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A - 3

RS 300R - RS 500R

SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER)

AFTER FIRST

3 HOURS

EVERY

4h MX /

8h EN

EVERY

8h MX /

16h EN

EVERY

16h MX /

32h EN

EVERY

32h MX /

64h EN

EVERY

40h MX /

80h EN

- REPLACE IF

NECESSARY -

OR EVERY

500 KM

OR EVERY

2000 KM

OR EVERY

4000 KM

OR EVERY

8000 KM

OR EVERY
10000 KM

VALVE TIMING DRIVEN GEAR

VALVE TIMING GEAR

TIMING CHAIN TENSIONER

STARTER DECOMPRESSOR SYSTEM

INTAKE MANIFOLD

CYLINDER ASSY.

PISTON ASSY

CONNECTING ROD ASSY.

Содержание RS 300 R

Страница 1: ...RS 300 R RS 500 R 2021 Manual Operation Maintenance...

Страница 2: ...vice This Owner s Manual is part and parcel of the motorcycle hence it shall remain with the motorcycle even when sold to another user This motorcycle uses components designed thanks to systems and st...

Страница 3: ...ly with the mainte nance plan is charged to the Client Note the warranty is NULL AND VOID if the motorcycle is rented Important Notice Readthismanualcarefullyandpayspecialattention to statements prece...

Страница 4: ...ETICAL INDEX 66 SCHEDULED MAINTENANCE APPENDIX A Note References to the left or right of the motor cycle are considered from the point of view of a person facing forward Z number of teeth A Austria AU...

Страница 5: ...amped on the steering head tube Always quote the number stamped on the frame when ordering spare parts or requesting further details about your vehicle and note it on this booklet CHASSIS NUMBER VEHIC...

Страница 6: ...ster 8 Rear shock absorber compression ad juster low and high damping speeds 9 Rear shock absorber rebound adjuster 10 L H switch 11 Clutch control lever 12 Gear shift control pedal 13 Air bleeding sc...

Страница 7: ...739 CLUTCH Type oil bath multiple disc clutch hydraulic control TRANSMISSION Type constant mesh gear type Transmission ratio 1st gear 2 000 z 28 14 2nd gear 1 611 z 29 18 3rd gear 1 333 z 24 18 4th ge...

Страница 8: ...p Gall 1 9 U S Gall Coolant capacity 2 0 2 4 Imp Pints 2 3 2 7 U S Pints Transmission oil Oil and oil filter replacement Imp Quarts 1 5 U S Quarts 1 8 Oil replacement Imp Quarts 1 3 U S Quarts 1 6 TAB...

Страница 9: ...oke or allow flames or sparks in the area where the motorcycle is refuelled or fuel is stored WARNING Do not overfill the tank Refer to the lower mark on filler After refuelling make sure the tank cap...

Страница 10: ...w the last configured function When the engine is turned off the instrument does not show any functions To select instrument functions and reset func tions use the SCROLL button A The functions which...

Страница 11: ...standard function in Fig 1 will reappear Note After the previously described operation the ODO setting will be converted and all other data reset the H Counter is unchanged 2 SPEED H RPM figure 2 SPE...

Страница 12: ...l be lost after detaching battery ToactivatethefunctionSTP1 pushtheknobSCROLL A for more than 3 seconds pressing SCROLL A for more than three seconds the counter starts pressing SCROLL A once only the...

Страница 13: ...3 seconds RPM engine r p m shown on the vertical bar in dicator 9 TRP 2 CLOCK RPM figure 9 TRIP 2 distance maximum value 999 9 km miles the data will be lost after detaching battery To set TRIP 2 to...

Страница 14: ...AKE CONTROL The brake control lever 2 is located on the right hand side of the handlebar The position of the throttle control can be adjusted by loosening the two retaining screws CAUTION Do not forge...

Страница 15: ...the lock To unlock the steering lock reverse the above pro cedure R H HANDLEBAR SWITCH The right hand switch features the following con trols 1 Engine start button 2 Engine KILL SWITCH L H HANDLEBAR S...

