Zion User manual
Contents
1. XN gt LIGHT CONTROL SWITCH START SWITCH c ron POWER LOCK BATTERY ELI AY WATER TEMPERATURE LIGHT CHES BRAKE SWITCH Fuaneour swrren c RELAY CONTROL RELAY d E BLACK B DARK GREEN Dg TURN SIGNAL INDICATOR LIGHT J ele gts BLUE BL BIR gt 5 z 4 ER LIGHT BLUE LBL ORANGE YELLOW N Y TURN SIGNAL INDICATOR LIGHT 7 m BROWN N RED GREEN R G Hate 4 WHITE PURPI FAILURE 1 V RED WHITE R W PURPLE BEAM INDICATOR LIGHT nm YELLOW RED Y R GREEN BLUE G BL 4 ORANGE 0 GRAY Gr WHITE G W YELLOW X n GREEN BLACK G B RED R n c Lo 1 1 ELLOW GREEN Y G JORANGE WHITE O W II T CO 7 Ti quip v dh LT Gf He RIGHT COMBINATION LIGHT 4 rl n s RIGHT TURN LIGHT CILE CY i e re i ES Y m 2 4 A t BL TAIL BRAKE LIGHT LEFT COMBINATION LIGHT lt m La be 42. gr ud LEFT TURN LIGHT HORN Bi TP d 1 w a BLW ok L I 1 1 1 1 I 1 1 f 1 NA n I 5 We mw amm s A 1 Beto CECE SE TURN SWITCH SPARK PLUG rum ueir RECTIFIER SPARK PLUG THERMO ELEMENT HEATER FAN HORN SWITCH BRAKE SWITCH NEUTRAL SWITCH 49 SPACE FOR NOTES
3. _ _ Decet _ _ T E _ 77 _ _ _ basse emerge EE CAUTION Variomatic belt fly wheels spark pluge fuel filter and air filter element have to be exchanged every 7000km Only use duration coolant Brake lines have to be exchanged at least every 4 years From 13 000km or 24th month the inspection should be made every 7000km The vehicle is constantly checked for rust The owner is responsible for rust prevention 47 SERVICE PLAN The warranty can be granted only if the vehicle has been serviced in accordance with this service plan 1000 km or 1 month Stamp Signature 7000 km or 12 month Stamp Signature 13000 km or 24 month Stamp Signature 19000 km Stamp Signature 4000 km or 6 month Stamp Signature 10000 km or 18 month Stamp Signature 16000 km Stamp Signature 21000 km Stamp Signature VEHICLE IDENTIFICATION NUMBER MODEL NAME OF THE CUSTOMER SIGNATION OF THE CUSTOMER 48 y WIRING DIAGRAM INSTRUMENT LIGHT cock FUELMETER SPEEDOMETER
4. 160kg When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the ve hicle as possible Make sure to dis tribute the weight as evenly as pos sible on both sides of the vehicle to minimize imbalance or instability Make sure that accessories and cargo are securely attached to ve hicle before riding Never attach any large or heavy items to the handlebar front fork or front fender Such items can create unstable handling or a slow steering response Accessorries Genuine accessories have been speci fically designed for use on this vehicle If need please contact with dealer for detail Since the maker can not test all other accessories you must perso nally be responble for the proper selec tion installation and use of non OEM accessories Keep the following guidelines in mind when mounting accessories Never install accessories or carry cargo that would influence on the ground clearance limit suspension travel steering or obscure lights or turning lights reflectors Accessories on the handle bar front suspension area will cause bad in fluence on steering the vehicle if you will install accessories please keep it as light in weight and not in terfere on steering the vehicle This vehicle is for On Road transportati on purpose only please do not ins tall any of extended cargo carrier as sulky that will make ve
5. AC 4 Check that the porcelain insulator 3 around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally If the 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 5 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if ne cessary 27 Specified spark plug CR8E WARNING Please note that no other spark plug model is allowed Using a different spark plug model can immediately lead to engine damage 6 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 PERIODIC MAINTENANCE AND MINOR REPAIR spark plug threads 7 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 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 a
6. INTRODUCTION Thanks for your purchasing of this vehicle This model is designed for safety built for durability and perfected for daily street use The unique vehicle design enrich of stylish and 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 IMPORTANT MANUAL INFORMATION In this manual with some important information is distinguished by the following notations It is WARNING instructions that need to follow failure of follow coulnd be end in result severe injuiry or lead to death to the operator A CAUTION indicates with special precautions to avoid damage to the vehicle Please always put this manual with vehicle for rider maintenance dealer tracking of service records even if vehicle is being sold This manual contains the 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 FOR YOUR OWN SAFETY PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION THIS VEHICLE ONLY OPERA TE THE VEHICLE UNTIL
7. safety from potential accidents Always wear an approved helmet With face shield to protect your eye from dust and rain drop The wear of proper jacket shoes groves etc can be better protection SAFETY INFORMATION reducing the degree of injuiry from un expected accident Never wear loose fitting clothes otherwise they could catch on the control levers or wheels and cause injury or an accident Never touch the engine or exhaust system during or after 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 or cargo to your vehicle may cause the different on the weight distribution of vehicle and in fluence on the steering amp balance It may cause possibility of an accident please extremely caution and follow below limitation when you equipped with accessories Below are some ge neral or accessories Here are some guidelines to follow if loading cargo or adding accessories to your vehicle Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Maximum load not include the vehicle
