Your Sachs dealer
SACHS
Recommends
Sachs Fahrzeug- und Motorentechnik GmbH
Nopitschstraße 70
• D-90441 Nürnberg
Telefon: +49 (0)911 4231 400
• Telefax +49 (0)911 4231 332
e-Mail: info@sachs-bikes.de
• www.sachs-bikes.de
Printed in Germany
Nr. P00 649 008 00 02 000 2004 .. ...
owners manual
GB
The MadAss is a sturdy light motorcycle in
modern design.
Its sound construction, the meticulous
selection of materials, the advanced manufacturing techniques and conscientious
work of dedicated employees provide the
motorcycle with all the characteristics that
are typical of Sachs: economical operation, quality, reliability and a high residual
value.
Because the factory is continuously involved
with the further development of all models,
we reserve the right to change the scope
of delivery in the form of model versions
and technology.
Technical changes to the standard motorcycles can void the EC operating license.
Therefore before implementing a change,
ask a specialized dealer whether it is allowable.
We cannot be held liable for any consequential damage caused by accessories
not approved by the factory.
The scope of delivery and version of the
motorbike is determined by the purchase
agreement concluded with the dealer.
This operating manual includes important
instructions for handling a light motorcycle.
Read it carefully, because professional
treatment – in addition to regular care
and maintenance – serves to maintain the
motorbike’s value and is one of the requirements for guarantee claims.
We wish you at all times a safe journey.
SACHS Fahrzeug- und Motorentechnik GmbH
You have purchased a Sachs MadAss
Congratulations – and thank you for
putting your trust in us.
PREFACE
1
CONTENTS
Summary and operation
Safety symbols .......................................................................... 3
Right-hand side view ................................................................. 4
Engine ....................................................................................... 5
Left-hand handlebar fittings....................................................... 6
Right-hand handlebar fittings..................................................... 6
Choke ........................................................................................ 6
Ignition lock................................................................................ 7
Cockpit....................................................................................... 8
Speedometer set-up, time adjustment....................................... 8
Speedometer battery change .................................................... 9
Safety test
Checklist.................................................................................. 10
Clutch ...................................................................................... 11
Fuel..................................................................................... 12-13
Engine oil............................................................................ 14-15
Front brake .............................................................................. 16
Rear brake............................................................................... 17
Drive chain............................................................................... 18
Tyre profile, tyre pressure and size.......................................... 19
Load / lights ............................................................................. 20
Riding instructions
Ride safely............................................................................... 21
Ride economically and be aware of the environment......... 22-23
Running-in instructions............................................................ 24
Side stand................................................................................ 25
Starting .................................................................................... 26
Starting with kick starter lever.................................................. 27
Starting withelectric starter...................................................... 28
Riding, changing gears............................................................ 29
Braking ............................................................................... 30-31
Stopping the engine / fork-column lock ................................... 32
Service instructions
Servicing the motorbike / cleaning agents.......................... 33-34
Operation in winter and anti-corrosion protection.................... 35
Repairing paint damage / servicing the tyres .......................... 36
Lay-up / commission................................................................ 37
Technical changes, accessories and spare parts .................... 38
2 3
CONTENTS
Maintenance
Maintenance activities ............................................................. 39
Checking the fork-column bearings......................................... 40
Removing the front wheel........................................................ 41
Installing the front wheel.......................................................... 42
Removing the rear wheel......................................................... 43
Installing the rear wheel........................................................... 44
Checking, adjusting the drive chain......................................... 45
Front brake ..............................................................................46
Rear brake.......................................................................... 47-48
Adjusting the clutch lever play ................................................. 49
Sparkplug ................................................................................50
Fuse......................................................................................... 51
Battery ...............................................................................52-53
Changing the bulbs ............................................................54-56
Adjusting the headlamps ......................................................... 57
Technical Data
Engine .....................................................................................58
Power transmission .................................................................59
Chassis.................................................................................... 60
Lubricants and operating fluids ............................................... 61
Electrical Equipment................................................................ 62
Dimensions and weights.......................................................... 63
Warranty
Warranty conditions................................................................. 64
List of wear parts ................................................................ 65-66
Inspection plan ................................................................... 67-69
Maintenance confirmations ................................................ 70-74
Motorbike data / Rating plate................................................... 75
SUMMARY AND OPERATION
NOTE
Special instructions for better handling
during operation and inspection and when
carrying out adjustment procedures and
service activities.
Observe the following:
WARNING
Precautionary measures against the risk of
accidents, injury and/or death.
FIRE HAZARD
The bike is supplied with a catalyst.
The exhaust system becomes very hot.
While riding, idling or parking, make sure
that no easily inflammable materials (such
as hay, leaves, grass, coverings, luggage,
etc.) can come into contact with it.
CAUTION
Important instructions and precautionary
rules to be followed in order to prevent
the motorbike from being damaged. Nonobservation can lead to the guarantee
becoming void.
Safety symbols and notes
4 5
1
2
3 4
5
6
789
SFM 649 051.1
SUMMARY AND OPERATION
Right-hand side view
1 Fuel tank cap
2 Handlebar fittings
3 Brake fluid reservoir front brake
4 Speedometer
5 Chassis number and rating plate
6 Fork column lock
7 Side stand
8 Battery and fuse
9 RH pillion footrest, fold-up
SFM 649 012.1
11
7
9 8
10
12
SFM 649 013.1
6
1
3
2
5
4
1 Carburattor
2 Air filter
3 Fuel cock with filter
4 Engine number
5 LH Foot rest
6 Gear lever
SUMMARY AND OPERATION
Engine left-hand side view
7 Spark plug connector
8 Electric starter
9 Footbrake lever
10 RH footrest
11 Oil filler cap
12 Kick starter
Engine right-hand side view
6 7
SFM 649 017.1
A B
1
2
3
SFM 649 024.1
5
6
4
7
8
SFM 649 025.1
9
1 Clutch lever
2 Head light switch
Push button upwards for
the upper low beam
Push button downwards for
the below low beam
2 Direction-indicator switch
Push to the left:
left-hand direction indicators
are activated
Push to the right:
right-hand direction indicators
are activated
3 Push-button horn
4 Emergency off switch
engine will not start
engine starts
5 Handbrake lever
6 Throttle
7 light switch
off
position light
driving light
8
Starter button
Right-handle handlebar ttings
Left-handle handlebar ttings
Choke lever right
9 Choke lever ( )
Operating positions:
A Cold start
B Warm start
SUMMARY AND OPERATION
1
2
SFM 649 015.1
Ignition-lock
NOTE
The ignition-lock as well as the tank cap are
operated with the same key.
Key positions
1 =
Operating position: ignition and all
circuits activated.
2 =
Ignition off.
WARNING
While riding, do not switch the ignition
off !
NOTE
Activate the parking light only for a limited
period. Take into account the charge of the
battery.
The key can be removed in positions .
SUMMARY AND OPERATION
8 9
SFM 649 059_2
1
4
3
2
A
B
5
0
KMH
0
DST
B A
0
KMH
0
TRP
B A
0
KMH
11 : 55
CLK
B A
0
KMH
12 : 00
CLK
B A
SUMMARY AND OPERATION
Cockpit
Seedometer
1 KMH - odometer or switchable on
MPH - speedometer (in miles)
2 DST - total distance (km)
TRP - trip odometer
CLK - time announcement
Instrument lights
3 Right and left direction indicator green
4 Change-over gear Neutral (N) green
5 Speedomter light
Speedometer time adjustment
Botton B press once
the clock (CLK) appears
the time can be set.
Botton B press once the hour signal is
flashing
set the hours by pressing botton
A.
Botton B press once the minute signal is
flashing
set the minutes by pressing
botton A.
Botton B press once the time is set
and ( : ) is flashing.
Speedometer set-up
Botton A press once
set-up from odometer
(DST) to trip odometer (TRP)
or
Botton A press once
set-up from trip odometer (TRP)
to clock (CLK)
or
Botton A press once
set-up from clock (CLK) to odo-
meter (DST)
SFM 649 058.1
4
SUMMARY AND OPERATION
Speedometer battery change
NOTE
If there is no reading on the display or very
poor change the batteries. Always replace
both batteries.
