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28 User manual

Lower fuel tank

Upper fuel tank

Filling lid

The engine of this motorcycle works with a mix-
ture of unleaded petrol and 2S oil, 100% syn-
thetic in a 0.9 proportion.

It’s recommended that a hose or funnel is used
to fill up to avoid spilling the petrol. This is es-
pecially important if the motorcycle is hot. DO
NOT fill up with petrol when the motorcycle is

Fuel tank

The Explorer has two fuel tanks, one forms a struc-
tural part of the chassis and is located on the front
inside part. The other one is made of polyamide
plastic and is located in the classic position on the
frame. To fill up with petrol, open the upper fuel tank
lid, situated on the upper part, by unscrewing in an
anti-clockwise direction.

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Summary of Contents for Explorer

Page 1: ...User manual 2012 ...

Page 2: ...2 User manual ...

Page 3: ...ative features of the such as the two stroke injection engine and the chassis A style of bike that is not found in the market it s a combination of a Trials and an Enduro bike It has a bigger seat and offers fun safety and comfort together with amazing handling sensations and inexpen sive maintenance OSSA motorcycles have been designed assembled and tested by experts and each of its parts has been...

Page 4: ...ed by icons to make reading quicker and easier ATTENTION This symbol indicates that special attentionmust be paid INFORMATION Informative note advice Some of the indications specified in this manual are to prevent possible harm from being inflicted on people or material Not following the instructions may result in serious consequences which could put people s lives at risk This manual has been put...

Page 5: ... exhaust system The exhaust system gets extremely hot during and after use of the motorcycle In the event of suffering burns see a doctor as soon as possible Take the time necessary to become familiar with your new mo torcycle Never drive if you have consumed alcohol or any type of subs tance medication drugs that might affect your driving capability Make sure your motorcycle is serviced regularly...

Page 6: ...6 User manual ...

Page 7: ...asic operations 31 Maintenance grid 32 33 Adjustments to the motorcycle controls 34 Electric connections 35 Simplified lighting wiring diagram 36 Simplified injection wiring diagram 37 Air filter 38 Radiator 39 Spark plug 40 Chain Tension adjustments 41 Lubriction of moving parts 42 44 Tyres Pressure and condition 45 Control of crankcase oil Filling up and draining 46 Brakes 47 Torque wrenches 48 ...

Page 8: ...e Made of CR MO steel tube with fuel tank and lower part made of forged aluminium Front suspension Hydraulic fork 40 mm diameter adjustable in rebound and compression Rear suspension Variable progressive system with Ollé mono shock absorber with adjustable spring preload Front brake 185 mm diameter disc with 4 piston brake caliper Freno trasero 150 mm diameter disc with 2 piston brake caliper 180 ...

Page 9: ...t 840 mm Ground clearance 340 mm Fuel tank capacity 7 6 litres 2 6 5 l Dry weight 78 Kg OSSA Factory reserves the right to make modifications without prior notification Kokusan Marzocchi OHlins are registered trademarks and their use is licensed Technical specifications ...

Page 10: ... engine works correctly and for a long lasting time period It is important to run the engine for some minutes until it reaches the correct temperature to work correctly The engine lubrication is a mixture of petrol oil with a 0 9 oil proportion Always use synthetic oil When the motorcycle is new the oil must be changed for the first time after 5 hours of use and for the second time after 12 hours ...

Page 11: ...User manual 11 Section 1 Components ...

Page 12: ...tion of elements 1 Front mudguard 2 OSSA multi function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide 7 Front tyre 8 Front fork bottles 9 Front fork stanchions 10 Shift pedal 11 Chain 12 Chain slider 13 Rear sprocket protector 14 Rear tyre ...

Page 13: ... Rear break caliper and anti theft immobilizer 16 Exhaust 17 Kick start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear brake lever 22 Crankcase protector 23 Front brake caliper 24 Front brake disc 25 Air filter 26 Rear footrests depen ding on version 27 Passenger handle ...

Page 14: ...manual Location of elements 27 Front brake lever 28 Throttle grip 29 Throttle control 30 Front brake pump 31 Front fork servicing cap 32 OSSA multi function box 33 Clutch pump 34 Lights control pad 35 Clutch lever 36 Headlights 37 Ignition key ...

