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5. Measure the spark plug gap with a

wire thickness gauge and, if neces-

sary, adjust the gap to specification.

Clean the surface of the spark plug

gasket and its mating surface, and

then wipe off any grime from the

spark plug threads.

6. Install the spark plug with the spark

plug wrench, and then tighten it to

the specified torque.

Spark plug gap: 0,6 - 0,7 mm

0,6-0,7 mm

4. Check the spark plug for electrode

(3) erosion and excessive carbon or

other deposits, and replace it if ne-

cessary.

Specified spark plug:

NGK BR8ES

WARNING

Please note that no other spark plug

model is allowed. Using a different

spark plug model can immediately lead

to engine damage.

WARNING

Please note the max. torque when in-

serting the plug. If you do not have the

ability to control you leave control of

the spark plug to the dealer.

Tightening torque: 12 Nm

FINAL TRANSMISSION OIL

The final transmission case (1) must

be checked for oil leakage before each

ride. If any leakage is found, have a

dealer check and repair the vehicle. In

addition, the final transmission oil must

be changed as follows at the intervals

specified in the periodic maintenance

and lubrication chart.

CAUTION

As long as the vehicle is within the war-

ranty period the dealer is responsible

to change the gear oil.

PERIODIC MAINTENANCE AND MINOR REPAIR

Содержание D01

Страница 1: ...mod USER MANUAL D01 ENG ...

Страница 2: ...nd peronality represents your outstanding taste and favor to pursue the state of the art living attitude This manual describes the correct usage of this motorcycle including safety riding simple inspection methods and so on For a more comfortable and safety riding please read this manual carefully If any questions concerning the operation or maintenance of your vehicle please consult a dealer ...

Страница 3: ...most of the vehicle information however the maker will continually imrprove it s product design and quality that lead to difference between the manual and vehicle If you have any questions concerning this manual please consult your dealer WARNING FOR YOUR OWN SAFETY PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION THIS VEHICLE ONLY OPERATE THE VEHICLE UNTIL YOU HAVE COMPLETELY AWARE OF ADEQUATE ...

Страница 4: ...3 IMPORTANT MANUAL INFORMATION Dealer label here ...

Страница 5: ...gine 25 Starting off 26 Shifting and riding 26 Acceleration and deceleration 26 Braking 27 Parking 27 Stop the Engine 27 Engine break in 27 PERIODIC MAINTENANCE AND MINOR REPAIR 29 Owner s tool kit 30 Spark plug 30 Final transmission oil 31 Coolant 32 Air filter 32 Carburetor 33 Idling speed 33 Throttle cable free play 33 Clutch lever free play 34 Tires 34 Rims 36 Brake lever free play Brake pedal...

Страница 6: ...prear to public will be very effective in reducing the change of this kind of accidents Therefore Wear a brightly colored and protecti ve clothes Jacket Operate the turning signals before turning and slow down the Speed when approaching and passthrough the intersection Keep proper distance with other Mo torists and let them aware of your location Know your skills and limits Never lend your vehicle...

Страница 7: ...r operation They become very hot and can cause burns Always wear protective clothing that covers your legs ank les and feet Modifications Modifications made to this vehicle that not approved by maker or the removal of original equipment may let vehicle unsafe for use and cause severe per sonal injury Modifications may also make your vehicle illegal touse Loading and accessories Adding accessories ...

Страница 8: ...g Do not smoke or use Mobile pho ne while re fueling Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of conscious ness and death within a short time Always turn the engine off before leaving the vehicle and remove the key from the main switch When parking the vehicle please note the following The engine and exhaust sys...

Страница 9: ...SAFETY INFORMATION 8 ANTI TAMPERING LABEL 1 Anti tampering label 1 Symbol image ...

Страница 10: ... VEHICLE 9 LEFT VIEW 1 Front wheel 2 Front disc brake 3 Headlight 4 Front turn signal light 5 Radiator 6 Fuel tank cap 7 Spark plug 8 Fuel cock 9 Side stand 10 Air filter 11 Pedal 12 Seat lock 12 8 9 10 2 1 4 3 6 11 7 5 ...

