Megelli Sport 250RR User Manual Download | Manualshive

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Maintenance

Service Schedule

For the services to be conducted by an authorized Megelli dealer, please refer to the separate Service/Warranty booklet.

Additional checks are required periodically as part of the routine maintenance and are listed in this manual.

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Summary of Contents for Sport 250RR

Page 1: ...1 Sport 250RR User Manual ...

Page 2: ...duration of its life We ask you to read the contents and ensure you are familiar with the maintenance controls and safety aspects of the bike prior to riding Should you have any questions regarding its function or operation please contact a Megelli authorized dealer The content of the manual represents the Sport 250RR motorcycle Megelli reserves the right to introduce changes to the product as par...

Page 3: ...3 Contents Page Introduction 7 Bike detail Identification 8 Delivery 10 PDI Records Controls Features 11 Safety General 26 Safety Pre Ride Checks 27 Rider Bike ...

Page 4: ...g the Engine 30 Stopping the Engine 32 Running in 33 Riding 34 Braking 35 Gear selection Riding 36 Steering lock 37 Side Stand 38 Fuel Tank 39 Seat Removal 40 Maintenance 41 Service Schedule 42 Access 43 Engine 44 Chain Adjustment 45 ...

Page 5: ...spension 52 Lubrication 54 Battery Electrical 55 Lights 57 Air Filter 62 Wheels Steering 63 Tyres 65 Technical Specification 66 Engine 66 Transmission 67 Electrical 68 Dimensions 69 Chassis Wheels Tyres 70 Capacities 71 Fluid Grade 72 ...

Page 6: ...6 Contents Cleaning Care 73 Storage 75 Warnings 76 Environmental 77 Parts 78 Warranty 79 ...

Page 7: ...ke air cooled engine with a battery operated electric start function The transmission has 6 manually selected gears with a chain drive to the rear sprocket The frame has a twin trellis construction with alloy outriggers and a tubular constructed rear swing arm Hydraulic 38mm forks are utilized for the front suspension with a mono shock absorber for the rear Braking is via hydraulically operated fr...

Page 8: ...8 Identification Each bike has an individual chassis number which is engraved on the headstock of the frame and a unique engine number engraved on the casing of the engine ...

Page 9: ...nd Warranty Manual It is advisable to make a note of these numbers and keep them in a safe location for future reference There is also a plate riveted to the chassis with details specific to the individual model and bike Note This plate may be in a different format in regions outside of Europe ...

Page 10: ... terms of the warranty service schedule and the operation of the controls has been explained A copy of the form with a list of completed checks will be passed to you once it has been signed and dated by both the dealer and purchaser of the bike You should also remember your responsibility to ensure any legal requirements to permit usage on the highway are in place before riding For example tax ins...

Page 11: ...R H Side View KEY 1 R H Rear View Mirror 5 Pillion Seat 9 Rear Brake Pedal 2 Instrument Panel 6 R H Pillion Footrest 10 Oil Level 3 Lockable Fuel Cap 7 Rear Suspension 11 Front Brake Lever 4 Rider Seat 8 R H Rider Footrest ...

Page 12: ...ntrols Features L H Side View KEY 1 L H Rear View Mirror 6 Gear Lever 2 Steering Lock 7 L H Rider Footrest 3 Battery under fuel tank 8 Side Stand 4 Air Filter under seat unit 9 Chain 5 L H Pillion Footrest 3 ...

Page 13: ...13 Controls Features Left Hand Switch Handlebar Assembly KEY 1 Hand Grip 4 Indicator Toggle 2 Clutch Lever 5 Horn Switch 3 High Low Beam Switch 6 Choke Lever ...

Page 14: ...14 Controls Features Clutch Lever To disengage the clutch allowing gear selection pull the lever towards the hand grip To engage drive release the lever smoothly to prevent transmission damage ...

Page 15: ...15 Controls Features High Low Beam Switch Position 1 Low Beam Position 2 High Beam Indicator Toggle Position 1 Turn Left Position 2 Turn Right Push to Cancel ...

Page 16: ...16 Controls Features Horn Push button to activate Choke Lever Move the lever in direction A to activate the choke Move the lever in Direction B to disengage the choke ...

Page 17: ...17 Controls Features Right Hand Switch Handlebar Assembly KEY 1 Throttle Grip 5 Front Brake Lever 2 Starter Button 3 Light Switch 4 Engine Kill Switch ...

Page 18: ...18 Controls Features Light Switch Position 1 Lights Off Position 2 Side Lights On Position 3 Headlight On Note Operation may vary in countries where their laws require ...