8. 1 0 I recommended type Castrol Power 1 Racing 4T TRANSMISSION OIL recommended type Castrol MTX Part Snth 80W or EP 80W 90 AIR FILTER Wet element FUEL Unleaded gasoline only Capacity 8 6 L 0 2 L 43 CAUTION BIOETHANOL FUEL E10 IS NOT PERMITTED CARBURETOR Manufacturer QJ CORUNDUM SPARK PLUG Manufacturer model CR8E Spark plug gap 0 6 0 7 mm CLUTCH Clutch type Dry centrifugal automatic Transmission type Variomatic CHASSIS Frame type Steel tube backbone FRONT TIRE Rim 3 75x15 Tyre 120 70 15 REAR TIRE Rim 3 75x14 Tyre 140 60 14 SPECIFICATIONS TIRE AIR PRESSURE COLD TIRES REAR SUSPENSION Rear turn signal light Front 2 1 bar 2 5 bar Type 12V 10 0W Rear 2 1 bar 2 5 bar Unit swing License plate light The selected tire pressure depends on the Spring shock absorber type 12V 5 0W load Coil spring oil damper Meter lighting FRONT BRAKE ELECTRICAL SYSTEM 12V 2W Type Ignition system Meter lighting fuel meter Single Hydraulic disc brake CDI 12V 2W 240mm Charging system High beam indicator light Operation CDI magneto 12V 2W Right hand BATTERY Oil level warning light RECOMMENDED FLUID Model 12V 3W DOT 4 CASTROL Super Disc YTX7A BS Turn signal indicator light Bremsfl ssigkeit DOT 4 Voltage capacity 12V 3W REAR BRAKE 12 V 3 0Ah FUSES Type HEADLIGHT Main fuse Single Hydraulic disc brake Halogen bulb 10 0A 220mm BULB VOLTAGE WATTAGE X QUAN Operation TITY Left
9. maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly If you do not have the tools or experi ence required for a particular job have a dealer perform it for you eI WARNING Modifications not approved by maker may cause loss of performance exces Sive emissions and render the vehicle unsafe for use Consult a dealer before attempting any changes Modifications without authorization of the manufacturer cause void the war ranty BATTERY COVER The covers 1 shown needs to be re moved to perform some of the mainte nance jobs described in this chapter 26 To remove the cover Remove the screws and then take the cover off To install the cover Place the cover in the original position and then install the screws SPARK PLUG The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic main tenance and lubrication chart In additi on the condition of the spark plug can reveal the condition of the engine REMOVE THE SPARK PLUG 1 Remove cover 2 Remove the spark plug cap 1 PERIODIC MAINTENANCE AND MINOR REPAIR 3 Remove the spark plug as shown with the spark plug wrench 2 inclu ded in the owner s tool kit gt
10. to prevent rusting Remove spark plug cap and the spark plug e 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 Putthe spark plug back in and put on the spark plug cap 42 WARNING To prevent damage or injury from spar king make sure to ground the spark plug electrodes while turning the engi ne over Lubricate all control cables and the pivoting points of all levers and pe dals as well as of the side stand main stand Check and if necessary correct the tire air pressure and then lift the ve hicle so that both of its wheels are off the ground Alternatively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plas tic bag to prevent moisture from en tering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 30 or more than 30 C 90 SPECIFICATIONS DIMENSIONS 1350 ENGINE Engine type Air cooled 4 stroke Cylinder arrangement Forward inclined single cylinder Displacement 125cm 151cm Compression ratio 10 4 1 11 1 Starting system Electric starter Lubrication system Separate lubrication 4 stroke engine oil ENGINE OIL Quantity
11. Adjusting the brake lever free play 32 Brake pads Brake fluid CADES 22 cxtat esta Throttle grip and 34 Lubricating the front and rear brake leVelS cs oc eet 34 Main stand 34 Etont fork e net met 35 Steering 35 Wheel bearings 36 2222 236 Hr 37 Headlight bulbs 37 Front indicator 22 38 Rearindicator 8 Tail brake and licenes plate light 38 TROUBLESHOOTING 39 Troubleshooting chart 40 CLEAN AND STORAGE 41 Clean the vehicle 41 42 SPECIFICATIONS 43 CONSUMER INFORMATION 44 Identification 44 WARRANTY INFORMATION 46 MAINTENANCE SCHEDULE 47 SERVICE PLAN 48 WIRING DIAGRAM 49 SPACE FOR NOTES 50 SAFETY INFORMATION THIS VEHICLE ARE TWO WHEEL SINGLE TRACK VEHICLES THE USE OF SAVETY AND OPERATION MAY IN DIFFERENT RESULT BY THE USE OF PROPER RIDING TECH NIQUES OF THE OPERATOR TO REMIND OF OPERATOR WHO SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING HE OR SHE SHOULD e WELL TRAINED AND FIMILIAR TO ALL THE ASPECTS OF Vehicle OPERATION FULLY READ AND AWARE OF MAINTENANCE REQUIREMENTS THAT NOTED IN THIS OWNER S MANUAL OBTAIN QUALIFIED TRAINING amp LEGAL LICENSE FOR OPERATI ON OF THIS VEHICLE e WELL AND PROFESSIONAL MAINTENANCE SERVICE FOR OPERATOR CERTIFICA TED REPAIR SHOP DEALER TO ACQUIRE GOOD MECHANICAL CONDITIONS OF VEHICLE Safe riding Alwa
12. FREE PLAY There should be no free play at the bra ke lever end If there is free play have a dealer inspect the brake system WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident BRAKE PADS The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart 1 Wear indicator 2 Brake disc 3 Brake pad Each brake pad is provided with wear indicators which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost tou ches the brake disc have a dealer re place the brake pads as a set PERIODIC MAINTENANCE AND MINOR REPAIR BRAKE FLUID WARNING Insufficient brake fluid may allow air to enter the brake system possibly causing it to become ineffective Befo re riding check that the break fluid is above the minimum level mark 1 and refill it if necessary Low position brake fluid level may in dicate worn brake pads and or
