Page 1: ......
Page 2: ...r art and experience of leading designers of motorcycles taking special care of drive safety and driving characteristics The materials used for the motorcycle are manufactured according to the latest knowledge of metallurgy and petrochemical industry and therefore they guarantee high reliability and long service life of all its parts The operation and maintenance manual includes all basic data of ...
Page 3: ...Maintenance 15 29 8 1 Lubrication and Maintenance Schedule 16 17 8 2 Torques 17 8 3 Table of Lubricants 18 8 4 Gear Oil Level Check 18 8 5 Gear Oil Replacement 18 8 6 Fuel Cock Cleaning 19 8 7 Air Filter Cleaning 19 8 8 Carburetter Check 20 8 9 Sparking Plug Check 20 8 10 Ignition 20 8 11 Clutch Check and Adjustment 21 8 12 Front Wheel Brake Check and Adjustment 22 8 14 Excessive Effect of Brakes ...
Page 4: ...ion With light coil Type contactless contactless ignition ISKRA ignition VAPE Light power 12 V 80 W Sparking plug Type BOSCH W 5 BC BOSCH W 3 A BRISK N 17 BRISK L N 14 NGK B6 HS NGK B8 HS CHAMPION L 81 CHAMPION L 78 Electrode spacing 0 5 0 6 mm Gearshift mechanism a Primary drive by gears with helical teeth Ratio 3 21 b Secondary drive by chain Ratio 2 71 3 09 2 53 c Clutch multi plate in oil bath...
Page 5: ...ipment voltage 12 V Main headlight round rectangular Main lamp 35 35 W Clearance light lamp rectangular lamp 5 W Pilot lamps 1 2 W Rear light Tail light lamp 5 W Stop light lamp 10 W Direction lights Lamps 10 W Horn electric Fuse 8 A Battery 12 V 4 5 Ah 3 4 Working Liquids Engine Fuel mixture of BA 90 95 mixture of BA 90 95 petrol with oil petrol with oil It is possible to use leadless petrol a Fu...
Page 6: ...Volume 40 ccm 3 5 Other Data Dimensions Length 1 950 mm Width 700 mm Height 1 070 mm Seat height 800 nini Wheel base 1 320 mm Ground clearance 240 mm Weights Kerb weight 81 kg with working liquids Useful weight 180 kg Total weight 261 kg Number of places to sit 2 Maximum speed 65 km h 85 km h Dimensional Drawing 5 ...
Page 7: ...nk 4 Rear direction light 5 Fuel tank 6 Clutch lever 7 Rear view mirrors 8 Brake lever 9 Front bonnet 10 front direction light 11 Engine 12 Carburetter 13 Rear brake lever 14 Front foot rest Type ACS ACP SC 15 Front headlight 16 Clutch lever 17 Fuel cock Type AKS AKP SK 6 ...
Page 8: ...he motorcycles exhaust piping with the exhaust silencer is led under the left rear side Under the engine there are a foot rest holder rear brakes parking stand and bearing of the rear swinging fork that is mounted on the central springing unit The rear part of the frame that bears lockable double seat rear mudguard with rear light and plastic sides with direction indicators is bolted in the upper ...
Page 9: ...ing when the direction light change over switch is in the right or left extreme positions Dimmed light pilot lamp This lamp goes on after start of the engine and switching on the dimmed lights and indicates the dimmed light function Distance light pilot lamp This lamp is on at use of the distance light The pilot lamp of separated lubrication of the engine This lamp indicates minimum amount of oil ...
Page 10: ...bath clutch serves for setting the motorcycle into motion and near shifting The clutch is operated by left hand using the clutch lever on the left side of the handlebars Figure 10 For smooth setting the motorcycle into motion it is necessary to learn how to handle the clutch carefully The clutch must be pressed down anytime you will shift the gear to eliminate the damage to the gearbox 5 4 Gear Sh...
