Sachs Bikes MadAss 125 Owner'S Manual Download Page 1

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Your Sachs dealer

SACHS

uses

and recommends

Sachs Fahrzeug- und Motorentechnik GmbH
Ernst-Sachs-Straße 6 • D-90441 Nürnberg
Phone: +49 (0)911 4231 400 • Fax +49 (0)911 4231 332
e-Mail: [email protected] • www.sachs-bikes.de

Nr. P00 646 008 00 02 000

2006 04 005

Summary of Contents for MadAss 125

Page 1: ...ses and recommends Sachs Fahrzeug und Motorentechnik GmbH Ernst Sachs Stra e 6 D 90441 N rnberg Phone 49 0 911 4231 400 Fax 49 0 911 4231 332 e Mail info sachs bikes de www sachs bikes de Nr P00 646 0...

Page 2: ...125 owners manual...

Page 3: ......

Page 4: ...tenance helps to maintain the motorbike s value and is one of the require ments for warranty claims We wish you at all times a safe journey Your SACHS Fahrzeug und Motorentechnik GmbH You have purchas...

Page 5: ...Operation in winter and anti corrosion protection 35 Repairing paint damage servicing the tyres 35 Lay up commission 36 Technical changes accessories and spare parts 37 OVERVIEW AND OPERATION Safety...

Page 6: ...47 Adjusting the clutch lever 48 Cleaning the air lter 49 Cleaning the fuel lter 50 Adjusting the play of the twist grip throttle control 50 Spark plug 51 Battery 52 53 Cheching the fuse 54 Changing t...

Page 7: ...damaged Non observation can lead to the guarantee becoming void NOTE Special instructions for better handling during operation and inspection and when carrying out adjustment procedures and service ac...

Page 8: ...Brake uid reservoir rear brake 2 Brake uid reservoir front brake 3 Chassis number and rating plate 4 Fork column lock 5 Footbrake lever rear brake 6 Footrest 7 Kick starter 8 Battery and fuse 9 Pilli...

Page 9: ...14 17 18 10 Cockpit 11 Handlebar ttings 12 Tank cap 13 Adjustment shock absorber 14 Pillion footrest fold up 15 Side stand 16 Footrest 17 Gear shift pedal 18 Air lter housing Left hand side view OVER...

Page 10: ...Exhaust valve adjuster cover 3 Spark plug connector 4 Electric starter 5 Oil drain plug 6 Clutch cover 7 Oil ller cap Engine right hand side view 8 Carburetor 9 Fuel tap 10 Engine number 11 Gear shif...

Page 11: ...tton Right handle handlebar ttings Left handle handlebar ttings 1 Fixed grip 2 Clutch lever 3 Head light switch High beam Low beam 4 Head light signal 5 Choke lever Operating positions A Cold start B...

Page 12: ...riding do not switch the ignition off NOTE Activate the parking light only for a limited period Take into account the charge of the battery The key can be removed in positions Cockpit 1 Speedometer 2...

Page 13: ...ter Button M press once changing from DST to TRIP or to CLK Button S press in TRIP Mode to clear the trip odometer to zero Button M press untill the clock time CLK appears Button S press once the hour...

Page 14: ...lock time needs to be reset Remove the screws 1 and take off the speedometer 2 Remove the screws 3 4 and take off the cover 5 Replace the batteries 6 by using new batteries type AG 13 Set in the batte...

Page 15: ...a Sachs dealer who will do everything pos sible to assist you WARNING While the engine is running or the ig nition is on do not touch the ignition system FIRE HAZARD The exhaust system becomes very h...

Page 16: ...s discernable resistance Measure the play Required value A 3 4 mm Adjustment Remove the rubber cap 1 Release the lock nut 2 Turn setting screw 3 as appropriate Tighten up the lock nut 2 Check the play...

Page 17: ...1 only insert the ignition key 3 and do not turn Open by using the cover 2 The fuel tank cap 1 is designed to allow for ventilation Do not make any changes to the cap Opening Tilt up the cover 2 in th...

Page 18: ...ke starting dif cult or lead to serious engine damage We cannot be held liable under the guarantee for damage caused by non observance of this caution Fuel tap 4 Fuel tap positions A OPEN fuel tank wi...

