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OSSA TRi and Explorer workshop manual

USER MANUAL TRi

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Summary of Contents for TRi

Page 1: ...OSSA TRi and Explorer workshop manual USER MANUAL TRi ...

Page 2: ...his tory of the brand of trial racing and of motorcycling as a sport The TR is a motorcycle that has been conceived for competition and then adapted to traffic regulations for use on public roads It has been specifically designed for trial competitions which means that its features are ideal for such conditions It is extremely light in weight both its gears and transmission systems and the dis tri...

Page 3: ...driving is not affected Ensure that there are no loose leashes or other elements that might get caught inside a mechanism Never apply additional weight to the handlebars fork or mudguards Be specially careful when transporting any type of load Do not clean the motorcycle with pressurized water equipment since this may damage the parts Safety Important Read this manual thoroughly and keep it in a s...

Page 4: ... Upper section 29 Section 2 Maintenance and basic 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 ...

Page 5: ...arbox 6 speeds Transmission Primary transmission by gears final transmission by chain Lubrication Mixture 100 synthetic oil lubrication 0 9 Gearbox and clutch lubrication 450 cc of Gear Extreme type 75 W oil FRAME Type Made of CR MO steel tube with fuel tank and lower part made of forged aluminium Front suspension Fork with aluminium bars 40 mm diameter Marzocchi depending on version adjustable in...

Page 6: ...ommended to ensure that the 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 ...

Page 7: ...inder 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 Location of elements 15 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 dis...

Page 8: ...mory 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 kilometres or miles The wheel circumference value can also be changed A temperature sensor warns us with a yellow light 1 when the engine temperature is excessive Another sensor provides a warning with a red light 2 when the rate at which the engi...

Page 9: ...n when the device is switched off 12 24 hour clock It displays the current time in 12 or 24 hour clock It indicates the temperature of the environment and engine The display screen on the upper left shows the environmental temperature Using an optional temperature sensor the screen displays the engine tem perature If excessive the yellow light comes on Indicator that engine turn rate is excessive ...

Page 10: ...he value 0 was entered Default value 1 0 If you don t know this value press button 2 to move on to the next screen To move on to the next digit press button 3 Confirm the selection by pres sing button 2 1 2 3 Activation of the adjustment mode To activate the adjustment mode for the multi function box set tings push buttons 1 2 and 3 si multaneously for 3 seconds and then release them 1 2 3 Select ...

Page 11: ...tton 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pres sing button 2 1 2 3 Dangerous turn rate selector When the set rate is near to be ing reached the right hand war ning light will flash indicating that the engine is turning at an excessive rate Default value 10 000 rpm En ter the value by pressing button 1 repeatedly To move on to the next digit press button...

Page 12: ...ceives no information for 20 minutes wheel signal turn signal or pressed button the screen will turn off displaying only the time When the vehicle moves or by pres sing any button it will start up again Measuring the wheel circumference Method 1 Measure the diameter of the front wheel Multiply the diameter obtained by 3 14 If necessary convert the measurement into mm by multiplying the obtained fi...

Page 13: ...o 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 suspension 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 pre charge of this spring can be adjusted...

Page 14: ...k start pedal is part of the mechanism that is used to kick start the motorcycle mechanically To kick start the motorcycle the kick start pedal must be sepa rated from the bike and moved outwards Once separated place your foot on top and press 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 secur...

Page 15: ...hose or funnel is used to fill up to avoid spilling the petrol This is especially important if the motorcycle is hot DO NOT fill up with petrol when the motorcycle is turned on 1 2 Remove the upper section Stage 1 2 1 3 4 Remove the upper section S To access different parts of the motorcycle or the motorcycle s electrical system the upper section should be removed This section is made up of 2 part...

Page 16: ...30 OSSA TRi User manual 31 OSSA TRi User manual Section 2 Maintenance and basic operations ...

Page 17: ...h use Each use Fuel tank When damaged Each use _ When necessary Each use Screw nuts and fastenings When damaged _ _ First useE ach use Crankcase protector When damaged _ Each use _ _ Protective stickers Check Inspect Replace Change Grease lubricate Adjust Clean Item Check Inspect Replace Change Grease lubricate Adjust Clean 30 Hours 30 Hours Each wash Each wash Each year Each year Each year When n...

Page 18: ...ce of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly Adjustments to the motorcycle controls The clutch lever is located on 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 import...

Page 19: ...36 OSSA TRi User manual 37 OSSA TRi User manual Simplified diagram of the lights wiring Simplified diagram of the injection wiring ...

Page 20: ...ld be used 30ºC To ensure that the motorcycle works correctly periodic controls must be carried out to check the coolant levels This will ensure that the motorcycle is running at an optimum temperature Always use special refrigerant for light alloy engines Air filter Air filter Cleaning and maintenance The air filter should be controlled periodically Lift the upper fuel tank as you can see in the ...

