Ossa Explorer 2012, Explorer, EXPLORER 2014, TRi User Manual

User manual 2012
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User manual 3
Introduction
We at OSSA Motor would like to thank you for purchasing one of our products. In response to the wishes of motorcycling enthusiasts, Ossa laun­ches an extraordinary model: the new Ossa Explorer 2012. Inheri­ting the spirit of the legendary Explorer presented in Paris in 1972, the new bike from Ossa maintains its philosophy: A comfortable and very light bike, easy to ride and designed to enjoy both the mountain and the city.
This model takes advantage of the innovative features of the , such as the two-stroke injection engine and the chassis. A style of bike that is not found in the market; it’s a combination of a Trials and an Enduro bike. It has a bigger seat and offers fun, safety and comfort, together with amazing handling sensations and inexpen­sive maintenance.
OSSA motorcycles have been designed, assembled and tested by experts, and each of its parts has been produced under the su­pervision of OSSA engineers so as to obtain the best possible re­sults and the best possible performance. At OSSA Motor we know that each motorcycle model is unique and has its own features, which is why we dedicate so much time on research and design for each item.
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Read this manual thoroughly and keep it in a safe place. This manual provides technical information necessary for keeping your new Explorer motorcycle in full working condition. It provides in­formation on common aspects for the motorcycle’s upkeep and fine tuning. In the event of questions or queries on aspects not mentioned in this manual, you should consult the OSSA official distributor or a specialist engineer.
Follow each stage of the instructions provided below for obtaining good results.
These instructions are accompanied by icons to make reading quicker and easier.
ATTENTION – This symbol indicates that special attentionmust be paid!
INFORMATION – Informative note, advice.
Some of the indications specified in this manual are to prevent possible harm from being inflicted on people or material. Not following the instructions may result in serious consequences, which could put people’s lives at risk.
This manual has been put together with the OSSA Explorer current layout. However, OSSA Motor reserves the right to make changes tothis layout without prior notification to consumers. In the event of this taking place, your dealer will provide you with the relevant
information.
- Never overload the motorcycle.
- Any additional weight could destabilise the mo­torcyclewhich may cause accidents that incur se­rious injury or even death.
Important
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Both your safety and the safety of others are very important when riding a motorcycle. Some important advice for using your motorcycle correctly is de­tailed below.
- Always drive in a responsible way.
- Always use a helmet.
- Never drive over the speed limit.
- Do not ride with passengers.
- This motorcycle is designed to be used in both urban and rural areas. It should be used, however, while respecting other people and the environment. If, in your geographical area, the use of motorcycles in rural areas is restricted, you must respect the law.
- Always wear appropriate clothing and protective accessories. Gloves, boots and thick trousers, among others, are recommen­dable. Do not wear baggy clothing that might get caught on a mechanism in the motorcycle.
- Be careful with the exhaust system! The exhaust system gets extremely hot during and after use of the motorcycle. In the event of suffering burns, see a doctor as soon as possible.
- Take the time necessary to become familiar with your new mo­torcycle.
- Never drive if you have consumed alcohol or any type of subs­tance (medication, drugs) that might affect your driving capability.
- Make sure your motorcycle is serviced regularly to avoid break­downs while driving.
- Do not clean the motorcycle with pressurized-water equipment, since this may damage the parts.
- Do not use your motorcycle for transporting or towing loads. In the event of needing to carry loads, always use the box under the seat. This load may be light-weight and small in volume so that driving is not affected. Ensure that there are no loose leashes or other elements that might get caught inside a mechanism. Never apply additional weight to the handlebars, fork or mudguards. Be specially careful when transporting any type of load.
Safety
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User manual 7
Introduction 3 Important warning 4 Saferty 5 Contents 7 Technical specifications 8-9 Recommendations 10
Section 1 - Components 11
Location 12-14 Multi-function box 15-22 Control pad 23 Front suspension
Settings 24
Air bleed 24 Seat 25 Anti-theft immobilizer 26 Start lever 27 Fuel tank 28-30
Section 2 – Maintenance and basic operations 31
Maintenance grid 32-33 Adjustments to the motorcycle controls 34 Electric connections 35
Simplified lighting wiring diagram 36 Simplified injection wiring diagram 37 Air filter 38
Radiator 39 Spark plug 40 Chain
Tension adjustments 41 Lubriction of moving parts 42-44 Tyres
Pressure and condition 45 Control of crankcase oil
Filling up and draining 46 Brakes 47 Torque wrenches 48
Storage 49 Troubleshooting 50-54 Registration, series number and key 55-60 Warranty conditions 61-68 Final considerations 69
Contents
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ENGINE
Cylinder size 272,2 cc Type 2 stroke inverted monocylinder with reed box admission Cooling Liquid cooled Bore x Stroke 76x60 mm Injection EFI Kokusan Indirect injection Ignition Digital flywheel CDI Kokusan Clutch Hydraulic Start Battery-assisted kickstart
TRANSMISSION
Gearbox 6 speeds Transmission Primary transmission by gears, final transmission by chain. Lubrication Mixture 100% synthetic oil lubrication 0.9% Gearbox and clutch lubrication 375 cc. of Gear Extreme type 75 W oil.
FRAME
Type Made of CR-MO steel tube, with fuel tank and lower part made of forged aluminium Front suspension Hydraulic fork, 40 mm diameter adjustable in rebound and compression Rear suspension Variable progressive system with Ollé mono shock absorber with adjustable spring preload Front brake 185 mm diameter disc with 4-piston brake caliper Freno trasero 150 mm diameter disc with 2-piston brake caliper / 180 mm diameter disc with 4-piston brake caliper (depending on version) Front wheel 28 spokes with 2.75x21 wheel Rear wheel 28 spokes with 4.00 x 18 tubeless wheel Engine protector Constructed in AA7075 T6 Kick-start pedal Forged aluminium Shift pedal Forged aluminium with retractable toe cap
Technical specifications
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WEIGHTS AND MEASUREMENTS
Wheelbase 1.328 mm Seat height 840 mm Ground clearance 340 mm Fuel tank capacity 7,6 litres (2,6 + 5 l.) Dry weight 78 Kg
OSSA Factory reserves the right to make modifications without prior notification. Kokusan, Marzocchi, OHlins are registered trademarks and their use is licensed.
