X&I D01 User Manual

mod.#

USER MANUAL

D01

ENG

INTRODUCTION

1

Thanks for your purchasing of this vehicle. This model is designed for safety, built for durability, and
perfected for daily street use. The unique vehicle design, enrich of stylish and peronality, represents your
outstanding taste and favor to pursue the state of the art living attitude.

This manual describes the correct usage of this motorcycle including safety riding, simple inspection methods
and so on. For a more comfortable and safety riding, please read this manual carefully. If any questions concerning
the operation or maintenance of your vehicle, please consult a dealer.

IMPORTANT MANUAL INFORMATION

2

In this manual with some important information is distinguished by the following notations:

!

WARNING

It is WARNING instructions that need to follow, failure of follow coulnd be end in result

severe injuiry or lead to death to the operator.

CAUTION

A CAUTION indicates with special precautions to avoid damage to the vehicle.

CAUTION

• Please always put this manual with vehicle for rider maintenance/ dealer tracking of service records even if vehicle is
being sold.

• This manual contains the most of the vehicle information, however, the maker will continually imrprove it’s product
design and quality that lead to difference between the manual and vehicle . If you have any questions concerning this
manual, please consult your dealer.

!

WARNING

FOR YOUR OWN SAFETY, PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION THIS VEHICLE. ONLY OPERATE
THE VEHICLE UNTIL YOU HAVE COMPLETELY AWARE OF ADEQUATE KNOWLEDGE OF CONTROLS AND OPERATION FEA­TURE AND YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. PERIODIC INSPECTIONS, WELL MAIN­TENANCE AND GOOD RIDING SKILLS, WILL ENSURE YOUR SAFETY RIDING AND INCEASE THE PRODUCT RELIABILITY OF
THIS VEHICLE.

*Product and specications are subject to change without notice.

3

IMPORTANT MANUAL INFORMATION

Dealer label here

TABLE OF CONTENTS

4

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

Other safe-riding points 7
Anti-tampering label 8

DESCRIPTION OF THE VEHICLE 9

Left view 9
Right view 10
Controls and instruments 11

INSTRUMENT AND CONTROL
FUNCTIONS 12

Main switch / steering lock 12
Dashboard unit - Analog 12
Dashboard unit - Digital 13
Handlebar switches - Left 16
Handlebar switches - Right 17
Kickstarter 17
Brake lever 17
Brake pedal 18
Clutch pedal 18
Fuel cock 18
Fuel tank cap 19
Fuel 19
Oil tank cap 20
Radiator and coolant reservoir 20
Catalytic converter 21
Seat 21
Owner’s tool kit 22
Side stand 22

PRE-OPERATION CHECKS 23

Pre-operation check list 24

OPERATION AND IMPORTANT RIDING
POINTS 25

Starting the engine 25
Starting off 26
Shifting and riding 26
Acceleration and deceleration 26
Braking 27
Parking 27
Stop the Engine 27
Engine break in 27

PERIODIC MAINTENANCE AND MINOR
REPAIR 29

Owner’s tool kit 30
Spark plug 30
Final transmission oil 31
Coolant 32
Air lter 32
Carburetor 33
Idling speed 33
Throttle cable free play 33
Clutch lever free play 34
Tires 34
Rims 36
Brake lever free play /
Brake pedal free play 36
Brake pads 37
Brake uid 37
Cables 38

Throttle grip and cable 38
Lubricating the front and rear brake 38
Front fork 39
Steering 39
Wheel bearings 40
Drive chain 40
Shock absorber 40
Battery 41
Fuse 42
Lighting - Option 1 42
Lighting - Option 2 44

TROUBLESHOOTING 46

Troubleshooting chart 47

CLEAN AND STORAGE 48

Clean the vehicle 48
Storage 49

SPECIFICATIONS 50
CONSUMER INFORMATION 52

Vehicle identikation number (VIN) 52

WARRANTY INFORMATION 53
MAINTENANCE SCHEDULE 54
SERVICE PLAN 55
WIRING DIAGRAM 56
SPACE FOR NOTES 57

SAFETY INFORMATION

5

THIS VEHICLE ARE TWO WHEEL
SINGLE TRACK VEHICLES. THE
USE OF SAVETY AND OPERATION
MAY IN DIFFERENT RESULT BY THE
USE OF PROPER RIDING TECH­NIQUES OF THE OPERATOR.
TO REMIND OF OPERATOR, WHO
SHOULD KNOW THE FOLLOWING
REQUIREMENTS BEFORE RIDING.

HE OR SHE SHOULD:

• WELL TRAINED AND FIMILIAR
TO ALL THE ASPECTS OF Vehicle
OPERATION.

• FULLY READ AND AWARE OF
MAINTENANCE REQUIREMENTS
THAT NOTED IN THIS OWNER’S
MANUAL.

• OBTAIN QUALIFIED TRAINING &
LEGAL LICENSE FOR OPERATI­ON OF THIS VEHICLE.

• WELL AND PROFESSIONAL
MAINTENANCE SERVICE FOR
OPERATOR AND CERTIFICA­TED REPAIR SHOP/DEALER TO
ACQUIRE GOOD MECHANICAL
CONDITIONS OF VEHICLE.

Safe riding

• Always pre-check your vehicle befo­re riding is key point to prevent an
accident.

• Please follow the maxium loads limi­ted of operator and passenger.

• Most of accident on the motorists is
cased by automobile driver who “fai­lure to recognize out the vehicle” and
caused mobile/vehicle accidents.
Therefore, to make yourself conspi­cuous apprear to public will be very
effective in reducing the change of
this kind of accidents.

Therefore:

• Wear a brightly colored and protecti­ve clothes/Jacket

• Operate the turning signals before
turning and slow down the Speed
when approaching and passthrough
the intersection

• Keep proper distance with other Mo­torists, and let them aware of your
location

• Know your skills and limits.

• Never lend your vehicle to oththers

who not qualied for riding

• Always follow the legal speed limit

on the vehicle and trafc law

• The posture of the operator and
passenger is important for proper
control. properly riding posture can
Keep vehicle in balance while riding.

• Operator should sit up-right with

two hand hold on handle bar, foot

on oorboard while driving.

• Passenger should make sure that

he/she can rmly hold on grip or

operator with foot step on footrest.

• Drving after Acohol drink or other il­legal drugs is strickly prohibited.

• This vehicle is designed for onroad
use only. It is not suitable for off-road
use.

Protective clothing

Properly clothing yourself will keep you
safety from potential accidents:

• Always wear an approved helmet.

• With face shield to protect your eye
from dust and rain drop.

uence on the steering & balance.

It
may cause possibility of an accident,
please extremely caution and follow
below limitation when you equipped
with accessories. Below are some ge­neral or accessories. Here are some
guidelines to follow if loading cargo or
adding accessories to your vehicle.

Loading

The total weight of the operator, pas­senger, accessories and cargo must
not exceed the maximum load limit.

Maximum load

(not include the vehicle): 150kg

When loading within this weight limit,
keep the following in mind:

• Cargo and accessory weight should

be kept as low and close to the ve­hicle as possible. Make sure to dis­tribute the weight as evenly as pos­sible on both sides of the vehicle to
minimize imbalance or instability.

SAFETY INFORMATION

6

• The wear of proper jacket, shoes,

groves etc., can be better protection,

reducing the degree of injuiry from

un-expected accident.

• Never wear loose-tting clothes,

otherwise they could catch on the
control levers or wheels and cause

injury or an accident.

• Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective
clothing that covers your legs, ank­les, and feet.