Страница 16: ...s The position of the gear shift lever on the shaft can be varied as follows loosen the screw pull the lever out and place the lever in a new position on the shaft Tighten the screw once operation is...

Страница 17: ...the rules mentioned herebelow Please note that FAILURE TO COMPLY WITH THESE RULES MAY COMPROMISE THE LIFE AND THE PERFORMANCE OF THE MOTORCYCLE warm up the engine by running at low revs before using...

Страница 18: ...safety switch is fitted on the clutch lever support that allows starting ONLY when the clutch lever is pulled The engine lacks power dirty air filter clean the spark plug electrode gap is too large ad...

Страница 19: ...and then release the button IMPORTANT NOTE IN CASE OF COLD STARTS AT LOW TEMPERATURES It is recommended to briefly warm up the engine at idle until after having disengaged the starter there is a norma...

Страница 20: ...removing key STOPPING THE MOTOR IN AN EMERGENCY Press the red button 7 to stop the motor after use bring it back to the out position WARNING Independent use of the front or rear brake may be advantage...

Страница 21: ...isoperationmadewithwarmengine WARNING Becarefulnottotouchhotengineoil ENGINE OIL REPLACEMENT AND BAG FILTERS FILTER CARTRIDGE CLEANING OR REPLACEMENT WARNING Be careful not to touch hot engine oil Dra...

Страница 22: ...e the cap 8 Clean the filters 9 and 10 using petrol Check the condition of the O rings 11 and 12 and replace them if worn Refit everything operating in reverse order from removal taking care to correc...

Страница 23: ...tart switch is in OFF position always keep at a safe distance from the fan blades Note Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water COOLANT LE...

Страница 24: ...Reassemble the screw 1 Pour the necessary quantity of coolant in the ra diator then warm up the engine in order to elimi nate any possible air bubbles Allow the coolant to cool down then remove cap 2...

Страница 25: ...3 WARNING Operation with damaged throttle cable could result in an unsafe riding condi tion WARNING Exhaust gas contains poisonous carbon monoxide gas Never run the engine in a closed area or in a co...

Страница 26: ...1650 RPM is reached turn clockwise to increase the speed and anticlockwise to reduce the speed ADJUSTING THE MANUAL DECOMPRESSOR CABLE TENSION In order to adjust the lever 1 decompressor free play ap...

Страница 27: ...should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the spark plug has overheated and in sulator tip is vit...

Страница 28: ...ways on the vehicle Remove screw 3 and the filter 4 Separate filter 5 from frame 6 AIR FILTER AND CLEANING Wash the filter with a specific detergent then dry it fully Plunge the filter in special oil...

Страница 29: ...ck steering wheel adjustment place kick stand or other support under the engine so that the front wheel is raised from ground Place slight pressure on the tips of the handlebars torotatesteeringwheel...

Страница 30: ...the rear brake pedal with respect to the footrest may be adjusted according to the individual needs For adjusting proceed as follows loosen the screw 1 turn the cam 2 in order to raise or lower the b...

Страница 31: ...er stroke WARNING If the brake lever feels mushy when pulled there may be air in the brake lines or the brake may be defective Since it is dangerous to operate the motorcycle under such conditions hav...

Страница 32: ...ION Do not spill brake fluid onto any painted surface or light lens CAUTION Do not mix two brands of fluid Completelychangethebrakefluidinthebrake system if you wish to switch to another fluid brand C...

Страница 33: ...ontal position check the fluid level is NOT BELOW 4 mm 0 16 in from the upper surface D of the pump body if necessary add fluid until the correct level is reached see TABLE FOR LUBRICATION SUPPLIES fo...

Страница 34: ...e bleeding nipple 3 mount a syringe in the bleeding nipple hole then refill with fresh fluid CAUTION NEVER use brake fluid refill until fluid is discharged from the lower hole B on the pump body WITHO...

Страница 35: ...ression and espe cially harder rebound settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork harder compression setting Shock absorber harder compr...

Страница 36: ...IR VENT to carry out monthly Set the motorcycle on a central stand release the fork fully extended and loosen the air vent valve D Once this operation is over tighten the valve Note Never force the ad...

