TR 125 User manual
Contents
1. GRAY COLOR BLACK RED WHITE BLUE GREEN ORANGE YELLOW PURPLE BROWN 48 FAN SWITCH WARRANTY INFORMATION Information on warranty claim 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 otarting 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 legal warranty regulations will not be restricted by this limited guarantee Maintenance work has to be exclusively done by authorized workshops entitled by us Warranty in generally 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 buye2. Never install a wet air filter element this will damage the engine If the air filter can not be dry cleaned use special cleaner from the dealer or replace the air filter Cil drain pipe It should be checked regularly if needs drain oil To drain the oil as follow 1 Put a suitable container below the oil drain pipe 2 Loosen the clamp and move it upward 3 Pull out the drain plug and drain the oil 9 Insert the drain plug and move down the clamp to fasten CHECKING MAINTAINING Bleeding the coolant system Coolant inspection Before starting the engine place the bike on a level place and hold it in an upright position then open the cap of the radiator to inspect the coolant level cootant radiator From the left side you can inspect the level of the expansion tank cap dm p Expansion Drain pipe WARNING Do not remove the radiator cap and expansion tank cap when engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury 1 2 3 4 9 Open the radiator cap Place a small container under the bike Open the hose clamp 1 and let the fluid bleed in the container Open the hose clamp 2 and let the fluid bleed Open the 3 screws 3 from the water pump cover only a little bit to bleed the pump Install all screws again and refill the system Recommend
3. IMPORTANT MANUAL INFORMATIONS Congratulations on your purchase of the motorcycle This model is the result of a vast experi ence in the production of fine sporting touring and racing machines lt represents the high de gree of craftsmanship and reliability that have made us to one of the leaders in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motor cycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a dealer The design and manufacture of this motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture We have met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATIONS Particularly important information is distinguished in this manual by the following notations Failure to follow WARNING instructions could result in severe injury or death of the motorcycle operator a bystander or a person inspecting or repairing the motorcycle A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE
4. 18 Fuel Fuel Tank 18 2 19 Engine oll 20 21 Catalytic converter 21 PRE OPERATIONCHECKS 22 Pre operation check list 23 OPERATION AND IMPORTANT RIDING POINTS 24 Starting the engine 24 Stop the engine 24 Shifting and riding 24 Acceleration and deceleration 25 Engine break in 25 Inspection Information 26 Parking 26 CHECKING MAINTAINING SERVICE INTERVALS 27 Periodic maintenance chart 28 Spark 30 30 Oil drain 30 Coolantinspection 31 Bleeding the coolant system 31 32 Adjust the idling 32 Checking the throttle cable free 2 eee entree eee eee 32 Clutch adjustment 33 Jic 39 Tire inspection 33 Cast 34 Front brake 34 Front brake adjustment 39 Rear brake adjustment 35 Brake
5. tt BRAKE SWITCH TACHOMETER inlet temperature sensor inlet air pressure sensor ENSOR T valva sensor Efe NC aS N Y R H FT al amp TEE Ree Tuo aL EM i RIGHT TURN LIGHT 21W ME cm SS cot ll 15 RIGHT TURN LIGHT 169 te LLL TD __ PHH 8 mouan Ae a 7 F E G W EEEH HIE SIMIC E a ee dB ERIT Tl LE 8 E HM AIL BREAK LIGHT 21 5W Hd GH BEAM INDICATION LIGHT SW LEFT TURN LIGHT 167 EFT TURN LIGHT 210 7 6 8 Ip eg A mm B E n5 P 7 I 0100 _ HORN Qu DEDE LICENSE PLATE LIGHT 5W 1 WE L c E g ZAA i 11117 VA y d 1 IL Pr 123456189101112151415161718 123456789101112131415161718 EA D BG HOM CONTROL us MN 7 ELEMENT STARTOR MOTOR i SWITCH IGNITION COIL FEASHER POWER LOGE NUEL L VEL GAUGE mec Dr TS DT DRTIGCTUR
6. In trip screen press the adjust but ton once to switch from trip to clock Press and hold the adjust for 3 sec to reset the trip In clock screen press the adjust button once to switch from clock to the main screen 4 Select button function instruc tion In main screen press and hold the select button for 3 sec to switch the backlight color In main screen press and hold the select and the adjust button for 3 sec to enter the clock settings OPERATION INSTRUMENTS Example You want to set the hour to 14h press the adjust button to choose the hour you want to set seting range 0 i Example You want to set the mi nute to 14 05 press the select but ton to enter the minute settings Press the Select button move fo the digit you want to set Then press the adjust button to choose the minute you want to set Meya range 0 59 minutes After the settings are done press the select button to store your settings and get back to the main Screen Handlebar switches 1 Light signal ZO Low beam switch gt High beam switch 2 D Turn signal switch 3 Horn switch 4 Clutch lever 1 Light signal When the switch is in the low beam position move the switch upwards to use the light signal switch will automatically return to the low beam position 1 High low beam switch When the switch is in the l