Modications

Modications made to this vehicle that

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

sonal injury. Modications may also

make your vehicle illegal touse.

Loading and accessories

Adding accessories or cargo to your
vehicle may cause the different on the
weight distribution of vehicle and in-

• Make sure that accessories and
cargo are securely attached to ve­hicle before riding

• Never attach any large or heavy
items to the handlebar, front fork, or
front fender. Such items can create
unstable handling or a slow steering
response.

Accessorries

Genuine accessories have been speci-

cally designed for use on this vehicle.

If need, please contact with dealer for
detail. Since the maker can not test all
other accessories , you must perso­nally be responble for the proper selec­tion, installation and use of non-OEM
accessories.
Keep the following guidelines in mind,
when mounting accessories.

• Never install accessories or carry

cargo that would inuence on the

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

turning lights, reectors.

SAFETY INFORMATION

7

• Accessories on the handle bar/front

suspension area will cause bad inu­ence on steering the vehicle. if you
will install accessories, please keep
it as light in weight and not interfere
on steering the vehicle.

This vehicle
is for On-Road transportation purpo­se only, please do not install any of
extended cargo carrier as sulky, that
will make vehicle unstable in cross
winds and vehicle turns.

• While equip with electrical accesso-

ries, please consult with qualiled

stores, to make sure such items
will not exceed the capacity of the
vehicle’s electrical system. Unpro­per install of such items may cause
a dangerous loss of lights, lower en­gine power or even damage the ve­hicle.

Gasoline and exhaust gas

• GASOLINE IS HIGHLY FLAMMAB­LE:

• Always turn the engine off when

refueling.

• Take care not to spill any gasoli-

ne on the engine (hot) or exhaust

system when refueling.

• Do not smoke or use Mobile pho­ne while re-fueling.

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

• Always turn the engine off before
leaving the vehicle and remove the
key from the main switch. When
parking the vehicle, please note the
following:

• The engine and exhaust system

remain hot, therefore, park the ve­hicle in a place where pedestrians
or children are not likely to touch
these hot areas.

• Do not park the vehicle on a slope

or soft ground, otherwise it may
fall over.

• Do not lay your vehicle to near

ammable place.

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

OTHER SAFE-RIDING POINTS

• Turn the signal before making turns.

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

• Be careful when passing parked
cars. A driver might not see you and
open a door in your path.

SAFETY INFORMATION

8

ANTI-TAMPERING LABEL

1. Anti-tampering label

1

Symbol image

DESCRIPTION OF THE VEHICLE

9

LEFT VIEW

1. Front wheel

2. Front disc brake

3. Headlight

4. Front turn signal light

5. Radiator

6. Fuel tank cap

7. Spark plug

8. Fuel cock

9. Side stand

10. Air lter

11. Pedal

12. Seat lock

12

8

9

10

2

1

4

3

6

11

7

5

DESCRIPTION OF THE VEHICLE

10

RIGHT VIEW

13. License plate light

14. Tail light / brake light

15. Rear wheel

16. Mufer

17. Rear turn signal light

18. Rear disc brake

19. Kickstarter

20. Brake pedal

21. Coolant reservoir

22. Brake lever

21

18

22

20

19

15

13 16

14 17

DESCRIPTION OF THE VEHICLE

11

CONTROLS AND INSTRUMENTS

23. Clutch lever

24. Left handlebar switches

25. Clutch pedal

26. Dashboard unit

27. Main switch

28. Brake pedal

29. Brake lever

30. Throttle grip

31. Right handlebar switches

23

24

31

28

29

26

27

30

25

INSTRUMENT AND CONTROL FUNCTIONS

12

MAIN SWITCH / STEERING LOCK

The main switch/steering lock controls
the ignition and lighting systems, and
also used to lock the steering. The va­rious positions are described as below.

On

All electrical circuits are supplied with
power, the engine can be started. The
key cannot be removed.

Off

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

Steering lock

The steering is locked, and all electri­cal systems are off. The key can be
removed.

Lock the steering

1. Turn the handlebars all the way to
the left.

2. Push the key in and turn it to the
position while still pushing it.

3. Remove the key.

Unlock the steering
Push the key in and then turn it to
position while still pushing it.

!

WARNING

Never turn the key to or , while
the vehicle is moving, otherwise the
electrical systems will be switched
off, which may result in loss of con­trol or an accident. Make sure that
the vehicle is stopped before tur­ning the key.

DASHBOARD UNIT - ANALOG

2

5

6

1

4

3

7

8

1. Turn signal indicator lamp

2. Main beam indicator lamp

3. Low beam indicator lamp

4. 2-stroke engine oil indicator

5. Coolant indicator light

6. Neutral indicator lamp N

7. Speedometer

8. Odometer

Turn signal indicator lamps

The relevant indicator lamp ashes

whenever you activate the turn signals.

DASHBOARD UNIT - DIGITAL

5

2

7

4

3

9

1

6

8

1. Turn signal indicator lamp

2. Main beam indicator lamp

3. 2-stroke engine oil indicator

4. Coolant indicator light

5. Neutral indicator lamp N

6. Speedometer

7. Odometer

8. SEL - button

9. ADJ - button

Turn signal indicator lamps

The relevant indicator lamp ashes

whenever you activate the turn signals.

INSTRUMENT AND CONTROL FUNCTIONS

13

Main beam indicator lamp

Lights up whenever main beam is swit­ched on.

Low beam indicator lamp

Low beam indicator comes on when
low beam headlight is on.

2-stroke engine oil indicator

The warning light when the engine oil
level in the 2-stroke engine oil tank is
low. If the warning light comes on du­ring operation, check the oil level and

ll the oil tank with an 2- stroke engine

oil. The warning light should go off after
the 2-stroke engine oil tank has been

relled.

CAUTION

Do not operate the vehicle until you
know that the 2-stroke engine oil level
is sufcient. Lack of engine oil will da­mage the engine.

!

WARNING

Please note that the engine oil war­ning light is model dependent. If
your vehicle has no engine oil war­ning you must check the oil level
before each ride.

Water thermometer indicator

It indicates the cooling uid tempera­ture. When it is on, means the water
temperature is too high and should
have a break sometime. If it is on by
a long time, please check the coolant
bottle.

Neutral indicator lamp (N)

Lights up whenever neutral (N) is se­lected.

Speedometer and odometer

The dashboard unit is equipped with
a speedometer and an odometer. The
speedometer shows the riding speed.
The odometer shows the total distance
traveled.

Water thermometer indicator

It indicates the cooling uid tempera­ture. When it is on, means the water
temperature is too high and should
have a break sometime. If it is on by
a long time, please check the coolant
bottle.

Neutral indicator lamp (N)

Lights up whenever neutral (N) is se­lected.

Speedometer and odometer

The dashboard unit is equipped with
a speedometer and an odometer. The
speedometer shows the riding speed.
The odometer shows the total distance
traveled.

INSTRUMENT AND CONTROL FUNCTIONS

14

Main beam indicator lamp

Lights up whenever main beam is swit­ched on.

2-stroke engine oil indicator

The warning light when the engine oil
level in the 2-stroke engine oil tank is
low. If the warning light comes on du­ring operation, check the oil level and

ll the oil tank with an 2- stroke engine

oil. The warning light should go off after
the 2-stroke engine oil tank has been

relled.

CAUTION

Do not operate the vehicle until you
know that the 2-stroke engine oil level
is sufcient. Lack of engine oil will da­mage the engine.

!

WARNING

Please note that the engine oil war­ning light is model dependent. If
your vehicle has no engine oil war­ning you must check the oil level
before each ride.

