Polini Minicross XP 4, Minimotard XP4 Use And Maintenance Manual

--a

-

USE

AND MAINTENANCE

MANUAL MINICROSS AND MlNlMOTARD

FOREWORD

INSTRUCTIONS

MAY

BE

REPEATED A NUMBER OF TIMES

IN

THE COURSE OF THlS MANUAL.

THlS

HAS

BEEN

DONE PLIRPOSEFUUY

TO

EMPHASISE THE

IMPORTANCE

OF

CERTAIN OPERATIONS AND THE NEED

TO

BEAR SAFETY CONSTANTLY

IN

MIND.

ALL ENGINE MAINTENANCE MUST

BE

REFERRED

TO

A

SPECIALIST DEALER.

IMPORTANT

Read this manual carefully throughout before riding your

new motorcycle.

This

manual contains important information that will help
you ovoid causing unnecessary damage to the machine and
serious or even fatal injury to

yourself to other persons and
things.
To ensure care-free

and satisfying oFfroad riding you must
get to know your new motorcycle thoroughly and set it up
correctly before you start riding.

IMPORTANT LEGAL NOTICE

THlS MOTORCYCLE

HAS BEEN

DESIGNED AND

MANUFACTURED EXCLUSIVELY

FOR

COMPETITION USE

AND

IS

SOLD "AS

SEEN"

WlTH

NO

WARRANTY.

MIS

MOTORCYCLE DOES

NOT

COMPLY WlTH CERTAIN

ROAD SAFETY

REGUIATIONS AND

IT

IS

THEREFORE

ILLEGAL TO

RIDE

IT

ON

PUBLIC ROADS, HIGHWAYS AND

MOTORWAY S.

APPLICABLE

LEGISLATION PERMITS

THE

USE OF THIS

MOTORCYCLE

ONLY

IN

ORGANISED COMPETITIONS

OR

CLOSED TRACK

SPOR-I'ING

EVENTS ORGANISED

IN

COMPIJANCE WlTH LOCAL BY-LAWS.

ALWAYS ENSURE THAT

IT

IS

LEGAL

TO

OPERATE THE

MOTORCYCLE

BEFORE

RIDING

IT.

IT

IS

STRICTLY

FORBIDDEN

TO

CARRY PASSENGERS.

This

minicross motorcycle has been designed and

manufactured

for use by one rider only.

NOTE

Children must always be supervised by an adult when riding
this motorcycle.

READ THlS MANUAL CAREFULLY.

A

CAUTION!

This

text identifies a risk of serious or even fatal
personal injury if the associated instructions are
not followed. The associated

insh.uctions must

be

followed carefully to avoid damage to the

motorcycle.

WARNING!

This text identifies a risk of personal injury or

damage to the motorcycle. The associated

instructions must

be

followed carefully to avoid

serious or fatal

accidents.

This

manual

is

an integral part of the motorcycle and must

accompany it

if

it

is

sold or transferred to a new owner or

keeper.

WELCOME NOTICE

Congratulations on your choice of a Polini minicross
motorcycle. By purchasing a Polini motorcycle you have
become one of

a

large Family of satisfied Polini motorcycle

owners and riders.

NOTE!
This Polini minicross is a high performance
competition motorcycle and incorporates the
latest motocross race technology. It must only

be

used in competitive racing by expert riders.

This

new Polini minicross model has been designed to
prform as competitively as possible.
Motocross

is

nevertheless a physical sport and winning

requires more than

iust a good motorcycle.

To achieve

good

results you must be in

good

physical
condition and be a skilful motorcycle rider.
The best results are achieved

by

riders who exercise

regulady to keep in peak physical

form

and who practise

their motorcycling

skills

frequently.

The purpose of this manual

is

to help you get the greatest

satisfaction

pssible from you new Polini minicross
motorcycle, both from the performance of the machine itself
and from success in competitions.