7. 5 36 Front and rear brake brake fluid 36 Lubricating of the cabes 37 Front 0 37 37 Wheel bearings 38 Adjusting the chain tension 38 Shock absorber 38 silii MPO 39 40 TABLE OF CONTENTS Replacing headlight bulb 41 Front and rear turnsignal lamp 41 Tail orake and license plate lamp nmt 41 Injectionsystem 41 Fuel 41 Fuelfilter 42 TROUBLESHOOTING 42 Troubleshooting chart 43 CLEAN AND 5 45 45 46 SPECIFICATIONS 47 WIRING DIAGRAM 48 WARRANTY INFORMATION 49 SAFETY INFORMATIONS THIS MOTORCYCLE IS A TWO WHEEL ON ROAD VEHICLE BEFORE YOU USE THE VEHIC LE THE FIRST TIME PLEASE READ THIS MANUAL CAREFUL LY IN ORDER TO FAMILIARIZE YOURSELF WITH YOUR NEW MOTORCYCLE THE USER OF THIS MOTORCYC LE SHOULD BE SHOULD HAVE e WELL TRAINED AND FAMILI AR TO ALL THE ASPECTS OF MOTORCYCLE OPERATION ES PECIALLY THE OPERATION OF THIS MODEL e FULLY INSTRUCTED IN THE MAINTENANCE REQUIRE MENTS TH
8. After installation make sure that the battery leads are properly connected to the battery terminals When recharging the battery make sure the amper and volts of char ger is suitable to the battery and the specific type 40 If you are not familiar with battery charging please contact a dealer otoring a discharged battery can cause permanent battery damage otore the battery only in a cool dry place Replacing the fuse fuse holder 15 located in the air box If a fuse is blown then replace it as follows 1 Turn off the main switch 2 Remove the blown fuse and install a new fuse of the specified amperage 3 Turn on the electrical circuits to check if all devices operate correctly If the fuse blows once again contact a dealer check the electrical system Fuses 15 A blue 20 A yellow Replacing the headlight bulb 1 If the headlight bulb does not glow remove the bolts and screws 1 to 4 to disassemble the head lamp assembly 2 out the rubber dust cover 5 and the pug 6 then turn the fixing disc 7 anti clockwise to take it out before replacing the bulb 8 When you need to the head light turn in or turn out the adjusting screw 9 Front and rear turn signal lamp If the front or rear turn signal light 10 does not glow contact a dealer to check the electrical circuit or to replace the lamp Tail brake light and license plate lamp If the tail
9. Parking Reduce the throttle to 0 position Pull the clutch lever Switch the gear to N neutral Operate the brakes After the vehicle is stopped turn off the ignition Lower the side stand with your foot while holding the motor cycle upright Remove the key from the main switch WARNING The exhaust system is hot after driving Make sure that the exhaust system has cooled down before doing any maintenance work The following precautions must be observed to prevent a fire hazard or other damages e Never park the vehicle near grass or other materials that easily burn eDo not allow egi ne to idle too long eDo not touch the exhaust after driving O oOcRON CHECKING MAINTAINING SERVICE INTERVALS The Safety and condition of motorcycle depend on a correct maintenance periodic inspection adjustment lubrication and cleaning The following contents help the operator to complete this tasks During the warranty period all repair and recommended service inspections have to be done by an authorized dealer WARNING Not authorized manipulation on the motorcycle leads to the loss of warranty If you are not familiar with maintenance work have a dealer to do it for you The vehicle has to be checked for rust constantly The owner is responsible for rust preventi on The drive chain must be cleaned and lubricated regularly The airfilter needs more frequent service if you ride in unusually wet