Page 15: ... time average speed maximum speed envi ronmental temperature running time and uptime This device has an internal memory unit that stores data like total Km and total running time even when it is switched off Some features may be personalised the device can measure in kilo metres or miles The wheel circumference value can also be chan ged A temperature sensor warns us with a yellow light 1 when the...

Page 16: ...r 0 0 999999 ODO 1 Km 0 1 Mileage 1 minute 0 999 hours 59 minutes RT 0 1 Uptime 1 minute 0 9999 hours 59 minutes ART 0 1 Accumulated uptime Each use 12 59 59 23 59 59 00 00 00 0 1 Clock Each use 1 year s duration approx LO 0 1 Battery low 0 3999 mm Tyre size Technical features Input voltage 9 400 V CA CC Speed sensor magnetic non contact sensor Tachometer input electrical pulse sensor Wheel circum...

Page 17: ...cords the distance or total accumulated mileage for the ve hicle The data is stored in the memory even when the device is switched off ART Running time controller It calculates the total running time It begins counting as soon as the engine is switched on RT Total running time controller It calculates the vehicle s running time from the last RESET It begins to count from when the vehicle starts to...

Page 18: ...function box set tings push buttons 1 2 and 3 si multaneously for 3 seconds and then release them Select the speed unit To select the speed unit between km h and m h press 1 Confirm your selection by pressing 2 Select the wheel circumference Enter the wheel circumference by pushing button 1 repeatedly To move to the next digit press button 3 Confirm the selection by pushing button 2 Note If you do...

Page 19: ... to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR The indicator receives an elec tric pulse each time the engi ne turns PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pres sing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution ...

Page 20: ...rm the selection by pressing button 2 Warning temperature selector Note This stage should only be imple mented for those vehicles that have an optional temperature sensor When the motorcycle temperature exceeds the set va lue the left hand warning light comes on Default value 90ºC 190ºF En ter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Con firm the select...

Page 21: ...sible to set the following functions to zero simultaneously Maximum speed Distance Chronometer Maximum temperature Maximum turn rate Confirm that you want to set these functions to zero by simultaneously pressing buttons 1 and 2 Setting the whole multi function box to zero Press the RESET button by using a suitable object The indicator will boot again excluding data that corresponds to total accum...

Page 22: ...is partially maintained for 3 seconds when the button is pressed When it is connected to the 12V vehicle installation the illumina tion will be brighter and will remain constant for 20 minutes after the vehicle has stopped Sleep Mode If the multi function box receives no information for 20 minutes wheel signal turn signal or pressed button the screen will turn off displaying only the time When the...

Page 23: ...horn and engine stop See the image with information about the control pad 1 Position lights 2 Cross lights 3 Long range lights 4 Lights for changing direction left right 5 Horn 6 Button to switch off engine See the image with information about the control pad 1 Pilot lamp for change of direction left right 2 Pilot lamp for cross lights 3 Pilot lamp for long range lights 4 Pilot lamp for footrest ...

Page 24: ...ion bar see photo To regulate the extension use the screw located on the right sus pension bar Fig A To regulate the compression use the screw located on the left sus pension bar Fig B Each of the suspension bars also has an air bleed to remove air that accumulates in the inside of the fork stanchion Fig C The rear suspension is formed by a single shock absorber spring The preloadof this spring ca...

Page 25: ...e wiring you must previously remove the seat 1 First you must open the rear seat lock with the ignition key 2 Then you must pull the back of the seat upwards and then bac kwards as in figure 2 3 To put the seat back on the bike repeat the process in inverse order Fig 2 Fig 1 ...

Page 26: ...hould be written down in the indicated space on the regis tration page and series number of this manual The Explorer has an immobilization system for protection against theft This system consists of a lock situated in the area of the brake discs on the rear wheel It is a mechanism that is operated with a key and blocks the rear wheel ...

Page 27: ...ss strongly to turn it counter clockweise It is necessary to ensure that the light signals are working properly that the tire pressure is correct and the security and control elements brakes and controls are in good condition If the motorcycle has been inactive for a long period of time its recommended that the kick start pedal is activated gently 3 or 4 times without actually kick starting the mo...

