-

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

ammable place.

• In case of swallow any gasoline, or
gasoline get into your eyes, please
see your doctor immeidately. Keep
away the gasoline to your skin and

water.

7

OTHER SAFE-RIDING POINTS

• Turn the signal before making turns.

• When raining or across on run on
the wet road, Iron Plates, keep your
speed low, slightly using braking to
avoid slipping or even fall down.

• Be careful when passing parked
cars. A driver might not see you and

open a door in your path.

LOCATION OF LABEL

1. Label, anti-tampering

SAFETY INFORMATION

1

Symbol image

8

SIDE VIEW

1. Front wheel

2. Front disc brake

3. Headlight

4. Front turn signal light

5. Horn

6. Spark plug

7. Clutch pedal

8. Fuel tank cap

9. Battery

10. Seat

11. Main stand

12. Side stand

13. Pedal

14. Rear disc brake

15. Tail/brake light

16. Rear turn signal light

17. Rear wheel

DESCRIPTION OF THE VEHICLE

5

8

10

13

4

3

1

2

6

9

7

11

12

14

15

16

17

9

CONTROLS AND INSTRUMENTS

18. Left handlebar switches

19. Clutch lever

20. Fuel gauge

21. Speedometer

22. Right handlebar switches

23. Front brake lever

24. Throttle grip

25. Main switch

26. Rear brake pedal

27. Clutch pedal

18

DESCRIPTION OF THE VEHICLE

19

20

21

23

24

22

10

27

26

25

INSTRUMENT AND CONTROL FUNCTIONS

MAIN SWITCH

1

The main switch controls the ignition
and lighting systems. 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.

Off

All electrical systems are off . The key
can be removed.

Main switch lock (1)

On the supplied key´s is lockated one
additional allen key for locking the ig­nition lock.

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.

DASHBOARD UNIT

2 4

3

5

6 7

1

1. Rev counter

2. Fuel gauge

3. Neutral indicatro lamp N

4. Turn signal indicator lamp

5. Clock

6. Gear indicator

7. High beam indicator lamp

8. Odometer / Tripmaster indicator

9. Odometer / Tripmaster display

10. Speedometer

11. ADJ - Button

12. SEL - Button

Rev counter

Displays the engine speed in RPM.

Fuel gauge

Displays how much fuel remains in the
fuel tank.
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.

12

8

11

11

9

10

CAUTION

Be take care not let the fuel tank to fully

INSTRUMENT AND CONTROL FUNCTIONS

empty it-self, that cause engine can not
run it-self anymore.

Neutral indicator lamp (N)

Lights up whenever neutral (N) is se­lected.

Turn signal indicator lamps

The relevant indicator lamp ashes

whenever you activate the turn signals.

Clock

Displays the time of day.

Gear indicator

Indicates which gear is currently enga­ged. In neutral (N), no light is lit.

High beam indicator light

This indicator light comes on when the
high beam of the headlight is switched
on.

Speedometer

Displays the current speed.

Odometer / Tripmaster indicator

Indicates whether you have currently
selected the odometer or the tripmas­ter.

Odometer / Tripmaster display

Displays total distance travelled or the
trip meter (Tripmaster).
Tripmaster: Displays the trip meter.
The Tripmaster is reset by pressing the
ADJ button for 3 seconds. Please note
that this function is available only when
the TRIP function is active.

ADJ - Button

Toggles the display between km/h and
mph or resets the Tripmaster to 0.

SEL - Button

Toggles between main odometer and
trip meter. Pressing and holding the
SEL button enables you to set the time.
Using SEL, select the hour or second

gure and adjust the value using ADJ.

12

HANDLEBAR SWITCHES - LEFT

1

3

5

1. Clutch lever

2. Light switch /

3. Turn signal switch

4. Head light asher

5. Horn button

6. Choke

Clutch lever

Pulling the clutch lever in disconnects
the transmission from the engine.