Страница 11: ...10 RIGHT VIEW 13 License plate light 14 Tail light brake light 15 Rear wheel 16 Muffler 17 Rear turn signal light 18 Rear disc brake 19 Kickstarter 20 Brake pedal 21 Coolant reservoir 22 Brake lever 21 18 22 20 19 15 13 16 14 17 ...

Страница 12: ...CLE 11 CONTROLS AND INSTRUMENTS 23 Clutch lever 24 Left handlebar switches 25 Clutch pedal 26 Dashboard unit 27 Main switch 28 Brake pedal 29 Brake lever 30 Throttle grip 31 Right handlebar switches 23 24 31 28 29 26 27 30 25 ...

Страница 13: ...t 2 Push the key in and turn it to the position while still pushing it 3 Remove the key Unlock the steering Push the key in and then turn it to position while still pushing it WARNING Never turn the key to or while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or an accident Make sure that the vehicle is stopped before tur ning the...

Страница 14: ...el and fill the oil tank with an 2 stroke engine oil The warning light should go off after the 2 stroke engine oil tank has been refilled CAUTION Do not operate the vehicle until you know that the 2 stroke engine oil level is sufficient Lack of engine oil will da mage the engine WARNING Please note that the engine oil war ning light is model dependent If your vehicle has no engine oil war ning you...

Страница 15: ...ion check the oil level and fill the oil tank with an 2 stroke engine oil The warning light should go off after the 2 stroke engine oil tank has been refilled CAUTION Do not operate the vehicle until you know that the 2 stroke engine oil level is sufficient Lack of engine oil will da mage the engine WARNING Please note that the engine oil war ning light is model dependent If your vehicle has no en...

Страница 16: ...creen press the adjust button once to switch from trip to clock Press and hold the adjust for 3 sec to reset the trip Select button Main screen In main screen press and hold the se lect button for 3 sec to switch the back light color Watch settings In main screen press and hold the se lect and the adjust button for 3 sec to enter the clock settings 15 ...

Страница 17: ...rn push this switch to When released the switch returns to the center posi Example You want to set the hour to 14h press the adjust button to choose the hour you want to set Example You want to set the minute to 14 05 press the select button to en ter the minute settings Then press the adjust button to choose the minute you want to set After the settings are done press the select button to store y...

Страница 18: ...witch to start the vehicle CAUTION At the same time you have to pull the brake lever to start the vehicle For st arting the vehicle read the notes in ma nual KICKSTARTER The kickstarter 1 is located on the right side of the vehicle It is used to start when the battery is empty or the electric starter would not work The en gine can only be started with the neut ral gear is selected To start the eng...

Страница 19: ...ossible switching positions you see in the pic ture The idle is between first and se cond gear CAUTION Never attempt to change gear without releasing the clutch Novices and retur ning riders are recommended to take a riding techniques course FUEL COCK 1 OFF No petrol can flow from the fuel tank to the carburettor Always turn the petrol tap to the OFF position as soon as you have parked the vehic l...

Страница 20: ...amage the painted surfaces or plastic parts Regular unleaded gasoline only Recommended fuel 95 oct 10 l 0 2l CAUTION BIOETHANOL E10 IS NOT SUITABLE 1 CAUTION Make sure that the fuel tank cap is pro perly closed and locked before riding FUEL 1 INSTRUMENT AND CONTROL FUNCTIONS RESERVE ON OFF CAUTION If you need switch to the RESERVE position visit a filling station at the ear liest opportunity to re...

Страница 21: ...roperly installed before riding the vehicle WARNING At each refuelling you have to controll the engine 2 stroke oil Capacity 1 l Recommendation Castrol Power 1 Racing 2T RADIATOR AND COOLANT RESER VOIR The radiator 2 is located under the fuel tank on the right front side The coolant reservoir 1 is located un der the fuel tank on the front left side 1 Remove cap by unscrew it 2 Top up the coolant 3...