Page 11: ...tand The side stand is fastened on the left side of the motorcycle frame and serves for the motorcycle parking The stand is drawn down to its lower position and the motorcycle is then put on it When the stand is released it returns back spontaneously to its initial position WARNING The motorcycle must not be used for drive with its side stand in lower position Should the stand not be return to its...
Page 12: ...nd then petrol Recommended petrol with minimum octane number 90 including leadless petrols Recommended oil MOGUL TS CASTROL Super TT SHELL Super 2TX Mixing ration table Oil Type Mixing ratio for running in for normal up to 500 km operation MOGUL TS 1 30 1 40 CASTROL Super TT SHELL Super 2TX 1 40 1 50 The capacity of the whole fuel tank is 6 5 lt out of which 0 6 lt is separated as a reserve If you...
Page 13: ...with separated engine lubrication Following warnings apply to all types of motorcycles WARNING It is forbiden to refill petrol on the engine running and in closed and poorly ventilated rooms WARNING The fuel tank closure ensures its venting and tightness at overtilting therefore it is forbiden to make any incompetent action on it 2 Engine Oil Fill Stand the motorcycle on a horizontal surface and u...
Page 14: ...ont tyre 180 kPa 26 psi rear tyre 230 kPa 33 psi load above 90 kg front tyre 230 kPa 33 psi rear tyre 280 kPa 41 psi Check condition of the tyres If the depth of pattern on the tyre centre is less than 1 mm or if the tyre side is cracked or otherwise damaged replace the tyre best of all in the special service Use only the tyres approved for this type of motorcycle Other tyres change characteristic...
Page 15: ...d its heating to the working temperature return the choke into its original position Figure 19 Hot Start You need not use the choke to start the hot engine WARNING Never start the engine or let it run in a closed room Exhaust gases are poisonous and may cause loss of consiousness or even death in a very short time Always lift up the side stand before any drive If it is not fully up it can cause se...
Page 16: ...nufacture for the engine running in see Section 5 10 0 to 500 km After each hour of drive stop the engine and let it cool down for approx 10 minutes Do not accelerate quickly nor load the motorcycle engine with full output use only 1 2 turn of the gas grip Do not maintain the drive speed constant long change it to change the speed of engine 500 to 1 000 km Do not drive long with more than 3 4 tum ...
Page 17: ...ut clearances x Gear oil Check the amount of oil and refill it if need be x Oil Replacement 400 ccm of gear oil See Section 8 4 8 5 x Sparking plug Check of the electrodes spacing and overall condition of the plug Replace it if need be See Section 8 9 x x Exhaust silencer and paper filter Clean the intake paper filter Replace it when to dirty See Section 8 7 x x Speedometer drive Grease the speedo...
Page 18: ...tightening especially before a long drive Check always torques at mounting or dismantling individual parts Torque Tables Screw Torque M 6 mm 8 12 N m M 8 mm 18 28 N m M 10 mm 40 60 N m M 12 mm 70 100 N m M 14 nun 110 160 N m M 16 mm 170 250 N m Engine drain plug 20 25 N m Rear brake lever screw 6 10 N m Sparking plug 15 20 N m Central springing unit Front wheel axle nut 35 40 N m screws 35 40 N m ...
Page 19: ...TROL Super TT SHELL Super 2TX 8 4 Gear Oil Level Check Stand the motorcycle vertically so that it is not deflected to one side Its deflection will cause incorrect measurement Unscrew the oil check plug 1 and check if the oil reaches minimally up to the lower edge of the check hole If the level is lower refill the relevant oil 8 5 Gear Oil Replacement Start the engine and let it heat up for 1 to 2 ...
Page 20: ...the frame and after it remove the cover from the tank Note Following operations are identical for both types Discharge fuel from the tank Dismantle the fuel cock out of the tank in the following way Set the cock control to ON Unscrew the screws M6 with the control pull rod bracket Remove the fuel cock Clean the fuel cock by petrol in various positions of its setting and blow it through by pressure...