Remove the speedometer for battery
change.
- Remove the screws (1) and take off the
speedometer.
- Remove the batteries (4) and replace
against new once, type AG 13.
- Set-in the batteries with the plus terminal showing upwards.
- Close the cover (3) properly.
NOTE
The batteries must be changed within 30
seconds, so that the odometer memory is
not deleted.
DISPOSAL
Take a dead battery to a collection point.
Never dispose of one with household
refuse.
- Remove the screws (2) and take off the
cover (3).
Conversion of kilometer to miles
In order to change the speedometer from
kilometer to miles, the key (5) must be
pressed approximately 2 seconds with a
ball-point pen.
10 11
SUMMARY AND OPERATION
Checklist
Before each ride, carry out a safety
check using the checklist.
Take the safety check seriously. Carry
out maintenance activities before you
start your ride ( MAINTENANCE) or
ask a specialized Sachs dealer to do so.
This will provide you with the certainty
th at your motorcycle cor respond s to
traffic regulations. A technically faultless
motorcycle is a basic requirement for the
safety of both yourself and other road
users.
Be for e star ti ng your ride, check the
following:
– Steering (smooth and free of play)
– Clutch lever play
– Fuel quantity
– Engine oil (level)
– Front brake
– Rear brake
– Tyres (profile and pressure)
– Telescopic fork
– Load / lights
– Total weight
– Lights
– Clutch (operation)
– Brake fluid (level)
– Brakes (operation)
In case of problems or difficulties, contact
a Sachs dealer, who will do everything
possible to assist you.
WARNING
While the engine is running or the
ignition is on, do not touch the ignition
system.
FIRE HAZARD
The exhaust system becomes very hot.
While riding, idling or parking, make sure
that no inammable materials (e.g. hay,
leaves, grass, coverings or luggage, etc.)
can come into contact with it!
SAFETY TEST
Important notes for the operation with
a catalyst.
The catalyst. is designed for a optimal
pe rfo r manc e an d li fet ime.Note the
following:
- Operate a catalyst. bike only with lead
free fuel.
- Don’t turn off the ignition if the bike still
rolls.
- Don’t drive on at misfiring, decline in
performance and poor engine run.
- In case of problems, contact the next
Sachs dealer.
- Longer starting tests by moving the bike
in cold or warm operating state should be
refrained.
At the mentioned operating states unburned
fuel can reach the catalyst., burn and cause
overheating of the exhaust system.
2
1
3
A
SFM 649 016.1
SAFETY TEST
Clutch
Clutch lever play
CAUTION
If you drive with no clutch lever play, the
clutch will be damaged.
Checks:
- Pull the lever until there is discernable
resistance.
- Measure the play. Required value:
A = min. 3-4 mm
Adjustment:
- Remove the rubber cap (1).
- Release the lock nut (2).
- Turn setting screw (3) as appropriate.
- Tighten up the lock nut (2).
- Check the play.
If this adjustment is not sufficient, adjust
by turning the setting screw at the other
end of the clutch cable in the direction of
the engine
MAINTENANCE.
12 13
SFM 649 007.1
1
2
SFM 649 011.1
3
SAFETY TEST
Fuel
WARNING
Fuel is highly inflammable and can
explode. Do not smoke or bring a naked
ame near the fuel tank.
Tank cap (1)
NOTE
For opening the tank cap (1) only insert the
ignition key (3) and do not turn. Open by
using the cover (2).
The fuel-tank cap (1) is designed to allow
for ventilation. Do not make any changes
to the cap.
Opening:
- Tilt up the cover (2) in the direction of the
arrow.
- Insert the ignition key (3), turn the cover
(2) to the left and open the tank cap (1).
Closing:
- Close the tank cap (1) by turing the cover
(2) to the right and pull out the ignition
key.
RES
OFF
ON
SFM 649 010.1
4
SFM 649 063.1
OFF
RES
ON
SAFETY TEST
Fuel
CAUTION
When you stop the engine, always set
the fuel cock to OFF. Otherwise, fuel
could enter the engine and this could
make starting difcult or lead to serious
engine damage.
We cannot be held liable under the
guarantee for damage caused by nonobservance of this caution.
Fuel cock (4)
Fuel cock positions:
ON = OPEN
fuel tank will empty down to a
reserve quantity of approx.
0,35 litres
RES = RESERVE
fuel tank is drained. There is a
remaining quantity which can
not be used.
OFF = CLOSED
fuel supply closed.
WARNING
Fuel expands under the inuence of heat
and the sun. Therefore, never ll the tank
to the brim. Never ll the tank while the
engine is running.
Never bring a glowing cigarette or naked
ame near an open tank, because fuel
vapour could suddenly ignite.
Checking the fuel level
- Open the tank cap (1) on the fuel tank.
- Visually inspect the fuel level.
- Close the tank cap (1) on the fuel tank.
Filling up with fuel
- Use only normal lead-free fuel (min. 91
octane)
14 15
MAX.
MIN.
SFM 649 005.1SFM 649 006.1
1
SAFETY TEST
Engine oil
Checking the oil level
CAUTION
Checking the oil while the engine is cold
will lead to a wrong measurement and
therefore the wrong oil quantity. In order
to avoid engine damage, never exceed
the maximum oil level nor let it drop
below the minimum level.
- Stop the wa r med-up engi ne, wait
for approx. 5 minutes and hold the
motorcycle upright.
NOTE
Make sure that the motorcycle during oillevel checks stands level in all respects.
Even the slightest inclination towards the
side will produce measurement errors.
- Stop the engine and remove the oil
filler cap (1) on the lower right of the
crankcase.
- Clean the oil filler cap at the MIN-MAX
aera with a clean rag.
CAUTION
For checking the oil level only insert the
oil ller cap and don't screw in!
Ot herwi se ther e wi ll be a wrong
measurement in order to avoid engine
damage.
- The oil level must be bet ween the
minimum and maximum marks.
If required, replenish the engine oil SAE
15W/40 via the oil-filler opening of the oil
filler cap.
- Tighten the oil filler cap by hand.
SAFETY TEST
Engine oil
CAUTION
Do not use additives. Since the oil
also serves to lubricate the clutch, do
not use car engine oils supplemented
with friction modiers (such energyco nserv ing oils ca n le ad to the
clutch slipping). Use a suitable, light
engine oil for motorcycles, such as
Motorex SAE 15W/40 mineral oil API (SG
or higher).
- If required, replenish the engine oil
(for classification and viscosity, see
the table) via the oil-filler openi ng
up to the maximum level marki ng.
Engine oil:
Recommended grade:
Per API: SG or higher or also with additional
release status: ACEA A3/96 (CCMC G5).
Recommended viscosity:
Vi scosity depends on the outside
te mperatur e. For short while, th e
temperature may exceed or fall short of
the limits of the SAE grades.
The recommended viscosity grade SAE
15W/40 covers the ambient temperature
range –15 °C to +40 °C and therefore
represents the optimum for our latitudes.
16 17
MAX.
MIN.
SFM 649 022.1
SAFETY TEST
Front brake
WARNING
Sudden changes in play or a spongy feel
of the brake lever can be caused by faults
in the hydraulic system. Do not ride on
when in doubt about the operability of
the brake system. Immediately consult
a Sachs dealer.
Check the brake-uid level
WARNING
Every two years, the brake uid must
be changed by a Sachs dealer. The
level must not drop below the MIN
mark. Use only brake uid of the DOT 4
classication.
- Turn the handlebars until the brake-fluid
tank is level.
- The sight glass must be fully covered with
brake fluid.
- If air bubbles can be seen, check the
brake linings for wear; if necessary,
replenish the brake fluid.
CAUTION
Do not spill any brake uid on painted
or plastic surfaces as it will demage the
surface severely.
Checking the brake linings
WARNING
The brake disks and brake linings must
be free of oil and grease.
Brake lini ngs are sub ject to we ar.
In order to guarantee the operability of the
brake system, the wear limits of the brake
linings must not have been reached.
Checking the brake linings:
MAINTENANCE
1
20 mm
SFM 649 035.1
SAFETY TEST
Rear brake
WARNING
Check the play of the footbrake lever (1)
before riding.