Страница 22: ...to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near possible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long SEAT To open the seat 2 1 Place the vehicle on the side stand 2 Insert the key in the lock 1 which is loc...

Страница 23: ...heat by the heat of sun and engine please do not put any thing that sen titive to the heat Do not put anything valuable or breakable objects in the storage lug gage box SIDE STAND 1 The side stand 1 is located on the left side of the Vehicle Release the side stand by using your feet to step on the bracket of side stand to up right positi on to stand the vehicle CAUTION The side stand with auto reb...

Страница 24: ...g points before each ride CAUTION Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle If failed to be corrected by yourse...

Страница 25: ...or spongy have dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage Throttle grip Make sure that operation is smooth Check cable free play If necessary have dealer adjust cable free play and lubricate cable and grip housing Wheels and tires Check for...

Страница 26: ...e on the open position if the engine ope rates smoothly it implies the war med engine When engine is warm do not use the choke system Do not crank the engine more than 5 seconds on any one attempt Starting with the kickstarter 1 Turn the fuel cock to the position ON 2 Turn the key to ON 3 Insert the neutral gear 4 Unfold the kickstart lever 1 and push with your foot down until you see a noticeable...

Страница 27: ...rds to change to the lower gears 5 Slowly release the clutch lever and open the throttle at the same time WARNING Always switch one gear only otherwise the transmission can be damaged ACCELERATION AND DECELERA TION The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in direction a To reduce the speed turn the thrott le grip in direction b 1 CA...

Страница 28: ...asing the pressure 3 Apply the front and rear brake at the same time WARNING Avoid hard or sudden braking espe cially when cornering otherwise the motorcycle may skid Railroad crossings street car rails iron plates on road construction si tes and manhole covers become extremely slippery when wet Therefore slow down when approa ching such areas and cross them with caution PARKING 1 Reduce the throt...

Страница 29: ...maneu vers steep slopes etc try to limit the time to a minimum OPERATION AND IMPORTANT RIDING POINTS Gearbox oil must be changed once the first 1000 km are covered Use the recommended oil type and specified quantity only To obtain optimum adjustment of mo bile parts a long life and better perfor mance it is necessary not to force the vehicle during the 1000 km The vehic le must have a suitable run...

Страница 30: ...hat help the operator to do such skills on the following pages WARNING Maintenance replacement or repair of the emission control devices and systems may be performed by any repair shop or individual that is certified and must follow the local law regulations If you are not familiar with maintenance work have a dealer do it for you PERIODIC MAINTENANCE AND MINOR REPAIR 29 ...

Страница 31: ... spark plug shows a distinctly dif ferent color the engine could be opera ting improperly Do not attempt to diag nose such problems yourself Instead have a dealer check the vehicle OWNER S TOOL KIT The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever addition...

Страница 32: ...other spark plug model is allowed Using a different spark plug model can immediately lead to engine damage WARNING Please note the max torque when in serting the plug If you do not have the ability to control you leave control of the spark plug to the dealer Tightening torque 12 Nm FINAL TRANSMISSION OIL The final transmission case 1 must be checked for oil leakage before each ride If any leakage ...

Страница 33: ...nder the final trans mission case to collect the used oil 4 Remove the oil filler cap 2 and drain bolt 3 to drain the oil from the final transmission case 1 2 3 5 Install the final transmission oil drain bolt and then tighten it to the speci fied torque COOLANT Before you start operating the vehic le check the coolant level The radi ator should be completely filled with coolant The reservoir is lo...

Страница 34: ...R REPAIR The minimum speed of the engine idling must be approxemately 1800 100 rev min THROTTLE CABLE FREE PLAY 1 The throttle cable free play 1 should measure 1 5 3 5 mm at the thrott le grip Periodically check the throttle cable free play and if necessary have a dealer adjust it Throttle cable free play adjustment 1 Release the locknut 1 2 Rotate the adjusting nut 2 to ad just the clearance 1 Re...