13. YOU HAVE COMPLETELY AWARE OF ADEQUATE KNOWLEDGE OF CONTROLS AND OPERATION FEATURE AND YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES PERIODIC INSPECTIONS WELL MAINTENANCE AND GOOD RIDING SKILLS WILL ENSURE YOUR SAFETY RIDING AND INCEASE THE PRODUCT RELIABILI TY OF THIS VEHICLE IMPORTANT MANUAL INFORMATION TABLE OF CONTENTS SAFETY INFORMATION Other safetyriding points Location of labels DESCRIPTION VIEW conces s cte Dose tad Right Controls and instruments INSTRUMENT AND CONTROL FUNCTIONS 2222 22 22 12 Main switch steering lock Indicator and warning lights Dashboard unit s Fuel gauge Handlebar switches Front brake lever 15 Rear brake lever r uel tank cap cose Fuel 16 Storage luggage box 18 Front hook helmet cts 18 Sidestand PRE OPERATION CHECKS Pre operation checklist OPERATION AND IMPORTANT RIDING POINTS 22 2 22 Starting the 22 Starting OTT i occorre 22 Acceleration and deceleration 23 Brakitg o e o eben ta Engine break in PARKING PERIODIC MAINTENANCE AND MINOR REPAIR 25 Owner s tool 26 Battery Cover 1 26 Spark a 26 Final transmission oil 28 BIETIIEGE ee contacts cated 29 Carburator eost 29 Checking the throttle cable free play 30 E 30 2 31
14. brake system leakage If the brake fluid le vel is low be sure to check the brake pads for wear and the brake system for leakage When checking the fluid level make sure that the top of the master cylinder is level by turning the handle bars Use only the recommended quality bra ke fluid otherwise the rubber seals 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 fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the master cylinder when refilling Wa ter will significantly lower the boiling point of the fluid and may result in va por lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down HOWEVER if the brake fluid level goes down suddenly have a dealer check CHANGING THE BRAKE FLUID WARNING Have a dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lub rication chart CABLES Checking and lubricating The operation of all control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubri cated if necessary If a cable is dama ged or do
15. do not smoke while checking or working on the fuel system 1 Fuel Operate the electric Check the compression Check the fuel level in starter the fuel tank Supply fuel The engine does not start Theretedomuet Check the compression 2 Compression There is compression igniti Operate the electric zu Check the ignition starter There is no compression ave a dealer check the vehicle 3 Ignition Wipe off with a dry cloth and correct the perate the electric starter Remove the spaik pi g Wet pans plug gaps or replace the spark and check the electrodes d Dry Have a dealer check the The engine does not start vehicle Check the battery 4 Battery The engine turns over quickly The battery is good 2 the electric The engine does not start starter The engine turns over slowly Check the battery lead connections Have a dealer check the and charge the battery if necessary vehicle 40 CLEAN AND STORAGE CLEAN THE VEHICLE Clean of the vehicle in proper and sui table way will make it attractive extend it s Ife and optimize the performance BEFORE CLEANING 1 Cover the muffler outlet with a plas tic bag to prevent water to come 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 Do not use
16. hand Headlight FRONT SUSPENSION 12 V 35 W 35 0 W Type Tail brake light Telescopic fork 12 V 5 0 W 21 0 W Spring shock absorber type Front turn signal light Coil spring oil damper 12 V 10 0 W 44 CONSUMER INFORMATION IDENTIFICATION NUMBERS VIN The chassis number is stamped into the frame To see this take the cover 1 Please write down the VIN vehicle iden the inner lining in the foot tification number to order replacement parts from your dealer or the vehicle should be stolen p 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 45 WARRANTY INFORMATION Please carefully read the instruction manual of your vehicle before operating it in order to make yourself familiar with its handling We explicitly point out that the instruction maintenance and care instructions given in the operating manual have to be complied with in order to sustain your claim towards warranty Only the strict compliance with customer specifications stated in the instruction manual ensures the prolonging of the natural life of your vehicle Starting with the date of the invoice a limited warranty of 24 months is granted regarding the accuracy of the vehicle in terms of material and manufacturing according to latest standards The legal warranty regulations will not be restricted by this limited guarantee
17. 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 2 Check the inner tubes for scratches damage and oil leakage 3 Apply the front brake and push the handlebars several times down hard to verify the suspension of the fork WARNING When damage to the fork please contact your dealer f you treat the telescopic fork with cleaning agents make sure that they get no contact with the tires or the brakes This can lead to dange rous accidents STEERING Checking the steering WARNING Worn or loose steering bearings may cause danger Therefore the operati on of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Place the vehicle on the center stand suitable motorcycle stand to raise the front wheel off the ground 2 Hold the lower ends of the front fork legs and try to move them forward and backward 3 If any free play can be felt have a dealer check or repair the steering PERIODIC MAINTENANCE AND MINOR REPAIR WHEEL BEARINGS Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel h