Page 19: ...oil API SG or higher Recommended grade Per API SG or higher or also with additional release status ACEA A3 96 CCMC G5 Recommended viscosity Viscosity depends on the outside tem perature For short whi...

Page 20: ...el checks stands level in all respects Even the slightest inclination towards the side will produce measurement errors Stop the engine and remove the oil ller cap 1 on the lower right of the crank cas...

Page 21: ...low the MIN mark Use only brake uid of the DOT 4 clas si cation If air bubbles can be seen check the brake linings for wear if necessary replenish the brake uid CAUTION Do not spill any brake uid on p...

Page 22: ...brake disks and brake linings must be free of oil and grease Brake linings 1 are subject to wear In order to guarantee the operability of the brake system the wear limits of the brake linings must no...

Page 23: ...heck the chain setting and the drive chain for damage before each run Check the chain tension Shift the gear to neutral Prop the motorbike up on the side stand Let the motorbike rear end drop to the l...

Page 24: ...2 7 bar Tyre pro le The standard motorbike is provided with the following tyre sizes Front 90 90 16 48J Rear 120 80 16 60J WARNING Use only tyres approved by the manu facturer The use of non approved...

Page 25: ...Sachs approved products as well as quali ed advice are available from all specialized Sachs dealers Correctly loaded Make sure that the left right weight distribution is balanced Check that fastening...

Page 26: ...your feet on the footrests Do not ride if your riding ability has been compromised On smooth slippery roads take into account that your riding stability and braking power are limited by the grip of t...

Page 27: ...ls Turn the engine off when waiting in traf c Different riding conditions affect fuel con sumption The following conditions are unfavourable for fuel consumption High traf c density especially in big...

Page 28: ...are fully running them in at various slanted positions Only then will the surface obtain its full grip Running in new brake linings WARNING New brake linings must be run in and will not have their ful...

Page 29: ...pported CAUTION The motorbike is equipped with a side stand switch If the side stand is folded up and a gear is shifted the ignition will be discon nected The engine is shoot off and will not start Pr...

Page 30: ...to position A ON or R RESERVE Mount the motorcycle Turn the ignition key 2 to its operating position WARNING Before beginning a ride the side stand must be tilted up all the way danger of crashing St...

Page 31: ...urned to its normal position As soon as the engine is no longer run ning smoothly turn back the CHOKE 1 in position B When the operating temperature is in creasing turn back the CHOKE all the way in t...

Page 32: ...h the start button for just a few seconds in order to save the battery Never push the start button for more than 10 seconds As soon as the engine is no longer run ning smoothly turn back the CHOKE 1 i...

Page 33: ...Push down on the foot operated gear lever without opening the throttle Carefully engage the clutch Simultaneously slightly open the throttle 2 Accelerate after engaging the clutch Shifting up to gear...

Page 34: ...not pose a risk to yourself or others e g a deserted parking area WARNING Operate the brakes to grind off the salt deposited on the brake discs Dirty brakes When riding on dirty streets the braking e...

Page 35: ...the right foot When stopping or slowing down release the throttle gas and operate both brakes at the same time On tight curves sandy dirty streets wet asphalt and icy roads use the front brake careful...

Page 36: ...the engine Non observance of this caution will lead to the guarantee becoming null and void for any damage attributable to such Stopping the engine Steering lock Safeguard the steering against unautho...

Page 37: ...tee claims for corrosion and other such damage CAUTION Rubber and plastic parts will be damaged by caustic or penetrating cleaning agents or solvents WARNING Always carry out a brake test after cleani...

Page 38: ...paint or covering Preservation agents When necessary the motorcycle must be preserved with commercially available preserving and cleaning agents By way of precaution especially in winter regularly tre...

Page 39: ...a boiler room for longer periods WARNING A minimum tyre profile depth of 2 0 mm must be maintained at all times Servicing tyres Operation in winter and anti corrosion protection NOTE Protect the envi...

Page 40: ...torcycle in a dry room and jack it up so that its weight is not on the wheels Commission Remove the preservation agents from the outside Clean the motorcycle Install the charged battery Preserve the b...