Page 19: ...19 Controls Features Throttle Rotate anti clockwise to increase the revs Rotate clockwise to reduce the revs Starter Button Press to activate starter Release as soon as engine fires ...

Page 20: ...s Kill Switch Switch to Run position for engine to start run Switch to Kill position to stop engine in an emergency Front Brake Lever Pull lever towards handlebar with a smooth but positive action to apply the front brake ...

Page 21: ...21 Controls Features ...

Page 22: ...lockwise with steering on full lock Warning Do not switch ignition off while riding Rev Counter Indicates the number of revolutions per minute rpm Caution Never run the engine with the rpm in the red sector a red warning light will illuminate Caution Refer to the Running in section for maximum rpm Green Turn Indicator Flashes when L H or R H indicator position is selected ...

Page 23: ...er Records distanced traveled and can be re set to zero when required Press adjust button to access from odometer trip meter max record Blue Full Beam Lamp Illuminates blue when the high beam position is selected Amber Low Fuel Warning Illuminates when there is approximately 1 litre of fuel remaining in the tank Amber Low Fuel Warning Blue Full Beam Lamp Digital Speed Trip Meter ...

Page 24: ...enter the minute adjusting mode Pressing the select button repeatedly will increase the minute digit Press the adjust button to save and exit the clock setting mode and return to the main screen Neutral Light When the neutral position is selected the N green light will illuminate Odometer Records the accumulative distance traveled Note this should be set as either miles or km s depending on releva...

Page 25: ...zero Press the adjust button twice to return to the main screen Max Record Records the maximum speed traveled Press the adjust button twice to enter the maximum speed display Press the adjust button for 3 seconds to set the display to zero Press the adjust button once to return to the main screen Battery Light Illuminates red when there is insufficient charge to the battery ...

Page 26: ...ody extremities and clothing away from any moving part Warning Do not expose unprotected skin to fluids used in the motorcycle When working with such fluids always use protective clothing Caution Motorcycles are heavy and should be handled with care to avoid injury Always seek assistance when required ...

Page 27: ...bike and ensure that you have fully read and understood the manual If you are unclear or unsure of any aspect seek the assistance of a qualified Megelli agent or instructor Protective clothing should be worn while riding the bike This should include an approved helmet and appropriate apparel No additional items should be carried on the bike which may impede access or operation of the controls or m...

Page 28: ...Do not overload the bike Adjust tyre pressures and suspension settings to suit the loading of the bike see tyres pressure suspension settings loading capacities Do not ride while under the influence of drugs alcohol or any medication which may adversely affect your reactions Take account of the road conditions and ride accordingly reducing speed if necessary Ensure the bike is road worthy and all ...

Page 29: ...ators and horn are functioning correctly Brake operation Brake pad wear see page 35 47 Steering is smooth from lock to lock Suspension is operational without fluid leaks Chain adjustment lubrication see page 45 46 Side Stand is fully retracted see page 38 Ensure the bike has not been modified in any way including the addition of accessories other than official Megelli items All fixings are in plac...

Page 30: ...ntenance checks refer to Safety Pre Ride Checks Release the steering lock mechanism refer to Steering Lock page 37 Mount the bike Switch the Kill Switch to run on position page 32 Insert the ignition key and turn to the On position Allow the self check system to complete its cycle Check the Green Neutral indicator light is illuminated and roll the bike forward ensuring the transmission is in the n...

Page 31: ...nd apply the throttle turn anti clockwise when engine fires As soon as engine fires release the starter button and allow the bike to idle turn the throttle fully clockwise Should the engine not start after 10 seconds release the starter button and repeat the procedure after waiting for 10 seconds As the engine warms gradually move the choke lever to the off position ...

Page 32: ...ge or the likelihood of people children touching these parts is minimal Select an area of level ground which is firm to avoid the side stand sinking under the weight of the bike Select neutral position and check the green neutral indicator is illuminated Turn the key to the off position Move the side stand to the down park position and gently lean the bike on the stand Apply the steering lock refe...

Page 33: ...this period also avoid harsh acceleration Warning For the first 300 km s 200 miles do not operate the engine for long periods above 4500 rpm During the running in period or when replacement brake pads are fitted avoid harsh prolonged or excessive braking This will allow the pads to be bedded in and the braking performance will be improved Warning During the running in period greater pressure on th...

Page 34: ...conditions and braking distances increase on wet and slippery road surfaces The style and manner in which you ride will affect aspects such as fuel consumption and the amount of wear on components of the bike By avoiding excessive acceleration engine revs and shifting quickly up through the gears the fuel consumption will be reduced and this will also reduce the wear on the engine brakes and tyres...