18. 2 If the LED position light defective please contact your dealer PERIODIC MAINTENANCE AND MINOR REPAIR FRONT INDICATOR TAIL BRAKE LIGHT AND LICENSE If the turn signal light bulb does PLATE LIGHT com on remove the screw of the indi cator lens 3 out and replace the bulb REAR INDICATOR 5 Tail brake light 6 License plate light If the tail brake light and licenes light If the turn signal light bulb does not bulb does not come on have a dealer com on remove the screw of the indi check its electrical circuit or replace the cator lens 4 out and replace the bulb bulb 38 TROUBLESHOOTING TROUBLESHOOTING Although the vehicles receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following 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 life and can lead to expensive repair bills 39 TROUBLESHOOTING TROUBLESHOOTING CHART A WARNUNG Keep away open flames and
19. Maintenance work has to be exclusively done by authorized workshops entitled by us Warranty in general is bound to the region of invoicing and can therefore only be carried out within the country the vehicle was bought Damages that can be traced back to inappropriate usage manipulation or neglecting of the maintenance care operating instructions will not be covered by warranty Warranty can only be granted if occurring damages are immediately being reported to the seller or any other authorized workshop by the buyer The warranty claim entitles the buyer to remedy deficiencies or to the reparation respectively the exchange of a 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 ment by the seller and that he has registered your vehicle correctly in our system Please also mind the following advices Body and panelling of the vehicle have to be kept free of dirt constantly Do not use high pressure water blasters strong jets of water sharp and corrosive or other aggressive detergents which could harm surfaces and varnish permanently and foster corrosion It is vital to use protecting cleansers Please consult ou
20. 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 care and cleaning agents Use best only water and mild deter gent or special cleaner from the dea ler to the sensitive components of the vehicle to prevent damage Dry the plastic parts then wipe with a soft dry cloth or sponge Protect particularly plastic parts paint headlight glass from harsh chemicals such as fuel rust remover brake cleaner or similar The use of such agents may result in malfunc tion damage and affect the security itself Do not use a high pressure washer or steam cleaner causing water in storage can penetrate electrical components such as connectors or switches lighting ventilation hoses brake shoes and brake linings or damage seals paint and other sur faces CLEANING AFTER NORMAL USE Remove dirt with warm water a mild de tergent and a soft clean sponge and then rinse thoroughly with clean wa ter Use a toothbrush or bottlebrush for hard to reach afe CLEANING AFTER RIDING IN THE RAIN NEAR THE SEA OR ON SALT SPRAYED ROADS Since sea salt or salt sprayed on the roads during winter are extremely cor rosive in combination with water carry out the following steps after each ride Wait until the engine exhaust have cooled Clean the vehicle with warm w
21. an making it dry 16 INSTRUMENT AND CONTROL FUNCTIONS CATALYTIC CONVERTER This model is equipped with a catalytic converter in the exhaust system WARNING The exhaust system is hot after opera tion Make sure that the exhaust sys tem has cooled down before doing any maintenance work The following precautions must be ob served to prevent a fire hazard or other damages e 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 1 Place the vehicle on the center stand 2 Insert the key into the rear lock and then turn the key anticlockwise to OPEN the seat Do not push inward when turning the key 3 Fold the seat up To close the seat 1 Fold the seat down and then push it down to lock it in place 2 Remove the key from the main switch if the vehicle will be left un attended When you close the seat by force or strike parts can be damaged Make sure that the seat is locked before driving or when you park the vehicle INSTRUMENT AND CONTROL FUNCTIONS STORAGE LUGGAGE BOX There storage luggage box 1 is under the seat Do not exceed the load limit of 2 5 kg for storage luggage box 1 Since the st
22. ater and a mild detergent Do not use hot water which increa ses the corrosive effect of the salt Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion AFTER CLEANING Drythe vehicle To prevent rust we recommend ap propriate care to use according to manufacturer s instructions Wax all painted surfaces CLEAN AND STORAGE Recommended Castrol care pro ducts Greentec Bike Reiniger Bike Politur Motorrad DWF oilspray 7 WARNING Make sure that there is no oil or wax on the brakes or tires f necessary clean the brake discs and brake linings with a regular bra ke disc cleaner and wash the tires with warm water and a mild deter gent Before operating the vehicle test the braking performance and tires STORAGE Short term for a few days Always store your vehicle in a cool dry place and if necessary protect it against dust with a vehicle cover A WARNING Please store the vehicle in a well air flow room with dry air if possible A place with wet humidity will cause rust Long term for weeks Clean the vehicle Drain the fuel from the carburetor Enter the drained fuel back into the fuel tank Fill the fuel tank to completely or add if necessary a fuel stabilizer to pro tect the fuel tank from rusting and the fuel from degradation Follow the steps below to cylinders pis ton rings etc