Technical specifications
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Recommendations
It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order.
- 12 hours of running-in is recommended to ensure that the engine works correctly and for a long-lasting time period.
- It is important to run the engine for some minutes until it reaches the correct temperature to work correctly.
- The engine lubrication is a mixture of petrol-oil with a 0.9% oil proportion. Always use synthetic oil.
- When the motorcycle is new the oil must be changed for the first time after 5 hours of use and for the second time after 12 hours of use.
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Section 1 - Components
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Location of elements
1 Front mudguard 2 OSSA multi-function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide 7 Front tyre 8 Front fork bottles 9 Front fork stanchions 10 Shift pedal 11 Chain 12 Chain slider 13 Rear sprocket protector 14 Rear tyre
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24
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27
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Location of elements
15 Rear break caliper and anti-theft immobilizer 16 Exhaust 17 Kick-start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear brake lever 22 Crankcase protector 23 Front brake caliper 24 Front brake disc 25 Air filter 26 Rear footrests (depen­ding on version) 27 Passenger handle
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34
35
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37
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Location of elements
27 Front brake lever 28 Throttle grip 29 Throttle control 30 Front brake pump 31 Front fork servicing cap 32 OSSA multi-function box 33 Clutch pump 34 Lights control pad 35 Clutch lever 36 Headlights 37 Ignition key
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Multi-function box
The OSSA Explorer multi-function box and the indicator lights next to it provide very useful information at all times. The multi-function box is a power box system with an LCD screen controlled by a con­sole with indicator lights, located in the centre of the handlebars. The information displayed on the multi-function box includes: the number of revolutions made by the engine, speed, distance covered, total distance covered, time, average speed, maximum speed, envi­ronmental temperature, running time and uptime.
This device has an internal memory unit that stores data like total Km and total running time, even when it is switched off.
Some features may be personalised: the device can measure in kilo­metres or miles. The wheel circumference value can also be chan­ged.
A temperature sensor warns us with a yellow light (1) when the engi­ne temperature is excessive.
Another sensor provides a warning with a red light (2) when the rate at which the engine turns is excessive.
OSSA Multifunction Display
Function selection button
Left buton
Right button
Temperature warning LED
LED warning of
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Multi-function box
Functions
Technical features
Accuracy
Symbol Increasess
Current speed 4 - 399,9 Km/h o M/hSDP0 ,1 Km/h o M/h+ /- 0,1%
0 - 19999 rpm
RPM
10 rpm+ /- 0,1%
Tachometer
Distance covered
0,1 Km/h o M/h+ /- 0,1%
0,0 - 19999 Km / M
DST
Maximum speed
MS
4 - 399,9 Km/h o M/h
0,1 Km/h o M/h+ /- 0,1%
TT
Running time 0 - 9999 hours 59 minutes
1 second +/- 0,1%
0 - 12000 rpm
-
Variable+ /- 0,1%
Tachometer bar
0,0 - 999999
ODO
1 Km +/- 0,1%
Mileage
1 minute
0 - 999 hours 59 minutes
RT
+/- 0,1%
Uptime
1 minute
0 - 9999 hours 59 minutes
ART
+/- 0,1%
Accumulated uptime
Each use
12:59:59 - 23:59:59
00:00:00
+/- 0,1%
Clock
Each use
1 year's duration approx
LO
+/- 0,1%
Battery low
0 - 3999 mm
-
--
Tyre size
Technical features
Input voltage: 9-400 V CA/CC. Speed sensor: magnetic non-contact sensor Tachometer input: electrical pulse sensor Wheel circumference adjuster: 1 mm -3.999 mm (increases of 1 mm)
Running temperature / storage: from 0ºC to 60ºC (from 32ºF to 140ºF) / from -20ºC to 80ºC (from - 4ºF to 176ºF) Battery / Life: 3V CR2032 / 1 year approx
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Multi-function box
Functions
RPM: Bar
Bar graph tachometer. The tachometer bar graph displays up to 12,000 rpm.
RPM: Digital tachometer
The RPM appear on the right side, on the second line. The digital tachometer displays up to 12,000 rpm. The tachometer signal can be captured from the sparkplug wire.
Warning of gear change due to rpm.
The rpm appear on the right side, on the second line. The digital tachometer displays up to 12,000 rpm. The tachometer signal is received from the sparkplug wire.
SPD: Speedometer
MS: Maximum speed meter
It displays the maximum speed reached during the last operation after having set the counter at zero.
DST: Distance covered
It appears on the right side, on the second line of the screen. The TRIP function records the mileage accumulated by the vehicle since the last RESET.
ODO: Mileage counter
It records the distance or total accumulated mileage for the ve­hicle. The data is stored in the memory, even when the device is switched off.
ART: Running time controller
It calculates the total running time. It begins counting as soon as the engine is switched on.
RT: Total running time controller
It calculates the vehicle’s running time from the last RESET. It begins to count from when the vehicle starts to move. The data is stored in the memory, even when the device is switched off.
12/24 hour clock
It displays the current time in 12 or 24 hour clock. It indicates the temperature of the environment and engine. The display screen on the upper left shows the environmental temperature. Using an optional temperature sensor, the screen displays the engine tem­perature. If excessive, the yellow light comes on.
Indicator that engine turn rate is excessive / Warning of gear change due to rpm.
If the engine turn rate is excessive a second red warning light will come on. This function acts as a warning to change gear when a specific number of rpm is reached. The red light flashes when the rpm reaches the established value and stops flashing when the gear is changed.
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3
2
1
1
2 3
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2
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Multi-function box
Adjustment of the multi-function box settings
After confirming each value, the multi-function box will move straight on to the next screen adjustment until the process is complete. If no button is pressed, the multi-function box will return to the initial screen after 15 seconds.
Activation of the adjustment mode
To activate the adjustment mode for the multi-function box set­tings, push buttons 1,2 and 3 si­multaneously for 3 seconds and then release them.
Select the speed unit
To select the speed unit between km/h and m/h, press 1. Confirm your selection by pressing 2.