PERSONAL PROTECTIVE EQUIPMENT

1

-

Most deaths in motorcycling are caused by head iniuries.
ALWAYS wear a helmet. Whenever possible, also wear a
visor or

goggles, as well as protective boots, gloves and

clothes.

2-

the exhaust system becomes extremely hot during use
and may remain

so

for quite some time afterwards.

Do

not touch any parts of the exhaust system. Always

wear clothes that completely cover your legs.

3-

Do

not wear loose or flowing clothing.

This

can become
entangled in the control levers, kick-start lever, footrests,
chain or wheels.

4-

Respect the environment.

A

DANGEROUS MODIFICATIONS

MODIFICATIONS TO OR THE REMOVAL OF
ORIGINAL PARTS FROM THlS

MINICROSS
MOTORCYCLE MAY CAUSE IT TO BECOME UNSAFE
OR ILLEGAL
ALWAYS COMPLY WlTH ALL LOCAL AND

NATIONAL LAWS, REGULATIONS AND SAFETY

STANDARDS.
THIS MOTORCYCLE HAS BEEN PROJECTED FOR A

DRIVER UNDER A WEIGHT OF

85

Kgs.

-

For your own safety and for the best

of your

motorcycle, always insist on

original Polini Motori spore

parts for all repairs. To be able to

recognise your motorcycle

-

and

to

keep track of its identity in case of theft, make a note

here of its specifications and frame number:

MODEL:

-.------------------

*

----------.

-----------*----------.-----.-.-----------------

-

ENGINE CAPACIW

------------------------------------.--------.----------------

TYRES: Front. Rear.

-------...---.-------------------------------------.----.------.------------------

FRAME NUMBER:

.---------.-*..------------.-----------------------------------*-

-

IDENTITY CODE: 144.000.

4 x M6x16 ROUNDED HEAD SCREW (IS0 7380)

1

x M8x18 SCREW (IS0 7380) (For the stand)

1

x RIGHT FOOTREST

1

x

LEFT FOOTREST

1

x FRONT WHEEL HUB

4 x M8 SELF-LOCKING NUT (UNI 7473)

4

x M8x30 ALLEN SCREW (cross-slot sunken hex screws)

(UNI 6593)

2

x

HANDLEBAR ClAMP

1

x HANDLEBAR WlTH

FOAM

ROLL

1

x FRONT WHEEL WlTH DISK

1

x

FRONT

MUDGUARD

1

x GEAR PEDAL

1

x FOOTREST SUPPORT

1 x NUMBER PLATE

I

x STAND

1

x STAND SPRING

LOCATION OF VEHICLE IDENTITY CODE

The motorcycle's identity code

is

stamped on the front of the

frame or on the right hand side of the steering head.

1.

PREPARING YOUR MOTORCYCLE FOR USE

When you first

open

the crate you will see that he motorcycle

3- Fit the rear shock-absorber, using the

MI

0x80 hex head

is

not

ready

for use, but has been partly dis-assembled for

bolt, two M10.5 spacers, two washers and the

MI0

nut.

-

reasons of packing and transport. Carefully unpack all the

Fit one of the washers

at

the bolt head and the other at

parts from the crate and

proceed as instructed below to

..

. .

.

.

-

the nut. The nut, bolt, spacers and washers are pre-fitted

check and assemble your motorcycle for use.
The

following instructions give the most practical order for

assembling the various ports of your motorcycle.

1

-

Remove he motorcycle from the crate (photo

1

).

2- Remove all the parts needed to reassemble the motorcycle
from the crate and check them thoroughly

(photo 2).

4 x WASHER (UNI 6593)

1

x PLASTIC

TIE

2

x FOOTREST SPRING

6

x

M8x20 ALLEN SCREW (cross-slot sunken hex screws)
(UNI 593

1

)

2

x

M8x40 ALLEN SCREW (cross-slot sunken hex screws)
(UNI 593

1

)

13-

Fit the engine stop button and

fix

it to the handlebar

with its mounting

clamp (photo

12).