10. Open the oil fill cap 2 to fill the recommended oil to the level between the upper and the lower li mit If the engine is cold the oil level should be visible near the lower level If the engine is warm the level 20 should be visible at the upper limit Add engine oil if necessary Recommended engine oil SAE 10W 40 Castrol Power 1 4T 10W 40 Capacity is 1 2L WARNING Never attempt to remove the oil fill cap just after high speed operation The heated oil could spout out Wait until the oil cools down Engine oil replacement 1 Start the engine and warm it up for several minutes 2 Place the vehicle on even survace and hold it in upright position 3 Place a suitable container under the engine 4 Remove the oil drain bolt 3 and mE clean the magnet from chips 5 Remove the 3 screws 4 of the oil filter cover Depollute the old Filter 6 Remove the the oil strainer 5 screw Blow up the strainer OPERATION INSTRUMENTS 7 Assemble a new oll filter 8 Install the 3 cover screws again Use a new gasket 9 Install the oil strainer 5 with the screw again 10 Install the oil drain bolt 3 with a new copper washer 11 Refill engine oil 1 21 12 Install the oil filler cap 2 13 Check the oil level Side stand The side stand is located on the left side of the frame Lower it with your foot while hol ding the motorcycle upright sid
11. e Please always put the manual with the vehicle for maintenance and service records e This manual contains important vehicle information However the producer will continually improve this product and the design and the quality that lead to difference between the manual and the current version of the vehicle If you have any questions concerning this manual please consult your dealer WARNING FOR YOUR OWN SAFETY PLEASE READ THIS MANUAL CAREFULLY BEFORE YOU DRIVE THIS MOTORCYC LE ONLY OPERATE THE MOTORCYCLE WHEN YOU HAVE BEEN COMPLETELY AWARE OF ADEQUATE KNOW LEDGE OF CONTROLS AND OPERATION AND FEATURES AND YOU HAVE BEEN TRAINED IN SAFETY AND PROPER RIDING TECHNIQUES PERIODIC INSPECTIONS AND MAINTENANCE AND GOOD DRIVING SKILLS WILL ENSURE YOUR SAFETY DRIVING AND INCREASE THE PRODUCT RELIABLITY OF THIS MOTORCYCLE IMPORTANT MANUAL INFORMATIONS MM EN TABLE OF CONTENTS SAFETY INFORMATION 6 Other Safe driving points 9 Location of labels 10 DESCRIPTION 11 Left view 11 Right 12 Operation instruments 13 INSTRUMENT AND CONTROL FUNCTIONS 14 Main switch steering lock 14 Indicator and warning lights 15 Handlebarswitches 17 Front brake lever 18 Rear brake pedal
12. Low brake fluid level may indicate worn brake pads or brake system leakage Use only the recommended quality brake fluid otherwise the rub ber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Brake fluid deteriorate painted sur faces or plastic parts Always clean up spilled fluid immediately As the brake pads wear the brake fluid level to gradually go down CHECKING MAINTAINING Recommended brake fluid DOT 4 CASTROL MOTORCYCLE BRAKE FLUID Changing the brake fluid Contact a dealer to change the bra ke fluid at the intervals specified in the periodic maintenance and lubri cation chart Checking the lubrication of the cables 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 lubricated if necessary If a cable is damaged or does not move smoothly contact a dealer to check or replace it Recommended multi purpo se lubricant CASTROL MOTORCYCLE DWF WARNING Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement Replace damaged cables as soon as possible to prevent dangerous wear of the cables Front fork Checking the front fork The condition and operation of the front fork mu
13. and blink in different diagnostic trouble codes On the display you 1 see the DIC Code DIC 1 1 failure DTC 2 2 failures Please contact a dealer as soon as possible to check the vehicle 8 Odometer and trip meter Odometer Display 0 99999km or mile Trip meter Display range range 0 999 9km or mile Display unit is O 1km or mile 9 Fuel meter Display range 15 6 levels When the fuel is below the first bar it will blink to remind for refuel 10 RPM meter The display range is 0 12000 rpm with minimum of 200 rpm Select button Press the Select button less than 3 sec to change the display colour form blue to orange and vice versa Press the Select button more than 3 sec the unit change between km h and miles Adjust button Press the Adjust button once to switch between ODO TRIP and CLOCK mode OPERATION INSTRUMENTS 1 Adjust button function instruc tion mS ee JE 1 The main screen In the main screen press the adjust button once to switch the function from odometer to trip When the odometer display range is over the Max starts at zero When the display range of trip me ter is over the Max it will also start at zero automatically but it can also be reset manually by holding the adjust button for 3 sec under the trip screen In the main screen press and hold the adjust button for 3 sec to switch from km to mile 16