Adjust button

Main screen

In the main screen press the adjust

button once to switch the function from
odometer to trip.
When the odometer display range is
over the Max it starts at zero. When the
display range of trip meter is over the
Max it will also start at zero automati­cally but it can also be reset manually

by holding the adjust button for 3 sec

under the trip screen.
In the main screen press and hold the

adjust button for 3 sec to switch from

km to mile.

Watch screen

In clock screen press the adjust button

once to switch from clock to the main
screen.

INSTRUMENT AND CONTROL FUNCTIONS

Trip screen

In trip screen press the adjust button

once to switch from trip to clock.

Press and hold the adjust for 3 sec to

reset the trip.

Select button

Main screen
In main screen press and hold the se­lect button for 3 sec to switch the back­light color.

Watch-settings
In main screen press and hold the se-

lect and the adjust button for 3 sec to

enter the clock settings.

15

HANDLEBAR SWITCHES - LEFT

1

2

4

3

1. High/Low beam switch /

2. Turn signal switch

3. Horn switch

4. Choke switch

High/Low bean switch /
Set this switch tof for the high
beam and to for the low beam.

Turn signal switch

To signal a right-hand turn, push this
switch to . To signal a left-hand turn,
push this switch to . When released,
the switch returns to the center posi-

Example: You want to set the hour to

14h press the adjust button to choose

the hour you want to set.

Example: You want to set the minute
to 14:05 press the select button to en­ter the minute settings.

Then press the adjust button to choose

the minute you want to set.

After the settings are done press the
select button to store your settings and
get back to the main screen.

INSTRUMENT AND CONTROL FUNCTIONS

16

tion. To cancel the turn signal lights,
push the switch in after it has returned
to the center position.

Horn switch

Press this switch to sound the horn.

Choke switch

The actuation of the lever facilitates the
ignition and start of the vehicle when
the engine is cold. Do not forget to give
back the handle to the starting position
after reaching the operating tempera­ture.

HANDLEBAR SWITCHES - RIGHT

1

1. Starter switch

Starter switch

Pull the clutch lever in and press the
electric starter switch to start the
vehicle.

CAUTION

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

KICKSTARTER

The kickstarter (1) is located on the

right side of the vehicle. It is used to
start when the battery is empty or the
electric starter would not work. The en­gine can only be started with the neut­ral gear is selected.
To start the engine with the kickstarter,
move it down lightly with your foot un­til the gears engage, and then push it
down smoothly but forcefully.

1

CAUTION

After starting the engine it is necessary
to bring back the kickstarter to the star­ting position.

BRAKE LEVER

INSTRUMENT AND CONTROL FUNCTIONS

17

The brake lever is for the front brake is
located in the right side of the handle­bar. Pull back the lever to operate the
brake.

BRAKE PEDAL

1

The brake pedal (1) is located on the

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

CLUTCH PEDAL

1

1

6,5,4,3,2

N

The clutch pedal (1) is located on the

left side of the vehicle. The possible
switching positions you see in the pic­ture. The idle is between rst and se­cond gear.

CAUTION

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

FUEL COCK

1. ▪ OFF
No petrol can ow from the fuel tank

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

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

hicle. Petrol ows from the fuel tank

to the carburettor.

3. RESERVE
Irregular vehicle behaviour is of­ten caused by a lack of fuel. In this
event, turn the petrol tap to the RES
position.

INSTRUMENT AND CONTROL FUNCTIONS

18

Make sure that there is sufcient fuel in

the tank. Fill the fuel tank to the bottom

of the ller tube as shown.

!

WARNING

• Do not overll the fuel tank, other­wise it may overow when the fuel

warms up and expands.

• Avoid spilling fuel on the hot engine.

CAUTION

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

Regular unleaded gasoline only.

Recommended fuel: 95 oct

10 l +/- 0,2l

!!CAUTION!!

BIOETHANOL E10 IS NOT SUITABLE

1

CAUTION

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

FUEL

1

INSTRUMENT AND CONTROL FUNCTIONS

RESERVE

ON

▪ OFF

CAUTION

If you need switch to the RESERVE
position, visit a lling station at the ear­liest opportunity to refuel.

FUEL TANK CAP

To open the fuel tank cap (1) you have

to turn it counterclockwise. After refue­ling, you must turn it clockwise to close.

19

OIL TANK CAP

The oil tank (1) is located under the fuel

tank on front left side.

1. Remove the 2-stroke oil tank cap by
unscrew it.

2. Top up the oil.

3. Install the 2-stroke oil tank cap by
screw it into the oil tank opening.

1

CAUTION

Make sure that the 2-stroke oil tank
cap is properly installed before riding
the vehicle.

!

WARNING

At each refuelling you have to controll
the engine 2-stroke oil.

Capacity: 1 l

Recommendation:

Castrol Power 1 Racing 2T

RADIATOR AND COOLANT RESER­VOIR

The radiator (2) is located under the

fuel tank on the right front side.

The coolant reservoir (1) is located un­der the fuel tank on the front left side.

1. Remove cap by unscrew it.

2. Top up the coolant

3. Install the cap by screw it into.

1

2

1

INSTRUMENT AND CONTROL FUNCTIONS

20

2

Capacity: 1 -1,5 l

Recommended coolant:

CASTROL RADICOOL PREMIX

CAUTION

Make sure that the cap is properly ins­talled before riding the vehicle.

CATALYTIC CONVERTER

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

!

WARNING

The exhaust system is hot after opera­tion. Make sure that the exhaust sys­tem has cooled down before doing any
maintenance work.

CAUTION

The following precautions must be ob-

served to prevent a re hazard or other

damages.

• Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the catalytic
converter.

• Never park the vehicle near possible

re hazards such as grass or other

materials that easily burn.

• Do not allow the engine to idle too
long.

SEAT

To open the seat (2)

1. Place the vehicle on the side stand.

2. Insert the key in the lock (1) which is

located under sead on the left side

3. Turn the key about 1/4 turn clockwi­se.

4. The lock is unlocked and the seat
opens and you can fold it up.

1

CAUTION

Do not push inward when turning the
key.

INSTRUMENT AND CONTROL FUNCTIONS

21

1

2

To close the seat (2)

Fold down the seat and press it direct­ly over the lock with the palm of your
hand into it.

CAUTION

• When you close the seat by force
or strike, parts can be damaged.

• Make sure that the seat is locked
before driving or when you park
the vehicle.

OWNER’S TOOL KIT

The owner‘s tool kit is located in the

tool box (1) under the seat and can be

used for repairs.

1

CAUTION

• Since the tool box will accumulates
heat by the heat of sun and engine,
please do not put any thing that sen­titive to the heat.

• Do not put anything valuable or
breakable objects in the storage lug­gage box.

SIDE STAND

1

The side stand (1) is located on the left

side of the Vehicle. Release the side­stand by using your feet to step on the
bracket of side stand to up-right positi­on to stand the vehicle.

CAUTION

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

• Please avoid to use side stand to
park the vehicle on the slope, soft

land or un-at ground.

INSTRUMENT AND CONTROL FUNCTIONS

22

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. The operator should check the vehicle by simple but thorough
inspection,to make sure of vehicle condition, quick inspect some key and important parts, to prevent the vehicle from seri­ous consquence/accident. Please carefully check the following points before each ride.

CAUTION

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.

!

WARNING

If any item in the Pre-operation check list is not working properly , have it inspected and repaired before operating
the vehicle. If failed to be corrected by yourself, please turn to repair shop immediately.
If failed to be corrected by yourself, please turn to repair shop immediately.