Select the wheel circumference
Enter the wheel circumference by pushing button 1 repeatedly. To move to the next digit, press button 3. Confirm the selection by pushing button 2. Note: If you don’t know the whe­el circumference, consult the “Measuring the wheel circumfe­rence” section.
Select the time format
To select the time format change between the 12 and 24, press 1. Confirm your selection by pres­sing 2.
1
2
1
2
3
1 2 3
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Multi-function box
Time adjuster
Set the time by pressing button 1 repeatedly. To move to the next digit, press button 3. Con­firm the selection by pushing button 2.
Adjustment of the revolution pulse (PPR) Note:
This step must only be fo­llowed for those vehicles that change the PPR pulse type to a specific turn rate. If you don’t know this value, press button 2 to move on to the next screen. Enter the value by pressing button 1 repea­tedly. To move on to the next digit, press button 3. Confirm the selection by pushing button 2.
Adjustment of the revolution pulse (PPR)
The indicator receives an elec­tric pulse each time the engi­ne turns (PPR). Default value for 2 and 4 stroke engines: 1 PPR. Enter the value by pres­sing button 1 repeatedly. To move on to the next digit, press button 3. Confirm the selection by pushing button 2.
Adjustment of the revolution pulse (PPR) Note:
This stage must only be im­plemented if in the previous stage the value 0 was entered. Default value: 1.0. If you don’t know this value press button 2 to move on to the next screen. To move on to the next digit, press button 3. Confirm the selection by pressing button 2.
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3
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2
2
3
3
1
2
3
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Multi-function box
Temperature selector
To select the unit of temperature,either ºC or ºF, press button 1. Confirm the selection by pressing button 2.
Danger temperature selector Note:
This stage should only be im­plemented for those vehicles that have an optional tempera­ture sensor. When the motor­cycle temperature exceeds the set value, right-hand warning light comes on. Default value: 110ºC (230ºF). Enter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3. Confirm the selection by pressing button 2.
Warning temperature selector Note:
This stage should only be imple­mented for those vehicles that have an optional temperature sensor. When the motorcycle temperature exceeds the set va­lue, the left-hand warning light comes on. Default value: 90ºC (190ºF). En­ter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3. Con­firm the selection by pressing button 2.
Gear change turn rate selector
When the set rate is near to be­ing reached, the left-hand war­ning light will flash, indicating the need to change gear. Default value: 6000 rpm Enter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3. Confirm the selection by pres­sing button 2.
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3
BAT T
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R Y
C
R
2
0
3
2
RESET
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Multi-function box
RESET
CLOSE
OPEN
POSITIVE
BATTERY CR2030
Dangerous turn rate selector
When the set rate is near to be­ing reached, the right-hand war­ning light will flash, indicating that the engine is turning at an excessive rate. Default value: 10,000 rpm. En­ter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3. Con­firm the selection by pressing button 2.
Setting the indicator functions to zero after each use of the vehicle
After each use of the vehicle, it’s possible to set the following functions to zero, simultaneously:
- Maximum speed
- Distance
- Chronometer
- Maximum temperature
- Maximum turn rate Confirm that you want to set these functions to zero by simultaneously pressing buttons 1 and 2.
Setting the whole multi-function box to zero
Press the RESET button by using a suitable object. The indicator will boot again, excluding data that corresponds to total accumu­lated
Internal battery
The multi-function box works with a 3V internal battery, type CR2032. When the battery tension falls beneath 2.45V, the screen displays the LO indicator. To change the battery, open the lid on the bottom of the indicator by unscrewing it as is indicated in the image, using a coin. Ensure that the positive side of the battery is facing
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Multi-function box
Screen Options
The multi-function box displays all information on three different screens. While on, it is possible to see screens 1 or 2. Screen 3 is displayed for three seconds and then returns to screen 1. To move from one screen to another repeatedly press button 2 (“Mode”). To edit the distance covered (DST) hold down button 3. Screen 1: Screen 1 displays the following information:
- Speed, distance covered, time, environmental temperature, ta­chometer (bar). Screen 2: Screen 2 displays the following information:
- Speed, digital tachometer, running time, uptime, engine tempe­rature*, tachometer (bar). Pantalla 3: Screen 3 displays the following information:
- Maximum speed, dangerous turn rate, accumulated running time, mileage counter, maximum temperature*.
* optional
Screen Illumination
The multi-function box works by using a 3V internal battery, type CR2032. To change the battery, open the lid on the bottom of the indicator by unscrewing it, as indicated in the image, using a coin. Ensure that the positive side of the battery is facing upwards. When the multi-function box is powered exclusively by the inter­nal battery, the screen illumination is partially maintained for 3 seconds when the button is pressed.
Sleep Mode
If the multi-function box receives no information for 20 minutes (wheel signal, turn signal or pressed button) the screen will turn off, displaying only the time. When the vehicle moves, or by pres­sing any button, it will start up again.
Measuring the wheel circumference
Method 1: Measure the diameter of the front wheel. Multiply the diameter obtained by 3.14. If necessary, convert the measurement into mm by multiplying the obtained figure by 25.4. The measurement obtained corresponds to the measurement of the wheel circumfe­rence. Method 2: On a smooth and flat surface, put a mark on the side of the tyre and in the area where it is touching the ground. Move forward with the vehicle until the wheel has tuned completely once and the mark is on the lowest part again. Put a new mark on the ground at this point. Measure the distance between the two marks on the ground. If necessary, convert the measurement in mm by multi­plying the figure obtained by 25.4. The measurement obtained corresponds to the wheel circumference. To obtain a more accu­rate measurement, the rider should remain on the vehicle when the measurement is taken.
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2
3
6
5
4
3 4
1 2
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Control Pad
Control Pad
The control pad is located on the left handlebar, within reach of the thumb. This control pad can be used to control the lights, indicators, horn and engine stop.
See the image with information about the control pad.
1 – Position lights 2 – Cross lights 3 - Long range lights 4 – Lights for changing direction (left – right) 5 – Horn 6 – Button to switch off engine
See the image with information about the control pad.
1 – Pilot lamp for change of direction (left – right) 2 – Pilot lamp for cross lights 3 – Pilot lamp for long range lights 4 – Pilot lamp for footrest
B
A
C
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Suspension
The front suspension is made up of a fork that fixes the wheel and the front brake system in place. This fork is formed by the suspen­sion bars that contain the shock absorber spring and the suspension mechanism. They are connected to the upper part where the di­rection pipe is located, a point of connection between the fork and the chassis. A regulating screw and an air bleed are located on the upper part of each suspension bar (see photo).