Target value 20 mm.
Adjusting the footbrake lever play:
MAINTENANCE
Checking the brake linings
WARNING
The brake disks and brake linings must
be free of oil and grease.
Brake lini ngs are sub ject to we ar.
In order to guarantee the operability of the
brake system, the wear limits of the brake
linings must not have been reached.
Checking the brake linings:
MAINTENANCE
18 19
SFM 649 009.1
30 - 35 mm
A
SAFETY TEST
Drive chain
CAUTION
The chain setting affects the wear on the
drive chain and sprocket as well as the
spring excursion of the rear wheel.
Regularly clean and lubricate the drive
chain.
Check the chain setting and the drive
chain for damage before each run.
Check the chain tension
- Shift the gear to neutral.
- Prop the motorbike up on the side
stand.
- Let the motorbike rear end drop to the
limit imposed by the suspension.
- Push in the drive chain from the top half
way between the sprocket and pinion.
Measure the travel.
Required value: A =30-35 mm
- Adjust the drive chain is necessary.
MAINTENANCE
SFM 649 008.1
1
2
SAFETY TEST
Checking the tyre proles
WARNING
Observe the minimum profile depth
prescribed by law.
- Measure the profile depth at the centre
(1) of the tyre’s tread.
Recommended minimum profile depth:
Front 2.0 mm
Rear 2.5 mm
Checking the tyre pressure
WARNING
Adjust the tyre pressure according to
the total weight load. Never exceed the
rated total weight or the bearing capacity
of the tyres.
Incorrect tyre pressure will have a considerable effect on the riding properties
of the motorbike and the lifespan of the
tyres.
Tyre prole, tyre pressure and size
WARNING
Never ride without valve caps. Firmly
tightened valve caps prevent the tyre
from suddenly losing pressure.
- While the tyres are cold:
- Twist off the valve caps.
- Check/adjust the tyre pressure.
- Twist on the valve caps.
Tyre pressure Solo With
passenger
Front 2.0 bar 2.2 bar
Rear 2,5 bar 2.7 bar
Tyre size
The standard motorbike is provided with the
following tyre sizes:
Front 90/90-16 48J
Rear 120/80-16 60J
WARNING
Us e only t yres a pproved by the
manufacturer. The use of non-approved
tyre brands, types or sizes leads to the
operating permit of the vehicle becoming
null and void. Use only pairs of tyres
produced by the same manufacturer.
TECHNICAL DATA
20 21
SAFETY TEST
Load / lights
WARNING
For the sake of your safety, use only
original Sachs accessories or products
released by Sachs.
Sachs cannot judge for each third-part
product whether it can be safely used in
combination with your Sachs motorcycle.
Nor can a official approval give such a
guarantee in all cases, since the test scope
is not always sufficient.
NOTE
Sachs accessories and Sachs-approved
products as well as qualified advice are
available from all specialized Sachs dealers.
Correctly loaded
- Make sure that the left-right weight
distribution is balanced.
- Check that fastenings are correct and
tight.
- Do not transport bulky loads.
- Do not cover the lights.
WARNING
The total allowable weight of 280 kg may
not be exceeded.
Adjust the telescopic forks and tyre
pressures to the total weight.
Checking the lights
WARNING
Before any ride, check the operation of
all lighting components.
- Check that the headlamps and lenses are
clean.
Adjusting the headlamps
MAINTENANCE.
RIDING INSTRUCTIONS
Ride safely
CAUTION
Riding safety is largely also determined
by the manner of riding.
Therefore:
– Put on a tested/approved safety helmet
and correct close the buckle.
– Wear suitable protective clothes.
– Rest your feet on the footrests.
– Do not ride if your riding ability has been
compromised.
On smooth, slippery roads take into account
that your riding stability and braking power
are limited by the grip of the tyres on the
road top.
Your reactions can be adversely affected
not only by alcohol, but also by drugs and
medicines.
– Strictly observe all traffic regulations.
– Always adapt your riding speed to the
traffic and road conditions.
22 23
RIDING INSTRUCTIONS
Ride economically and be aware of the environment
Fuel consumption, environmental pollution
and wear of engine, brakes and tyres depend on various factors.
Your personal riding style is highly determinant for economical fuel consumption
and exhaust gas and noise generation.
While idling, the engine takes a long time
to warm up to operational temperature. In
the warm-up phase, however, the wear level
and pollutant emissions are very high. It is
therefore best to start riding immediately
after start-up.
Unnecessary acceleration and hard
braking cause high fuel consumption
and increased pollution levels.
Turn the engine off when waiting in traffic.
Different riding conditions affect fuel consumption. The following conditions are
unfavourable for fuel consumption:
– High traffic density, especially in big cities
with many stops for traffic lights.
– Frequent short rides with repeated starts
and warm-ups of the engine.
– Riding in a column of motor cycles at low
speed, meaning riding with relatively high
revs.
Plan rides ahead of time in order to avoid
heavy traffic.
Avoid rapid acceleration
Open the throttle not further than needed,
in order to reduce fuel consumption as well
as pollution and wear levels.
Do not use excessive revs; change up as
soon as possible and do not change down
until it is necessary to do so.
Ride as evenly as possible and look
ahead as far as possible.
Unnecessary acceleration and braking operations must be paid for with a high fuel
consumption and a higher environmental
burden.
RIDING INSTRUCTIONS
Ride economically and be aware of the environment
Fuel consumption is also affected by
conditions that are out of your control, for
instance, poor road condition, hills, riding
in winter.
Observe the following aspects for economical fuel consumption:
– The planned inspection intervals must be
closely observed.
– Regular service by a specialized Sachs
dealer will guarantee not only continued
operability, but also economical fuel
consumption, low environmental pollution and a long lifespan.
– Check the tyre pressure every two
weeks.
Low ty re pressu re increases rolling
resistance. This increases fuel consumption
and tyre wear and adversely affects riding
behaviour.
– Continually check fuel consumption.
– Frequently check the engine-oil level.
24 25
RIDING INSTRUCTIONS
Running-in
Running-in instructions for engine
and transmission
CAUTION
Excessive revs while running-in the
engine increases the wear of the engine.
Engine faults during the running-in
period must be immediately reported to
a specialized Sachs dealer.
NOTE
During the running-in per iod , rid e in
frequently changing load and rpm ranges.
Select winding and slightly hilly routes.
Avoid constantly low rpm counts and full
throttle under load.
Maximum speed of the gears during
running-in period:
Kilometer
km/h of each
gear
1. 2. 3. 4.
0-500 18 28 35 40
500-1000 25 35 40 45
Slowly increase the rpm. Avoid high rpm
running until 1000 km.
CAUTION
The rst inspection must be carried out
immediately after the rst 1000 km.
You can save yourself delays by making
an appointment with a specialized Sachs
dealer in advance.
Running-in new tyres
CAUTION
New tyre s have a smo oth sur face.
They must therefore be roughened by
carefully running them in at various
slanted positions.
Only then will the surface obtain its full
grip!
Running-in new brake linings
WARNING
New brake linings must be run-in and
will not have their full friction power until
after 500 km.
The slightly reduced braking effect can
be compensated for by an increase in
the pressure on the brake lever.
During this period, avoid unnecessary
hard braking actions!
SFM 649 049.1
RIDING INSTRUCTIONS
Side stand
Propping up the motorbike on the side
stand.
WARNING
Always make sure that the stand is
resting on rm ground. On sloping roads,
always park the motorbike facing uphill
and in 1st gear. When you kick the stand
in, do not stand within the pivoting arc
of the stand.
The stand pivots automatically upwards
with considerable momentum. It is
essential that the side stand is folded
up before starting off!
-Risk of accidents !
- Switch off the engine.
- Left hand on the left-hand handlebargrip.
- Right hand on the seat.
- Fold out the side side stand as far forward
as it will go and stop by foot.
- Slowly tilt the motorbike to the left until its
weight is supported.
26 27
2
SFM 649 015.1
SFM 649 003.1
3
RES
OFF
ON
SFM 649 010.1
1
RIDING INSTRUCTIONS
Before starting
- Put the motorcycle it in a vertical position
and allow the side standard to tilt up.