14. bolt 2 until the lever position is within speci fied position 10 20 mm free play on the lever 3 Tighten the locknut again WARNING After adjusting make sure that the break pads do not drag When there is no free play on the lever the pressure in the brake system will increase and the system can over heat and fail If proper adjustment cannot be obtained as described contact a dealer to make this adjustment 35 CHECKING MAINTAINING Brake pads The front and rear brake pads must be checked for wear in periodical intervals WARNING Check brake pads for wear espe cially before every trip The pads present a groove that must always be visible Disc brake pads wear depends on use riding style and road conditions If the friction ma terial of the pads reach the 1 mm thickness limit change both pads The excessive wear of the friction material would cause the contact of the pad metal support with the 36 disc with consequent metallic noise and production of sparks from the caliper Braking efficiency safety and soundness of the disc would thus be negatively affected Checking the front and rear brake fluid level Place the vehicle that the master cy linder is in horizontal position If the brake fluid is below the mini mum level mark please refill up to the max indication Insufficient bra ke fluid may allow air to enter the brake system possibly causing it to become ineffective
15. brake light 11 and the license plate light 12 do not glow disassemble the bolts 1 and 2 for CHECKING MAINTAINING changing the bulb Injection system The injection system consists afuel pump with tubes a fuel filter and the injector Fuel pipes should not be bent curved or compressed Fuel pump The fuel pump module supplies fuel to the engine at system pressure 41 CHECKING MAINTAINING The fuel pump module is mounted Inside of the fuel tank Fuel filter The fuel filter protect the engine and the injector against impurity from fuel The fuel filter should be changed from by dealer Injector The injector is controlled by ECU timely and accurately injecting the fuel into the inlet manifold 42 Troubleshooting Although our company s motorcy cles receive a thorough inspection before shipment from the factory trouble may occur during operation The following trouble shooting chart represents a quick and easy proce dure for checking these vital sys tems by yourself However should your motorcycle require any repair contact an autho rized dealer who is a skilled tech nician He has the necessary tools experience and know how to ser vice the motorcycle properly Use only genuine spare parts TROUBLESHOOTING FAILURE Cause To Do Engine does not start when the electric Battery discharged Charge the battery Check if the generator is working correctly Engine turns
16. headlight lenses meter lenses etc After cleaning use only a soft clean cloth or sponge to dry the plastics Please prevent any harsh chemical products like fuel rusty removers break fluid on plastic parts especially on painted covers lens and wind shield It will damage them and even cause safety consideration Do not use high pressure washer steam cleaner since it will cause water seepage and deterioration on bearings electric components as connectors and switches lights breathe hose and tube brake shoes and pads and seals oea salt or salt sprayed on the roads during winter are extremely corrosive After riding in the rain near the sea or on salt sprayed roads Clean the motorcycle with cold water and a mild detergent after the engine has cooled down Apply a corrosion protection spray on all metal including chrome plated and nickel plated surfaces to prevent corrosion Do not use warm water since it increases the corrosive action of the salt After cleaning Dry the motorcycle with a absorbing cloth To prevent corrosion it is recommended to apply a corrosion pro tection spray onall metal including chrome and nickel plated surfaces Use spray oil as a universal cleaner to remove any remaining dirt Wax all painted surfaces 45 CLEANING STORAGE Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner and wash the tires with wa
17. AT NOTED IN THIS MANUAL e OBTAIN A QUALIFIED TRAI NING amp LEGAL LICENSE FOR OPERATING OF THIS VEHICLE e A WELL AND PROFESSIONAL MAINTENANCE AND CERTIFICA TED REPAIR SHOP TO ACQUIRE GOOD MECHANICAL TIONS OF VEHICLE Safe riding e check your vehicle before each ride is one of the key points to prevent an accident e please follow the maximum loads limited of operator and passenger e Most of accidents on the moto rists are cased by automobile dri vers who failure to recognize out the vehicle and caused mobile motorcycle accidents Therefore making yourself cons picuous in the public will be very effective in preventing this kind of accidents Therefore e Wear a brightly colored protective suits jacket e Operate the turning signals befo re turning and slow down the speed approaching and pass through the intersection e Keep proper distance with Moto rists and make them aware of your location e Know your skills and limits e Never lend your motorcycle to others who not qualified for riding it e Always follow the legal speed limit on the motorcycle and traffic law SAFETY INFORMATIONS e he posture of operator and passenger is important for proper control Properly riding posture can keep motorcycle in balance while riding e Operators should sit up right with two hands on the handle bar and feet on the floorboard while driving e Passengers should make sure that she