Page 35: ...ike has been ridden in wet conditions been washed or has not been used for a long period allowing corrosion of the discs apply the brakes gently several times to clear the friction surfaces Apply both the front and rear brakes to improve braking performance and reduce the chance of a wheel locking skidding Warning Always check operation of the braking system prior to riding ...

Page 36: ...de stand is fully retracted to its stowage position To select the gears disengage the clutch pull fully towards the hand grip and move the gear selector from the neutral position down to 1st gear position Release the clutch leversmoothly while applying the throttle at the same time ...

Page 37: ...ck is located on the headstock and is applied by the ignition key To operate the lock turn the steering fully to the left and then insert the ignition key Depress the key and turn anti clockwise to apply the lock To release the lock insert the key and turn it clockwise and remove the key The steering is now free to be turned ...

Page 38: ...at the stand swings through on itsreturn to the stowage position as it returns with considerable force Caution Check the stand returns fully to its stowage position before riding Riding with the stand fully or partially down is unsafe To apply the stand move the stand fully forward with your foot against the pressure of the spring At the same time gently lean the bikes onto the stand until it take...

Page 39: ...insert the key Turn the key anti clockwise to release the lock allowing the cap to be opened To close the fuel cap push the cap into position and turn the key clockwise engaging the lock The key can now be removed and the cover closed Warning Ensure the cap is correctly closed before riding ...

Page 40: ...ar of the bike as a single operation To replace the seat align the guides at the front of the seat with their respective locations Lower and move the seat forward as a single operation until fully forward At this point press firmly at the back of the seat until it clicks and then remove the key Caution ensure the seat is correctly fitted before riding the bike ...

Page 41: ...by the rider Caution If you are unsure of how to perform any adjustments checks or do not have the correct tools consult a Megelli technician Your bike should also be kept clean and free from dirt and also be correctly lubricated Caution Do not use high pressure washer systems to clean your bike as this could cause water ingress into electrical and fuel systems It may also remove essential lubrica...

Page 42: ...le For the services to be conducted by an authorized Megelli dealer please refer to the separate Service Warranty booklet Additional checks are required periodically as part of the routine maintenance and are listed in this manual ...

Page 43: ...43 Maintenance Access Once the seat has been removed see seat removal page 40 all areas which require daily or weekly attention are accessible without the need to remove any further panels or bodywork ...

Page 44: ... This should be checked daily Ensure the bike is on level ground and upright for this operation The oil level must be between Up and Low marks Warning If the oil level is either too high or too low the engine may be seriously damaged ...

Page 45: ... axle 3 Loosen the locking nuts from the chain adjuster 4 Screw the adjusting bolts allowing the rear wheel to move further from the bike thus tightening the chain Adjustment should be equal on both sides Marks on the swing arm assist in this operation 5 Correct tension is achieved when the chain can be flexed 15 25mm at point A ...

Page 46: ...46 Maintenance Warning If the chain is incorrectly adjusted the motorcycle may be damaged and the life expectancy of the chain reduced ...

Page 47: ...ngs should be free from corrosion 2 Check the thickness of the brake pads If there is less than 1 75mm of friction material left the pads should be replaced by a Megelli authorized dealer Front Brake Disc Pads 4 15 3 60 Rear Brake Disk Pads ...

Page 48: ...48 Maintenance 3 Check the thickness of the brake discs If they are damaged or the thickness is less than 3 5mm have them replaced by a Megelli authorized dealer ...

Page 49: ...ed daily With the bike on level ground and upright the fluid level in the front master cylinder reservoir must be between the minimum and maximum marks If the level is low check the system for leaks To add fluid remove the lid secured by 2 screws Always use fluid from a sealed source ...

Page 50: ... the rear reserve incorporated into the rear master cylinder must be central in the viewing glass REMOVE SCREWS TO ADD FLUID If the level is low check the system for leaks To add fluid remove the lid secured by 2 screws Always use fluid from a sealed source ...

Page 51: ...nt before the clutch starts to be activated To adjust the cable 1 Loosen the locking nut 2 Turn the adjusting nut to achieve correct free play 3 Tighten lock nut Warning An incorrectly adjusted clutch will reduce its life expectancy and affect the performance of the motorcycle ...

Page 52: ...d loading of the bike Spring adjustment a Using a 2 5mm allan key release the locking screw on the adjusting nut b Using an appropriate special tool turn the adjusting nut clockwise to increase the pre load harden the suspension or anti clockwise to decrease the pre load soften the suspension 1 Locking screw 2 Adjusting nut 3 Tool for turning adjusting ring ...