23. d 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 The tire air pressure must be adjusted in accordance with the riding condition If you are not familiar to this please have dealer for help 30 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 braking steering than original design and may could cause damge or even lead to accident Allocation of your cargo and weight of your vehicle is very important for your own safety and vehicle performance Load your cargo rmly on vehicle and put the heaviest cargo to the center of vehic le then distribute the weight evenly from side to side It will Keep you to have good steering after load PERIODIC MAINTENANCE AND MINOR REPAIR Maximum load 160 kg Total weight of rider passenger cargo and accessoriesr TIRE INSPECTION v 4 PO 1 Tire tread depth 2 Tire sidewall 3 Tire wear indicator WARNING The tires must be checked before each ride If a tire tread shows crosswise li nes minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a dealer replace the ti
24. ds 2 Do not crank the engine more than 5 seconds on any one attempt 22 OPERATION AND IMPORTANT RIDING POINTS 3 Switch the turn signal on to the di rection you wish to turn 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signal off ACCELERATION AND DECELERATI ON 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 BRAKING 1 Close the throttle completely 2 Apply both front and rear brakes si multaneously while gradually increa sing the pressure 23 FRONT REAR WARNING Avoid braking hard or suddenly otherwise the vehicle may skid OPERATION AND IMPORTANT RIDING POINTS e Railroad crossings streetcar rails iron plates on road const ruction sites and manhole covers become extremely slippery when wet Therefore slow down when approaching such areas and cross them with caution Keep in mind that braking on a wet road is much more difficult Ride slowly down a hill as bra king downhill can be very difficult ENGINE BREAK IN Since the engine is brand new do not put an excessive load on it for the first 1000 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this pe
25. eck list is not working properly have it inspected and repaired before operating the vehicle If failed to be corrected by yourself please turn to repair shop immediately If failed to be corrected by yourself please turn to repair shop immediately 20 PRE OPERATION CHECKS PRE OPERATION CHECK LIST CHECKPOINT TO VERIFY Fuel Check fuel level in fuel tank if necessary Check fuel line for leakage 4 stroke engine oil Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage Final transmission oil Check vehicle for oil leakage Front brake Check operation If soft 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 Rear brake Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 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 damage Check tire condition and tread depth Check air pressure Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary Main stand Make sure that operation is smooth Lubricate pivot if necessary Chassis fasteners Make sure that all
26. es not move smoothly have a dealer check or replace it Recommended lubricant Castrol Motorrad DWF oilspray PERIODIC MAINTENANCE AND MINOR REPAIR A WARNING Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement Re place damaged cables as soon as pos sible to prevent unsafe conditions THROTTLE GRIP AND CABLE The operation of the throttle grip should be checked before each ride In additi on the cable should be lubricated at the intervals specified in the periodic main tenance chart LUBRICATING THE FRONT AND REAR BRAKE LEVERS The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Front brake lever Rear brake lever A A U Recommended lubricant Castrol Motorrad DWF oilspray 34 MAIN STAND The operation of the main stand should be checked before each ride and the pivots and metal to metal contact sur faces should be lubricated if necessary WARNING If the main stand does not move up and down smoothly have a dealer check or repair it Recommended lubricant Castrol Multi Purpose Grease PERIODIC MAINTENANCE AND MINOR REPAIR FRONT FORK Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic
27. hicle unstab le in cross winds and vehicle turns While equip with electrical accesso SAFETY INFORMATION ries please consult with qualifiled stores to make sure such items will not exceed the capacity of the vehicle s electrical system Unpro per install of such items may cause a dangerous loss of lights lower engine power or even damage the vehicle Gasoline and exhaust gas GASOLINE IS HIGHLY FLAMMAB LE Always turn the engine off when refueling Take care not to spill any gasoli ne on the engine hot or exhaust system when refueling Do not smoke or use Mobile pho ne while re fueling parking the vehicle please note the following The engine and exhaust system remain hot therefore park the ve hicle in a place where pedestrians or children are not likely to touch these hot areas Donot park the vehicle on a slope or soft ground otherwise it may fall over Do not lay your vehicle to near flammable place In case of swallow any gasoline or gasoline get into your eyes please see your doctor immeidately Keep away the gasoline to your skin and water Other safe riding points Turn the signal before making turns When raining or across on run on 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