Light switch

By toggling the position of the switch,
you can change between main beam

and dipped beamt .

4

6

2

INSTRUMENT AND CONTROL FUNCTIONS

Turn signal switch

By changing the position of the switch,
you can indicate left or right . With
the switch in the centre position, the
turn signals are switched off.

Head light asher

As log as this button is pressed the
high beam is on.

Horn button

Sounds the horn.

Choke

Twisting opens or closes the choke.

HANDLEBAR SWITCHES - RIGHT

1

3

1. Engine - ON / OFF

2. Light switch / /

3. Electric starter switch

4. Front brake

5. Throttle grip

6. Lever adjustment

Engine - ON / OFF

By toggling the position of the switch,
you can switch the engine on and
off .
Caution when starting the vehicle.

Light switch / /
Change the switch position to select
lights OFF , position lights and nor-

6

2

13

4

5

mal lights .
Caution, control illumination, main
beam, dipped beam and rear light func­tion only in the latter switch position.

Electric starter switch

Pull the clutch lever in and press the
electric starter switch to start the
vehicle. Caution, operate the starter for
no more than 5 seconds.

CAUTION

At the same time you have to pull the
right brake lever to start the vehicle.
For starting the vehicle read the notes
in manual.

Front brake

Pull to operate the front brake.

Throttle grip

Twist back to increase throttle and
forwards to reduce throttle.

Lever adjustment

You can adjust the lever distance to

INSTRUMENT AND CONTROL FUNCTIONS

suit your needs. Push the lever for­ward slightly and turn the screw in the
desired positions of the four, this must
be on the lever opposite the arrow
symbol. Position 1 is the longest and
the shortest distance position 4.

BRAKE PEDAL

The brake pedal (1) is located on the
right-hand side of the vehicle and ope­rates the rear brake. Familiarise your­self with how it works before you ride
the vehicle on public roads. Novices
and returning riders are recommended
to take a riding techniques course.

1

SHIFT LEVER

The foot-operated gear lever (1) is lo­cated on the left side of the vehicle.
The vehicle is equipped with a 5-speed
manual transmission.

1

To rule out the risk of serious damage
or injury, you should familiarise your­self with this type of transmission befo­re you start the vehicle.

CAUTION

Never attempt to change gear without
releasing the clutch. Novices and retur­ning riders are recommended to take a
riding techniques course.

14

STEERING LOCK

The steering lock (1) is located on the
front right of the steering head between
the two fork bridges. To use it, it is ne­cessary to turn the handlebars to the
left, insert the ignition key, press the
key down gently and turn it to the right.

CAUTION

To rule out the risk of a serious acci­dent, disengage the steering lock befo­re you start the vehicle.

1

FUEL COCK

1. ▪ OFF

No petrol can ow from the fuel tank

to the carburettor. Always turn the
petrol tap to the OFF position as
soon as you have parked the vehic­le.

2. ON
Turn the petrol tap to this position
before you attempt to start the ve-

hicle. Petrol ows from the fuel tank

to the carburettor.

3. RESERVE
Irregular vehicle behaviour is of­ten caused by a lack of fuel. In this

INSTRUMENT AND CONTROL FUNCTIONS

event, turn the petrol tap to the RES
position. If you need to do this, visit
a lling station at the earliest oppor­tunity to refuel.

CAUTION

After refuelling, always turn the petrol
tap back to the ON position.

FUEL TANK CAP

The fuel tank cap (1) is located on the
upper side of the vehicle.

15

Open the fuel tank cap (1)

Fold up the lock cover (2). Insert the ig­nition key into the lock (3) and turn it a
quarter turn clockwise. The closure cap
can be unlocked and opened rearward.

Close the fuel tank cap (1)

In reverse order.

1

INSTRUMENT AND CONTROL FUNCTIONS

2

3

CAUTION

Make sure that the fuel tank cap is pro­perly closed and locked before riding.