Страница 37: ...1 18 25 30 mm 5 To get the right SAG according to your weight adjust the shock absorber spring preload as de scribed at side B rear mudguard top height C rear wheel axle height WARNING The shock abso...

Страница 38: ...oke is independ ent from the rebound stroke A COMPRESSION Standard setting 1 Low damping speed 14 clicks adjuster 7 2 High damping speed 1 turn adjuster 8 To reset the standard setting turn upper adju...

Страница 39: ...and the rear wheel axle as shown on drawing Than let turn three times the rear wheel Now the chain should not be tight FAST ADJUSTMENT FIG B In the point shown in the figure fit a bush a 1 37 in 35 mm...

Страница 40: ...be as the one shown in fig ure Remove the wheel and check the wear of the rear sproket teeth The below figure shows the outline of teeth in normal and excessive wear Should the sprocket be badly worn...

Страница 41: ...correctly set the clip 3 and mas ter link 4 as well as the relevant O rings 2 Make sure that the chain is neither worn out nor damaged If the rollers or the links are damaged replace the chain by foll...

Страница 42: ...g a brush and engine oil with SAE 80 90 viscos ity inside and outside parts CAUTION The chain lubricant shall NEVER get in contact with the tyres or the rear brake disc Chain guide roller chain guide...

Страница 43: ...1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out Note Do not operate the front brake le...

Страница 44: ...H forkleg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the...

Страница 45: ...sc into the calliper Note Do not operate the rear brake pedal when the wheel has been removed this causes the cal liper pistons to move outwards After removal lay down the wheel with brake disc on top...

Страница 46: ...nt or pedal rear brake lines calliper assembly and disc LEGEND 1 Front brake control lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake di...

Страница 47: ...ads WARNING Donotworkthebrakeleverorped al while removing the pads PADS WEAR Check brake pad wear Respect the service limit A indicated in the relative figures If service limit is exceeded always repl...

Страница 48: ...s with new ones if they cannot be cleaned satisfactorily PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 WARNING Do not attempt to ride the motor cycle until the bra...

Страница 49: ...e the thickness of each disc at the point where it has worn the most Replace the disc if it has worn past the service limit Disc thickness DISC CLEANING Poor braking can also be caused by oil on the d...

Страница 50: ...f any length of time to avoid moisture contami nation of the fluid Handle brake fluid with care because it can damage paint Don t mix two types of fluid for use in the brake This lowers the brake flui...

Страница 51: ...he brake lever or pedal close the bleeding valve with the brake lever or pedal applied and then quickly release the lever or pedal Repeatthisoperationuntilthebrakelineisfilled and clear fluid starts c...

Страница 52: ...ance card if the hoses A and B are worned or cracked their re placement is advised FRONT BRAKING SYSTEM BLEEDING The braking system must be bled after the fluid replacement or when due to air in the c...

Страница 53: ...aking fluid is a very corrosive sub stance in the case it comes in contact with your eyes wash them abundantly with water During the bleeding of the braking circuit keep the handlebar turned leftwards...

Страница 54: ...g the union slightly Release the pedal and wait for a few seconds before repeating the operation until only fluid come out of the tube Close the bleed union to the prescribed torque and check the flui...

Страница 55: ...ignition coil 2 under the fuel tank Electronic power unit C D I 3 under the fuel tank Voltage regulator 4 under the fuel tank Spark plug 5 on the R H side of cylinder head Starting motor 12V 450W 6 b...

Страница 56: ...4 15A and one 15 20A on the right side of the rear mudguard Coolant temperature sensor 17 Lambda probe 18 Headlamp 19 with two filaments bulb of 12V 35 35W and parking light bulb of 12V 5W LED tail li...

Страница 57: ...e regulator 4 Rear stop switch 5 Front stop switch 6 Injector 7 Instrument 8 R H front turn indicator 9 Front headlamp 10 Cooling fan 11 L H front turn indicator 12 Horn 13 L H commutator 14 Turn indi...

Страница 58: ...30 28 10 31 26 29 27 35 23 33 39 20 15 21 41 16 17 18 1 13 7 8 9 11 4 5 14 12 6 25 36 37 38 40 22 2 3 34 24 32 28 SM RS EN 58...