28. is on means the water temperature is too high and should have a break sometime If it is on by a long time please check the coolant bottle Low beam indicator ZO Low beam indicator comes on when low beam headlight is on Right turn indicator gt The indicator will be flashing against the position when right turn signal is on DASHBOARD UNIT FUEL GAUGE 1 Tachometer 2 Speedometer 3 Odometer The dashboard unit is equipped with a tachometer a speedometer and an odometer The tachometer indicate the engine rev min The speedometer shows the riding speed The odometer shows the total distance traveled 1 Fuel gauge indicator The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E refuel as soon as possible Be take care not let the fuel tank to fully empty it self that cause engine can not run it self anymore INSTRUMENT AND CONTROL FUNCTIONS HANDLEBAR SWITCHES LEFT 1 High Low beam switch ZLO D 2 Turn signal switch Q D 3 Horn switch pe High Low beam switch ZO O Set this switch tof EO for the high beam and to ZO for the low beam Horn switch Press this switch to sound the horn Turn signal switch lt 1 0 gt To signal a right hand turn push this switch to gt To signal a left hand turn push this switch to lt When released the
29. lock and turn it 1 4 turn counter clockwise The lock will be released and the fuel tank cap can be removed To install the fuel tank cap 1 Push the fuel tank cap into position Turn the cap clockwise to the original position Make sure that the fuel tank cap is pro perly closed and locked before riding INSTRUMENT AND CONTROL FUNCTIONS FUEL 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING Do not overfill the fuel tank other wise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine CAUTION 2 Reinsert oil level gauge 1 don t it Take out oil level gauge Immediately wipe off spilled fuel with pos dst a clean diy soft cloth since fuel may 1 and check it the oil level should damage the painted surfaces or plas be between the upper 2 and lo tic parts wer 3 limits Regular unleaded gasoline only Recommended fuel 95 oct 8 61 0 21 IICAUTION BIOETHANOL E10 IS NOT SUITABLE ENGINE OIL Make sure that the oil level gauge is properly installed before riding the ve At each refuelling you have to controll higie the engine oil Capacity 1 Recommendation Castrol Power 1 Racing 4T 1 Open the main stand and take out 9 the oil level gauge 1 to wipe or cle
30. nance schedule Replace the air filter more often if you drive in unusually wet or dusty areas REPLACE THE AIR FILTER 1 Remove the air filter case 1 2 Pull the air filter 2 out 3 Replace the filter with a new one 4 Coat the mating surfaces of the air filter case and air filter case cover lightly with grease for an airtight seal 5 Install the air filter 6 Install the air filter case cover by ins talling the screws 29 Make sure that the air Iter element is properly seated in the air filter case The engine should never be opera ted without the air Iter element ins talled otherwise the piston and or cylinder may become excessively worn CARBURETOR The carburetor is an important part of the engine and its emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad PERIODIC MAINTENANCE AND MINOR REPAIR justments should be left to dealer who has the necessary professional know ledge and experience CHECKING THE THROTTLE CABLE FREE PLAY 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 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 checke
31. nuts bolts and screws are properly tightened e Tighten if necessary Instruments lights signals and switches Check operation e Correct if necessary 21 OPERATION AND IMPORTANT RIDING POINTS A WARNING Before riding the vehicle please make sure that you are fully fimi liar with all operating controls amp their functions before riding To STARTING THE ENGINE Note the point Engine break befo re you start to riding the vehicle The engine starts immediately upon actuation of the starter then wait a few seconds before you try to start it again Each starting process should be as short as possible in order to save battery and the starter consult a dealer shop if you not thoroughly understand Please do not start the engine in a closed area the exhaust air are poisonous and inhaling them can cause loss of consciousness and even death in short time STARTING OFF Before starting off allow the engine to warm up to avoid damages 1 While pulling the rear brake lever with your left hand and holding the carrier with your right hand push the vehicle off the main stand Sit astri de the seat and then adjust the rear view mirrors Sit astride the seat and then adjust the rear view mirrors Starting with the electric starter Turn the key to ON Pull the right brake lever otherwise the vehicle will not start Push the start swich button 1 for a few secon
32. ny 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 As long as the vehicle is within the war ranty period the dealer is responsible to change the gear oil CHANGE THE FINAL TRANSMISSI ON OIL 1 Start the engine warm up the final transmission oil by riding the vehicle for several minutes and then stop the engine 2 Place the vehicle on the main stand 3 Place an oil pan under 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 5 Install the final transmission oil drain bolt and then tighten it to the speci fied torque Tightening torque 18 Nm 6 Add the requested amount of the recommended final transmission oil and then install and tighten the oil filler cap PERIODIC MAINTENANCE AND MINOR REPAIR Recommended final transmission oil Castrol MTX Part Synth 80W or EP 80W 90 Oil quantity Full 0 12 1 Change 0 11 WARNING Make sure that no foreign material enters the final transmission case Make sure that no oil gets on the tire or wheel T Check the final transmission case for oil leakage If oil is leaking check for the cause AIR FILTER The air filter should be replaced ac cording to the mainte