18. ading cargo or ad ding accessories to your motorcycle SAFETY INFORMATIONS Loading The total weight of the operator the passenger the accessories and the cargo may not exceed the maxi mum load limit Maximum payload do not include the vehicle 150 kg When loading within this weight limit keep the following in mind e Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imba lance or instability e Make sure that accessories and cargo are securely attached to mo torcycle e Never attach any large or heavy items to the handlebar the front fork or the front fender Such items can create unstable handling or a slow steering response Accessories Original accessories have been specifically designed for use on this motorcycle Keep the following guidelines in mind when mounting accessories e Never install accessories or car ry cargo that would influence the ground clearance the suspension limit the steering or obscure lights and reflectors e Accessories on the handle bar will influence the steering of the motorcycle If you install accesso ries please keep it light in weight e When you equip the motorcycle with electrical accessories please consult a qualified dealer to make sure that the items will not exceed the capacity of the electrical sys tem U
19. but does not start or dies off A fuse is blown Check the fuses Idle speed is not set correctly Adjust the idle speed Clean the spark plug check the electrode dis plug is contaminated tance Engine power is poor No or not enough coolant in the Engine overheats system Refill coolant Coolant leakage Check the colland circuit Air in the coolant system Ventilate the system Thermostat damaged Replace Thermostat 43 TROUBLESHOOTING FAILURE Cause To Do EOBD alarm light is on and DTC ap Failure in the fuel injection electric pears system otop the motorcycle and identify the faulty part by pushing the Select Button on the speedo on the speedometer meter Check the wiring harness for any damage Use the diagnostic tool to erase the DTC 44 CLEANING Cleaning Clean the motorcycle in a proper and suitable way It will keep it attractive extend it s life and optimize the performance Before cleaning Cover the muffler outlet and the two airbox inlet holes with a plastic bag or cap to prevent water to come inside Close every caps covers and electrical connectors while you are doing the cleaning We do not suggest to use any acidic cleaners for cleaning If such products have been used on hard to remove dirt please only do the spot cleaning and use water afterwards Then dry it and use corrosion protection spray after finishing Please only use mild detergent and water to clean plastic covers panels
20. d 5 from the top co ver After this take off the plastic covers The air filter box is exposed Release the screws around the air box You can see air filter element Remove the caliper connecting it with the throttle body to remove the element Now the battery is accessible The battery model YTZ7 S is a sealed type MF battery which does not require any maintenance WARNING Electrolyte is poisonous and dange rous it contains sulfuric acid which causes several burns Avoid any contact with skin eyes or clothing Protect your eyes when you handle a battery In case of contact flush with plenty of water In case of eyes contact flush with plenty of water and seek immediate medical attention Batteries produce explosive hyd rogen gas Therefore keep sparks flames cigarettes etc away from the battery Provide sufficient ventilation when charging the battery KEEP ALL BATTERIES OUT OF THE REACH OF CHILDREN 39 CHECKING MAINTAINING Charging the battery 1 Switch off all consumers 2 Measure the battery voltage using a multimeter Fully charged 13 8V 3 If the voltage is below 12V disconnect the minus wire from the battery 4 Connect a suitable charger To store the battery If the vehicle will not be used for a longer period remove the battery and recharge it If the battery will be stored for a longer period check it at least once a month and fully re charge it if necessary