- Turn the fuel chock (1) to ON or RES.
- Mount the motorcycle.
- Turn the ignition key (2) to its operating
position .
WARNING
Before beginning a ride, the side stand
must be tilted up all the way (danger of
crashing).
Starting
- Shift the foot-operated gear lever (3) to
neutral.
NOTE
Once you have shifted to neutral, the green
neutral indicator light must become active.
SFM 649 018.1
2
3
SFM 649 031.1
SFM 649 017.1
A
B
1
RIDING INSTRUCTIONS
Starting with kick starter
CAUTION
Avoid high engine-speed counts after
a cold start.
- Turn the CHOKE (1) in the direction
of the arrow "A" for cold start.
- Do not open the throttle.
- Push down the EMERGE NCY- OFF
switch (2) to position .
- Depress the kick starter lever (3) quickly
and the engine will start.
CAUTION
After starting the engine, check that
the kick starter lever is returned to its
normal position.
- As soon as the engine is no longer
running smoothly, turn back the CHOKE
(1) one lock in position "B".
WARNING
Never allow the engine to run in an enclosed space. Exhaust gases are highly
toxic and can kill.
NOTE
The EMERGENCY OFF switch is a safety
device and should normally be in position
.
ON:
Switch downwards. The engine will start
when the kick starter lever is used.
OFF:
Switch upwards. The engine will not start.
28 29
SFM 649 018.1
2
3
SFM 649 017.1
1
A B
RIDING INSTRUCTIONS
Starting with electric starter
CAUTION
Avoid high engine-speed counts after
a cold start.
- Turn the CHOKE (1) in the direction
of the arrow "A" for cold start.
- Do not open the throttle.
- Push down the EMERGE NCY- OFF
switch (2) to position .
- Operate the start button (3).
CAUTION
If the engine won’t start immediately,
release the start button, wait a few
seconds and push it again. Each time,
push the start button for just a few
seconds in order to save the battery.
Never push the start button for more
than 10 seconds.
- When the operating temperature is
increasing, turn back the CHOKE (1)
all the way in the opposite direction to the
arrow "B".
WARNING
Never allow the engine to run in an
enclosed space. Exhaust gases are
highly toxic and can kill.
NOTE
The EMERGENCY OFF switch is a safety
device and should normally be in position
.
ON:
Switch downwards. The engine will start
when the electric starter is used.
OFF:
Switch upwards. The engine will not start.
Riding, shifting gears
RIDING INSTRUCTIONS
CAUTION
Avoid:
– Crashing the gears
– Changing gear without operating the
clutch
– Changing down at high rpm's
– Too low and too high rpms
(unnecessary wear and fuel
consumption).
Starting / shifting up
- Pull in the clutch lever
- Push down on the foot-operated gear
lever (without opening the throttle)
- Carefully engage the clutch
- Simultaneously slightly open the throttle
- Accelerate after engaging the clutch.
Shifting up to gears 2, 3 and 4 is done
similarly.
Shifting down
- Close the throttle
- Pull in the clutch lever
- Push down on the foot-operated gear
lever
- Accelerate after engaging the clutch
- When stopping, change into neutral
(control light N in cockpit lights green).
30 31
RIDING INSTRUCTIONS
Braking
Oil and grease
WARNING
The brake discs and linings must be free
of oil and grease!
WARNING
If the motorcycle is not used for a while,
a rust lm may form on the brakes and
thus increase the braking effect. A thick
rust lm can cause the brakes to lock
up. When setting out on a ride after a
long lay-up period, carefully operate
the brakes several times until they work
normally.
NOTE
Ma ke sure you practice braking for
emergency situations, but do so where you
will not pose a risk to yourself or others (e.g.
a deserted parking area).
WARNING
Operate the brakes to grind off the salt
deposited on the brake discs.
Dirty brakes
When riding on dirty streets, the braking
effect can be delayed due to dirty brake
discs and linings.
WARNING
Op erate th e brake s until th ey are
clean. Lining wear is increased by dirty
brakes!
Wet brakes
Washing the motorcycle or riding through
water or rain can delay the braking effect
due to wet or (in winter) ice-covered brake
discs and linings.
WARNING
The brakes must rst be operated until
they are dry
Salt lm on the brakes
When riding on salted streets without
braking for a while, the full braking effect
may be delayed.
SFM 649 019.1
1
SFM 649 035.1
2
RIDING INSTRUCTIONS
Braking
Braking
The front brake and rear brake are operated
independently from each other. The front
brake is operated via the handbrake lever
(1) on the handlebars, and the rear brake is
operated by stepping on the footbrake lever
(2) with the right foot.
When stopping or slowing down, release
the throttle gas and operate
both brakes
at the same time.
On tight curves, sandy / dirty streets, wet
asphalt and icy roads, use the front brake
carefully: if the front wheel locks, the bike
will slide sideways.
Brake with care. Locked wheels do not have
much braking effect and can lead to skid
ding / crashing. In principle, do not brake
on a curve, but before the curve.
Braking on a curve increases the danger
of sliding.
32 33
1
SFM 649 015.1
SFM 649 021.1
3
RES
OFF
ON
SFM 649 010.1
2
RIDING INSTRUCTIONS
Stopping the engine
- Turn the ignition key to the position
(1).
- Pull out the ignition key.
CAUTION
Turn the fuel chock (2) to th e OFF
position. In the ON or RES position,
fuel could enter the engine, leading
to serious damage when starting the
engine.
Non-observance of this caution will lead
to the guarantee becoming null and void
for any damage attributable to such.
Stopping the engine
Fork- column Lock
Safeguard the steering assembly against
unauthorized use.
Locking:
- Turn handlebars to extreme left.
- Insert key (3) in lock and turn in clockwise
direction.
- Remove key.
Unlocking:
- Insert key (3) in lock and turn in
counterclockwise direction.
- Remove key.
CAUTION
Al way s remove the k ey before
travelling.
SERVICE INSTRUCTIONS
Servicing the motorbike / cleaning agents
NOTE
Regular, expert service will help maintain
the value of your motorcycle and is a
condition for guarantee claims for corrosion
and other such damage.
CAUTION
Rubber and plastic parts will be damaged by caustic or penetrating cleaning
agents or solvents.
WARNING
Always carry out a brake test after
cleaning and before starting a ride!
CAUTION
Do not use steam or high-pressure jet
devices!
Such devices can damage seals, the
hydrau lic br akin g syst em and the
electrical system.
34 35
SERVICE INSTRUCTIONS
Servicing the motorbike / cleaning agents
Cleaning
- To wash the motorcycle, use a soft
sponge and clean water.
- Afterwards, dry off with a polishing cloth
or chamois.
- Do not wipe off dust or dirt with a dry
cloth, to avoid scratching the paint or
covering.
Preservation agents
When necessary, the motorcycle must
be preserved with commercially available
preserving and cleaning agents.
- By way of precaution (especially in
winter), regularly treat parts liable to
corrosion with preservation agents.
CAUTION
Never use paint-polishing agents on
plastic parts.
- After a longish ride, thoroughly clean the
chassis and the aluminium parts and
preserve them with a commercially
available anti-corrosion agent.
SERVICE INSTRUCTIONS
Operation in winter and anti-corrosion protection
Winter operation / anti-corrosion
protection
Use of the motorcycle in the winter can
cause considerable damage due to the
presence of salt on the roads.
NOTE
Protect the environment by using only environmentally friendly preservation agents,
and use them frugally.
CAUTION
Do not use hot water, which would increase the effect of the salt.
- At the end of each ride, wa sh th e
motorcycle with cold water.
- Thoroughly dry the motorcycle.
- Treat parts liable to corrosion with wax-
borne anti-corrosion agents.
36 37
SERVICE INSTRUCTIONS
Repairing paint damage / servicing the tyres
Repairing paint damage
Minor paint damage should be immediately
repaired. Major damage must be repaired
by a Sachs dealer.
Servicing tyres
If the motorcycle is not used for a longer
period, it is recommended to support the
motorcycle so that its weight is not on the
tyres.