Page 41: ...hanges CAUTION We recommend using only approved Sachs accessories and original Sachs spare parts for Sachs motorcycles This is in your own interests the safety suitability and reliability of these acc...

Page 42: ...ing shows noticeable play it must be adjusted by a specialised Sachs dealer Pull the hand brake to block the front wheel brake Now pump the fork girders several times up and down using the handlebar T...

Page 43: ...nitely ad justed Slacken the locking nut 1 with a suitable spanner to adjust the spring preload Turn the adjustment nut 2 with the span ner in direction A to increase the spring preload harder suspen...

Page 44: ...ter the wheel has been removed Protect the wheel bearings from dirt and moisture Support the motorcycle so that the front wheel can move freely and the motor cycle is standing securely Loosen the shaf...

Page 45: ...insert the spacer bush 4 on the right as seen from the riding direc tion Grease the full oating axle 3 and push it in with the spacer bushing 5 as far as it will go Attach the axle nut 2 and screw tig...

Page 46: ...eel hub is not lost Raise the rear wheel remove the full oating axle 4 with brake support 6 and brake caliper and take off the rear wheel to the back Prop up the motorbike so that the rear wheel can t...

Page 47: ...oating axle 4 chain adjuster 7 brake support 8 with brake caliper 6 into rear suspension Insert right chain adjuster 2 and reassemble with axle nut 1 Adjust the drive chain 5 see adjusting drive chain...

Page 48: ...stand Hold the chain 1 at the furthest rear point of the sprocket and pull it off With correct chain tension it should not be possible to lift the chain higher than the teeth of the sprocket If the c...

Page 49: ...cket and pinion Measure the travel Adjusting the chain CAUTION The adjustment of the chain in uences the wear of chain and sprocket It is essential to have the tightening torques checked by a Sachs de...

Page 50: ...s to the brake system carried out by a Sachs dealer Front wheel brake Visually inspect the brake calliper 1 Check the thickness of the brake lining Minimum thickness Frontbrake A 2 5 mm Rear brake A 1...

Page 51: ...foot brake indicates that there is air in the brake system You should have the brake system bled by a Sachs dealer Air in the brake system is a considerable safety risk NOTE The footbrake pedal posit...

Page 52: ...2 Check the play NOTE If the clutch play cannot be corrected with this adjustment the following adjustment must be made Release the lock nut 2 Tighten setting screw 3 all the way so thattheclutchcabl...

Page 53: ...rder to disassembly Remove the air lter Loosen the clamp 1 and take off the hose Unscrew the screw 2 Pull out the lter case 3 from the guide 4 on both sides Take off the manifold pipes 5 from the lter...

Page 54: ...e the handlebar to check whether the throttle cable moves freely Check whether the throttle cable is obstructed by other parts Open the twist grip throttle control until resistance can be felt Measure...

Page 55: ...only when the engine is cold Pull the spark plug connector 1 Unscrew the spark plug 2 Check the electrode gap 0 7 0 8 mm replace the plug if it is severely burnt away Insert new spark plug NGK CR7 HSA...

Page 56: ...spots must be ushed with plenty of water If acid is swallowed immediately visit call a doctor CAUTION Do not expose batteries to direct sun light Discharged batteries can freeze so they must be store...

Page 57: ...us terminal 4 black cable When installing the battery rst connect the plus terminal 5 red cable The battery is maintenance free Do not try to open it Remove the screws 1 on both sides and take off the...

Page 58: ...he fuse is located behind the cover 2 Replace the fuse Turn off the ignition Remove the lower battery cover Remove the three screws 1 and take off the cover 2 to the left side Open the fuse case 3 A f...

Page 59: ...oth when installing or removing them Headlight 1 low beam bulb 12V 55W E1 2 High beam bulb 12V 55W E1 3 Position light bulb 12V 5W Remove the screws 4 on both sides Detach the rubber cover 5 from the...

Page 60: ...a replaceable light bulb diode light If the tail light does not work you should rst check whether a cable connection is interrupted Tail brake light If this is not the case the tail light must be rep...

Page 61: ...touchthebulbswithyourbarehands Use a clean dry cloth for installation and removal Indicator bulbs front rear 12 V 21W Rear indicator Front indicator Release the light case 2 Push the bulb 3 back and r...