Page 28: ... petrol This is es pecially important if the motorcycle is hot DO NOT fill up with petrol when the motorcycle is Fuel tank The Explorer has two fuel tanks one forms a struc tural part of the chassis and is located on the front inside part The other one is made of polyamide plastic and is located in the classic position on the frame To fill up with petrol open the upper fuel tank lid situated on th...

Page 29: ...he seat see page 25 Seat 2 Unscrew only the four upper screws of the side tank pannels 3 Disconnect the air hose located in the front of the upper fuel tank see fig 2 4 Disconnect the conector that connects both fuel tanks 5 Unscrew the upper tank central screw which is located where indicated with number 5 6 We proceed to lift the tank from the front pivoting backwards ...

Page 30: ...ls never release the screws that attach the pannels to the radiator as it could pierce it or eventually damage the threads Fuel tank When performing the operation No 4 Disconnect the connector that connects the two fuel tanks You must mind the existence of residual fuel in the quick connector ...

Page 31: ...User manual 31 Section 2 Maintenance and basic operations ...

Page 32: ...h Each useE ach wash Each use _ _ _ _ Air filter Each use Each use Each use Each use Each use Each use Each use 60 horas 15 Hours _ _ _ _ _ _ _ _ _ _ _ 30 Hours 60 Hours 60 Hours 60 Hours _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Silencer Change kick start pedal Radiator tube and connections Item When damaged When damaged When damaged When damaged When damaged When damaged When damaged When damaged Tran...

Page 33: ...se _ When damaged Brake discs Each use _ _ When necessary When damaged 30 horas Wheel bearings Each wash _ _ When damaged Each use Steering bearings Each wash _ _ When damaged Each use Secondary transmission Each wash Each use When necessary When damaged Each use _ Each use 5 Hours Front rear spokes _ When damaged _E ach use Each use Fuel tank When damaged Each use _ When necessary Each use Screw ...

Page 34: ...n the left handlebar grip and is used to activate the clutch mechanism to change gear The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake It s important that the levers can be easily activated by the rider while he she is riding the bike using the index and middle fingers Front brake lever Clutch lever ...

Page 35: ...n good working order As seen in the image on the right these are located at the left side of the cylinder between the steering bar and the front headlight and in the fuel system apparatus Carry out a regular and thorough maintenance of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly ...

Page 36: ...36 User manual Simplified diagram of the lights wiring ...

Page 37: ...User manual 37 Simplified diagram if the injection installations ...

Page 38: ...ase and the clamp Then remove the filter according to the illustration To clean use water and detergent leave to dry and then lubricate with a special liquid for filters Reassemble using the steps outlined previously but in reverse Make sure that the parts areput in their correct po sitions Carry out regular and thorough maintenance of your motorcycle Always use original spare parts and top qualit...

Page 39: ...is could cause burns Avoid contact of the liquid with the eyes mouth or na sal passage Do not ingest In the event of this happening follow the product instructions and consult a doctor The radiator has an electric fan to force air through it as can be seen To fill the radiator special coolant should be used 30ºC To ensure that the motorcycle works correctly periodic controls must be carried out to...

Page 40: ...h use For this reason it can be removed and cleaned so that it lasts longer To access the sparkplug detach the right side cover see fig 1 Once the cover has been removed the motorcycle s electrical sys tem can be accessed Carefully but firmly pull away the hood that provides current leaving the upper part of the sparkplug exposed Using a special sparkplug tool unscrew it and take it out from the r...

Page 41: ...ould be positioned in an oppo site direction to the gear as can be seen in the photo The chain tension should permit 2 cm of oscilla tion in the chain tension adjuster The transmission chain transmits the engine s movement to the rear wheel To ensure that is works correctly it should be checked Cadena Reglajes de tensión ...

Page 42: ...s will help protect the motorcycle and guarantee that it works better If using a high pressure hose to clean the motorcycle bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle Lubricate using specific products 1 Transmission chain 2 Clutch and brake lever joints 3 Gear lever joints 4 Rear brake pedal joints and bearings 5 Footrest brackets and springs ...

Page 43: ...ricated Check it each time the motorcycle is used and apply lubrication when necessary Gear change lever joints Chain drive Rear brake pedal Chain drive joints and bearings The chain must be lubricated using special oil for chain Lubrication of moving parts ...