To regulate the extension, use the screw located on the right sus­pension bar (Fig. A) To regulate the compression use the screw located on the left sus­pension bar (Fig. B) Each of the suspension bars also has an air bleed to remove air that accumulates in the inside of the fork stanchion (Fig. C)
The rear suspension is formed by a single shock absorber spring. The preloadof this spring can be adjusted by turning the toothed rings that dictate its direction.
Adjustable rings for the
spring pre-charge
A special key is needed to adjust these toothed rings.
The fork contains oil SAE 5, with 230 cc in the left bar (C) and 130 cc in the right bar (R).
1
2
User manual 25
Seat
In order to access some parts of the engine or the wiring, you must previously remove the seat.
1: First, you must open the rear seat lock with the ignition key. 2: Then you must pull the back of the seat upwards and then bac­kwards, as in figure 2. 3: To put the seat back on the bike, repeat the process in inverse order.
(Fig. 2)
(Fig. 1)
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Anti-theft immobilizer
IMPORTANT: this key has a code which is needed for making duplicate copies of the key. This code should be written down in the indicated space on the regis­tration page and series number of this manual.
The Explorer has an immobilization system for protection against theft.
This system consists of a lock situated in the area of the brake discs on the rear wheel. It is a mechanism that is operated with a key and blocks the rear wheel.
User manual 27
Kick start pedal
Before starting the motorcycle, you must ensure that the key switch at the right hand side of the headlight is activated. Also, it must be in neutral gear. DO NOT try to start in a gear .
The kick-start pedal is part of the mechanism that is used to kick start the motorcycle mechanically.
To kick start the motorcycle, the kick-start pedal must be se­parated from the bike and moved outwards. Once separated, place your foot on top and press strongly to turn it counter­clockweise.
It is necessary to ensure that the light signals are working properly, that the tire pressure is correct and the security and control elements (brakes and controls) are in good condition.
If the motorcycle has been inactive for a long period of time, its recommended that the kick-start pedal is activated gently 3 or 4 times, without actually kick-starting the motorcycle. This will enable the engine to move which will help when kick-starting it. If the motorcycle has been inactive for a very long period of time, change the oil and petrol because they might have become degraded. This could affect the motorcycle’s per­formance.
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Lower fuel tank
Upper fuel tank
Filling lid
The engine of this motorcycle works with a mix­ture of unleaded petrol and 2S oil, 100% syn­thetic in a 0.9 proportion.
It’s recommended that a hose or funnel is used to fill up to avoid spilling the petrol. This is es­pecially important if the motorcycle is hot. DO NOT fill up with petrol when the motorcycle is
Fuel tank
The Explorer has two fuel tanks, one forms a struc­tural part of the chassis and is located on the front inside part. The other one is made of polyamide plastic and is located in the classic position on the frame. To fill up with petrol, open the upper fuel tank lid, situated on the upper part, by unscrewing in an anti-clockwise direction.
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2
4
5
3
User manual 29
(fig. b2)
Fuel tank
In order to access some parts of the engine or the wiring, you must previously lift the upper fuel tank.
1: First you must remove the seat. (see page 25, Seat) 2: Unscrew only the four upper screws of the side tank pannels. 3: Disconnect the air hose located in the front of the upper fuel tank. (see fig.2) 4: Disconnect the conector that connects both fuel tanks. 5: Unscrew the upper tank central screw (which is located where indicated with number 5). 6: We proceed to lift the tank from the front, pivoting backwards.
6
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In operation No. 2 (Unscrew only the four upper screws of the side tank pannels) never release the screws that attach the pannels to the radiator, as it could pierce it or eventually damage the threads.
Fuel tank
When performing the operation No. 4 (Disconnect the connector that connects the two fuel tanks), You must mind the existence of residual fuel in the quick connector.
User manual 31
Section 2 – Maintenance and basic operations
32 User manual
Check / Inspect
Replace / Change Grease / lubricate
Adjust Clean
30 Hours
30 Hours
Each wash
Each wash
Each year
Each year
Each year
When necessary
When necessary
When necessary
When necessary
When necessary
When necessary
Wire and throttle grip
Cylinder
Clutch discs
Exhaust
Clutch
Each useE ach washEach use
_
_
_
_
Air filter
Each use
Each use
Each use
Each use
Each use
Each use
Each use
60 horas
15 Hours
_
_
_
__
_
_
_
_
__
30 Hours
60 Hours
60 Hours
60 Hours
_
_
_
_
_
__
__
_
_
_
_
_
_
_
__
Silencer
Change / kick-start pedal
Radiator tube and connections
Item
When damaged
When damaged
When damaged
When damaged
When damaged
When damaged
When damaged
When damaged
Transmission oil
Refrigerant
Sparkplug
Reed block
Piston and piston ring
Maintenance grid – Engine
User manual 33
__Each year Every 2 years
_
Rear shock absorber
_When damaged_E ach useChassisE ach use
When necessaryBrakes Each useW hen damaged __
Each yearFront suspension Every 2 years __When necessary
_E ach washEach useEach useW hen damagedSwing arm and linkage arms
Front suspension lubricant 60 Hours__ __
When damagedTyres Each use ___
When damagedFront/rear tyre Each use _Each use_
When damagedBrake discs Each use __When necessary
When damaged30 horasWheel bearings Each wash__
When damagedEach useSteering bearings Each wash__
When damagedEach useSecondary transmission Each washEach useWhen necessary
When damagedEach use _Each use5 HoursFront/rear spokes
_When damaged_E ach useEach useFuel tank
When damagedEach use _When necessary Each use
Screw, nuts and fastenings
When damaged_ _First useE ach useCrankcase protector
When damaged_Each use __
Protective stickers
Check / Inspect
Replace / Change Grease / lubricate
Adjust Clean
Item
Maintenance grid - Cycle
min. 3 mm
min. 3 mm
34 User manual
It’s important that the levers and rear brake pedal have a 2-3 mm give.