23

PRE-OPERATION CHECKS

PRE-OPERATION CHECK LIST

CHECKPOINT TO VERIFY

Fuel • Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

Engine oil • Check oil level in oil tank.

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

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

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

• Check brake pads for wear.

• Replace if necessary.

• Check uid level in reservoir.

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

• Check hydraulic system for leakage.
Rear brake • Check operation.

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

• Check brake pads for wear.

• Replace if necessary.

• Check uid level in reservoir.

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

• Check hydraulic system for leakage.
Throttle grip • Make sure that operation is smooth.

• Check cable free play.

• If necessary, have dealer adjust cable free play and lubricate cable and grip housing.
Wheels and tires • Check for damage.

• Check tire condition and tread depth.

• Check air pressure.
Brake levers • Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.
Side stand • Make sure that operation is smooth.

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

• Tighten if necessary.
Instruments, lights, signals and switches • Check operation

• Correct if necessary

24

OPERATION AND IMPORTANT RIDING POINTS

!

WARNING

• Before riding the vehicle, please
make sure that you are fully mi­liar with all operating controls &
their functions before riding. To
consult a dealer shop if you not
thoroughly understand.

• Please do not start the engine in
a closed area, the exhaust air are
poisonous, and inhaling them can
cause loss of consciousness and
even death in short time.

CAUTION

• When engine is cold set the choke
on the close position, use the kick­starter or the electric starter to start
the engine. Then set the choke on
the midway position in order to warm
the engine. At last set the choke on
the open position, if the engine ope­rates smoothly, it implies the war­med engine.

• When engine is warm do not use the
choke system.

• Do not crank the engine more than 5
seconds on any one attempt.

Starting with the kickstarter

1. Turn the fuel cock to the position
ON

2. Turn the key to ON .

3. Insert the neutral gear.

4. Unfold the kickstart lever (1) and
push with your foot down until you
see a noticeable resistance.

5. Then kick the kickstarter evenly and
powerfully downwards.

STARTING THE ENGINE

CAUTION

Note the point „Engine break in“ before
you start to riding the vehicle.

1

Starting with the electric starter

1. Turn the fuel cock to the position
ON

2. Turn the key to ON .

3. Insert the neutral gear.

4. Pull the right brake lever otherwise
the vehicle will not start.

5. Push the start swich button (1)
for a few seconds.

25

CAUTION

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

STARTING OFF

1. Pull the clutch lever

2. Shift the engine to the rst gear

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

SHIFTING AND RIDING

a) Shifting gears upwards

1. Release the throttle

2. Pull the clutch lever

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

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

b) Shifting gears downwards

1. Release the throttle

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

3. Pull the clutch lever

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

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

!

WARNING

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

ACCELERATION AND DECELERA­TION

The speed can be adjusted by opening

and closing the throttle. To increase the
speed, turn the throttle grip in direction

(a). To reduce the speed, turn the thrott­le grip in direction (b).

1

CAUTION

• The engine starts immediately upon
actuation of the starter, then wait a
few seconds before you try to start it
again. Each starting process should
be as short as possible in order to
save battery and the starter.

• The vehicle must periodically (re-

commended weekly) start with the

kick starter, otherwise the grease
can gum up the kick starter gear and
the kick starter not to operate. den
Anlasser zu schonen.

OPERATION AND IMPORTANT RIDING POINTS

26

STOP THE ENGINE

1. Reduce the throttle to 0 position.

2. Pull the clutch lever

3. Switch the gear to N - neutral

4. Operate the brakes

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

ENGINE BREAK IN

During the rst 1000 km do not ride

the vehicle over 75% of its maximum
speed. Avoid opening the accelerator
completely and varies speed repea-

tedly over long distances. After the rst

1000 km increase speed gradually until
reaching maximum performance.

CAUTION

• The durability and the efciency of
your scooter depend strongly on the
care received during the run-in pe­riod. The mechanisms of the mobi­le parts are mutually hardened and
adapted.

BRAKING

1. Release the throttle.

2. Apply the clutch lever gradually in­creasing the pressure.

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

!

WARNING

• Avoid hard or sudden braking (espe­cially when cornering) otherwise the

motorcycle may skid.

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

• Therefore slow down when approa­ching such areas and cross them
with caution.

PARKING

1. Reduce the throttle to 0 position.

2. Pull the clutch lever

3. Switch the gear to N - neutral

4. Operate the brakes

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

6. Lower the side stand with your foot
while holding the motorcycle up­right. Remove the key from the main
switch.

!

WARNING

Since the engine and exhaust system
can become very hot, park in a place
where pedestrians or children are not
likely to touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle may
overturn.

OPERATION AND IMPORTANT RIDING POINTS

27

• After better run-in is obtained not by
riding slowly but softly and careful­ly. During this period, it is advisable
to ride the vehicle at ¾ of maximum
performance. In the event that full

acceleration is necessary (overta­king maneuvers, steep slopes, etc.)

try to limit the time to a minimum.

• Gearbox oil must be changed once

the rst 1000 km are covered. Use

the recommended oil type and spe-

cied quantity only.

The durability and the efciency of your

scooter depend strongly on the care
received during the run-in period. The
mechanisms of the mobile parts are
mutually hardened and adapted.
After better run-in is obtained not by ri­ding slowly but softly and carefully. Du­ring this period, it is advisable to ride
the vehicle at 3/4 of maximum perfor­mance. In the event that full accelera-

tion is necessary (overtaking maneu­vers, steep slopes, etc.) try to limit the

time to a minimum.

OPERATION AND IMPORTANT RIDING POINTS

Gearbox oil must be changed once

the rst 1000 km are covered. Use the
recommended oil type and specied

quantity only.

To obtain optimum adjustment of mo­bile parts, a long life and better perfor­mance, it is necessary not to force the
vehicle during the 1000 km. The vehic­le must have a suitable run-in period,
during which the following precautions
must be considered:

• After starting the engine, warm it up
progressively, without maximum ac­celeration (we recommend not to ex­ceed 3/4 of the throttle grip opening

for 1st gear) or overcharge.

• In long stretches, do not use full
speed consistently and varies the
speed repeatedly.

• When facing steep slopes, downs­hift to have better power.

• After a long run do not stop the en­gine suddenly, leave it running at
minimum acceleration for some se­conds.

• Check the non-existence of oil, fuel
or brake liquid leaks.

• In case of anomalous noise, try to
identify its cause immediately.

28

CAUTION

Most of the Safety and condition of vehicle depend on how you do the correct maintenance , periodic inspection,

adjustment and lubrication. The following are contents that help the operator to do such skills on the following pages.

!

WARNING

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair shop or

individual that is certied and must follow the local law regulations.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

29

SPARK PLUG

The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main­tenance and lubrication chart. In additi­on, the condition of the spark plug can
reveal the condition of the engine.

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

the vehicle.

1

Remove the spark plug

1. Remove the spark plug cap

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

3. Check that the porcelain insulator

(2) around the center electrode of

the spark plug is a medium-to-light

tan (the ideal color when the vehicle
is ridden normally).

2

CAUTION

If the spark plug shows a distinctly dif­ferent color, the engine could be opera­ting improperly. Do not attempt to diag­nose such problems yourself. Instead,
have a dealer check the vehicle.

OWNER’S TOOL KIT

The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

CAUTION

If you do not have the tools or experi-

ence required for a particular job, have

a dealer perform it for you.

!

WARNING

Modications not approved by maker

may cause loss of performance, exces­sive emissions, and render the vehicle
unsafe for use. Consult a dealer before
attempting any changes.