Page 44: ...44 User manual Lubrication of moving parts Footrest bracket and springs Engine kick start pedal joints Chain drive and tension adjuster springs Gas handle right grip ...

Page 45: ... to check the tyre pressure and that the wheels are in good working condition before each use Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability It also ensures that trial riding is safer and more efficient NEVER forget to periodically check the tyre pres sure to ensure that the tyres have a good grip Tyre in good working cond...

Page 46: ... of the engine The oil level should be lower than the indicated maximum level Optimum oil level To add oil remove the cap A located on the top of the clutch cover D Use a funnel to add the oil NEVER fi lling above the Maximum level Replace the cap If you fill above the Maximum level oil must be removed To remove oil from the hood place a receptacle under the motorcycle and remove the lid B located...

Page 47: ... on the front and rear brake pads must be periodically controlled so that the brakes work effectively The oil level can be checked using the indicator on the front handle and on the rear pump tank The oil level should be situated between the min and max values To remove surplus air from the break circuit the calipers are equipped with air bleeds See image ...

Page 48: ... 50 40 50 40 50 18 25 7 10 7 10 7 10 27 32 18 25 80 90 27 32 27 32 27 32 18 25 7 10 11 7 8 7 8 25 7 8 3 4 7 8 7 8 7 8 40 10 7 8 12 12 13 7 8 8 9 25 Handles Handlebar Front wing bridge section Break pedal Rear wheel axle Sparkplug Water separator Ignition cover Engine drain plug Kick start pedal screw Transmission pedal screw Cylinder block screws Cylinder nuts ...

Page 49: ...stic bag to prevent rust Position the motorcycle so that the wheels don t touch the ground to prevent possible tyre deformation If this is not possi ble cardboard can be placed underneath the wheels Place a cover over the motorcycle such as canvas plastic or material This will protect the motorcycle from dust and other external factors Avoid storing the motorcycle outside or in direct sunlight Sta...

Page 50: ... connection Lack or deterioration of petrol Change the old petrol for new petrol Dry clean or change the sparkplug Change general fuse Check electrical connections and position correctly Take the motorcycle to a specialist mechanic Fill the fuel tank with new petrol Take the motorcycle to a specialist mechanic In the event of breakdown always take the motorcycle to a specialist mechanic Troublesho...

Page 51: ...ent Tyre pressure too great Rear shock absorber badly adjus ted Move wire or loosen it a bit Loosen the steer axle screw Replace steering bearings Change the steer axle Contact an officially registered mechanic Remove surplus oil until it reaches the correct level Drain fork oil and fill up with viscous oil Change the front fork Contact an officially registered mechanic Check the pressure of the t...

Page 52: ... oil to the fork until it reaches a sufficient level Drain fork oil and fill up with suitably viscous oil Change the front fork Contact an officially registered mechanic Adjust the rear shock absorber Adjust chain Change chain rear crown and secondary transmission pinion Change rear crown Lubricate chain Align rear wheel Contact an officially registered mechanic Add oil to the fork until it reache...

Page 53: ...sive tolerance Handlebar support loose steer axle nut loose Replace the damaged cylinder Check and adjust using suitable torque wrench Change worn parts for new parts Centre wheel rim Check the tension of the spokes and readjust Check and add engine oil Tighten the handlebar support and the steer axle nut using suitable torque wrenches Tighten the handlebar support and the steer axle nut using sui...

Page 54: ...la bomba roto Frenos mal ajustados Cambiar el chasis Ir a un taller especializado Ajustar dirección Ir a un taller especializado Cambiar eje dirección Ir a un taller especializado Cambiar horquilla delantera Alinear las ruedas Cambiar disco Verificar circuitos de freno Cambiar los que esten dañados o rotos Vaciar fluido de freno y reponer con uno nuevo recomendado por el constructor Reponer el pis...

Page 55: ...User manual 55 Standardisation components ...

Page 56: ...edy the problem Standardisation components Your Ossa Explorer is standardised in compliance with UE regulations It adheres to all standardisation requirements EURO 3 regula tions The obligatory elements to be registered for driving on public roads and for passing the vehicle s MOT are listed below The elements to be registered among others are identified with a specific mark and registration ...