FUEL

1

2

1. Fuel tank ller tube

2. Fuel level

Make sure that there is sufcient fuel in

the tank. Fill the fuel tank to the bottom

of the ller tube as shown.

WARNING

!

• Do not overll the fuel tank, other-

wise it may overow when the fuel

warms up and expands.

• Avoid spilling fuel on the hot engine.

CAUTION

Immediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel may
damage the painted surfaces or plas­tic parts.

Regular unleaded gasoline only.

Recommended fuel: 95 oct

17l +/- 0.5l

!!CAUTION!!

BIOETHANOL E10 IS NOT SUIT ABLE

CATALYTIC CONVERTER

This model is equipped with a catalytic
converter in the exhaust system.

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 ob-

served to prevent a re 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

re hazards such as grass or other

materials that easily burn.

• Do not allow the engine to idle too
long.

16

INSTRUMENT AND CONTROL FUNCTIONS

SIDE STAND

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-at ground.

MAIN STAND

1

The main 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 main stand with auto-rebound
system. Make sure your vehic­le have been park well are stable
enough to stand the vehicle.

TOOLS

The tools are located under the side
cover (1). It allows you to perform mi­nor work.

With the vehicle you also get a tool kit
for minor repairs.

1

17

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.

18

PRE-OPERATION CHECKS

PRE-OPERATION CHECK LIST

CHECKPOINT TO VERIFY

Fuel • Check fuel level in fuel tank.

Engine oil • Check oil level in oil tank.

Final transmission oil • Check vehicle for oil leakage.
Front brake • Check operation.

Rear brake • Check operation.

Throttle grip • Make sure that operation is smooth.

Wheels and tires • Check for damage.

Brake levers • Make sure that operation is smooth.

Main stand / Side stand • Make sure that operation is smooth.

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.

Instruments, lights, signals and switches • Check operation

• Refuel if necessary.

• Check fuel line for leakage.

• If necessary, add recommended oil to specied level.

• Check vehicle for oil leakage.

• If soft or spongy, have dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check uid level in reservoir.

• If necessary, add recommended brake uid to specied level.

• Check hydraulic system for leakage.

• If soft or spongy, have dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check uid level in reservoir.

• If necessary, add recommended brake uid to specied level.

• Check hydraulic system for leakage.

• Check cable free play.

• If necessary, have dealer adjust cable free play and lubricate cable and grip housing.

• Check tire condition and tread depth.

• Check air pressure.

• Lubricate lever pivoting points if necessary.

• Lubricate pivot if necessary.

• Tighten if necessary.

• Correct if necessary

19

OPERATION AND IMPORTANT RIDING POINTS

WARNING

!

• Before riding the vehicle, please
make sure that you are fully mi­liar 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.

1

1. Turn on the ignition .

2. Switch the gear to neutral N

3. Actuating one of the brakes

4. Operate the starter button (1) wi­thout accelerating

5. Let the side stand raise up

CAUTION

• The engine starts immediately upon
actuation of the starter, then wait a
few seconds before you try to start it

20

again. Each starting process should
be as short as possible in order to
save battery and the starter.

STOP THE ENGINE

1. Reduce the throttle to 0 position.

2. Pull the clutch lever

3. Switch the gear to neutral N

4. Operate the brakes

5. After the vehicle is stopped turn off
the ignition.

CAUTION

Before starting off allow the engine
to warm up otherwise the spark
plug and engine can be damaged
early.

STARTING OFF

1. Pull the clutch lever

2. Shift the engine to the rst gear

3. Slowly release the clutch lever and
open the throttle at the same time.

OPERATION AND IMPORTANT RIDING POINTS

SHIFTING AND RIDING

a) Shifting gears upwards

1. Release the throttle

2. Pull the clutch lever

3. Lift the gear lever upwards to change
to the higher gears.

4. Slowly release the clutch lever and
open the throttle at the same time.

b) Shifting gears downwards

1. Release the throttle

2. Operate the brakes and reduce the
speed to a appropriate speed.

3. Pull the clutch lever

4. Lift the gear lever down wards to
change to the lower gears.

5. Slowly release the clutch lever and
open the throttle at the same time.

WARNING

!