Adjustments to the motorcycle controls
The clutch lever is located on the left handlebar grip and is used to activate the clutch mechanism to change gear.
The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake.
It’s important that the levers can be easily activated by the rider while he/she is riding the bike, using the index and middle fingers.
Front brake lever Clutch lever
User manual 35
Electrical connections
Check the condition of the motorcycle’s electrical connections in order to ensure they are maintained in good working order. As seen in the image on the right, these are located at the left side of the cylinder, between the steering bar and the front headlight, and in the fuel system apparatus.
Carry out a regular and thorough maintenance of your motorcycle. Always use original spare parts and top quality products to ensure that it works correctly.
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Simplified diagram of the lights wiring
User manual 37
Simplified diagram if the injection installations
38 User manual
Air filter
Air filter. Cleaning and maintenance
The air filter should be controlled periodically. Lift the upper fuel tank, as you can see in the image on page 29, in order to access the filter box. Remove the sensor on the filter base and the clamp. Then remove the filter, according to the illustration. To clean, use water and detergent, leave to dry and then lubricate with a special liquid for filters. Reassemble using the steps outlined previously but in reverse. Make sure that the parts areput in their correct po­sitions.
Carry out regular and thorough maintenance of your motorcycle. Always use original spare parts and top quality products to ensure that it works correctly.
User manual 39
Radiator
The radiator contains the engine coolant. To fill up with or add coolant to the radiator, locate the tank lid. To locate this lid, lift the upper fuel tank (see pag. 29, Fuel tank). Once the tank is lifted the radiator lid is visible. Unscrew the lid and pour in the coolant.
ATTENTION: Use gloves. Do not open the lid if the engine is hot. This could cause burns. Avoid contact of the liquid with the eyes, mouth or na­sal passage. Do not ingest. In the event of this happening, follow the product instructions and consult a doctor.
The radiator has an electric fan to force air through it, as can be seen
To fill the radiator, special coolant should be used
-30ºC.
To ensure that the motorcycle works correctly, periodic controls must be carried out to check the coolant levels. This will ensure that the motorcycle is running at an optimum temperature.
Always use special refrigerant for light alloy engines.
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1
2
40 User manual
(Fig. 2)
Spark
(Fig. 1)
To extract the side cover, 1: bend it slightly until releasing one of the fixing snaps. 2: move the cover laterally, without turning it, to release the other fixing snap. 3: pull the cover out.
Fig:
Sparkplug
The sparkplug should be checked regularly and a spare sparkplug should be carried at all times in case it co­mes off. The sparkplug can accumulate charcoal and dirt with use. For this reason, it can be removed and cleaned so that it lasts longer.
To access the sparkplug detach the right side cover (see fig. 1). Once the cover has been removed, the motorcycle’s electrical sys­tem can be accessed. Carefully but firmly, pull away the hood that provides current, leaving the upper part of the sparkplug exposed. Using a special sparkplug tool, unscrew it and take it out from the right side of the motorcycle (see fig. 2).
Right side panel
Observe the distance between the electrode and the arch. This distance should be 0.7 mm. NOTE: The sparkplug should not be handled if the motorcycle is hot.
User manual 41
The axle has easily adjustable eccentrics for ten­sing the chain and centring the wheel.
The chain hook should be positioned in an oppo­site direction to the gear, as can be seen in the photo.
The chain tension should permit 2 cm of oscilla­tion in the chain tension adjuster.
The transmission chain transmits the engine’s movement to the rear wheel. To ensure that is works correctly, it should be checked.
Cadena - Reglajes de tensión
42 User manual
Lubrication of moving parts
Clutch and brake lever joints
Take care NOT to accidentally lubricate the brake caliper or brake pads. If this happens clean off the lubricant and carry out controlled braking until the brakes work correctly again.
Cleaning the motorcycle and lubricating the mobile parts will help protect the motorcycle and guarantee that it works better.
If using a high pressure hose to clean the motorcycle, bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle.
Lubricate using specific products::
1.Transmission chain
2.Clutch and brake lever joints
3.Gear lever joints
4.Rear brake pedal joints and bearings
5.Footrest brackets and springs
6.Engine kick-start pedal joints
7.Gas handle (right grip)
Use specific lubricants for each part of the motorcycle.
User manual 43
The chain drive should always be well lubricated. Check it each time the motorcycle is used and apply lubrication when necessary.
Gear change lever joints
Chain drive
Rear brake pedal Chain drive joints and bearings
The chain must be lubricated using special oil for chain
Lubrication of moving parts
44 User manual
Lubrication of moving parts
Footrest bracket and springs
Engine kick-start pedal joints
Chain drive and tension adjuster springs
Gas handle (right grip)
User manual 45
Front tyre:
2.75x21”
Rear tyre:
4.00x18”
Front tyre pressure: 0,5 bars
Rear tyre pressure: 0,6 bars - normal 0,9 bars - with passenger
Tyres
Pressure and condition
To ensure that the motorcycle works correctly, it’s very important to check the tyre pressure and that the wheels are in good working condition before each use. Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability. It also ensures that trial riding is safer and more efficient.
NEVER forget to periodically check the tyre pres­sure to ensure that the tyres have a good grip.
Tyre in good working condition
Tyre in bad working condition
MAX.
MIN.
(A)
(B)
46 User manual
Clutch cover (D)
Ignition cover (C)
The oil level should be checked when the motor­cycle is in an upright position and on a at surface. The motorcycle should be cold. If it is not cold, wait some minutes until it goes cold.
Checking the crankcase oil
Filling and draining the crankcase
Crankcase oil is used for lubricating the change pedal and the clutch. Check the oil level with the indicator located on the lower part of the clutch cover, which is on the right side of the engine. The oil level should be lower than the indicated maximum level.
Optimum oil level
To add oil, remove the cap (A) located on the top of the clutch cover (D). Use a funnel to add the oil, NEVER fi­lling above the Maximum level. Replace the cap. If you fill above the Maximum level, oil must be removed. To remove oil from the hood, place a receptacle under the motorcycle and remove the lid (B) located on the side of the hood, leaning the bike over in both directions to ensure that no oil remains inside the hood.
IMPORTANT: Clean the plug and change the sealing washer each time the oil is changed.