Page 53: ...shock absorbers add or reduce the air pressure Recommended air pressure is 150psi Caution the shock absorber contains pressurized gases and the spring is under considerable pressure It is important to exercise caution when handling this component If in doubt contact a Megelli dealer ...

Page 54: ...be supplied by Megelli outlets The frequency of lubrication is dependant on the amount of use and the conditions the bike is ridden in As a guide a weekly lubrication is required for a bike used regularly but every time after washing or riding in the rain Cables The cables should be checked prior to each ride ensuring they operate smoothly They should have lubricant on them at all times and not be...

Page 55: ...y If the bike is not to be used for periods in excess of 2 months it should be removed and stored fully charged in a cool and dry place The battery should be charged every 2 months to maintain a full charge Warning Batteries contain acid and should be handled with care Warning Expired batteries should be disposed of in accordance with local legislation Caution When conducting repairs in particular...

Page 56: ...de of fuel tank left panel To access the fuse by removing the fuel tank left panel If the fuse has blown always replace it with a fuse of the same rating 20A If it continues to blow have the bike checked by a Megelli dealer to establish the reason and take action to prevent recurrence For any further electrical issues with the exception of lights please consult a Megelli dealer Fuse Spare Fuse ...

Page 57: ...ife expectancy of the bulb Caution bulbs do become very hot and you should not work with them until they have cooled Warning do not replace the bulb with a higher wattage unit Warning do not place any tinted cover or decal over the lens To replace the bulb 1 Disconnect the electrical plug 2 Remove the headlight rubber cover 3 Unclip the bulb and remove 4 Fit a new bulb and secure it using the reve...

Page 58: ...58 Maintenance Bulbs Side Light 1 Remove light holder with bulb still fixed 2 Pull the bulb from the holder and replace with new bulb 3 Replace using the reverse of removal ...

Page 59: ...rs use LED and can only be replaced as an assembly Removal 1 Disconnect the electrical connector 2 Pull the unit off the rubber mount Replacement 1 Feed wire through rubber mount and connect to main wiring connector 2 Push unit into rubber mount ...

Page 60: ...e rear light The tail brake light uses LED s and can only be replaced as an assembly Removal 1 Remove seat page 40 2 Disconnect electrical connector 3 Remove 2 nuts securing the light shroud and assembly 4 Pull the light assembly to rear to remove Replacement use the reverse procedure of removal ...

Page 61: ...ntenance Bulbs License Plate Light Caution ensure the exhaust is cool prior to working on the rear light 1 Remove fixing bolt securing the assembly and unplug the cable wiring 2 Replace the assembly complete ...

Page 62: ...tions where the filter is contaminated with foreign material it may require additional inspection Filter inspection Remove retaining screws from the air filter housing Remove the element and inspect for contamination Contamination can be removed by using low pressure air stream or gently tapping the filter Warning Do not use high pressure air stream or hit the filter aggressively against a hard su...

Page 63: ...should be checked to ensure there is a smooth action turning the handlebars from one full lock to the other To check the steering bearings apply the front brake to prevent the wheel from turning Rock the bike to and fro feeling for any movement play in the bearings ...

Page 64: ... The wheel should rotate freely Grip the wheel and rock from side to side checking for movement free play at the hub bearings If there is any free play have the bike checked by a Megelli dealer Inspect the rims before each ride for any form of damage Any dents cracks or defects should be checked by a Megelli dealer ...

Page 65: ...including cuts splits or bulges Check air pressure see capacities Ensure there is sufficient tread to meet legal requirements Check there are no foreign bodies embedded in the tyres Warning Riding with a defective tyre may impair the handling and performance of the motorcycle resulting in serious safety issues ...

Page 66: ...r notice Engine Cylinder Arrangement Single Cylinder Cooling system Liquid Cooled Compression Ratio 11 5 1 Carburetor Type TK MV34 Idle Speed rpm 1500 100 Valve Train SOHC Lubrication System Forced and Wet Sump Maximum Speed 140KM h Oil Capacity 1500ml Starter System Electric System ...

Page 67: ... Multi Plates Gear Box 6 Speed Gear Change Gear Ratios 1st 2nd 3rd 4th 5th 6th 2 583 1 800 1 333 1 100 0 958 0 880 Primary Reduction 2 909 Final Reduction 2 846 37 13 Gear Shift pattern 1 N 2 3 4 5 6 Final Drive Type Chain Final Drive Cushioned Sprocket 520 37T ...

Page 68: ...enerator Ignition C D I Starter Electrical Starter Battery 12V8AH Sealed Maintenance Free Spark plug RG6YC Fuse 20A Bulb Headlight high beam Headlight dipped Tail Light Rear Brake Light Indicator Side License Plate 12V 55W 12V 55W 12V 0 23W LED 12V 0 58W LED 12V 2W LED 12V 5W 12V 5W ...