Страница 35: ... LEVER FREE PLAY 1 TIRES To maximize the performance durabi lity and safe operation of your vehicle note the following points regarding the specifed tires Tire air pressure The tire air pressure should be che cked and if necessary adjusted before each ride WARNING The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature T...

Страница 36: ...mum load 150 kg Total weight of rider passenger cargo and accessories Tire inspection 1 2 3 1 Tire tread depth 2 Tire sidewall 3 Tire wear indicator WARNING The tires must be checked before each ride 35 Tire air pressure Front 2 1 bar 2 5 bar Rear 2 1 bar 2 5 bar Total weight of rider passenger cargo and accessories WARNING Do not over load your vehicle since it will increase pressure on the tire ...

Страница 37: ...orcyc le note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage befo re each ride If any damage is found have a dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whe never either the tire or wheel has been changed or replaced An unba l...

Страница 38: ...inish the braking performance which may result in loss of control and an accident Brake padel free play 1 Loosen the locknut 1 2 Turn the adjusting bolt 2 until the lever position is within specified po sition 10 mm free play on the lever 3 Tighten the locknut again 1 2 disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake p...

Страница 39: ... may deteriorate causing leakage and poor braking performance Recommended brake fluid Castrol Super Disc Brake Fluid DOT 4 Refill with the same type of brake flu id Mixing fluids may result in a harm ful chemical reaction and lead to poor braking performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boi ling point of the fluid and ma...

Страница 40: ...s follows at the intervals specified in the periodic main tenance and lubrication chart Recommended lubricant Castrol Motorrad DWF oilspray WARNING Securely support the motorcycle so that there is no danger of it falling over 1 Place the vehicle flat and upright from STEERING WARNING Worn or loose steering bearings may cause danger Therefore the operati on of the steering must be checked as follow...

Страница 41: ...gs DRIVE CHAIN 10 20 mm If the chain tension is too great parts within the secondary power trasmission chain chain sprockets transmission and rear wheel bearings will be sub jected to unnecessary stress resulting in early wear and even chain breaka ge Too much slack in the chain on the other hand can result chain jumping off the chain wheels If this happens the chain could also block the rear whee...

Страница 42: ...h the help of the nut 2 to ad just the preload of the shock absorber Secure the damper then again with the locknut 1 1 2 BATTERY This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water 41 KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILD REN To charge the battery Have a dealer charge the ba...

Страница 43: ... Remove the bolts on the left and right side of the headlight 1 3 Remove the headlight 2 WARNING Please contact your dealer if you are not familiar with handling the battery CAUTION Always keep the battery charged Sto ring a discharged battery can cause permanent battery damage FUSE The fuse holder is located beside bat tery Replacing the fuse 1 Turn the key to and turn off all electrical circuits...

Страница 44: ...icator lens 1 out and replace the bulb 1 1 5 When you need to adjust the headlight turn in or turn out the adjusting screw 5 Rear turn signal light If the turn signal light bulb does not com on remove the screw of the indi cator lens 1 out and replace the bulb 1 1 PERIODIC MAINTENANCE AND MINOR REPAIR ...

Страница 45: ...er 5 and the pug 6 1 2 5 4 5 6 3 3 Turn the fixing disc anti clockwise to take out the the blup 7 Taillight Brake light and license plate lamp 2 1 If the tail brake light 1 or the license plate light 2 do not glow disassemble the bolts for changing the bulb 7 7 8 When you need to adjust the headlight turn in or turn out the adjusting screw 8 PERIODIC MAINTENANCE AND MINOR REPAIR ...

Страница 46: ... 1 Front turn signal light If the turn signal light bulb 1 does not com on please contact your dealer to replace it 1 1 Taillight Brake light and license plate lamp 2 1 If the tail brake light 1 or the license plate light 2 do not glow disassemble the bolts for changing the bulb PERIODIC MAINTENANCE AND MINOR REPAIR ...