Always switch one gear only,
otherwise the transmission can
be damaged.

ACCELERA TION 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).

BRAKING

1. Release the throttle.

2. Apply the front and rear brake at the
same time.

3. Apply the clutch lever gradually in­creasing the pressure.

21

WARNING

!

• Avoid hard or sudden braking (es­pecially when cornering) otherwi­se the motorcycle may skid.

• Railroad crossings, street-car
rails, iron plates on road const­ruction sites, and manhole covers
become extremely slippery when
wet.

• Keep in mind that braking on a

wet road is much more difcult

• Ride downhill slowly because
braking downhill can be very dif-

cult.

• When you brake, the brake discs,

brake pads and the brake id heat

up. The hotter these parts get,
the weaker the braking effect. In
extreme cases the entire braking
system might malfunction.

• Take time to become familiar with
the braking system.

OPERATION AND IMPORTANT RIDING POINTS

ENGINE BREAK IN

Since the engine is brand new, do not

put an excessive load on it for the rst

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
avoided.

CAUTION

If any engine trouble should occur du­ring the engine break-in period, imme­diately have a dealer check the vehicle.

PARKING

1. Reduce the throttle to 0 position.

2. Pull the clutch lever

3. Switch the gear to neutral N

4. Operate the brakes

5. After the vehicle is stopped turn off
the ignition.

6. Lower the side stand with your
foot while holding the motorcycle
upright. 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.

22

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 certied and must follow the local law regulations.

If you are not familiar with maintenance work, have a dealer do it for you.

23

PERIODIC MAINTENANCE AND MINOR REPAIR

OWNER’S TOOL KIT

With the vehicle you also get a tool kit
for minor repairs.
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.

CAUTION

If you do not have the tools or experi-

ence required for a particular job, have

a dealer perform it for you.

WARNING

!

Modications 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.

Modications without authorization of

the manufacturer cause void the war­ranty.

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.

The spark plug (1) is on the left front of
the vehicle.

1

24

Remove the spark plug

1. Remove the spark plug cap

2. Remove the spark plug, with the
spark plug wrench included in the
owner’s tool kit.

3. Check that the porcelain insulator
(1) around the center electrode of
the spark plug is a medium-to-light
tan (the ideal color when the vehicle
is ridden normally).

1

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.

PERIODIC MAINTENANCE AND MINOR REPAIR

4. Check the spark plug for electrode
(2) erosion and excessive carbon or
other deposits, and replace it if ne­cessary.

2

Specied spark plug:

NHSP LD - B7RC

NGK - DR8EA

WARNING

!

Please note that no other spark plug
model is allowed. Using a different
spark plug model can immediately lead
to engine damage.

5. Measure the spark plug gap with a

wire thickness gauge and, if neces-

sary, adjust the gap to specication.

Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.

6. Install the spark plug with the spark
plug wrench, and then tighten it to

the specied torque.

Spark plug gap: 0,6 - 0,7 mm

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

25

the spark plug to the dealer. .

Tightening torque: 12 Nm

ENGINE OIL

Use a high-quality engine oil and
change it regularly to extend the life
of your engine. Check the oil level at
every refuelling stop and top up the
oil in good time. To check the oil level,
run the engine for a few minutes then
switch it off and wait one minute:

• Position the vehicle on its centre
stand and check the oil level at the
sight glass illustrated above. The oil
level must be between the MAX (1)
and MIN (2) marks.

• In dusty, cold or poor road condi­tions, the condition of the oil dete­riorates more rapidly. Oil changes
should therefore be carried out more
frequently.