Page 69: ...69 Technical Specification Dimensions Overall Height 1060mm Overall Length 1990mm Overall Width 780mm Seat Height 800mm Wheel Base 1350mm Ground Clearance 150mm Weight Dry 135Kg Maximum Weight 280Kg ...

Page 70: ...egree Suspension Front Rear Conventional Fast Ace Mono Shock Wheel Front Rim Rear Rim Cast Aluminium Rim 2 75 17 Cast Aluminum Rim 3 50 17 Tyre Front Rear Front Tyre Pressure Rear Tyre Pressure CST 100 70 17TL Tubeless CST 130 70 17TL Tubeless 200Kpa 28P S I 220Kpa 32 P S I Chain Pitch Number of Links 520 104 ...

Page 71: ...71 Technical specification Capacities Fuel Tank Full Reserve 11 litre 1 litre Engine Sump 1 5 litre Brake Fluid DOT4 or DOT3 ...

Page 72: ...72 Technical specification Fluid Grade Fuel Unleaded with min octane 90 Oil SJ 5W 40 Brake DOT4 or DOT3 Chain Lubricant Bespoke chain lubricant or SAE 80 or 90 weight gear oil ...

Page 73: ...may be used to aid the cleaning process Ensure the sponge and water is clean and not contaminated with abrasives as this may damage scratch the surface of the bike particularly plastic bodywork and the transparent wind shield Rinse with clean warm water and finally dry with a polishing cloth or chamois leather Using a chain and or engine cleaner degreasing agent will assist in the removal of exces...

Page 74: ...n When using proprietary cleaners ensure they do not have an adverse effect on the area being cleaned Caution Do not use a high pressure washer as this may cause damage to the seals drive chain and the electrical system Caution Always carry out a brake test after cleaning as the braking systems may still be damp which may lengthen the baking distance ...

Page 75: ...sufficiently lubricated see lubrication section Apply a protective wax avoiding all contact points eg seat handlebar grips foot rests etc Fully inflate the tyres see capacities If possible remove the weight from the wheels by the use of a bike stand Remove and charge the battery The charge on the battery should be topped up every month using a suitable battery charger Store in a dry well ventilate...

Page 76: ...6 Warning After storage replace the battery Clean the bike Perform the standard pre ride checks Start the bike and initially ride at low speed to ensure all aspects of the bike are functioning correctly ...

Page 77: ...the effect transport has on the environment and strives to produce efficient motorcycles during their working life and also in the production process We respectfully ask owners of Megelli motorcycle to ride efficiently conserving fuel where possible and care for the environment All waste oils fluids and replaced components should be disposed of in accordance with local legislation ...

Page 78: ...any items on your Megelli motorcycle Use of non genuine parts may have an adverse effect on the performance of the bike and their use will invalidate any warranty Genuine parts can be sourced from authorized Megelli dealers and can be viewed at www megelli parts com ...

Page 79: ...ranty information and Service Schedule booklet which should accompany the motorcycle for the duration of its life The terms explained in this booklet must be adhered to so in the event any item requires replacing or rectification it can be conducted within these terms with the minimum of disruption ...

Page 80: ...he manual Table 1 lubrication Interval Items 6 000 kms 4 000 miles OR 6 months 12 000 kms 8 000 miles OR 12 months Throttle Cable X Throttle X Clutch Cable X Drive Chain Every 1000kms 600 miles OR week OR after washing or use in rain Brake Pedal Collar X Gear change Collar X Steering bearing 10 000 kms 6000 miles OR 12 months Swingarm Spacers 10 000 kms 6000 miles OR 12 months ...

Page 81: ... 2500 miles OR 12 months 7 000kms 4500 miles OR 24 months Cylinder Head bolts and Exhaust pipe bolts X X Cam Chain Tighten Tighten Air Cleaner 3000km Valve Gap X X Spark Plug X X X Fuel Hose Replace every four years Oil X Every 3000km 2000 miles Oil Filter X X Carburetor X X Clutch X X Fuel Filter X Replace ...

Page 82: ...ial 1 000kms 600 miles OR 3 months 4 000kms 2500 miles OR 12 months 7 000kms 4500 miles OR 24 months Drive Chain X X X X Brake Hoses Replace every 4 years Brake Oil Replace every 2 years Brakes X X Tyres X X Steering System X X Front and Rear suspension X X Bolts and Nuts X X ...

Page 83: ...83 WWW COM ...

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