You can prevent the tyres from becoming
dry and brittle by spraying them with a
silicone-rubber treatment. First thoroughly
clean the tyres.
Do not store the motorcycle or the tyres
in hot spaces (such as a boiler room) for
longer periods.
WARNING
A m inimum ty re-p rof ile de pth o f
2. 0 mm mu st be ma inta ined at all
times.
SERVICE INSTRUCTIONS
Lay-up / commission
Lay-up
- Clean the motorcycle.
- Remove the battery.
Observe the maintenance instructions.
- Spray suitable lubricants onto the brakelever and clutch-lever joints and the sidestandard and main-standard bearings.
- Rub bright / chromium-plated parts with
acid-free grease (Vaseline).
- Store the motorcycle in a dry room and
jack it up so that its weight is not on the
wheels.
Commission
- Remove the preservation agents from the
outside
- Clean the motorcycle.
- Install the charged battery.
- Preserve the battery ter minals with
terminal grease.
- Check / adjust the tyre pressure .
- Check the brakes.
- Carry out activities according to the
inspection plan.
- Carry out the safety checks.
NOTE
Before laying up the motorcycle, have a
Sachs dealer change the engine oil.
Combine lay-up / commission activities with
an inspection by a Sachs dealer.
38 39
SERVICE INSTRUCTIONS
Technical changes, accessories and spare parts
WARNING
Technical changes to the motorcycle can
lead to cancellation of the EC operating
license.
Sh ould you want to make techni cal
changes, observe our guidelines. This will
serve to prevent the motorcycle from being
damaged and the traffic and operational
safety being retained. A specialised Sachs
dealer can carry out these activities with
meticulous care.
Always consult a Sachs dealer before buying accessories or making any technical
changes.
CAUTION
We recommend using only approved
Sachs accessories and original Sachs
spare parts for Sachs motorcycles.
Th is is in you r own inter ests : th e
sa fet y, suit abi lity and reli ability of
these accessories and parts will have
be en tested sp eci fic ally for Sachs
motorcycles.
Although we keep track of the market, we
cannot evaluate nor be held liable for the
quality of non-approved accessories and
parts, even if they have a certicate of
acceptance from an ofcially recognised
technical testing/supervision agency, or
a license issued by the authorities.
For approved Sachs accessories and original Sachs spare parts, see a specialised
Sachs dealer.
He will also ensure that they are professionally installed.
MAINTENANCE
Maintenance activities
Before carrying out any maintenance
activities, read the relevant section of
this operating manual.
- Checking the fork-column bearing
- Removing the front wheel
- Installing the front wheel
- Removing the rear wheel
- Installing the rear wheel
- Checking , adjusting the drive chain
- Front brake
- Rear brake
- Adjusting the clutch lever play
- Spark plug
- Battery, fuse
- Replacing bulbs
- Adjusting the headlamps
40 41
SFM 649 048.1
MAINTENANCE
Checking the fork-column bearings
NOTE
The telescopic fork must not stick when
turned, and at both limit positions it must
easily tilt back.
- Jack up the machi ne on a st urdy
installation jack.
- Take hold of the lower fork tubes and try
to move them to and fro in the direction
of the arrow.
If the fork-column bearing shows noticeable
play, it must be adjusted by a specialised
Sachs dealer.
SFM 649 026.1
1
SFM 649 027.1
2
3
MAINTENANCE
Removing the front wheel
CAUTION
Take care not to damage the brake discs
and linings while removing them.
Do not operate the handbrake lever after
the wheel has been removed.
Protect the wheel bearings from dirt and
moisture.
- Support the motorcycle so that the front
wheel can move freely and the motorcycle
is standing securely.
- Loosen the axle nut (1).
- Lift the front wheel and pull out the fullfloating axle (2) and remove the spacer
bush (3).
- Remove the front wheel downwards.
42 43
SFM 649 027.1
2
3
1
SFM 649 026.1
4
MAINTENANCE
Installing the front wheel
CAUTION
Take care not to damage the brake
discs and linings (4) while installing
them. Have a Sachs dealer check the
tightening torques.
- Roll the front wheel in between the fork
tubes and insert the spacer bush (3)
(on the right as seen from the riding
direction).
- Grease the full floating axle (2) and push
it in from the right as far as it will go.
- Attach the axle nut (1) and screw tight.
- Before tightening the screws, stand the
motorbike on its wheels and push the
telescopic forks several times to prevent
twisting of the fork struts.
Torque
Axle nut (1): 35-45 Nm
SFM 649 030.1
4
2
5
SFM 649 029.1
3
1
2
MAINTENANCE
Removing the rear wheel
CAUTION
Do not damage brake disc and linings
during removal!
Protect the wheel bearings from dirt and
moisture!
NOTE
When taking off the rear wheel, make sure
that the bush (3) to the left of the wheel
hub is not lost.
- Raise the rear wheel, remove the full
floating axle (1) with brake support (5)
and brake caliper and take off the rear
wheel to the back.
- Prop up the motorbike so that the rear
wheel can turn freely and that the
motorbike is secure.
- Hold the full floating axle (1) and release
the axle nut (4).
- Unscrew the setting nuts (2) on the left
and right-hand sides of the chain adjuster
all the way.
- Remove the drive chain.
44 45
5
7
2
4
SFM 649 032.1 SFM 649 030.1
4
2
5
SFM 649 029.1
3
1
2
6
MAINTENANCE
Installing the rear wheel
CAUTION
Do not damage brake disc and linings
during installation!
Have a Sachs dealer check the tightening
torques.
- Clean and grease the full floating axle
(1).
- Introduce full floating axle, chain adjuster
(2), brake support (5) with brake caliper
into rear suspension
- Adjust the drive chain (s. adjusting drive
chain page 45).
- Tighten axle nut (4).
Torque
Axle nut (4): 50-60 Nm
NOTE
Insert brake support into the guide (7) of
rear suspension.
- Install the drive chain (6).
- Install rear wheel with spacer bush (3)
and full floating axle (1).
- Inse r t l eft chain adjuster (2) and
reassemble with axle nut (4).
SFM 649 033.1
1
2
3
30 - 35 mm
A
4
MAINTENANCE
Checking, adjusting the drive chain
- Release the axle nut (4).
- Evenly adjust the setting nuts (3) on both
sides of the chain adjuster (rear wheel
must be aligned with the front wheel).
- Let the motorbike rear end drop to the
limit imposed by the suspension.
- Push in the drive chain from the top half
way between the sprocket and pinion.
Measure the travel.
Required value: A =30-35 mm
- Tightening lock nuts (3).
Torque
Axle nut (2): 50-60 Nm
Checking the chain for wear
CAUTION
The chain, sprocket and pinion must be
changed as a single unit.
- Prop the motorbike up on the side
stand.
- Take hold of the chain (1) at the point on
the sprocket furthest to the rear and pull
the chain off.
- When the chain tension is correct, it should
not be possible to raise the chain further
than the height of the sprocket teeth.
- If the chain can be pulled further away,
have the chain, sprocket and pinion
replaced by your Sachs dealer.
Adjusting the chain
CAUTION
How the chain is adjusted affects the
rate of wear on the chain and sprocket. It
is essential to have the tightening torques
checked by a Sachs dealer.
A too tight adjustment of the chain will
cause bearing- damages on engine
and rear wheel. The chain will wear out
sooner.
46 47
SFM 649 014.1
SFM 649 047.1
3
4
MAINTENANCE
Checking the brake linings
CAUTION
The minimum lining thickness must be
maintained.
NOTE
For your own safety, we recommend having
activities to the brake system carried out by
a Sachs dealer.
Front brake
- Visually inspect the brake calliper (1).
- Check the thickness of the brake lining:
minimum thickness: A = 2,5 mm
- If the lining thickness is below the minimum, have the brake lining (2) replaced
by a Sachs dealer.
Brake light switch
NOTE
The brake light switch (3) is placed in the
hand brake lever.
By operating the front brake lever (4) the
brake light must flash up immediately.
An adjustment is not required.
SFM 649 034.1
MAINTENANCE
Rear brake
Checking the brake linings
CAUTION
The minimum lining thickness must be
maintained.