The crankcase has a 375cc oil capacity. 2T 100% synthetic oil should always be used.
Indicator
MAX.
MIN.
User manual 47
Brakes
The brakes permit precise and controlled riding. It is necessary to check them in order to ensure that they work correctly.
Wear on the front and rear brake pads must be periodically controlled so that the brakes work effectively.
The oil level can be checked using the indicator on the front handle and on the rear pump tank. The oil level should be situated between the min and max values.
To remove surplus air from the break circuit, the calipers are equipped with air bleeds. See image.
48 User manual
Torque wrenches
These grids show the pressure that should be used to tighten parts.
CHASSIS ENGINE
Part N-mN -mPart
Front wheel axle 40 - 50
70 - 80
40 - 50
40 - 50
40 - 50
18 - 25
7 - 10
7 - 10
7 - 10
27 - 32
18 - 25
80 - 90
27 - 32
27 - 32
27 - 32
18 - 25
7 - 10
11
7 - 8
7 - 8
25
7 - 8
3 - 4
7 - 8
7 - 8
7 - 8
40
10
7 - 8
12
12 - 13
7 - 8
8 - 9
25
Handles
Handlebar
Front wing bridge section
Break pedal
Rear wheel axle
Sparkplug
Water separator
Ignition cover
Engine drain plug
Kick-start pedal screw
Transmission pedal screw
Cylinder block screws
Cylinder nuts
User manual 49
Storage
Storage
If the motorcycle is to be stored for a long period of time, the fo­llowing procedure should be followed to ensure that it is stored co­rrectly.
- Clean the motorcycle as much as possible because dirt can cause the deterioration of components.
-Turn on the engine for a few minutes to warm up the transmission fluid and then drain. (see section on draining fluid).
-Fill up with new transmission fluid.
-Empty the fuel tank (petrol degrades over time).
-Lubricate the chain and all wires.
-Apply oil to non-painted metal surfaces to prevent rust. Avoid putting oil on the brakes and rubber parts.
-Wrap the outside of the exhaust pipe in a plastic bag to prevent rust.
-Position the motorcycle so that the wheels don’t touch the ground to prevent possible tyre deformation. If this is not possi­ble, cardboard can be placed underneath the wheels.
-Place a cover over the motorcycle such as canvas, plastic or material. This will protect the motorcycle from dust and other external factors. Avoid storing the motorcycle outside, or in direct sunlight.
Starting the motorcycle again
To start up the motorcycle after a period of inactivity, the following procedure should be followed:
-Remove the plastic covers that were placed over the mo­torcycle before storing, including the exhaust pipe and those parts that had special protection.
-Tighten the sparkplug.
-Fill up the fuel tank with new petrol.
-Carry out general lubrication.
-Check tyre pressure.
-Leave the engine running for some minutes to warm up the engine oil.
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The engine won’t start
The engine starts and then stops
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
- Long period of engine inactivity
- Sparkplug dirty or wet
- General fuse damaged
- Bad electrical connection
- Lack or deterioration of petrol
- Change the old petrol for new petrol
- Dry / clean or change the sparkplug
- Change general fuse
- Check electrical connections and position correctly
- Take the motorcycle to a specialist mechanic
- Fill the fuel tank with new petrol
- Take the motorcycle to a specialist mechanic.
In the event of breakdown always take the motorcycle to a specialist mechanic
Troubleshooting
User manual 51
The motorcycle is unstable
The shock absorption is too hard
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
- Wire makes it difficult for the han­dlebar to turn
- Steer axle screw is very tight
- Steering bearings are damaged or with wear
- Steer axle bent
- Excessive oil on front fork
- Oil too viscous on front fork
- Front fork bent
- Tyre pressure too great
- Rear shock absorber badly adjus­ted
- Move wire or loosen it a bit
- Loosen the steer axle screw
- Replace steering bearings
- Change the steer axle. Contact an officially registered mechanic.
- Remove surplus oil until it reaches the correct level.
- Drain fork oil and fill up with viscous oil.
- Change the front fork. Contact an officially registered mechanic.
- Check the pressure of the tyres
- Adjust the rear shock absorber
In the event of breakdown always take the motorcycle to a specialist mechanic
Troubleshooting
52 User manual
The shock absorption is too soft
The motorcycle makes abnormal noises
- Too little oil in front fork
- Front fork oil not sufficiently viscous
- Front fork bent
- Rear shock absorber badly adjusted
- Chain badly adjusted
- Chain wear
- Rear crow teeth wear
- Insufficient chain lubrication
- Rear wheel badly adjusted
- Front fork with insufficient oil
- Front fork spring weak or broken
- Brake disc wear
- Brake pads badly positioned or crystallised
- Add oil to the fork until it reaches a sufficient level
- Drain fork oil and fill up with suitably viscous oil
- Change the front fork. Contact an officially registered mechanic.
- Adjust the rear shock absorber
- Adjust chain
- Change chain, rear crown and secondary transmission pinion
- Change rear crown
- Lubricate chain
- Align rear wheel. Contact an officially registered mechanic.
- Add oil to the fork until it reaches a sufficient level.
- Replace front fork spring
- Replace brake disc
- Change position of break pads or replace them.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
Troubleshooting
In the event of breakdown always take the motorcycle to a specialist mechanic
User manual 53
The motorcycle makes abnormal noises
The handlebar vibrates
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
- Cylinder damaged
- Supports, screws or nuts are not pro­perly fastened
- Tyres wear, swing arm or its needle bearings wear
- Wheel rim not centred
- Wheel not centred
- Lack of engine oil
- Steer axle with excessive tolerance
- Handlebar support loose, steer axle nut loose
- Replace the damaged cylinder
- Check and adjust using suitable torque wrench
- Change worn parts for new parts
- Centre wheel rim
- Check the tension of the spokes and readjust
- Check and add engine oil
- Tighten the handlebar support and the steer axle nut using suitable torque wrenches.
- Tighten the handlebar support and the steer axle nut using suitable torque wrenches.
Troubleshooting
In the event of breakdown always take the motorcycle to a specialist mechanic
54 User manual
La moto tiende a inclinarse a un lado
Los frenos no actúan correctamente
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
-Chasis torcido.
-Dirección mal ajustada.
-Eje de dirección torcido.