33. orage luggage box will accumulates heat by the heat of sun and engine please do not put any thing that sentitive to the heat Do not put anything valuable or breakable objects in the storage lug gage box FRONT HOOK HELMET REAR CARRIER Do not exceed the load limit of 1 kg for the front Hook 1 Do not exceed the load limit of 5kg for the carrier 1 INSTRUMENT AND CONTROL FUNCTIONS SIDE STAND 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 The side stand with auto rebound system Make sure your vehic le have been park well are stable enough to stand the vehicle Please avoid to use side stand to park the vehicle on the slope soft land or un flat ground PRE OPERATION CHECKS The condition of a vehicle is the owner s responsibility The operator should check the vehicle by simple but thorough inspection to make sure of vehicle condition quick inspect some key and important parts to prevent the vehicle from seri ous consquence accident Please carefully check the following points before each ride 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 A WARNING If any item in the Pre operation ch
34. r dealers for the right and appropriate products Aluminium parts or other refined parts chrome parts anodized parts or other processed surfaces have to be treated with appropriate maintenance products in order to prevent oxidation Frame and metal parts are continuously to be treated with anticorrosive A vehicle constantly parked outside has to be covered to avoid weathering and crack formations on seat and plastic parts Vehicles used off road and for racing purposes are excluded from warranty Material which is to be used in the context of service and maintenance works are excluded from warranty as well as the following parts incandescent bulbs brake pads clutch lining filter elements spark plugs drive sprocket wheel and axle as well as the tires 46 MAINTENANCE SCHEDULE The guarantee can be granted only if the vehicle has been serviced in accordance with this maintenance schedule be granted 1 month 6 month 12 month 18 month 24 month m5 C __ e oOo E e DENM gt western Seemgbemmy Screws _ _ _ a 2 gt ee ema omm ema E
35. re immediately The tread depth may vary depending on country Observe local regulations The values listed here are technical values and may differ from the legal values of your region Minimum tire tread depth Front and rear gt 1 6 mm WARNING Drive with worn tire is illegal reduces stability and can lead to loss of con trol over the vehicle Let worn or damaged tires replaced immediately by your dealer Working tires and the dealer is res ponsible 31 DIMENSIONS TIRES RIMS Front Rim 3 75x15 Tire 120 70 15 Rear Rim 3 75x14 Tire 140 60 14 TYRE TYPE tubless RIMS To maximize the performance durabi and safe operation of your motor cycle note the following points regar ding the specified wheels The wheel rims should be checked for cracks bends or warpage before 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 PERIODIC MAINTENANCE AND MINOR REPAIR The wheel should be balanced whe never either the tire or wheel has been changed or replaced An un balanced wheel can result in poor performance adverse handling cha racteristics and a shortened tire life Ride at moderate speeds after chan ging a tire since the tire surface must first be broken in for it to develop its optimal characteristics ADJUSTING THE BRAKE LEVER
36. riod prolonged full thrott le operation or any condition that might result in engine overheating must be avoided If any engine trouble should occur du ring the engine break in period imme diately have a dealer check the vehicle PARKING When parking stop the engine and then remove the key from the main Switch WARNING Since the engine and exhaust system can become very hot park in a place where pedestrians or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn beim Parken einen sicheren Stand hat 24 PERIODIC MAINTENANCE AND MINOR REPAIR Most of the Safety and condition of vehicle depend on how you do the correct maintenance periodic inspection adjustment and lubrication The following are contents that help the operator to do such skills on the following pages A 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 25 PERIODIC MAINTENANCE AND MINOR REPAIR OWNER S TOOL KIT The owner s tool kit 1 is located in side the rear storage luggage box 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
37. s the ignition and lighting systems and also used to lock the steering The va rious positions are described as below oN O All electrical circuits are supplied with power the engine can be started The key cannot be removed orr amp electrical systems are off The key can be removed Lock i The steering is locked and all electri cal systems are off The key can be removed Lenker verriegeln 1 Turn the handlebars all the way to the left 2 Push the key in and turn it to the n position while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to e position while still pushing it WARNING Never turn the key to 54 In 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 key INDICATOR AND WARNING LIGHTS 1 Left turn indicator a 2 High beam indicator 3 Water thermometer indicator 4 Low beam indicator ZO 5 Right turn indicator D Left turn indicatur lt The indicator will be flashing against the position when left turn signal is on High beam indicator light O This indicator light comes on when the high beam of the headlight is switched on INSTRUMENT AND CONTROL FUNCTIONS Water thermometer indicator It indicates the cooling fluid tempera ture When it