NOTE
For your own safety, we recommend having
activities to the brake system carried out by
a Sachs dealer.
- Visually inspect the brake calliper (1) on
the right motorbike side.
- Check the thickness of the brake lining:
minimum thickness: A = 1,5 mm
- If the lining thickness is below the mini-
mum, have the brake lining (2) replaced
by a Sachs dealer.
48 49
1
2
3
20 mm
SFM 649 035.1
SFM 649 052.1
7
6
SFM 649 036.1
4
5
MAINTENANCE
Setting the footbrake pedal position
NOTE
The footbrake pedal position can be adjusted
with the setting screw (1).
- Release the lock nut (2).
- Adjust the foot brake pedal (3) position
with the setting screw (1).
WARNING
Check the play on the footbrake pedal
and ensure that the brake is functioning
properly.
Rear brake
Adjusting the foot brake
NOTE
After a longer period of operation, adjustment
of the brakes is essential due to natural wear
of the brake-shoe linings.
- Release the lock nut (4) so that the pedal
(3) has reached a guideline of approx.
20 mm.
CAUTION
Insuf cient play on the brake lever may
cause the rear wheel brake to drag when
jouncing. Have adjustment checked by
a Sachs dealer.
Adjusting the brake light switch
NOTE
By correct adjustment of the brake light
switch (6) the brake light must flash up
immediately.
Adjustment
- Release the lock nuts (7) and adjust the
brake light switch.
- Thighten up the lock nuts.
2
1
3
A
SFM 649 016.1
SFM 649 038.1
4 4
5
SFM 649 037.1
7 6
MAINTENANCE
Adjusting the clutch lever play
CAUTION
If you drive with no clutch lever play, the
clutch will be damaged.
Check:
- Pull the lever until there is discernable
resistance.
- Measure the play. Required value:
A = min. 3-4 mm
Adjustment:
- Push back protective cap (1).
- Release the lock nut (2).
- Turn setting screw (3) as appropriate.
- Tighten up the lock nut (2).
- Check the play.
NOTE
If the clutch play cannot be corrected with
this adjustment, the following adjustment
must be made.
- Release the lock nut (2).
- Tighten setting screw (3) all the way, so
that the clutch cable can be made as slack
as possible.
- Tighten up the lock nut (2).
- Remove screws (4) and take off the clutch
cover (5).
- Release the lock nut (6).
- Adjust the setting screw (7) until the
desired clutch lever play (A = 3-4 mm) is
reached.
- Tighten up the lock nut (6).
- Reassemble the clutch cover (5) with
gasket.
CAUTION
Have adjustment checked by a Sachs
dealer.
50 51
SFM 649 040.1
1
2
MAINTENANCE
Spark plug
Check and change
CAUTION
Check or change the spark plug only
when the engine is cold.
- Pull the spark plug connector (1).
- Unscrew the spark plug (2).
- Check the electrode gap (0,7-0,8 mm),
replace the plug if it is severely burnt
away.
- Insert new spark plug NGK CR7 HSA
and tighten up.
Torque 20 Nm.
- Plug in the connector (1).
SFM 649 042.1
3
SFM 649 041.1
2
2
1
MAINTENANCE
Fuse
CAUTION
Never install a fuse with a larger rating,
since this could destroy the entire elec
-
trical system.
The fuse is located behind the battery
cover (1).
NOTE
The spare fuse is placed in the fuse case.
Replace fuse
-
Remove three screws (2) and lift off cover
(1) to the left side.
- Open the fuse case (3).
-
A faulty or blown fuse must be replaced
by a new one with 15 A.
52 53
MAINTENANCE
Battery
WARNING
Always wear safety glasses.
Keep children away from acids and
batteries.
EXPLOSION DANGER
A battery being charged produces a
highly explosive gas, which is why re,
sparks, naked ames and smoking are
prohibited.
FIRE HAZARD
Avoid generating sparks and electrostatic
discharges when handling cables and electrical devices.
Avoid short circuits.
DANGER - CAUSTIC ACTION
Battery acid is highly caustic, so always
wear safety gloves and glasses.
Do not tilt the battery as acid can leak
from the ventilation openings.
FIRST AID
If acid comes into contact with an eye,
immediately flush the eye for several
minutes with fresh water. Then immediately
visit / call a doctor.
Acid on the skin or clothing must immediately
be neutralised using acid converter or soap
suds, and the spots must be flushed with
plenty of water.
If acid is swallowed, immediately visit / call
a doctor.
CAUTION
Do no t expos e batte ries to dir ect
su nli ght. Di sch arg ed ba tteries can
freeze, so they must be stored in a
place where the temperature remains
above 0 °C.
Professional maintenance, charging
and storage will increase the lifespan
of the battery and are a condition for
the honouring of guarantee claims.
DISPOSAL
Take a dead battery to a collection point.
Never dispose of one with household
refuse.
Charging the battery
After a long lay-up (3-4 months), charge the
battery. The charging current (in amperes)
must not exceed 1/10th of the battery
capacity (Ah).
The battery must not be fast-charged. The
battery may only be charged using a special
charger approved for MF batteries.
Maintenance
Although the battery is maintenance-free.
Never leave the battery discharged. Keep
the battery clean and dry and make sure
that the connection terminals are firmly
seated.
SFM 649 036.1
4
1
1
2
SFM 649 060.1
3
5
5
2
SFM 649 041.1
MAINTENANCE
Rem oving a nd insta l ling the
battery
CAUTION
For removing the battery hang out the
brake rod (1) and remove the splint pin
behind the srew (4). For installing use
a new splint pin. For reasons of safety,
the work should be done by a Sachs
dealer.
The Battery is located behind the cover
(2).
CAUTION
The battery may only be connected
or disconnected while the ignition is
inactive.
First disconnect the minus terminal
(black cable). When in stall ing the bat tery, rst connect the plus terminal (red
cable). The battery is main te nance-free.
Do not try to open it.
Battery
- Remove the screw (4) with the splint pin
and hang out the brake rod (1).
- Remove three screws (5) and lift off cover
(2) to the left side.
- Remove the battery band (3) and uninstall
the battery.
- Assemble in reverse order.
CAUTION
Tighten screw (4) and lock with a new
split pin.
54 55
SFM 649 046.1
5
6
7
SFM 649 044.1
3
1
2
4
MAINTENANCE
Changing the bulbs
NOTE
Use only tested, incandescent bulbs with
the ‘E’ designation. Use of non-approved
bulbs will void the operating license. Do
not touch the bulbs with bare fingers. Hold
bulbs with a clean, dry cloth when installing
or removing them.
Headlight
1 = low beam
bulb S3 12V 15W E9
2 = low beam
bulb S3 12V 15W E9
3 = Position light
bulb 12V/3W
- Remove the screws (4) on both sides.
- Detach the rubber cover (5) from the
headlight.
- Release the holder clamp (6) and remove
the bulb (7).
- Pull the position light (3) with the bulb
holder carefully out of the headlight
housing and remove the bulb (7).
- Assemble in reverse order.
NOTE:
When assemble, bend the holder clamp (6)
for a safety contact.
3
SFM 649 045.1
2
SFM 649 043.1
1
MAINTENANCE
Tail / brake light bulb
The tail light is not fitted with a replaceable
light bulb (diode light).
If the tail light does not work you should
first check, whether a cable connection is
interrupted.
Tail / brake light bulb
- Push back the cable protection (2)
underneath the seat. Check the cable
connections (3) green/ yellow, green
and black.
If this is not the case, the tail light must be
replaced by a Sachs dealer.
56 57
5 3
SFM 649 053.1
SFM 649 061.1
2
3
4
SFM 649 054.1
2
3
SFM 649 055.1
1
MAINTENANCE
Changing the bulbs
Indicator lamps
NOTE
For changing the bulbs an opening of the
glass cover (1) is not required.
Do not touch the bulbs with your bare hands.
Use a clean, dry cloth for installation and
removal.
Front:
- Pull the light case (2) carefully out of the
handlebar and hold the thread bolt (3)
with a pair of pliers.
- Release the light case.
-
Push the bulb (5) back and release it by
turning to the left. Take the bulb out.