-Horquilla delantyera torcida.
-Ruedas mal alineadas.
-Disco desgastado.
-Fluido del freno deteriorado.
-Pérdida del fluido de freno.
-Pistón de la bomba roto.
-Frenos mal ajustados.
-Cambiar el chasis. Ir a un taller especializado.
-Ajustar dirección. Ir a un taller especializado.
-Cambiar eje dirección. Ir a un taller especializado.
-Cambiar horquilla delantera.
-Alinear las ruedas.
-Cambiar disco.
-Verificar circuitos de freno. Cambiar los que esten dañados o rotos
-Vaciar fluido de freno y reponer con uno nuevo recomendado por el constructor.
-Reponer el pistón de la bomba.
-Ajustar los frenos.
Troubleshooting
In the event of breakdown always take the motorcycle to a specialist mechanic
User manual 55
Standardisation components
56 User manual
Each of the registered elements should be part of the vehicle. In the event of breakages, loss or bad functioning, it is recommended that you go to an official OSSA mechanic to remedy the problem.
Standardisation components
Your Ossa Explorer is standardised in compliance with UE regulations. It adheres to all standardisation requirements EURO-3 regula­tions.
The obligatory elements to be registered for driving on public roads and for passing the vehicle’s MOT are listed below.
The elements to be registered among others are identified with a specific mark and registration.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
16
User manual 57
Each of the registered elements should be part of the vehicle. In the event of breakages, loss or bad functioning, it is recommended that you go to an official OSSA mechanic to remedy the problem.
Standardisation components
1.Front headlight
2.Front indicators
3.Rear indicators
4.Rear pilot
5.License plate support
6.Reector
7.Mirrors
8.Manufacturer’s plate
9.Exhaust system
10.Speedometer
11.Pinion output
12.Lock
13.Horn
14.Kickstand
15.Throttle limiting bolt
16. Handle
17. Passenger footrests (in the bike homologated for 2 people).
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Element
1. Front headlight Front position lamp Driving beam Passing Beam
2. Front indicators
3. Rear indicators
4. Rear pilot
5. License plate support
6. Reflector
7. Mirror
8. Manufacturer plaque
9. Exhaust system
10. Speedometer
11. Pinion output
12. Lock
13. Horn
14. Kickstand
15. Throttle limiting bolt
16. Passenger handle
17. Passenger footrests (in the bike homologa­ted for 2 people).
Homologation identification
11/12-e9*97/24*97/24/*4367*00 R55.00.14839 R113.00.14839 R113.00.14839 11001200e94367 11001200e94367 e13*50 R00*50R00*12448*00
IA.E9.02.01269 L-e9*80/780*80/780*0143*01
z=11
e13*28R00*28R00*0037*00
Standardisation components
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Manufacturer’s plate Serial number
Standardisation components
60 User manual
El número de llave se encuentra marcado debajo del tapón rojo, se debe retirar para ver el número.
Engine number Key number
Standardisation components
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Warranty
62 User manual
Warranty
Terms and conditions of the warranty
The warranty is associated to the product indicated in the “CERTIFICATE OF DELIVERY AND INSPECTION”, which shall be filed out by authorised staff in OSSA FACTORY, SL (hereinafter referred to as OSSA). It is valid for those countries indicated on page 33. The warranty is only applicable to motorcycles that have been initially imported via the official OSSA importer for your country, meeting all the regulatory requirements and authorisations of each country. This warranty does not limit or adversely affect consumers’ legal rights and guarantees by virtue of any obligatory national regulations. It is independent of the legal warranty provided by the official dealer.
Name and address of guarantor
The guarantor is the commercial organisation OSSA FACTORY, SL, Crta Antiga d’Amer, nave 12, Pol. ind. Domeny, 17007 Girona (Giro­na).
Consumer’s rights as warranty holder
With this document OSSA provides the final user with a guarantee that the motorcycle manufactured by OSSA is free from defects and that it has been manufactured in compliance with the strictest quality control regulations. Therefore, the warranty extends to both the parts and the labour costs in the event of any repair provoked by faulty materials or manufacture detected in a new motorcycle. This is applicable for the time period stipulated within the warranty without limitation, except for those that are listed in this manual. The main­tenance and service requirements indicated by OSSA must have been adhered to, in compliance with the conditions herewith, for the warranty to be valid. OSSA is held responsible before the purchaser in the event of the product’s non-compliance at the time of product delivery. When the pro­duct is non-conforming, the purchaser must decide whether they want the product to be repaired or replaced. The purchaser’s decision, when notified to the seller, is binding for both parties with one sole exception: if the cost of reparation or replacement is disproportionate to the product’s value, the most reasonable solution will be taken into account. Rectification considered as disproportionate is that which implies costs for the seller which are not reasonable in contrast with the other means of rectification. This takes into account the value the product would have if the non-compliance did not exist, as well as the relevance of the non-compliance and if the alternative means of rectification could be carried out without any inconvenience.
User manual 63
Warranty
The repair is disproportionate when it is uneconomic, or when the reparation is more expensive than the value of the product. If this oc­curs, the purchaser can choose between a price reduction or contract resolution. Resolution is not permitted when the non-compliance is insignificant.
Regulations for repairs, product replacement, price reduction or contract resolution:
1. It will be free for the purchaser.
2. It will be carried out in a reasonable time period.
3. In the six months following delivery of the repaired product the seller will be answerable for those faults which necessitated the repair. When defects occur of the same origin as those initially repaired, it will be presumed that it is the same fault.
4. If, after the product has been repaired, the product still has faults while the warranty is in force, the purchaser can choose between a replacement, a price reduction or refund. If the purchaser selected a product replacement, they can request a repair – always while the cost of this repair is not disproportionate – a price reduction or refund.
5. The seller is not obliged to replace fungible or second hand goods.
6. The price reduction will be proportional to the difference between the value that the product would have had on delivery if the fault did not exist and the value that the product had at the time of delivery.
7. In the event of it being impossible for the purchaser to address the seller for the product’s non-compliance with the purchase agree­ment, they will be allowed to claim directly to the manufacturer in order to obtain a replacement or product repair.