PERIODIC MAINTENANCE AND MINOR REPAIR

Recommended engine oil:

Castrol Power 1 Racing 4T 10W40

Full: 1,2 l / Change: 1 l

1

2

Oil change

The engine oil can be topped up whe­never this is needed but oil changes

and oil lter replacements should be

carried out by the specialist dealer be­cause failure to carry out this work cor­rectly could result in engine damage.

WARNING

!

• Make sure that no foreign material

enters the nal transmission case.

• Make sure that no oil gets on the tire
or wheel.

PETROL FILTER

The petrol lter (1) is located directly

next to the petrol tap underneath the

fuel tank. Handling the petrol lter is

hazardous as petrol may escape. Have
the replacement carried out by the spe­cialist dealer.

1

AIR CLEANER

The air cleaner should be checked at

26

regular intervals, especially if you ride
the vehicle in very dusty and/or humid
conditions.
The air cleaner is located on the left­hand side of the vehicle behind the
side cover.

1

2

Remove screws (1), open cover (2).
It is now possible to remove the air
cleaner. The air cleaner should be
cleaned dry or using only a specially
formulated cleaning agent. If necessa­ry, have the air cleaner exchanged by
the specialist dealer.

CAUTION

• Make sure that the air lter element is

PERIODIC MAINTENANCE AND MINOR REPAIR

properly seated in the air lter case.

• The engine should never be opera­ted without the air lter element ins­talled, otherwise the piston and/or
cylinder may become excessively
worn.

CARBURETOR

The carburetor is an important part of
the engine and its emission control sys­tem, which requires very sophisticated

adjustment. Therefore, carburetor ad-

justments should be left to dealer, who

has the necessary professional know­ledge and experience.

IDLING SPEED

If the idle is not correct consult a dealer
to check it. The minimum speed of the
engine (idling) must be approxemately
1600 ±100 rev/min.

THROTTLE CABLE FREE PLAY

1. Release the locknut (1)

2. Rotate the adjusting screw (2) to

adjust the clearance.

3. Tighten the lock nut (1) after adjus­tingthe nut (2).

1

The throttle cable free play should
measure 1.5 ~ 3.5 mm at the throttle
grip.

CLUTCH ADJUSTMENT

1. Loosen the locknut (1)

2. Turn the adjusting bolt (2) and the

2

27

adjusting nut (3) in or out to meet

the requirements of clutch free play.

3. The free play should be 10-20 mm
on the clutch lever.

4. Tighten the lock nut (1) after adjus­ting the nut (2).

1

3

2

TIRES

To maximize the performance, durabi­lity, and safe operation of your vehicle,
note the following points regarding the
specifed tires.

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!

Maximum load*: 150 kg

* Total weight of rider, passenger,

cargo and accessories

Tire air pressure

The tire air pressure should be che-

cked and, if necessary, adjusted before

each ride.

WARNING

!

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.

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.

28

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 li­nes (minimum tread depth), if the tire

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

DIMENSIONS TIRES/

RIMS

Front: Rim: 2.5x17

Tire: 100/80-17 M/C

Rear: Rim: 3.0x17

Tire: 130/70-17 M/C

TYRE TYPE: tubless

RIMS

To maximize the performance, durabili­ty , and safe operation of your motorcyc­le, note the following points regarding

the specied 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

29

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

rst be “broken in” for it to develop its

optimal characteristics.

BRAKE FREE PLAY

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
in the hydraulic system. If there is air
in the hydraulic system, have a dealer

PERIODIC MAINTENANCE AND MINOR REPAIR

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

There should be no free play at the
brake padal‘s end. If there is free play,
have a dealer inspect the brake sys­tem.

WARNING

!

A soft or spongy feeling in the brake
padel can indicate the presence of air
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.

Brake padel free play

1. Loosen the locknut (1)

2. Turn the adjusting bolt (2) until the le-
ver position is within specied positi­on (10-20 mm free play on the lever)

3. Tighten the locknut again.

1

2

WARNING

!