Page 21: ... access the sparkplug detach the upper section of the motor cycle see page 29 Once the upper cover has been removed the motorcycle s electrical system can be accessed Carefully but firmly pull away the hood that provides a current leaving the upper part of the sparkplug exposed Using a special sparkplug key unscrew it The sparkplug should be checked regularly and a spa re sparkplug should be carri...

Page 22: ...e 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 Take care NOT to accidentally lubricate the brake caliper or brake pads If this happens clean off the lubricant and carry out controlled braking until the brakes work correctly again Lubricate using specific products 1 Transm...

Page 23: ... best of its ability It also ensures that trial riding is safer and more effi cient Front tyre 2 75x21 Rear tyre 4 00x18 Front tyre pressure 0 45 bar normal 0 40 bar competition Rear tyre pressure 0 35 bar normal 0 30 bar competition NEVER forget to periodically check the tyre pressure to ensure that the tyres have a good grip Tyre in good working condition Tyre in bad working condition Lubricatio...

Page 24: ...ver which is on the right side of the engine The oil level should be lower than the indicated maximum level MAX MIN Optimum oil level The oil level should be checked when the motorcycle is in an upright position and on a at surface The motorcycle should be cold If it is not cold wait some minutes until it goes cold To add oil remove the cap A located on the top of the clutch cover D Use a funnel t...

Page 25: ... Starting the motorcycle again To start up the motorcycle after a period of inactivity the fo llowing procedure should be followed Remove the plastic covers that were placed over the motorcycle before storing including the exhaust pipe and those parts that had special protection Tighten the sparkplug Fill up the fuel tank with new petrol Carry out general lubrication Check tyre pressure Leave the ...

Page 26: ...ic Troubleshooting In the event of breakdown always take the motorcycle to a specialist mechanic PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The motorcycle is unstable Wire makes it difficult for the handlebar to turn Move wire or loosen it a bit Steer axle screw is very tight Loosen the steer axle screw Steering bearings are damaged or with wear Replace steering bearings Steer axle bent Change the s...

Page 27: ...ith insufficient oil Add oil to the fork until it reaches a sufficient level Front fork spring weak or broken Replace front fork spring Brake disc wear Replace brake disc Brake pads badly positioned or crystallised Change position of brake pads or replace them In the event of breakdown always take the motorcycle to a specialist mechanic PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The motorcycle makes...

Page 28: ... Adjust steering Go to specialist me chanic Steer axle bent Change steering axle Go to specialist mechanic Front fork bent Change front fork Wheels badly centred Align wheels The brakes don t work correctly Disc wear Change disc Loss of brake fluid Check brake circuits Change if dama ged or broken Brake fluid in bad condition Drain brake fluid and replace with new fluid recommended by a mechanic P...

Page 29: ...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 Standardisation components Each of the registered elements should be part of the vehicle In the event of breakages loss or bad functioning it is recommended that you go to an official OSSA mechanic to remedy the problem 1 2 3 4 5 6 7 8 9 10...

Page 30: ...Passing Beam R113 00 14839 2 Front indicators 11001200e94367 3 Rear indicators 4 Rear pilot e13 50 R00 50R00 12448 00 5 License plate support 6 Reflector IA E9 02 01269 7 Mirror L e9 80 780 80 780 0143 01 8 Manufacturer plaque 9 Exhaust system 10 Speedometer 11 Pinion output z 11 12 Lock 13 Horn e13 28R00 28R00 0037 00 14 Kickstand 15 Throttle limiting bolt Standardisation components Manufacturer ...

Page 31: ...60 OSSA TRi User manual 61 OSSA TRi User manual Standardisation components The key number can be found under the red cover Engine number Key number Warranty ...

Page 32: ...both parties with one sole exception if the cost of reparation or replacement is dispro portionate to the product s value the most reasonable solution will be taken into account Rectification considered as disproportionate is that which implies costs for the seller which are not reasonable in contrast with the other means of rectification This takes into ac count the value the product would have i...

Page 33: ...d out EXCEPTIONS TO THE WARRANTY The OSSA warranty does not cover the following items a Damages that arise from not carrying out periodical revisions as stipulated by OSSA b Damages due to repairs or revisions carried out using methods that have not been specified by OSSA c Damages due to using the vehicle in races rallies or other similar competition sports d Damages due to the practice of functi...

Page 34: ...ormance MAINTENANCE AND SERVICE It is your responsibility to ensure that the services are carried out on your motorcycle within the specified time periods and that the services are correctly registered This means that your motorcycle will receive all the benefits of the OSSA warranty It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was pur...

Page 35: ... depen ding upon which country you are in If one of the afore mentioned terms is invalid due to regional or federal laws all other terms stipulated in this warranty continue to be valid Final information We recommend that you stay in contact with your OSSA dealer so that you can receive help advice and information about your new motorcycle as well as information about the new products laun ched by...

Page 36: ...www ossamotor es Ossa Motor Carretera antiga d Amer nau 12 17007 Girona Spain tel 0034 972 107 107 fax 0034 972 117 899 ...

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