Sachs Bikes madass Owner'S Manual Download

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Your Sachs dealer

SACHS
Recommends

Sachs Fahrzeug- und Motorentechnik GmbH

Nopitschstraße 70

•

D-90441 Nürnberg

Telefon: +49 (0)911 4231 400

•

T49 (0)911 4231 332

e-Mail: [email protected]

•

www.sachs-bikes.de

Printed in Germany Nr. P00 649 008 00 02 000 2004 .. ...

Summary of Contents for madass

Page 1: ...mmends Sachs Fahrzeug und Motorentechnik GmbH Nopitschstra e 70 D 90441 N rnberg Telefon 49 0 911 4231 400 Telefax 49 0 911 4231 332 e Mail info sachs bikes de www sachs bikes de Printed in Germany Nr...

Page 2: ...owners manual GB...

Page 3: ...the EC operating license Therefore before implementing a change ask a specialized dealer whether it is al lowable We cannot be held liable for any conse quential damage caused by accessories not appr...

Page 4: ...re pressure and size 19 Load lights 20 Riding instructions Ride safely 21 Ride economically and be aware of the environment 22 23 Running in instructions 24 Side stand 25 Starting 26 Starting with kic...

Page 5: ...Front brake 46 Rear brake 47 48 Adjusting the clutch lever play 49 Sparkplug 50 Fuse 51 Battery 52 53 Changing the bulbs 54 56 Adjusting the headlamps 57 Technical Data Engine 58 Power transmission 59...

Page 6: ...and or death FIRE HAZARD The bike is supplied with a catalyst The exhaust system becomes very hot While riding idling or parking make sure that no easily inflammable materials such as hay leaves gras...

Page 7: ...RY AND OPERATION Right hand side view 1 Fuel tank cap 2 Handlebar fittings 3 Brake fluid reservoir front brake 4 Speedometer 5 Chassis number and rating plate 6 Fork column lock 7 Side stand 8 Battery...

Page 8: ...r 2 Air filter 3 Fuel cock with filter 4 Engine number 5 LH Foot rest 6 Gear lever SUMMARY AND OPERATION Engine left hand side view 7 Spark plug connector 8 Electric starter 9 Footbrake lever 10 RH fo...

Page 9: ...hand direction indicators are activated Push to the right right hand direction indicators are activated 3 Push button horn 4 Emergency off switch engine will not start engine starts 5 Handbrake lever...

Page 10: ...me key Key positions 1 Operating position ignition and all circuits activated 2 Ignition off WARNING While riding do not switch the ignition off NOTE Activate the parking light only for a limited peri...

Page 11: ...N green 5 Speedomter light Speedometer time adjustment Botton B press once the clock CLK appears the time can be set Botton B press once the hour signal is flashing set the hours by pressing botton A...

Page 12: ...new once type AG 13 Set in the batteries with the plus termi nal showing upwards Close the cover 3 properly NOTE The batteries must be changed within 30 seconds so that the odometer memory is not del...

Page 13: ...or difficulties contact a Sachs dealer who will do everything possible to assist you WARNING While the engine is running or the ignition is on do not touch the ignition system FIRE HAZARD The exhaust...

Page 14: ...there is discernable resistance Measure the play Required value A min 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 Che...

Page 15: ...p 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...

Page 16: ...a reserve quantity of approx 0 35 litres RES RESERVE fuel tank is drained There is a remaining quantity which can not be used OFF CLOSED fuel supply closed WARNING Fuel expands under the influence of...

Page 17: ...during oil level checks stands level in all respects Even the slightest inclination towards the side will produce measurement errors Stop the engine and remove the oil filler cap 1 on the lower right...

Page 18: ...replenish the engine oil for classification and viscosity see the table via the oil filler opening up to the maximum level marking Engine oil Recommended grade Per API SG or higher or also with addit...

Page 19: ...the DOT 4 classification Turn the handlebars until the brake fluid tank is level The sight glass must be fully covered with brake fluid If air bubbles can be seen check the brake linings for wear if...

Page 20: ...ing the footbrake lever play MAINTENANCE Checking the brake linings WARNING The brake disks and brake linings must be free of oil and grease Brake linings are subject to wear In order to guarantee the...