Modications without authorization of

the manufacturer cause void the war­ranty.

PERIODIC MAINTENANCE AND MINOR REPAIR

30

5. Measure the spark plug gap with a
wire thickness gauge and, if neces-

sary, adjust the gap to specication.

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

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

the specied torque.

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

0,6-0,7 mm

31

4. Check the spark plug for electrode

(3) erosion and excessive carbon or

other deposits, and replace it if ne­cessary.

3

Specied spark plug:

NGK BR8ES

!

WARNING

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

!

WARNING

Please note the max. torque when in­serting the plug. If you do not have the
ability to control you leave control of
the spark plug to the dealer.

Tightening torque: 12 Nm

FINAL TRANSMISSION OIL

The nal transmission case (1) must

be checked for oil leakage before each
ride. If any leakage is found, have a
dealer check and repair the vehicle. In

addition, the nal transmission oil must

be changed as follows at the intervals

specied in the periodic maintenance

and lubrication chart.

CAUTION

As long as the vehicle is within the war­ranty period the dealer is responsible
to change the gear oil.

PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torque: 18 Nm

6. Add the requested amount of the

recommended nal transmission oil,

and then install and tighten the oil

ller cap.

Recommended nal transmission

oil:

Castrol Power 4T 10W40 or ATF Öl

Oil quantity: Full: 0,5 l / Change: 0,4 l

!

WARNING

• Make sure that no foreign material

enters the nal transmission case.

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

7. Check the nal transmission case
for oil leakage. If oil is leaking, check
for the cause.

Change nal transmission oil

1. Start the engine, warm up the nal

transmission oil by riding the vehicle
for several minutes, and then stop
the engine.

2. Place the vehicle on the main stand.

3. Place an oil pan under the nal trans-

mission case to collect the used oil.

4. Remove the oil ller cap (2) and

drain bolt (3) to drain the oil from the
nal transmission case.

1

2

3

5. Install the nal transmission oil drain

bolt, and then tighten it to the speci-

ed torque.

COOLANT

Before you start operating the vehic­le, check the coolant level. The radi-

ator should be completely lled with

coolant. The reservoir is located right

in front of the tank xed to the frame.

In the expansion tank, the coolant
should be between the MIN and MAX
mark stand.

Recommended coolant:

CASTROL RADICOOL PREMIX

CAUTION

The new lling and bleeding of the coo­ling system should be carried out by a
dealer.

AIR FILTER

The air lter should be replaced ac­cording to the maintenance schedule.

Replace the air lter more often if you

drive in unusually wet or dusty areas.

32

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION

• Make sure that the air lter element is

properly seated in the air lter case.

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

CARBURETOR

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

adjustment. Therefore, carburetor ad­justments should be left to dealer, who

has the necessary professional know­ledge and experience.

IDLING SPEED

If the idle is not correct consult a dealer
to check it.

33

PERIODIC MAINTENANCE AND MINOR REPAIR

The minimum speed of the engine

(idling) must be approxemately 1800

±100 rev/min.

THROTTLE CABLE FREE PLAY

1

The throttle cable free play (1) should

measure 1.5 ~ 3.5 mm at the thrott­le grip. Periodically check the throttle
cable free play and, if necessary, have

a dealer adjust it.

Throttle cable free play adjustment

1. Release the locknut (1)

2. Rotate the adjusting nut (2) to ad-

just the clearance.

1

Replace the air lter

1. Remove the seat

2. Remove the side cover

3. Unscrew the screws of the air lter

housing (1).

4. Pull the air lter out.

5. Replace the lter with a new one.

6. Coat the mating surfaces of the air

lter case and air lter case cover

lightly with grease for an airtight
seal.

7. Install the air lter.

8. Mount the air lter housing.

9. Mount the side cover

10. Install the seat.

34

The clutch lever free play (1) should

measure 1.0 ~ 2.0 mm. Periodically
check the clutch lever free play and if

necessary, have a dealer adjust it.

Clutch lever free play adjustment

1. Release the locknut (1)

2. Rotate the adjusting nut (2) to ad-

just the clearance.

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

1

2

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

1

2

CLUTCH LEVER FREE PLAY

1

TIRES

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

Tire air pressure

The tire air pressure should be che-

cked and, if necessary, adjusted before

each ride.

!

WARNING

The tire air pressure must be checked

and adjusted on cold tires (i.e., when

the temperature of the tires equals the

ambient temperature).
The tire air pressure must be adjusted

in accordance with the riding condition.
If you are not familiar to this, please
have dealer for help.

PERIODIC MAINTENANCE AND MINOR REPAIR

If a tire tread shows crosswise lines

(minimum tread depth), if the tire has

a nail or glass fragments in it, or if the
sidewall is cracked, have a dealer re­place the tire immediately.

CAUTION

The tread depth may vary depending
on country. Observe local regulations.
The values listed here are technical va­lues and may differ from the legal valu­es of your region.

Minimum tire tread depth:

Front and rear: > 1,6 mm

!

WARNING

• Drive with worn tire is illegal, redu­ces stability and can lead to loss of
control over the vehicle.

• Let worn or damaged tires replaced
immediately by your dealer.

• Working tires and the dealer is res­ponsible.

•

Maximum load*: 150 kg

* Total weight of rider, passenger,

cargo and accessories

Tire inspection

1

2

3

1. Tire tread depth

2. Tire sidewall

3. Tire wear indicator

!

WARNING

The tires must be checked before each
ride.

35

Tire air pressure:

Front: 2,1 bar - 2,5 bar

Rear: 2,1 bar - 2,5 bar

Total weight of rider, passenger,

cargo and accessories!

!

WARNING

Do not over load your vehicle, since
it will increase pressure on the tire,
braking, steering than original design,
and may could cause damge or even
lead to accident.
Allocation of your cargo and weight of
your vehicle is very important for your
own safety and vehicle performance.
Load your cargo rmly on vehicle and
put the heaviest cargo to the center
of vehicle, then distribute the weight
evenly from side to side. It will keep
you to have good steering after load.

PERIODIC MAINTENANCE AND MINOR REPAIR

BRAKE LEVER FREE PLAY / BRA­KE PEDAL FREE PLAY

CAUTION

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

!

WARNING

A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a dealer
bleed the system before operating the
motorcycle. Air in the hydraulic system
will diminish the braking performance,
which may result in loss of control and
an accident.

Rear brake

CAUTION

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

RIMS

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

the specied wheels.

• The wheel rims should be checked
for cracks, bends or warpage befo­re each ride. If any damage is found,
have a dealer replace the wheel. Do
not attempt even the smallest repair
to the wheel. A deformed or cracked
wheel must be replaced.

• The wheel should be balanced whe­never either the tire or wheel has
been changed or replaced. An unba­lanced wheel can result in poor per­formance, adverse handling charac­teristics, and a shortened tire life.

• Ride at moderate speeds after chan­ging a tire since the tire surface must

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

optimal characteristics.

DIMENSIONS TIRE / RIMS

SM model

Front: Rim: 17x2.5

Tire: 100/80-17

Rear: Rim: 17x3.0

Tire: 130/80-17

TYRE TYPE: tubeless

DIMENSIONS TIRES / RIMS

X model

Front: Rim: 21x1.6

Tire: 100/80-17

Rear: Rim: 18x1.85

Tire: 130/80-17

TYRE TYPE: tubeless

36

PERIODIC MAINTENANCE AND MINOR REPAIR

37

!

WARNING

If proper adjustment cannot be obtai­ned as described contact a dealer to

make this adjustment.