Page 21: ...t in decreased power increased consumption or even damage to the engine 8 9 Sparking Plug Check Unscrew the sparking plug and check if its electrodes are not fouled by a layer of carbon or burnt Clean the sparking plug electrodes by a smooth wire brush at big fouling replace the plug by a new one When installing the plug back check the electrode spacing and adjust it if need be Recommended sparkin...
Page 22: ...s down the pull stranded wire unhang it and withdraw it upwards Remove its end terminal through the opening in the engine block cover Insert the pull stranded wire through the opening in the engine block cover lift up the clutch lever and hung the pull stranded wire Connect the stranded wire to the clutch lever on the handlebars Clutch adjustment Figure 28 Release the nut 1 unscrew the adjusting s...
Page 23: ...y out its deaeration Release the locking sheet of the brake yoke upper fastening bolt nut and release the bolt Unscrew the lower fastening bolt and remove it with all distance washers Turn the yoke in such a way that the deaerating screw will be in the highest position Insert a washer between the brake linings which thickness corresponds to the brake disk thickness Figure 30 Brake disk thickness 4...
Page 24: ...the reverse order with following adjustment of the rear wheel brake Rear Wheel Brake Adjustment During operation the wear of the brake shoes results in increased dead travel of the pedal The recommended dead travel on the foot brake lever is 30 mm with the motorcycle unloaded At maximum loading of the motorcycle 180 kg the dead travel of the foot brake lever changes to the value of 10 mm Figure 32...
Page 25: ...chain is tightened most of all Carry out its adjustment in this position At the check the motorcycle must stand vertically to the ground with both wheels on it and without a driver It must be possible to slag the chain within 20 to 30 mm with the unloaded motorcycle If the sag exceeds 30 mm adjust it Figure 34 Tighten the chain as follows Release the wheel axle nut on the right side Shift both cha...
Page 26: ...Figure 37 8 19 Front Wheel Mounting and Dismantling Dismantle the front vheel axle nut and release the forcing off socket screw of the left glider Withdraw the wheel axle using a pin Ø 6 mm Withdraw the front wheel downwards remove the distance rings and speedometer drive assembly Mounting is carried out in the reverse order Tighten the forcing off screw only after the multiple pressing the telesc...
Page 27: ...th the damping element and withdraw them from the exhaust body Clean the surface of the damping element by a scraper Clean the openings in the damping element and exhaust end by a drill Ø 12 mm 8 26 Headlight Adjustment Headlisht Basic Adjustment It is recommended to have the following operations made in the special service If the setting is changed it is possible to carry out readjustment in the ...
Page 28: ...tening screws of the rear group lamp cover and take out the cover Dismantle the clearance light and stop light lamps Check the lamps and replace them if need be Lamp type 12V 5W clearance light 12V 10W stop light Mounting is carried out in the reverse order Drive Direction Indicators Check and or replace the lamps in the following way Dismantle fastening screw of the direction light cover and take...
Page 29: ...hes must also be washed in water and neutralized It is forbiden to use open fire close to the battery 8 31 Table of Failures WARNING It is forbiden to smoke or use open fire close to the motorcycle on fuel system inspection Failure Failure Cause I Failure Removal Ignition Sparking plug without sparks or with low sparks Wet sparking plug Faulty sparking plug Ignition failure Cable socket incorrectl...
Page 30: ...8 30 Electric Installation Diagram Electrical equipment location and wire identification 29 ...
Page 31: ...to remain soft and glossy Apply a mean for rubber protection such as RIWAX Gummi Reiniger to rubber parts and tyres It is possible to use a car wax to all varnished and chrome plated parts After cleaning start the engine and let it idle run for a short time 9 2 Motorcycle Storage Long term storage of the motorcycle requires to use preventive actions to prevent from deterioration of its technical s...
Page 32: ...ction and or adjustment of the motorcycle carried out in a special service regularly Have the exhaust piping end cleaned in time Do not do any design changes on the carburetter and or exhaust system 9 5 Ecologic Information Engine oil gear oil and fuel contain the matters harmful to the environment Observe relevant ecologic rules for their handling and liquidation Always give the spent oil to the ...