Page 21: ...ive chain Check 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 dr...

Page 22: ...he lifespan of the tyres Tyre profile tyre pressure and size WARNING Never ride without valve caps Firmly tightened valve caps prevent the tyre from suddenly losing pressure While the tyres are cold T...

Page 23: ...Sachs approved products as well as qualified advice are available from all specialized Sachs deal ers Correctly loaded Make sure that the left right weight distribution is balanced Check that fasteni...

Page 24: ...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 th...

Page 25: ...traffic Different riding conditions affect fuel con sumption The following conditions are unfavourable for fuel consumption High traffic density especially in big cities with many stops for traffic li...

Page 26: ...anned inspection intervals must be closely observed Regular service by a specialized Sachs dealer will guarantee not only continued operability but also economical fuel consumption low environmental p...

Page 27: ...00 1000 25 35 40 45 Slowly increase the rpm Avoid high rpm running until 1000 km CAUTION The first inspection must be carried out immediately after the first 1000 km You can save yourself delays by ma...

Page 28: ...stand in do not stand within the pivoting arc of the stand The stand pivots automatically upwards with considerable momentum It is essential that the side stand is folded up before starting off Risk...

Page 29: ...dard to tilt up Turn the fuel chock 1 to ON or RES 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 d...

Page 30: ...and the engine will start CAUTION After starting the engine check that the kick starter lever is returned to its normal position As soon as the engine is no longer running smoothly turn back the CHOK...

Page 31: ...ew seconds and push it again Each time push the start button for just a few seconds in order to save the battery Never push the start button for more than 10 seconds When the operating temperature is...

Page 32: ...utch lever Push down on the foot operated gear lever without opening the throttle Carefully engage the clutch Simultaneously slightly open the throttle Accelerate after engaging the clutch Shifting up...

Page 33: ...will 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 braki...

Page 34: ...lever 2 with 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...

Page 35: ...to serious damage when starting 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 Fork column Lock Saf...

Page 36: ...tee claims for corrosion and other such damage CAUTION Rubber and plastic parts will be dam aged by caustic or penetrating cleaning agents or solvents WARNING Always carry out a brake test after clean...

Page 37: ...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 38: ...ue to the presence of salt on the roads NOTE Protect the environment by using only en vironmentally friendly preservation agents and use them frugally CAUTION Do not use hot water which would in creas...

Page 39: ...not used for a longer period it is recommended to support the motorcycle so that its weight is not on the tyres You can prevent the tyres from becoming dry and brittle by spraying them with a silicone...

Page 40: ...otorcycle 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...

Page 41: ...anges 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 acce...

Page 42: ...f this operating manual Checking the fork column bearing Removing the front wheel Installing the front wheel Removing the rear wheel Installing the rear wheel Checking adjusting the drive chain Front...

Page 43: ...n turned and at both limit positions it must easily tilt back Jack up the machine on a sturdy installation jack Take hold of the lower fork tubes and try to move them to and fro in the direction of th...

Page 44: ...t operate the handbrake lever after 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 motorcycle is st...

Page 45: ...l the front wheel in between the fork tubes and insert the spacer bush 3 on the right as seen from the riding direction Grease the full floating axle 2 and push it in from the right as far as it will...

Page 46: ...sh 3 to the left of the wheel hub is not lost Raise the rear wheel remove the full floating axle 1 with brake support 5 and brake caliper and take off the rear wheel to the back Prop up the motorbike...

Page 47: ...he full floating axle 1 Introduce full floating axle chain adjuster 2 brake support 5 with brake caliper into rear suspension Adjust the drive chain s adjusting drive chain page 45 Tighten axle nut 4...

Page 48: ...ain sprocket and pinion must be changed as a single unit Prop the motorbike up on the side stand Take hold of the chain 1 at the point on the sprocket furthest to the rear and pull the chain off Whent...

Page 49: ...a Sachs dealer Front brake Visually inspect the brake calliper 1 Check the thickness of the brake lining minimum thickness A 2 5 mm If the lining thickness is below the mini mum have the brake lining...

Page 50: ...or your own safety we recommend having activities to the brake system carried out by a Sachs dealer Visually inspect the brake calliper 1 on the right motorbike side Check the thickness of the brake l...