After adjusting make sure that the break

pads do not drag. When there is no
free play on the lever the pressure in
the brake system will increase and the
system can overheat and fail. If proper
adjustment cannot be obtained as de­scribed contact a dealer to make this

adjustment.

30

BRAKE PADS

The brake pads must be checked for

wear at the intervals specied in the

periodic maintenance and lubrication
chart.

Each 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 the
brake. If a brake pad has worn to the
point that a wear indicator almost tou­ches the brake disc, have a dealer re­place the brake pads as a set.

PERIODIC MAINTENANCE AND MINOR REPAIR

BRAKE FLUID

WARNING

!

Insufcient brake uid may allow air to

enter the brake system, possibly
causing it to become ineffective. Befo-

re riding, check that the break uid is

above the minimum level mark (1) and

rell it if necessary.

1

1

Recommended brake uid:

Castrol Super Disc Brake Fluid DOT 4

• Rell with the same type of brake u­id. Mixing uids may result in a harm-

ful chemical reaction and lead to poor
braking performance.

• Be careful that water does not enter

the master cylinder when relling. Wa-

ter will signicantly lower the boiling

point of the uid and may result in va-

por lock.

• Brake uid may deteriorate painted
surfaces or plastic parts. Always clean

up spilled uid immediately.

• As the brake pads wear, it is normal

for the brake uid level to gradually
go down. However, if the brake uid

level goes down suddenly, have a
dealer check.

Changing the brake uid

WARNING

!

Have a dealer change the brake uid
at the intervals specied in the NOTE

after the periodic maintenance and lub­rication chart.

31

CABLES

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

WARNING

!

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.

SIDE STAND

CAUTION

The operation of the side stand should
be checked before each ride, and the

PERIODIC MAINTENANCE AND MINOR REPAIR

pivots and metal-to-metal contact sur­faces should be lubricated if necessary .

WARNING

!

If the side stand does not move up and
down smoothly , have a dealer check or
repair it.

Recommended lubricant:

Castrol Multi Purpose Grease

MAIN STAND

CAUTION

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 .

WARNING

!

If the main stand does not move up and
down smoothly , have a dealer check or
repair it.

Recommended lubricant:

Castrol Multi Purpose Grease

FRONT FORK

The condition and operation of the front
fork must be checked as follows at the
intervals specied 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 at and upright
from.

2. Apply the front brake and push the
handlebars several times down hard
to verify the suspension of the fork.

32

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

WARNING

!

Worn or loose steering bearings may
cause danger. Therefore, the operati­on of the steering must be checked as

follows at the intervals specied in the

periodic maintenance and lubrication
chart.

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.

PERIODIC MAINTENANCE AND MINOR REPAIR

3. If any free play can be felt, have a
dealer check or repair the steering.

WHEEL BEARINGS

The front and rear wheel bearings must

be checked at the intervals specied 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.

DRIVE CHAIN

Please note that the drive chain must
be checked regularly before every ride.
The drive chain free play (1) should be
between 10mm and 20mm. Suitable
care products are available from spe­cialist dealers.

CAUTION

An inadequately maintained and poorly
tensioned chain accelerates the rate of
wear of the chain itself, the chain drive
and the output pinion.

WARNING

!

If the chain tension is too great, parts
within the secondary power trasmission
(chain, chain sprockets transmission
and rear wheel

bearings) will be subjected to

unnecessary stress resulting in
early wear and even chain
breakage. Too much slack in the chain,
on the other hand, can result chain jum­ping off the chain wheels.
If this happens the chain could also
block the rear wheel or damage the en­gine. In either case the operator is likely
to lose control of the
motorcycle.

1

Tensioning the chain drive

1. Loosen collar nut (2)

2. Loosen counter nuts (3)

3. Turn right and left adjusting screws
(4) equally far. The drive chain free
play (1) should be between 10mm
and 20mm.

4. Tighten counter nuts (3) and the col­lar nut (2). Tightening torque of the
collar nut (2): 70 Nm

33

PERIODIC MAINTENANCE AND MINOR REPAIR

BATTERY

This model is equipped with a sealedty­pe (MF) battery , which does not require

1

any maintenance. There is no need to
check the electrolyte or to add distilled
water.