38. switch returns to the center posi tion To cancel the turn signal lights push the switch in after it has returned to the center position HANDLEBAR SWITCHES RIGHT 1 Engine O OFF amp 2 Light switch C e 3 Start switch Engine OFF 524 power switch is and ignition Switch is at 14 position at the mean time grip the brake the engine can be 2 And press engine off switch at position the engine is will be off Light switch e Turning the light switch to turns on the position light mater light and taillight Tur ning the light switch to X turns the headlight on also Start switch Push this switch pull the brake le ver at same time to the start the en gine At the same time you have to pull the right brake lever to start the engine Before starting the vehicle check the notes in the user manual INSTRUMENT AND CONTROL FUNCTIONS BRAKE LEVER RIGHT FRONT BRAKE BRAKE LEVER LEFT FRONT BRA KE The front brake lever is located on the right handlebar grip To apply the front brake pull this lever toward the hand lebar grip The rear brake lever is located on the left handlebar grip To apply the rear brake pull this lever toward the hand lebargrip FUEL TANK CAP The fuel cap is located in the footwell To remove the fuel tank cap 1 Open the lock cover Insert the key in the
39. ttery fully charge it and then place it in a cool dry place f the battery will be stored for more than two months check it at least once a month and fully charge it if necessary Fully charge the battery before ins tallation After installation make sure that the battery leads are properly connec ted to the battery terminals PERIODIC MAINTENANCE AND MINOR REPAIR A WARNING Please contact your dealer if you are not familiar with handling the battery Always keep the battery charged Storing a discharged battery can cause permanent battery damage FUSE The fuse holder is located behind bat tery cover REPLACING THE FUSE 1 Turn the key to e and turn off all electrical circuits 2 Remove the blown fuse and then in stall a new fuse of the specified am perage Specified fuse 10 Amp WARNING Do not use a fuse of a higher am perage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to and turn on the electrical circuits to check if the de vices operate 4 If the fuse immediately blows again have a dealer check the electrical system 37 LIGHTING HEADLIGHT BULBS This model is equipped with halogen bulb headlight 1 If a headlight bulb burns out have a dealer replace it and if necessary adjust the headlight beam This model has furthermore a LED po sition light
40. ub or if the wheel does not turn smoothly have a dealer check the wheel bearings 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 WARNING Do not remove the battery vent seal this can be dangerous the battery permanently damaged Battery acid is poisonous and dan gerous it contains sulfuric acid and leads to dangerous burns Avoid skin eye and clothing contac Protect your eyes always when wor king near the battery Upon contact with the battery aicd make immediate FIRST AID f skin or eye contact with battery acid rinse the affected areas with plenty of water When accidentally swallowed battery acid drink large amounts of water n both cases as soon as possible see a doctor Batteries develop explosive hydro gen gas Keep open flames smoking materials away from the battery and make sure there is adequate venti lation when you charge a battery in doors KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILD REN 36 TO CHARGE THE BATTERY Have a dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the bat tery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories TO STORE THE BATTERY f the vehicle will not be used for more than one month remove the ba
41. vehicle and remove the key from the main switch When the wet road Iron Plates keep your speed low slightly using braking to avoid slipping or even fall down Be careful when passing parked cars A driver might not see you and open a door in your path 7 SAFETY INFORMATION LOCATION OF LABEL 1 LABEL ANTI TAMPERING TRADE NAME GENERIC 1 9 AFTGK6 gt 26 018 VEHICLE CATEGORY B 2 026 A raleSTGeneric Cu2x70 48 GENERIC EX T58A D1 X 9 0122 1 as Q 10 0155 N w 11 153 2 12 Symbolbild DESCRIPTION OF THE VEHICLE LEFT VIEW Front wheel Front disc brake Front turn signal light Helmet holder Storage compartment Battery Rear turn signal light Rear wheel Air filter element 10 Pedal 11 Side stand 12 Rear disc brake 13 Main stand 07 090 POON DESCRIPTION OF THE VEHICLE RIGHT VIEW 14 Tail brake lightt 8 9 9 15 Rear carrier H i 16 Seat b 18 Headlight Be 9 19 Spark plug CS 20 Muffler 4 FEN W Sa DESCRIPTION OF THE VEHICLE CONTROLS AND INSTRUMENTS 21 Rear brake lever 22 Left handlebar switches 23 Speedometer unit 24 Fuel gauge 25 Right handlebar switches 26 Front brake lever 27 Throttle grip 28 Main switch steering lock INSTRUMENT AND CONTROL FUNCTIONS MAIN SWITCH STEERING LOCK The main switch steering lock control
42. ys pre check your vehicle befo re riding is key point to prevent an accident Please follow the maxium loads limi ted of operator and passenger Most of accident on the motorists is cased by automobile driver who fai lure to recognize out the vehicle and caused mobile vehicle accidents Therefore to make yourself conspi cuous apprear 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 to oththers who not qualified for riding Always follow the legal speed limit on the vehicle and traffic law The posture of the operator and passenger is important for proper control properly riding posture can Keep vehicle in balance while riding Operator should sit up right with two hand hold on handle bar foot on floorboard while driving Passenger should make sure that he she can firmly hold on grip or operator with foot step on footrest Drving after Acohol drink or other il legal drugs is strickly prohibited This vehicle is designed for onroad use only It is not suitable for off road use Protective clothing Properly clothing yourself will keep you
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