Страница 59: ...so the battery needs to be charged Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK or BLUE negative cable to the ba...

Страница 60: ...uncouple from the two lower supports remove the headlamp carrier remove the two filaments bulb connector 1 and the boot 2 remove the screw 3 release the bulb holding spring 4 and then the bulb 5 itsel...

Страница 61: ...s not function REPLACING THE NUMBER PLATE BULB loosen screw 1 and remove the number plate bulb 2 from the mudguard take bulb holder 3 and bulb 4 out of the sup port pull the bulb 4 to detach it from b...

Страница 62: ...at 33 ft from a wall or screen Then trace a hori zontal line at the height of headlight centre and a vertical one in line with vehicle longitudinal axis If possible execute this operation in a shaded...

Страница 63: ...de rapide Kurzanleitung Gu a r pida Cope_retro QUICK 300 500_codA000P01249_ed00_12 2016 indd 1 16 12 16 12 31 EN EN 63 EQUIPMENT Pos No Part no DESCRIPTION 1 A000P01249 MULTILANGUAGE QUICK MANUAL 1 2...

Страница 64: ...back ready for use after stor age Make sure the spark plug is tight Fill the fuel tank Run the engine to warm the oil up then drain the oil Refill with fresh oil Check all the points listed under the...

Страница 65: ...ke control Check operation Flexible controls and transm Check Adjust Drive chain Check Adjust Description Operation Pre delivery Tyres Check pressure Side stand Check operation Side stand switch Check...

Страница 66: ...TMENT OF THE HYDRAULIC CLUTCH CONTROL LEVER 32 AIR FILTER AND CLEANING 28 AIR FILTER CHECK 28 APPENDIX 64 ASSEMBLY 29 B BATTERY 59 BATTERY CHARGER 59 BRAKE DISC WEAR 49 BRAKE PADS REMOVAL 47 BRAKES 46...

Страница 67: ...FRONT WHEEL 44 REPLACING THE NUMBER PLATE BULB 61 REGOLAZIONE TENSIONE CAVO 26 REMOVING THE FRONT WHEEL 43 REMOVING THE REAR WHEEL 45 RIDING 17 RIMS 8 R H HANDLEBAR SWITCH 15 S SECONDARY DRIVE 7 SIDE...

Страница 68: ...A A 1 APPENDIX A...

Страница 69: ...MX 16h EN EVERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM VALVES CLEARANCE CLEARA...

Страница 70: ...ERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM VALVE TIMING DRIVEN GEAR C X VALVE T...

Страница 71: ...EVERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM CRANKCASE BEARINGS S ENGINE OIL S...

Страница 72: ...EVERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM CLUTCH DISCS PRESSURE PLATE C MOC...

Страница 73: ...MX 16h EN EVERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM PARK PLUG P S SPARK PLUG...

Страница 74: ...16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM COOLANT C X FOOTRESTS FOOTRESTS PINS AND...

Страница 75: ...EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM FRONT FORK R HANDLEBAR HOLDERS AND FASTENING SET C...

Страница 76: ...RY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM REAR SHOCK ABSORBER R REAR SUSPENSION LINKS NEEDLE BEARIN...

Страница 77: ...X 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM REAR BRAKE DISC C X REAR BRAKE SYSTEM FLUID C...

Страница 78: ...8h MX 16h EN EVERY 16h MX 32h EN EVERY 32h MX 64h EN EVERY 40h MX 80h EN REPLACE IF NECESSARY OR EVERY 500 KM OR EVERY 2000 KM OR EVERY 4000 KM OR EVERY 8000 KM OR EVERY 10000 KM WHEEL HuB BEARINGS S...

Страница 79: ...S REPLACEMENT C CHECK P CLEAN R OVERHAUL L IGREASING LUBRICATION MX MOTOCROSS EN ENDURO REFER TO MANUAL WORKSHOP NOTE EVERY REMOVAL REPLACE ALL GASKETS REPLACE SCREWS AND NUTS IF WORN GENERAL CHECK AF...

Страница 80: ...SWM Motorcycles USA 605 878 1005 www swm usa com...

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