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Warranty
PERIOD OF WARRANTY
OSSA is answerable for faults that appear over a two-year period from the product delivery, but if the non-compliance shows up after the sixth month, the purchaser must demonstrate that the fault was present at origin and existed when the product was delivered. Complaints made for the non-compliance of that which is set out in the warranty must be done within a six month period from when the warranty ends. Complaints will not be accepted after three years from the product delivery, which is understood to have been made on the date that appears on the “CERTIFICATE OF DELIVERY AND INSPECTION” or on the invoice if a later date is shown.
ACTIVATING THE WARRANTY
We request that you make an appointment with the OSSA sales representative that sold you the motorcycle, or with any authorised OSSA sales representative, providing this warranty manual. The OSSA dealer is under obligation to repair or change, at the discretion of OSSA, any part that is faulty due to either the material used or manufacture process.
WARRANTY FOR SPARE PARTS AND/OR ACCESSORIES
This warranty covers the repair or exchange, at the discretion of OSSA, of any original part due to faulty material or fabrication. The ma­terials and/or labour will be free of charge. Other damages are not included in the warranty, nor are repairs included that appear due to the replacement of the original part. In any case you must certify that the attached table has been duly filled out.
User manual 65
Warranty
EXCEPTIONS TO THE WARRANTY
The OSSA warranty does not cover the following items:
a) Damages that arise from not carrying out periodical revisions as stipulated by OSSA. b) Damages due to repairs or revisions carried out using methods that have not been specified by OSSA. c) Damages due to using the vehicle in races, rallies or other similar competition sports. d) Damages due to the practice of functions that are not indicated in the Owner’s Manual using the motorcycle beyond those limits or specifications indicated by OSSA (maximum load, passenger capacity, speed of motor and others) e) Damages due to the use of parts that are not original or not recommended by OSSA, or the use of fuel, lubricant and compound liquids with specifications that are different to those indicated in the Owner’s Manual. f) Damages due to modifications that are not approved by OSSA (motorcycle preparations, modifications for increased vehicle performance, light reduction, increases and other changes). g) Damages due to the vehicle’s aging (natural decolouration of painted or chrome surfaces, peeling and other types of deteriora­tion). h) The replacement or repair labour with non-original OSSA parts, or that are assembled by staff not authorised as part of the Official OSSA Post-Sales Service or as OSSA dealers. i) Damages due to incorrect storage or transportation. j) Damages due to uses that disregard traffic regulations and damages due to accidents. k) Spare parts that need to be replaced frequently.
OSSA does not offer a guarantee for parts or fluids that have deteriorated due to use. The parts or elements mentioned below are not covered by the warranty except when it is necessary to replace them during a repair carried out under warranty.
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Warranty
Parts
Spark plugs, fuel and oil filters and their components, transmission chains, air filters, engine sprockets, back crown gears, disk brake and break pads, clutch disks, light bulbs (except for those that are sealed), fuses, belts, tyres and inner tubes, wires and other rubber and/or tire parts specified by OSSA.
Fluids
Lubricants (such as oil, grease, etc.), and fluids for functioning (for example, refrigerant liquid for the radiator, break and gear fluids, transmission fluids, suspension oil, etc).
l) Cleaning: inspection, adjustments and other elements of periodical maintenance. m) Additional costs on top of warranty service, including: notifications, accommodation, maintenance and other costs due to breakdowns in isolated places. Compensation for wasted time, commercial losses or hire costs of a substitute product during the adjustment period. n) Any part replaced under warranty will become the legitimate property of OSSA. The parts replaced during the period of warranty will be guaranteed for the time remaining for the substituted part. OSSA reserves the right to introduce modifications and improvements it deems appropriate for all its models. o) OSSA does not guarantee repairs for noise, vibration, oil filtrations and other elements that don’t affect the product quality, functioning and performance.
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Warranty
MAINTENANCE AND SERVICE
It is your responsibility to ensure that the services are carried out on your motorcycle within the specified time periods and that the servi­ces are correctly registered. This means that your motorcycle will receive all the benefits of the OSSA warranty. It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was purchased, where both you and your motorcycle are known. Under normal circumstances, periodical revisions reduce overall maintenance costs. If you need to use the warranty service, please contact your authorised OSSA dealer immediately and make an appointment so that the necessary work can be carried out. It is recommended that periodical motorcycle services are planned in advance.
LOOKING AFTER YOUR MOTORCYCLE
Inspect your motorcycle on a daily basis before driving. The Owner’s Manual contains a list of things to be checked. These inspections will help avoid problems. Remember that minor adjustments are made more easily at home, rather than on the road. As well as improving the motorcycle’s appearance, thorough cleaning (take care when using pressure or steam cleaning equipment as it can damage the paint and lacquer of the product’s finish) provides the perfect opportunity for inspecting your motorcycle. The appearance and value of your motorcycle depends greatly on how it is looked after. It is important to clean your motorcycle periodically during the winter because, if not, salt on the roads can cause uncovered metal sur­faces to deteriorate.
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Warranty
Procedure for obtaining repairs under warranty
If your motorcycle needs a repair to be carried out under warranty, it should be taken to your official OSSA dealer where the repair will be made (YOU ARE RESPONSIBLE FOR THE TRANSPORT COSTS TO AND FROM THE DEALER).
Ossa recommends that you go to the dealer where your purchase was made. However, you can go to any Ossa dealer for repairs to be carried out under guarantee.
This guarantee provides you as a consumer with specific legal rights. You may also have additional consumer rights that vary depen­ding upon which country you are in.
If one of the afore-mentioned terms is invalid due to regional or federal laws, all other terms stipulated in this warranty continue to be valid.
User manual 69
We recommend that you stay in contact with your OSSA dealer so that you can receive help, advice and information about your new motorcycle, as well as information about the new products laun­ched by OSSA Factory, SL. We aim to provide full customer satisfaction. If the service you have received is not adequate, we would ask you to send us a written account, stating specific instances with as much detail as possible about the incident concerning our dealer. This will enable us to im­prove the OSSA MOTOR customer service and services in general.
Thank you and we hope you enjoy your new motorcycle.
Final information
www.ossamotor.es
Ossa Motor
Carretera antiga d’Amer, nau 12
17007 Girona, Spain
tel 0034 972 107 107
fax 0034 972 117 899
70 User manual
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