BRAKE PADS

The brake pads must be checked for

wear at the intervals specied in the

periodic maintenance and lubrication
chart.

Each brake pad is provided with wear
indicators, which allows you to check
the brake pad wear without having to

!

WARNING

A soft or spongy feeling in the brake
padel can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a dealer
bleed the system before operating the
motorcycle. Air in the hydraulic system
will diminish the braking performance,
which may result in loss of control and
an accident.

Brake padel free play

1. Loosen the locknut (1)

2. Turn the adjusting bolt (2) until the

lever position is within specied po­sition (10 mm free play on the lever)

3. Tighten the locknut again.

1

2

disassemble the brake. To check the
brake pad wear, check the position of
the wear indicators while applying the
brake. If a brake pad has worn to the
point that a wear indicator almost tou­ches the brake disc, have a dealer re­place the brake pads as a set.

BRAKE FLUID

!

WARNING

Insufcient brake uid may allow air to

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

re riding, check that the break uid is
above the minimum level mark (1) and
rell it if necessary.

1

PERIODIC MAINTENANCE AND MINOR REPAIR

Recommended lubricant:

Castrol Motorrad DWF oilspray

!

WARNING

Damage to the outer housing of cables
may result in internal rusting and cause
interference with cable movement. Re­place damaged cables as soon as pos­sible to prevent unsafe conditions.

THROTTLE GRIP AND CABLE

The operation of the throttle grip should
be checked before each ride. In addi­tion, the cable should be lubricated at

the intervals specied in the periodic

maintenance chart.

LUBRICATING THE FRONT AND
REAR BRAKE

The pivoting points of the front and rear
brake must be lubricated at the inter-

Low position brake uid level may in­dicate worn brake pads and/or brake
system leakage. If the brake uid le­vel is low, be sure to check the brake
pads for wear and the brake system for

leakage. When checking the uid level,

make sure that the top of the master
cylinder is level by turning the handle­bars. Use only the recommended qua-

lity brake uid, otherwise the rubber

seals may deteriorate, causing leakage
and poor braking performance.

Recommended brake uid:

Castrol Super Disc Brake Fluid DOT 4

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

ful chemical reaction and lead to poor
braking performance.

• Be careful that water does not enter

the master cylinder when relling.
Water will signicantly lower the boi­ling point of the uid and may result

in vapor lock.

38

• Brake uid may deteriorate painted

surfaces or plastic parts. Always clean

up spilled uid immediately.

A

• s the brake pads wear, it is normal

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

level goes down suddenly, have a
dealer check.

Chaning the brake uid

!

WARNING

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

after the periodic maintenance and lub­rication chart.

CABLES

The operation of all control cables
and the condition of the cables should
be checked before each ride, and the
cables and cable ends should be lubri­cated if necessary. If a cable is dama­ged or does not move smoothly, have
a dealer check or replace it.

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Check the inner tubes for scratches,
damage and oil leakage.

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

!

WARNING

• When damage to the fork, please
contact your dealer.

• If you treat the telescopic fork with
cleaning agents, make sure that they
get no contact with the tires or the
brakes. This can lead to dangerous
accidents.

39

vals specied in the periodic mainte­nance and lubrication chart.

Recommended lubricant:

Castrol Motorrad DWF oilspray

FRONT FORK

The condition and operation of the front
fork must be checked as follows at the
intervals specied in the periodic main­tenance and lubrication chart.

Recommended lubricant:

Castrol Motorrad DWF oilspray

!

WARNING

Securely support the motorcycle so
that there is no danger of it falling over.

1. Place the vehicle at and upright

from.

STEERING

!

WARNING

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

follows at the intervals specied in the

periodic maintenance and lubrication
chart.

1. Place the vehicle on the side stand/
suitable motorcycle stand to raise
the front wheel off the ground.

2. Hold the lower ends of the front fork
legs and try to move them forward
and backward.

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

PERIODIC MAINTENANCE AND MINOR REPAIR

1

3

2

Tightening torque of the collor nut

(1): 70 Nm

SHOCK ABSORBER

Press the rear of the vehicle down to
test the function of the rear damper.
Make sure that no pressure is exerted
on the exhaust in order not to damage
it.

The shock absorber can be adjusted

to suit the weight of the driver and the
load.

WHEEL BEARINGS

The front and rear wheel bearings must

be checked at the intervals specied in

the periodic maintenance and lubrica­tion chart.

CAUTION

If there is play in the wheel hub or if the
wheel does not turn smoothly, have a
dealer check the wheel bearings.

DRIVE CHAIN

10-20 mm

If the chain tension is too great, parts
within the secondary power trasmission

(chain, chain sprockets transmission
and rear wheel bearings) will be sub­jected to unnecessary stress resulting

in early wear and even chain breaka­ge. Too much slack in the chain, on the

other hand, can result chain jumping off

the chain wheels. If this happens the
chain could also block the rear wheel
or damage the engine. In either case
the operator is likely to lose control of
the vehicle.

Tensioning the chain drive

1. Loosen collar nut (1)

2. Loosen counter nut (2)

3. Turn right and left adjusting screws

(3) equally far. The drive chain free

play should be between 10 mm and
20 mm.

4. Tighten counter nut (2) and the collar

nut (1).

40

PERIODIC MAINTENANCE AND MINOR REPAIR

!

WARNING

• Do not remove the battery vent seal,
this can be dangerous, the battery
permanently damaged.

• Battery acid is poisonous and dan­gerous, it contains sulfuric acid and
leads to dangerous burns.

• Avoid skin, eye and clothing contac.
Protect your eyes always when wor­king near the battery.

• Upon contact with the battery aicd,
make immediate FIRST AID.

• If skin or eye contact with battery
acid, rinse the affected areas with
plenty of water.

• When accidentally swallowed battery
acid drink large amounts of water.

• In both cases, as soon as possible,
see a doctor.

• Batteries develop explosive hydro-

gen gas. Keep open ames, smoking

materials away from the battery and
make sure there is adequate venti­lation when you charge a battery in­doors.

Adjust the shock absorber

Use the nuts (1) and (2) to adjust the
rear shock. Loosen the locknut (1) and
adjust with the help of the nut (2) to ad­just the preload of the shock absorber.

Secure the damper then again with the

locknut (1).

1

2

-

+

BATTERY

This model is equipped with a sealed­type (MF) battery, which does not re­quire
any maintenance. There is no need to
check the electrolyte or to add distilled
water.

41

• KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHILD­REN.

To charge the battery

Have a dealer charge the battery as
soon as possible if it seems to have di­scharged. Keep in mind that the battery
tends to discharge more quickly if the
vehicle is equipped with optional elec­trical accessories.

To store the battery

• If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.

• If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.

• Fully charge the battery before ins­tallation.

• After installation, make sure that the
battery leads are properly connected
to the battery terminals.

PERIODIC MAINTENANCE AND MINOR REPAIR

42

!

WARNING

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

re.

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

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

LIGHTING - OPTION 1

Headlight bulbs

1. If the headlight bulp does not glow,
switch off all consumers and switch
off the engine.

2. Remove the bolts on the left and right

side of the headlight (1).

3. Remove the headlight (2).

!

WARNING

Please contact your dealer if you are
not familiar with handling the battery.

CAUTION

Always keep the battery charged. Sto­ring a discharged battery can cause
permanent battery damage.

FUSE

The fuse holder is located beside bat­tery.

Replacing the fuse

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

2. Remove the blown fuse, and then

install a new fuse of the specied

amperage.

Specied fuse:

10 Amp

2

1

4. Take out the rubber dust cover (3).

5. Turn the xing disc anti-clockwise to

take out the the blup (4).