2 3

4

SHOCK ABSORBER

The shock absorber is equipped with a

preload adjuster. The shock absorber‘s
preload adjuster is innitely variable.

This allows the shock absorber to be
adapted to match your body weight
and the payload.

Adjust the shock absorber

To adjust the spring tension, place the

vehicle on the main stand.

• Turn the adjusting ring (1) clockwise
to increase the preload

• Counterclockwise to decrease the
preload

WARNING

!

The shock absorber is lled with high

density nitrogen. Do not disassembly
the shock Absorber. This may lead to

injury.

34

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.

PERIODIC MAINTENANCE AND MINOR REPAIR

• Batteries develop explosive hydro­gen gas. Keep open ames, 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.

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.

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

The fuse holder is located behind batte­ry cover, behind the side cover.

Replacing the fuse

1. Turn the key to and turn off all
electrical circuits.

2. Remove the blown fuse, and then in­stall a new fuse of the specied am­perage.

35

Specied fuse:

15 Amp

WARNING

!

Do not use a fuse of a higher am­perage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a

re.

3. Turn the key to and turn on the
electrical circuits to check if the de­vices operate.

4. If the fuse immediately blows again,
have a dealer check the electrical
system.

PERIODIC MAINTENANCE AND MINOR REPAIR

LIGHTING

Headlight bulbs

2

CAUTION

This model is equipped with halogen
bulb headlight (1).If a headlight bulb
burns out,have a dealer replace it and,

if necessary,adjust the headlight beam.

This model has furthermore a LED po­sition light. If the LED position light de­fective, please contact your dealer.

1

Front indicator

If the turn signal light bulb does not com
on, remove the screw of the indicator
lens (2) out and replace the bulb.

Rear indicators

3

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

4

If the tail/brake light (4) and licenes
light bulb (5) does not come on,have
a dealer check its electrical circuit or
replace the
bulb.

5

36

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.

37

TROUBLESHOOTING

TROUBLESHOOTING CHART

WARNUNG

!

Keep away open ames and do not smoke while checking or working on the fuel system.

1. Fuel

Check the fuel level in
the fuel tank.

2. Compression

Operate the electric
starter.

3. Ignition

Remove the spark plug
and check the electrodes.

4. Battery

Operate the electric
starter.

Operate the electric
starter.

There is no fuel.

There is compression.

There is no compression.

Wet

Dry

The engine turns over quickly.

The engine turns over slowly.

Check the compression.
Supply fuel.

Check the ignition.
Have a dealer check the

vehicle.

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark
plug.

Have a dealer check the
vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

38

The engine does not start.
Check the compression.

Operate the electric starter.

The engine does not start.
Check the battery.

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 mufer 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
dealer 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 normal use

Remove dirt with warm water, a mild de­tergent, and a soft, clean sponge, and
then rinse thoroughly with clean wa­ter. Use a toothbrush or bottlebrush for
hard-to-reach areas.

39

Cleaning after riding in the rain,
near the sea or on salt-sprayed
roads

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.

After cleaning

• Dry the vehicle.

• To prevent rust, we recommend ap­propriate care to use according to
manufacturer‘s instructions.

• Wax all painted surfaces.

Recommended Castrol care pro-

ducts:

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

!

Please store the vehicle in a well air

ow 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.

40

CLEAN AND STORAGE

WARNING

!

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 mufer 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 4-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
124,5 cm³ / 148 cm³
Compression ratio

10.6:1 / 9.27:1
Starting system
Electric starter
Lubrication system
Separate lubrication
4-stroke engine oil

ENGINE OIL

Quantity: 1.2 l
recommended type:
Castrol Power 1 Racing 4T

AIR FIL TER

Wet element

FUEL

Unleaded gasoline only
Capacity
17 +/- 0.5l

CAUTION
!! BIOETHANOL FUEL ­E10 IS NOT PERMITTED !!