Rear:
- Release the nut (4) and hold the thread
bolt (3) with a pair of pliers.
-
Release the light case (2).
- Push the bulb (5) back and release it by
turning to the left. Take the bulb out.
- Install ation is i n reverse order to
removal.
-
Indicator bulbs front/rear:
12 V/21W
SFM 649 045.1
SFM 649 044.1
1
2
Adjusting the headlamps
Adjusting the headlight
- Activate the dipped beam.
- Use the adjusting screw (1 and 2) on
both sides to adjust the angle of the
asymmetrically illuminated surface area
of the road top.
- Release srews (1) and (2), adjust and
tighten up.
NOTE
If you have problems adjusting t he
headlamps, see a specialised Sachs dealer.
An incorrect adjustment is punishable by
law. Remember, you are responsible for
the correct adjustment of the motorbike’s
headlamp.
WARNING
Do not run the engine in an enclosed
space (risk of asphyxiation).
Position the motorcycle on a level floor 5
m (measured from the headlamp) from a
light coloured wall with a rider seated on
the motorcycle and the tyres filled at the
correct pressure.
- Measure the distance from the floor to
the centre of the headlamp and mark
the height on the wall with a cross. Draw
a second cross 12 cm beneath the first
cross.
- Start the moto rcycle and r u n the
engine.
MAINTENANCE
58 59
Type: FY139FMB
Construction: One cylinder 4-stroke petrol engine
Valve steering: 1 overhead cam with rocker arms
Valve: 2 valve
Valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm
Pistion displacement: 49,5 cm
3
Bore: ø 39 mm
Stroke: 41,4 mm
Compression ratio: 10:1
Lubrication system: forced oil lubrication
Cooling: air cooled
Maximum net power output: 2,0 kW at 7.000 1/min
Maximum net torque: 3,2 Nm at 4.300 1/min
Ignition system: transistorized ignition system with electronic ignition control (CDI)
Spark plug: NGK CR7 HSA electrode gap 0,7- 0,8 mm
Carburettor: Mikuni type VM 12 101 6
Air-filter: paper air-filter
Idle speed: 1.800 +/- 200 1/min
Typ of starter: electric starter / kick starter
TECHNICAL DATA
Engine
TECHNICAL DATA
Power transmission
Clutch: Wet multi-plate type
Gear box: 4-seed constant mesh, foot operated
Gear ratios: 1. gear = 36/11 (3,273)
2. gear = 31/16 (1,938)
3. gear = 27/20 (1,350)
4. gear = 24/23 (1,044)
Primary transmission ratio: 4,059
Chain pinion: 11 teeth
Sprocket: 53 teeth
Drive chain: 420
60 61
TECHNICAL DATA
Chassis
Motorbike version: Type 649
Frame: Center-type frame made of tubular steel
Front suspension: Telescopic fork ø 37 mm , hydraulic shock absorption, travel 100 mm
Rear suspension: Mono shock absorber, travel 65 mm
Wheels: Light metal (Alu)
Front rim size: = 1,85 x 16"
Rear rim size: = 2,50 x 16"
Tires: Front = 90/90-16 48J
Rear = 120/80-16 60J
Tire pressure, solo
pillion driver
Front = 2,0 rear = 2,5 bar
Front = 2,2 rear = 2,7 bar
Brakes, front:
Minumim lining thickness
Disc brake ø 260 mm, hydraulic two piston floating caliper
2,0 mm
Brakes, rear:
Minumim lining thickness
Disc brake ø 215 mm, mechanical two piston caliper
1,5 mm
TECHNICAL DATA
Lubricants and operating uids
Fuel tank capacity: 4,6 litres, including 0,35 litres reserve
Fuel: Unleaded fuel min. 91 octane
Telescopic-fork oil: Viscosity SAE 10 W
Filling quantity per fork tube: 180 cm
3
Engine oil:
Filling quantity:
SAE 15 W 40 mineral oil API (SG or higher)
800 cm3
Brake fluid: DOT 4
62 63
TECHNICAL DATA
Electrical Equipment
Generator: 12 V 80 W
Battery: 12 V 3 Ah MF
Fuse: 15 A
Lights:
- Headlight:
- Position light:
- Instrument lights:
- Brake/rear light:
- Turn signal light:
Low beam 2x 12V 15W
12 V 3W
Direction-indicator 12V 3W
Change over gear 12 V 3W
Cockpit 12 V 3W
12 V diode light
12V 21W
TECHNICAL DATA
Dimensions and weights
Overall length: 1830 mm
Width across handlebars
without rear view mirror:
780 mm
Maximum height: 1010 mm without rear view mirror
Wheel base: 1235 mm
Seat height: 865 mm
Weight empty: 85 kg
Weight in running order: 89,5 kg
Max. transport weight allowed: 190,5 kg
Max. permitted total weight: 280 kg
Top speed: 45 km/h
64 65
WARRANTY
Warranty conditions
In case of an occurring fault the company
Sachs Fahrzeug- und Motorentechnik
GmbH will provide the customer with
the following performances through the
authorized Sachs-dealer (seller) within the
scope of its statutory warranty obligations:
1. Within a period of 24 months after
the delivery of the motorbike to the
end customer the company Sachs
Fahrzeug- und Motorentechnik GmbH
will rectify any deficiencies caused
by material or manufacturing faults
through the authorized Sachs-dealer
(seller) by repairing or replacing the
affected part according to the statutory
warranty regulations. Sachs Fahrzeugund Motorentechnik GmbH may deny
the requested repair or replacement
of the faulty part if this would only be
possible with disproportionately high
costs. In this case Sachs Fahrzeugund Motorentechnik GmbH may rectify
the deficiency through the authorized
Sachs-dealer (seller) by applying the
other possibl e type of subsequent
fulfillment. If both types of subsequent
fu lfillment are only possible w ith
unproportionately high costs, Sachs
Fahrzeug- und Motorentechnik GmbH
may deny the subsequent fulfillment
alltogether through the au thorized
Sachs-dealer (seller). The customer is
then entitled to legal claims. Replaced
parts pass over into the possession of
Sachs Fahrzeug- und Motorentechnik
GmbH.
2. The installation of spare parts within the
scope of warranty does not extend the
warranty period that has started with the
date of delivery of the motorcycle.
3. The warranty does not cover normal
wear and tear caused by normal use
as well as wear and tear caused by
inappropriate handling and inappropriate
use. Oxidation and corrosion are caused
by environmental influences and are also
not covered under warranty
4. Warranty claims lodged by the cuistomer
will be rejected in case of: Manipulations
to the motorcycle, installation of a
different exhaust system, changes to the
gearbox or secondary transmission ratio
and installation of accessories or spare
parts which have not been approved
by Sachs Fahrzeugtechnik. Repairs
carried out in workshops not authorized
by Sachs Fahrzeug- und Motorentechnik
GmbH and the non-compliance with the
maintenance intervals in the workshop
of an authorized Sachs-dealer will also
cause the rejection of warranty claims.
5. When lodging a warranty claim the
customer must present the correctly
filled in service book to the seller.
6. The following table gives the customer
an overview of the average limits of the
respective wear parts:
WARRANTY
List of wear parts:
Wear parts Wear limits
Tires, hoses, rims depending on riding style, load and tire pressure the wear limit may already be reached
after only 1000 km or even earlier.
Wheels, hubs depending on riding style, load and tire pressure the wear limit may already
be reached after only 2500 km or even earlier. Check during each maintenance.
Oxidation is a lack of maintenance!
Oils, air filter, leakage inspection on engine during the first inspection, then with every maintenance interval.
Check oil level before every ride.
Spring fork, spring strut Cleaning / inspection during every maintenance.
Lamps, incandescent bulbs, electric system depending on road conditions / unevenness of the road surface the lifetime will be reduced,
this may already occur after 500 km.
Brake linings, brake shoes, brake lines depending on riding style and load these may already be worn after 2500 km,
in cross-country operation even earlier.
Sedal rings, sealants, O-rings must be replaced during each maintenance interval to ensure proper function.
Radial seals on engine, gearbox,
fork and wheels
depending on road conditions and care wear may start after 500 km.