Page 51: ...Adjusting the foot brake NOTE Afteralongerperiodofoperation adjustment ofthebrakesisessentialduetonaturalwear of the brake shoe linings Releasethelocknut 4 sothatthepedal 3 has reached a guideline of...

Page 52: ...3 as appropriate Tighten up the lock nut 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...

Page 53: ...r change the spark plug 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 ne...

Page 54: ...since this could destroy the entire elec trical system The fuse is located behind the battery cover 1 NOTE The spare fuse is placed in the fuse case Replace fuse Remove three screws 2 and lift off cov...

Page 55: ...soap suds and the spots must be flushed with plenty of water If acid is swallowed immediately visit call a doctor CAUTION Do not expose batteries to direct sunlight Discharged batteries can freeze so...

Page 56: ...the cover 2 CAUTION The battery may only be connected or disconnected while the ignition is inactive First disconnect the minus terminal black cable When installing the bat tery first connect the plus...

Page 57: ...cloth when installing or removing them Headlight 1 low beam bulb S3 12V 15W E9 2 low beam bulb S3 12V 15W E9 3 Position light bulb 12V 3W Remove the screws 4 on both sides Detach the rubber cover 5 f...

Page 58: ...t bulb diode light If the tail light does not work you should first check whether a cable connection is interrupted Tail brake light bulb Push back the cable protection 2 underneath the seat Check the...

Page 59: ...and removal Front Pull the light case 2 carefully out of the handlebar and hold the thread bolt 3 with a pair of pliers Release the light case Push the bulb 5 back and release it by turning to the lef...

Page 60: ...stment is 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 mot...

Page 61: ...atio 10 1 Lubrication system forced oil lubrication Cooling air cooled Maximum net power output 2 0 kW at 7 000 1 min Maximum net torque 3 2 Nm at 4 300 1 min Ignition system transistorized ignition s...

Page 62: ...Wet multi plate type Gear box 4 seed constant mesh foot operated Gear ratios 1 gear 36 11 3 273 2 gear 31 16 1 938 3 gear 27 20 1 350 4 gear 24 23 1 044 Primary transmission ratio 4 059 Chain pinion...

Page 63: ...sorber travel 65 mm Wheels Light metal Alu Front rim size 1 85 x 16 Rear rim size 2 50 x 16 Tires Front 90 90 16 48J Rear 120 80 16 60J Tire pressure solo pillion driver Front 2 0 rear 2 5 bar Front 2...

Page 64: ...k capacity 4 6 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...

Page 65: ...12 V 80 W Battery 12 V 3 Ah MF Fuse 15 A Lights Headlight Position light Instrument lights Brake rear light Turn signal light Low beam 2x 12V 15W 12 V 3W Direction indicator 12V 3W Change over gear 1...

Page 66: ...oss handlebars without rear view mirror 780 mm Maximum height 1010 mm without rear view mirror Wheel base 1235 mm Seat height 865 mm Weight empty 85 kg Weight in running order 89 5 kg Max transport we...

Page 67: ...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 68: ...urface 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 countr...

Page 69: ...re 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 inte...

Page 70: ...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 specified in this manual must be applied as follows Ev...

Page 71: ...e paper filter x Carburetor Check and adjust idle and cold start x x x Throttle cable x x x Fuel filter Clean fuel cock x x Fuel hoses Check and replace if necessary change at least every 4 years x x...

Page 72: ...for leaks 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 nece...

Page 73: ...70 WARRANTY Maintenance confirmations Workshop activities carried out Workshop activities carried out Activities carried out km date Activities carried out km date...

Page 74: ...71 WARRANTY Maintenance confirmations Workshop activities carried out Workshop activities carried out Activities carried out km date Activities carried out km date...

Page 75: ...ter 12 000 km 12 months dealer 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...

Page 76: ...m 40 months dealer stamp km date 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 d...

Page 77: ...Maintenance confirmation New brake fluid Yes no Km Date Stamp signature New brake fluid Yes no Km Date Stamp signature New brake fluid Yes no Km Date Stamp signature New brake fluid Yes no Km Date Sta...

Page 78: ...approval agency write out a certificate of approval Send us the certificate along with the vehicle data You will then receive from us a copy of the operating license for a fee EC license Federal Bure...

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