41

CARBURETOR

Manufacturer
EXACT

SPARK PLUG

Manufacturer / model
NHSP LD / B7RC
NGK / DR8EA
Spark plug gap

0.6-0.7 mm

CLUTCH

Clutch type
Multiple plate clutch
Transmission type
5-speed constant mesh transmis­sion

CHASSIS

Frame type
Steel tube backbone

FRONT TIRE

Rim: 2.5x17
Tyre: 100/80-17 M/C

REAR TIRE

Rim: 3.0x17
Tyre: 130/70-17 M/C

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
160mm
Operation
Right hand

RECOMMENDED FLUID

DOT 4 - CASTROL Super Disc

Bremsüssigkeit DOT 4

REAR BRAKE

Type
Single Hydraulic disc brake
260mm
Operation
Right food

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
12N7-4A
Voltage, capacity
12 V, 7.0 Ah

HEADLIGHT

Halogen bulb

BULB VOL TAGE, WATTAGE X QUAN­TITY

Headlight
12 V, 35 W/35.0 W
Tail/brake light
12 V, LED
Front turn signal light
12 V, 10.0 W

Rear turn signal light
12 V, 10.0 W
License plate light
12 V, 5.0 W
Meter lighting
12 V, 2 W
High beam indicator light
12 V, 2 W
Neutral gear lamp
12 V, 2 W
Turn signal indicator light
12 V, 3 W
Horn
12 V, 3 A

FUSES

Main fuse

15.0 A

42

CONSUMER INFORMATION

IDENTIFICA TION NUMBERS

VEHICLE IDENTIFIKA TION NUMBER
(VIN)

Please write down the VIN (vehicle iden-

tication number) to order replacement

parts from your dealer or the vehicle
should be stolen.

The vehicle identication number of the

vehicle (1) is stamped on the steering
head.

1

CAUTION

The vehicle identication number is used

to identify your motorcycle and may be
used to register your vehicle with the
licensing authority in your area.

43

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 specications 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 deciencies 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 lled 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 rened 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, lter elements, spark plugs, drive sprocket, wheel and axle., as well as the tires.

44

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.

PART TO DO
Air lter Clean/ exchange
Wheels, rims Control
Tires Control/ tire pressure
Wheel bearing Control/ exchange
Steering bearing Control/ clean/ 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 Exchange Exchange Exchange
Variomatic belt Control/ exchange
Fly wheels Control/ 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 lter Control/ exchange Exchange
Idle speed Control/ adjust
Exhaust system Control/ tighten
Coolant Control

CAUTION: Variomatic belt, y wheels, spark pluge, fuel lter and air lter 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.

1000 km or

1. month

√ √

√ √ √ √ √

√ √ √

√ √ √ √ √

√ √ √ √ √

√ √ √ √ √

√ √ √ √ √

√ √ √ √ √

4.000 km or

6. month

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √

√

√

√ √ √ √

√ √ √ √

7.000 km or

12. month

Exchange

Exchange
Exchange

10.000 km or

18. month

√ √

Lubricate

√

√

45

13.000 km or

24. month

√

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

7000 km or 12. month

Stamp / Signature

13000 km or 24. month

Stamp / Signature

19000 km

Stamp / Signature

VEHICLE IDENTIFICATION NUMBER:.........................................................................................................................................................................................................................................

MODEL:.................................................................................................................................................................................................................................................................................................................................................................................................

Stamp / Signature

10000 km or 18. month

Stamp / Signature

16000 km

Stamp / Signature

21000 km

Stamp / Signature

NAME OF THE CUSTOMER:.......................................................................................................................................................................................................................................................................................

SIGNATION OF THE CUST OMER:............................................................................................................................................................................................................................................................

46

WIRING DIAGRAM

47

SPACE FOR NOTES

48