4

3

PERIODIC MAINTENANCE AND MINOR REPAIR

43

Front turn signal light

If the turn signal light bulb does not com
on, remove the screw of the indicator

lens (1) out and replace the bulb.

1

1

5

When you need to adjust the headlight
turn in or turn out the adjusting screw
(5).

Rear turn signal light

If the turn signal light bulb does not
com on, remove the screw of the indi-

cator lens (1) out and replace the bulb.

1

1

PERIODIC MAINTENANCE AND MINOR REPAIR

44

LIGHTING - OPTION 2

Headlight bulbs

1. If the headlight bulp does not glow

remove the bolts and screws (1 to 4)

to disassemble the head light assem­bly.

2. Take out the rubber dust cover (5)

and the pug (6).

1

2

5

4

5

6

3

3. Turn the xing disc anti-clockwise to
take out the the blup (7).

Taillight / Brake light and license
plate lamp

2

1

If the tail/brake light (1) or the license
plate light (2) do not glow disassemble

the bolts for changing the bulb.

7

7

8

When you need to adjust the headlight
turn in or turn out the adjusting screw
(8).

PERIODIC MAINTENANCE AND MINOR REPAIR

45

Rear turn signal light

If the turn signal light bulb (1) does not

com on, please contact your dealer to
replace it.

1

1

Front turn signal light

If the turn signal light bulb (1) does not

com on, please contact your dealer to
replace it.

1

1

Taillight / Brake light and license
plate lamp

2

1

If the tail/brake light (1) or the license
plate light (2) do not glow disassemble

the bolts for changing the bulb.

PERIODIC MAINTENANCE AND MINOR REPAIR

46

TROUBLESHOOTING

Although the vehicles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
However, should your vehicle require any repair, take it to a dealer, whose skilled technicians have the necessary tools,
experience, and knowhow to service the vehicle properly.
Use only genuine replacement parts. Imitation parts may look like parts, but they are often inferior have a shorter service
life and can lead to expensive repair bills.

TROUBLESHOOTING

47

TROUBLESHOOTING CHART

!

WARNUNG

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

TROUBLESHOOTING

1. Fuel

2. Compression

3. Ignition

4. Battery

Check the fuel level in
the fuel tank.

Operate the electric
starter.

Remove the spark plug
and check the electrodes.

Operate the electric
starter.

Operate the electric
starter.

There is no fuel.

There is compression.

There is no compression.

Check the compression.

Supply fuel.

The engine does not start.
Check the compression.

Check the ignition.

Have a dealer check the
vehicle.

Wet

Dry

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

Have a dealer check the
vehicle.

Operate the electric starter.

The engine does not start.
Check the battery.

The engine turns over quickly.

The engine turns over slowly.

The battery is good.

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

The engine does not start.
Have a dealer check the
vehicle.

CLEAN AND STORAGE

48

of the vehicle to prevent damage.
Dry the plastic parts then wipe with a
soft, dry cloth or sponge.

• Protect particularly plastic parts,
paint, headlight glass from harsh
chemicals such as fuel, rust remover,
brake cleaner or similar. The use of
such agents may result in malfunc­tion, damage and affect the security
itself.

• Do not use a high pressure washer
or steam cleaner, causing water
in storage can penetrate electrical
components such as connectors or
switches, lighting, ventilation hoses,
brake shoes and brake linings or
damage, seals, paint and other sur­faces.

Cleaning after normal use

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

CLEAN THE VEHICLE

Clean of the vehicle in proper and sui­table way will make it attractive, extend
it’s lfe and optimize the performance.

Before cleaning

1. Cover the mufer outlet with a plas-

tic bag to prevent water to come . in­side. Please do it only after the

2. Closed every caps, covers, electri­cal connectors that are well install
and water can be avoid to get into,

while you do the clean job.

CAUTION

• Do not use acid-based cleaners. If
such funds used for stubborn stains,
so use this only occasionally, dry it
immediately after and then apply a
corrosion protection spray.

• Always follow the manufacturer‘s
instructions on care and cleaning
agents.

• Use best only water and mild de­tergent or special cleaner from the
dealer to the sensitive components

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

CAUTION

Since sea salt or salt sprayed on the
roads during winter are extremely cor­rosive in combination with water, carry
out the following steps after each ride.

• Wait until the engine / exhaust have
cooled.

• Clean the vehicle with warm water
and a mild detergent.

• Do not use hot water, which increa­ses the corrosive effect of the salt.

• Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.

After cleaning

• Dry the vehicle.

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

• Wax all painted surfaces.

Recommended Castrol care pro-

ducts:

Greentec Bike Reiniger

Bike Politur

Motorrad DWF oilspray

!

WARNING

• Make sure that there is no oil or wax
on the brakes or tires.

• If necessary, clean the brake discs
and brake linings with a regular bra­ke disc cleaner and wash the tires
with warm water and a mild deter­gent.

• Before operating the vehicle, test
the braking performance and tires.

STORAGE

Short-term (for a few days)

• Always store your vehicle in a cool,
dry place and, if necessary, protect
it against dust with a vehicle cover.

49

CLEAN AND STORAGE

!

WARNING

Please store the vehicle in a well air

ow room with dry air if possible. A

place with wet humidity will cause rust.

Long-term (for weeks)

• Clean the vehicle.

• Drain the fuel from the carburetor.

• Enter the drained fuel back into the
fuel tank.

• Fill the fuel tank to completely or add
if necessary a fuel stabilizer to pro­tect the fuel tank from rusting and
the fuel from degradation.

Follow the steps below to cylinders,
piston rings, etc. to prevent rusting.

• Remove spark plug cap and the
spark plug.

• Give a teaspoon of engine oil into
the spark plug hole.

• Join the Kickstarter to slow down and
let the engine several times slowly

rotate (thus the cylinder is oiled).

• Put the spark plug back in and put
on the spark plug cap.

!

WARNING

To prevent damage or injury from spar­king, make sure to ground the spark
plug electrodes while turning the engi­ne over.

• Lubricate all control cables and the
pivoting points of all levers and pe­dals as well as of the side stand/
main stand.

• Check and, if necessary, correct the
tire air pressure, and then lift the ve­hicle so that both of its wheels are
off the ground. Alternatively, turn the
wheels a little every month in order
to prevent the tires from becoming
degraded in one spot.

• Cover the mufer outlet with a plas­tic bag to prevent moisture from en­tering it.

• Remove the battery and fully charge
it. Store it in a cool, dry place and
charge it once a month. Do not store
the battery in an excessively cold or

warm place [less than 0 °C (30 °F) or
more than 30°C (90 °F)].

ENGINE

Engine type
2-stroke liquid cooled
Cylinder arrangement
Forward-inclined single cylinder
Displacement
49,6 cm 3
Compression ratio
7,0:1
Starting system
Electric starter and kickstarter
Lubrication system
Separate lubrication
2-stroke engine oil

ENGINE OIL

Quantity 1 l
recommended type:
Castrol Power 1 Racing 2T

TRANSMISSION OIL

Type SAE 10W-40
recommended type:
Castrol Power 4T oder ATF Öl

AIR FILTER

Sponge

FUEL

Unleaded gasoline only 95 Oct
Capacity
10 +/- 0,2 l

CAUTION
!! BIOETHANOL FUEL ­E10 IS NOT PERMITTED !!