Dirt reduces the lifetime. Do not clean with a high pressure cleaner!
Wheel bearings, steering bearings depending on road conditions and care wear may start after 500 km.
Soiling of the wheel hub reduces the lifetime.
Check during each maintenance interval, do not clean with a high pressure cleaner!
Swing arm bearing depending on load and care after 2500 km, check with every maintenance.
Cables depending on care starting after 500 km. Check with every maintenance.
66 67
WARRANTY
Wear parts Wear limits
Cleaning and lubrication of drive chain according of use and of every washing.
Drive chain, pinion, sprocket wheels,
chain guidance, chain pulley
depending on road conditions / ground and care, a wear is possible after 1500 km.
Do not wash with high pressure cleaner! Control during every maintenance.
Starter battery, batteries, fuses, starter brushes depending on ambient temperatures failures can be expected in the 6th month,
when used for short rides even earlier.
Mirror glasses depending on ambient temperatures and care failures can be expected in the 6th
month, in winter operation even earlier. Oxidation is a lack of maintenance!
Bowden cables, brake cables, throttle cables depending on use and care from the 6th month.
Free-wheel sprockets, free-wheel of starter depending on care from the 6th month.
Self-locking nuts, cotter pins locking plates
bonded screw connections
during each maintenance interval or after unscrewing the nut or unlocking the lock.
Inspection, cleaning and adjustment of the carburettor after each cleaning and max. every 200 hours, at least 1x per year.
Clutch linings / friction discs depending on riding style and load these may be worn after 2500 km.
Pistons, cylinders, crankshaft, conrods, engine
bearings
depending on riding style, load and care these parts may be worn after
500 hours. When riding mainly with full throttle even earlier.
Spark plugs with each or every second maintenance interval, max. very 200 hours.
Exhaust system, inspection of mountings depending on use and care from the 6th month, in winter and short distance
operation even earlier. Oxidation is a lack of maintenance!
List of wear parts:
WARRANTY
Please observe the following:
- During and after the warranty period all
inspections should solely be performed
by a specialised dealer approved by us.
- Observe the inspection intervals and
have the specialised dealer confirm them
on the guarantee certificate.
- Use only original spare parts.
CAUTION
In case of non-compliance the warranty
will become null and void.
The various activities carried out are listed
on the inspection plan.
During the warranty period the following
inspection intervals must be complied
with:
At 1.000 km (1st service)
Every 4.000 km / or after 4 months
Every 8.000 km / or after 8 months
After the warranty period the inspection
intervals specified in this manual must be
applied as follows:
Every 4.000 km / 4 months
Every 8.000 km / 8 months
Inspection plan
WARNING
For safety reasons, do not carry out any
repair or adjustment activities to the
motorcycle and chassis that exceed a
closely restricted scope. Tinkering with
safety-relevant parts could threaten the
safety of yourself and third parties.
This applies especially to the exhaust
system, carburettor, ignition system,
clutch, gears, fork column, brake system
and lights.
Before starting work on the electrical
system, disconnect the minus terminal
of the battery.
68 69
WARRANTY
Inspection plan type 649
Component
Assembly
Servicing Tasks
(*Only by an authorised Sachs dealer)
Before
each
trip
1st service
after
1000 km
Every
4.000 km /
4 months
Every
8.000 km /
8 months
Valves Check and adjust valves if necessary (cold)* x x
Spark plugs Check condition and accordingly clean or replace x x
Replace x
Air filter Clean filter and housing.* x x
Replace paper filter* x
Carburetor Check and adjust idle and cold start* x x x
Throttle cable x x x
Fuel filter Clean (fuel cock) x x
Fuel hoses Check and replace if necessary (change at least
every 4 years)
x x x
Engine oil Change (operating temperature) x x
Exhaust system Check for leads and repair if necessary* x x
Brakes Check brake function and brake fluid as well as
housing, correcting if necessary. Adjust rear brake*
x x x
Check and replace brake pads* x x
Brake fluid Change* Every 24.000km / 2 Years
Brake hoses Check and renew* (min. every 4 years)* x x x
Clutch Check and adjust x x x
WARRANTY
Inspection plan type 649
Component
Assembly
Servicing Tasks
(*Only by an authorised Sachs dealer)
Before
each
trip
1st service
after
1000 km
Every
4.000 km /
4 months
Every
8.000 km /
8 months
Rear suspension Check, retighten, replace if necessary or lubricate* Every 24.000km / 2 Years
Tyres Check gereral condition and profile depth and
replace if necessary
x x x
Wheels Check for damage, balance* x x x
Stearing
and bearings
Check and adjust free play* x x x
Front forks Check general condition as well as for leaks
and repair if necessary*
x x x
Chain Check adjustment and condidtion and grease,
adjust and renew if necessary
inspect clean and lubricate every 1000 km
Side stand Check, grease, repair if necessary* x x x
Nut and bolt
tightness
Check that all bolts and nuts are tightened to
the correct torque settings*
x x
Cables Check the throttle, brake and clutch cabels for de-
mage and smooth operation, if necessary replace*
x x
Headlight Check and adjust x x x
Battery Check, recharge if necessary x x x
General safety
check
Check for traffic/operational safety:
clutch, gear, idling speed, handbrake and footbrake, fork column, lighting and direction-indicator
system, check indicator lights, check tyre pressure
x x x
70 71
WARRANTY
Maintenance conrmations
Workshop activities carried out Workshop activities carried out
Activities carried out km date Activities carried out km date
WARRANTY
Maintenance conrmations
Workshop activities carried out Workshop activities carried out
Activities carried out km date Activities carried out km date
72 73
WARRANTY
Maintenance conrmations
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
km ..................................
date.................................
After 12.000 km/12 months
dealer stamp:
4.000 km/4 months
dealer stamp:
1.000 km/1 months
1st service
dealer stamp:
After 24.000 km/24 months
dealer stamp:
After 8.000 km/8 months
dealer stamp:
After 16.000 km/16 months
dealer stamp:
After 20.000 km/20 months
dealer stamp:
After 28.000 km/28 months
dealer stamp:
WARRANTY
Maintenance conrmation
km ..................................
date.................................
After 44.000 km/44 months
dealer stamp
km ..................................
date.................................
After 40.000 km/40 months
dealer stamp
km ..................................
date.................................
After 36.000 km/36 months
dealer stamp
km ..................................
date.................................
After 32.000 km/32 months
dealer stamp
km ..................................
date.................................
After 60.000 km/60 months
dealer stamp
km ..................................
date.................................
After56.000 km/56 months
dealer stamp
km ..................................
date.................................
km ..................................
date.................................
After 48.000 km/48 months
dealer stamp
After 52.000 km/52 months
dealer stamp
74 75
WARRANTY
Maintenance conrmation
New brake fluid
Yes no
Km.....................................
Date ..................................
Stamp, signature
New brake fluid
Yes no
Km.....................................
Date ..................................
Stamp, signature
New brake fluid
Yes no
Km.....................................
Date ..................................
Stamp, signature
New brake fluid
Yes no
Km.....................................
Date ..................................
Stamp, signature
dB ( A)
min —
Sachs Fahrzeug-und
Motorentechnik GmbH
e1-0212*00
WSF 649B1040000101
69 3000
Rating plate (sample):
Motorbike data
(fill out on purchase)
Model designation: ......................................................
Vehicle identily No: ......................................................
(Chassis No)
Key No: ......................................................
......................................................
EC license: ......................................................
Owner: ......................................................
......................................................
......................................................
Important
If you lose the operating license, immediately have a
motor-vehicle approval agency write out a certificate of
approval.
Send us the certificate along with the vehicle data. You
will then receive from us a copy of the operating license
for a fee.
EC-license:
Federal Bureau for Motorised Vehicles (State’s Eagle)
Förderstraße 16 D-24944 Flensburg
EC Operating License
According EEC 92/61
EC license: e1 2002/24 0212 00
Motorcycle: (under §18 StVZO)
Vehicle type: 649
Holder of the EC operating license and manufacturer:
Sachs Fahrzeug- und Motorentechnik GmbH
90327 Nürnberg
76 77
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