Page 57: ...t you go to an official OSSA mechanic to remedy the problem Standardisation components 1 Front headlight 2 Front indicators 3 Rear indicators 4 Rear pilot 5 License plate support 6 Reector 7 Mirrors 8 Manufacturer s plate 9 Exhaust system 10 Speedometer 11 Pinion output 12 Lock 13 Horn 14 Kickstand 15 Throttle limiting bolt 16 Handle 17 Passenger footrests in the bike homologated for 2 people ...

Page 58: ...m 10 Speedometer 11 Pinion output 12 Lock 13 Horn 14 Kickstand 15 Throttle limiting bolt 16 Passenger handle 17 Passenger footrests in the bike homologa ted for 2 people Homologation identification 11 12 e9 97 24 97 24 4367 00 R55 00 14839 R113 00 14839 R113 00 14839 11001200e94367 11001200e94367 e13 50 R00 50R00 12448 00 IA E9 02 01269 L e9 80 780 80 780 0143 01 z 11 e13 28R00 28R00 0037 00 Stand...

Page 59: ...User manual 59 Manufacturer s plate Serial number Standardisation components ...

Page 60: ...60 User manual El número de llave se encuentra marcado debajo del tapón rojo se debe retirar para ver el número Engine number Key number Standardisation components ...

Page 61: ...User manual 61 Warranty ...

Page 62: ...ore the warranty extends to both the parts and the labour costs in the event of any repair provoked by faulty materials or manufacture detected in a new motorcycle This is applicable for the time period stipulated within the warranty without limitation except for those that are listed in this manual The main tenance and service requirements indicated by OSSA must have been adhered to in compliance...

Page 63: ...esumed that it is the same fault 4 If after the product has been repaired the product still has faults while the warranty is in force the purchaser can choose between a replacement a price reduction or refund If the purchaser selected a product replacement they can request a repair always while the cost of this repair is not disproportionate a price reduction or refund 5 The seller is not obliged ...

Page 64: ...on the invoice if a later date is shown ACTIVATING THE WARRANTY We request that you make an appointment with the OSSA sales representative that sold you the motorcycle or with any authorised OSSA sales representative providing this warranty manual The OSSA dealer is under obligation to repair or change at the discretion of OSSA any part that is faulty due to either the material used or manufacture...

Page 65: ...ifferent to those indicated in the Owner s Manual f Damages due to modifications that are not approved by OSSA motorcycle preparations modifications for increased vehicle performance light reduction increases and other changes g Damages due to the vehicle s aging natural decolouration of painted or chrome surfaces peeling and other types of deteriora tion h The replacement or repair labour with no...

Page 66: ...ments of periodical maintenance m Additional costs on top of warranty service including notifications accommodation maintenance and other costs due to breakdowns in isolated places Compensation for wasted time commercial losses or hire costs of a substitute product during the adjustment period n Any part replaced under warranty will become the legitimate property of OSSA The parts replaced during ...

Page 67: ...he necessary work can be carried out It is recommended that periodical motorcycle services are planned in advance LOOKING AFTER YOUR MOTORCYCLE Inspect your motorcycle on a daily basis before driving The Owner s Manual contains a list of things to be checked These inspections will help avoid problems Remember that minor adjustments are made more easily at home rather than on the road As well as im...

Page 68: ...THE DEALER Ossa recommends that you go to the dealer where your purchase was made However you can go to any Ossa dealer for repairs to be carried out under guarantee This guarantee provides you as a consumer with specific legal rights You may also have additional consumer rights that vary depen ding upon which country you are in If one of the afore mentioned terms is invalid due to regional or fed...

Page 69: ...OSSA Factory SL We aim to provide full customer satisfaction If the service you have received is not adequate we would ask you to send us a written account stating specific instances with as much detail as possible about the incident concerning our dealer This will enable us to im prove the OSSA MOTOR customer service and services in general Thank you and we hope you enjoy your new motorcycle Fina...

Page 70: ...www ossamotor es Ossa Motor Carretera antiga d Amer nau 12 17007 Girona Spain tel 0034 972 107 107 fax 0034 972 117 899 70 User manual ...

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