DIMENSIONS - SM MODEL

DIMENSIONS - X MODEL

CARBURETOR

Manufacturer
QJ or LEADER

SPARK PLUG

Manufacturer / model
NGK / BR8ES
Spark plug gap
0,6-0,7 mm

CLUTCH

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

CHASSIS

Frame type
Steel tube backbone

FRONT TIRE - SM MODEL

Rim: 17x2.5
Tyre: 100/80-17

REAR TIRE - SM MODEL

Rim: 17x3.0
Tyre: 130/80-17

FRONT TIRE - X MODEL

Rim: 21x1,6
Tyre: 100/80-17

REAR TIRE - X MODEL

Rim: 18x1,85
Tyre: 130/80-17

SPECIFICATIONS

50

51

FRONT SUSPENSION

Type
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper

REAR SUSPENSION

Type
Unit swing
Spring/shock absorber type
Gas/oil damper

ELECTRICAL SYSTEM

Ignition system
CDI
Charging system
CDI magneto

BATTERY

Model
YT4L-BS
Voltage, capacity
12 V, 3 Ah

HEADLIGHT

Halogen bulb

BULB VOLTAGE, WATTAGE X QUAN­TITY

Headlight
12 V, 35 W/35 W

TIRE AIR PRESSURE (COLD TIRES)

Front: 2,1 bar - 2,5 bar
Rear: 2,1 bar - 2,5 bar
The selected tire pressure depends
on the load!

FRONT BRAKE - SM MODEL

Type
Single Hydraulic disc brake
230 mm
Operation
Right hand

REAR BRAKE - X MODEL

Type
Single Hydraulic disc brake
280 mm
Operation
Right hand

REAR BRAKE

Type
Single Hydraulic disc brake
220 mm
Operation
Right food

RECOMMENDED FLUID

DOT 4 - CASTROL Super Disc

Bremsüssigkeit DOT 4

Tail/brake light
12 V, 5 W/21 W
Front turn signal light
12 V, 10 W or LED
Rear turn signal light
12 V, 10 W or LED
License plate light
12 V, 5 W
Meter lighting
12 V, 2 W
High beam indicator light
12 V, 2 W
Engine oil indicator
12 V, 3 W
Turn signal indicator light
12 V, 3 W

SICHERUNGEN

Hauptsicherung
10 A

SPECIFICATIONS

CONSUMER INFORMATION

52

VEHICLE IDENTIFIKATION NUMBER
(VIN)

Please write down the VIN (vehicle iden­tication number) to order replacement

parts from your dealer or the vehicle
should be stolen.

The vehicle identication number of the
vehicle (1) is stamped on the steering

head.

1

CAUTION

The vehicle identication number is used

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

WARRANTY INFORMATION

53

Please carefully read the instruction manual of your vehicle before operating it in order to make yourself familiar with its handling. We
explicitly point out that the instruction, maintenance, and care instructions given in the operating manual have to be complied with in order

to sustain your claim towards warranty. Only the strict compliance with customer specications stated in the instruction manual ensures

the prolonging of the natural life of your vehicle. Starting with the date of the invoice a limited warranty of 24 months is granted regarding
the accuracy of the vehicle in terms of material and manufacturing according to latest standards. The legal warranty regulations will not
be restricted by this limited guarantee. Maintenance work has to be exclusively done by authorized workshops entitled by us. Warranty in
general is bound to the region of invoicing and can therefore only be carried out within the country the vehicle was bought. Damages that
can be traced back to inappropriate usage, manipulation, or neglecting of the maintenance/care/operating instructions will not be covered
by warranty. Warranty can only be granted if occurring damages are immediately being reported to the seller or any other authorized

workshop by the buyer. The warranty claim entitles the buyer to remedy deciencies or to the reparation respectively the exchange of

a damaged part in an authorized workshop after our approval. Compensation for remote or instantaneous damages cannot be granted.
Vehicles in desolate condition will not be covered by warranty. Repair works carried out on warranty do not enlarge the guarantee period.
Only this document entitles you to call on warranty services. Therefore please make sure that you are delivered this fully lled in docu­ment by the seller and that he has registered your vehicle correctly in our system. Please also mind the following advices.

Body and panelling of the vehicle have to be kept free of dirt constantly. Do not use high pressure water blasters, strong jets of water,

sharp and corrosive or other aggressive detergents which could harm surfaces and varnish permanently and foster corrosion. It is vital

to use protecting cleansers. Please consult our dealers for the right and appropriate products. Aluminium parts or other rened parts
(chrome parts, anodized parts or other processed surfaces)have to be treated with appropriate maintenance products in order to prevent

oxidation. Frame and metal parts are continuously to be treated with anticorrosive. A vehicle constantly parked outside has to be covered
to avoid weathering and crack formations on seat and plastic parts. Vehicles used off-road and for racing purposes are excluded from
warranty.

Material which is to be used in the context of service and maintenance works are excluded from warranty as well as the following parts:

incandescent bulbs, brake pads, clutch lining, lter elements, spark plugs, drive sprocket, wheel and axle., as well as the tires.

MAINTENANCE SCHEDULE

54

The guarantee can be granted only if the vehicle has been serviced in accordance with this maintenance schedule.

CAUTION: Variomatic belt, y wheels respectively drive chain/sproket, spark pluge, fuel lter and air lter element have to be exchanged every 7000km. Only use duration coolant. Brake lines have to be exchanged at least every 4 years. From 13.000km or 24th month the inspection should be made every

7000km. The vehicle is constantly checked for rust. The owner is responsible for rust prevention.

* Model specic deviations are possible

The inspection intervals are required, otherwise, no guarantee can be granted. 1000 km or

1. month

4.000 km or

6. month

7.000 km or

12. month

10.000 km or

18. month

13.000 km or

24. month

PART TO DO

Air lter Clean / exchange √ √ exchange √ √

Wheels, rims Control √ √ √ √ √

Tires Control / tire pressure √ √ √ √

Wheel bearing Control / exchange √ √ √ √

Steering bearing Control / clean / lubricate √ √ √ lubricate √

Screws Coverparts Control / tighten √ √ √ √

Brake system Control / clean / exchange √ √ √ √

Main stand Control / clean / lubricate √ √ √ √

Front fork Control √ √ √ √

Rear suspension Control √ √ √ √

Oil lter Clean √ √ √

Engine oil Control / exchange exchange √ exchange √ exchange

Valves (Engine) Control / adjust √ √ √ √ √

Transmission oil* Exchange exchange exchange exchange

Variomatic belt* Control / exchange √ exchange √

Fly wheels* Control / exchange √ exchange √

Driven chain / sprokets* Control / clean / exchange √ √ √ √ √

Clutch Control √ √ √ √ √

Cable / bowden Control / clean / lubricate √ √ √ √ √

Throttle Control / adjust / lubricate √ √ √ √

Lights / switches Control / adjust √ √ √ √ √

Fuel line / fuel lter Control / exchange

√ exchange √ √

Idle speed Control / adjust

√ √ √ √ √

Exhaust system Control / tighten

√ √ √ √

Coolant* Control

√ √ √ √ √

The warranty can be granted only if the vehicle has been serviced in accordance with this service plan.

55

SERVICE PLAN

1000 km or 1. month

Stamp / Signature

4000 km or 6. month

Stamp / Signature

7000 km or 12. month

Stamp / Signature

10000 km or 18. month

Stamp / Signature

13000 km or 24. month

Stamp / Signature

16000 km

Stamp / Signature

19000 km

Stamp / Signature

21000 km

Stamp / Signature

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

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

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

SIGNATION OF THE CUSTOMER:............................................................................................................................................................................................................................................................

WIRING DIAGRAM

56

SPACE FOR NOTES

57