Страница 47: ...ing troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself However should your vehicle require any repair take it to a dealer whose skilled technicians have the necessary tools experience and knowhow to service the vehicle properly Use only genuine replacement parts Imitation parts may look like parts but they are often inferior have a shorter service...

Страница 48: ... compression There is no compression Check the compression Supply fuel The engine does not start Check the compression Check the ignition Have a dealer check the vehicle Wet Dry Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plug Have a dealer check the vehicle Operate the electric starter The engine does not start Check the battery The engine turns over quickly The...

Страница 49: ...ome in side Please do it only after the 2 Closed every caps covers electri cal connectors that are well install and water can be avoid to get into while you do the clean job CAUTION Do not use acid based cleaners If such funds used for stubborn stains so use this only occasionally dry it immediately after and then apply a corrosion protection spray Always follow the manufacturer s instructions on ...

Страница 50: ...gradation Follow the steps below to cylinders piston rings etc to prevent rusting Remove spark plug cap and the spark plug Give a teaspoon of engine oil into the spark plug hole Join the Kickstarter to slow down and let the engine several times slowly rotate thus the cylinder is oiled Put the spark plug back in and put on the spark plug cap WARNING To prevent damage or injury from spar king make s...

Страница 51: ...F Öl AIR FILTER Sponge FUEL Unleaded gasoline only 95 Oct Capacity 10 0 2 l CAUTION BIOETHANOL FUEL E10 IS NOT PERMITTED DIMENSIONS SM MODEL DIMENSIONS X MODEL CARBURETOR Manufacturer QJ or LEADER SPARK PLUG Manufacturer model NGK BR8ES Spark plug gap 0 6 0 7 mm CLUTCH Clutch type Multiple plate clutch Transmission type 6 speed constant mesh transmission CHASSIS Frame type Steel tube backbone FRON...

Страница 52: ...tire pressure depends on the load FRONT BRAKE SM MODEL Type Single Hydraulic disc brake 230 mm Operation Right hand REAR BRAKE X MODEL Type Single Hydraulic disc brake 280 mm Operation Right hand REAR BRAKE Type Single Hydraulic disc brake 220 mm Operation Right food RECOMMENDED FLUID DOT 4 CASTROL Super Disc Bremsflüssigkeit DOT 4 Tail brake light 12 V 5 W 21 W Front turn signal light 12 V 10 W o...

Страница 53: ... order replacement parts from your dealer or the vehicle should be stolen The vehicle identification number of the vehicle 1 is stamped on the steering head 1 CAUTION The vehicle identification number is used to identify your motorcycle and may be used to register your vehicle with the licensing authority in your area ...

Страница 54: ... damaged part in an authorized workshop after our approval Compensation for remote or instantaneous damages cannot be granted Vehicles in desolate condition will not be covered by warranty Repair works carried out on warranty do not enlarge the guarantee period Only this document entitles you to call on warranty services Therefore please make sure that you are delivered this fully filled in docu m...

Страница 55: ... 12 month 10 000 km or 18 month 13 000 km or 24 month PART TO DO Air filter Clean exchange exchange Wheels rims Control Tires Control tire pressure Wheel bearing Control exchange Steering bearing Control clean lubricate lubricate Screws Coverparts Control tighten Brake system Control clean exchange Main stand Control clean lubricate Front fork Control Rear suspension Control Oil filter Clean Engin...

Страница 56: ... km or 1 month Stamp Signature 4000 km or 6 month Stamp Signature 7000 km or 12 month Stamp Signature 10000 km or 18 month Stamp Signature 13000 km or 24 month Stamp Signature 16000 km Stamp Signature 19000 km Stamp Signature 21000 km Stamp Signature VEHICLEIDENTIFICATIONNUMBER MODEL NAMEOFTHECUSTOMER SIGNATIONOFTHECUSTOMER ...

Страница 57: ...WIRING DIAGRAM 56 ...

Страница 58: ...SPACE FOR NOTES 57 ...

Страница 59: ......

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