Page 62: ...s punishable by law Remember you are responsible for the correct adjustment of the motorbike s headlamp WARNING Do not run the engine in an enclosed space risk of asphyxiation Position the motorcycle...

Page 63: ...ession ratio 9 3 1 Lubrication system forced oil lubrication Cooling air cooled Maximum net power output 6 0 kW at 8 400 1 min Maximum net torque 9 0 Nm at 5 400 1 min Ignition system transistorized i...

Page 64: ...Wet multi plate type Gear box 4 gear claw dog clutch engagement pedal gear shifting Gear ratios 1 gear 34 12 2 832 2 gear 29 17 1 706 3 gear 26 21 1 238 4 gear 23 24 0 958 Chain pinion 16 teeth Sprock...

Page 65: ...k absorber travel 65 mm Wheels Light metal Alu Front rim size 1 85 x 16 DOT Rear rim size 2 50 x 16 DOT Tires Front 90 90 16 48J Rear 120 80 16 60J Tire pressure solo pillion driver Front 2 2 rear 2 5...

Page 66: ...capacity 5 1 litres including 0 35 litres reserve Fuel Unleaded fuel min 91 octane Telescopic fork oil Viscosity SAE 10 W Filling quantity per fork tube 180 cm3 Engine oil Filling quantity SAE 15 W 4...

Page 67: ...Battery 12 V 6 Ah MF Fuse 15 A Lights Headlight Position light Instrument lights Brake rear light Turn signal light Low beam 12V 55W E1 high beam 12V 55W E1 12 V 5W Direction indicator 12V 3W Change...

Page 68: ...ss handlebars without rear view mirror 760 mm Maximum height 1035 mm without rear view mirror Wheel base 1235 mm Seat height 835 mm Weight empty 100 kg Weight in running order 105 5 kg Max transport w...

Page 69: ...r through the authorized Sachs dealer seller The customer is then entitled to legal claims Replaced parts pass over into the possession of Sachs Fahrzeug und Motorentechnik GmbH 2 The installation of...

Page 70: ...face the lifetime will be reduced this may already occur after 500 km Brake linings brake shoes brake lines depending on riding style and load these may already be worn after 2500 km in cross country...

Page 71: ...are from the 6th month Free wheel sprockets free wheel of starter depending on care from the 6th month Self locking nuts cotter pins locking plates bonded screw connections during each maintenance int...

Page 72: ...be complied with At 1 000 km 1st service Every 4 000 km or after 4 months Every 8 000 km or after 8 months After the warranty period the inspection intervals speci ed in this manual must be applied as...

Page 73: ...ce foam lter x Carburetor Check and adjust idle and cold start x x x Throttle cable x x x Fuel lter Clean x x Fuel hoses Check and replace if necessary change at least every 4 years x x x Engine oil C...

Page 74: ...s and repair if necessary x x x Chain Check adjustment and condidtion and grease adjust and renew if necessary inspect clean and lubricate every 1000 km Side stand Check grease repair if necessary x x...

Page 75: ...71 Workshop activities carried out Workshop activities carried out Activities carried out km date Activities carried out km date MAINTENANCE CONFIRMATION...

Page 76: ...72 MAINTENANCE CONFIRMATION Workshop activities carried out Workshop activities carried out Activities carried out km date Activities carried out km date...

Page 77: ...stamp 4 000 km 4 months dealer stamp 1 000 km 1 months 1st service dealer stamp After 24 000 km 24 months dealer stamp After 8 000 km 8 months dealer stamp After 16 000 km 16 months dealer stamp Afte...

Page 78: ...ate After 36 000 km 36 months dealer stamp km date After 32 000 km 32 months dealer stamp km date After 60 000 km 60 months dealer stamp km date After56 000 km 56 months dealer stamp km date km date A...

Page 79: ...ew brake uid Yes no Km Date Stamp signature New brake uid Yes no Km Date Stamp signature New brake uid Yes no Km Date Stamp signature New brake uid Yes no Km Date Stamp signature MAINTENANCE CONFIRMAT...

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Page 81: ...approval agency write out a certi cate of approval Send us the certi cate along with the vehicle data You will then receive from us a copy of the operating license for a fee EC license Federal Bureau...

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