21. d and the electrical systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Turn the key in from the 49 position and then turn it to while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to Gd while still pushing it WARNING Never turn the key to 69 Or fr while the vehicle is moving Otherwise the electrical systems Will be switched off which may re sult in loss of control or an acci dent Make sure that the vehicle is stopped before turning the key to OY Ay OPERATION INSTRUMENTS Indicator and warning lights Speedometer Display unit km h or mp h 1 Display Range 0 199km h or 0 124mp h Indicator lights 2 Neutral light N Green 3 High beam light z Blue 4 Direction light lt 10 gt Green 9 Oll alarm YZ Red 6 Temp alarm Red 7 EOBD Orange 1 After the first 500km the oil alarm 4 will come on to re mind for the first oil change Press the adjust button for 3 sec and the alarm light will turn off After every 1000 km it will come again to remind checking the oil le vel 2 In the normal condition when you switch on the ignition the light will go on and after starting the engine some seconds later it will disappear If there is are dia gnostic trouble s after starting the engine the EOBD will appear
22. d in any gear It is recommended not to drive the motorcycle at full throttle ADT Speed limit km h limit km h 300 15 30 35 40 45 50 600 1000km 15 30 40 45 50 1000 Top speed for the running in period of the motorcycle 25 OPERATION AND IMPORTANT POINTS Do not keep the engine run at the same speed long time du ring the running in period Of ten change it because it is hel pful for the running in of parts During the running in period it is necessary to put load on each part of the engine to gu arantee complete coordination but do not over load the engine Avoid also running the engine al ways at low speed During the running in the engine al ways works at low speed the parts will get not in good condition Ac celerate the engine in any gear but do not exceed the suggested limit Do not accelerate the motorcycle to full throttle during the running in period 26 First inspection and routine main tenance The inspection immediately after the first 1000 km is the most important one This inspection shall be done comprehensively Every fastening piece shall be refastened and the engine oil must be replaced After the first 1000 km the final engine oil and the oil filter must be changed the oil sieve and the oil drain bolt must be cleaned If any engine problem occur du ring the running in period im mediately consult your dealer to check the vehicle
23. e lines minimum tread depth or if the tire has a nail or glass fragments in it or if the sidewall is cracked contact a dealer to replace the tire immediately The tire treads depth limits may differ from country to country Always comply with the local regu lations 33 CHECKING MAINTAINING WARNING To operate the motorcycle with worn tires decrease riding stability and can lead to loss of control Ple ase replace the worn tires by new one immediately Front tire size 100 80 17 52H 2 5X17 wheelrim Rear tire size 130 80 17 65H 3 0 17 wheelrim Cast wheels To maximize the performance du rability and safe operation of your motorcycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage befo re each ride 34 If any damage is found contact a dealer to 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 been changed or replaced An unbalanced wheel can result in poor performance adverse handling characters and a shortened tire life Hide at moderate speeds after changing a tire since the tire surface must first be break for it to deve lop its optimal characteristics Front brake There should be no free play at the brake lever end If there is free play con
24. e stands 15 equiped with a auto rebound system To raise the side stand bring the motorcycle in a up right position Pay attention to your legs when the side stand is soaring Make sure that your torcycle park stable Please avoid to park the motor cycle on a precipitous or soft ground Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING The exhaust system is hot after driving Make sure that the ex haust system has cooled down before doing any maintenance Work The following precautions must be observed to prevent a fire hazard or other damages eNeverparkthe vehicleneargrass or other materials thateasily burn eDo allow the egi ne to idle too long eDo not touch the exhaust after driving PRE OPERATION CHECK The condition of a vehicle is in the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage or fluid leakage or loss of tire air pressure can have serious consequences Therefore it is very important to check the following points before each ride NOTE The pre operation check should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and guarantee more safety WARNING If any in the pre operation check list is not working properly have t
25. e throttle cable free play should measure 1 5 3 5 mm at the throttle grip CHECKING MAINTAINING Clutch adjustment Tires Put the heaviest cargo to the cen 1 Loosen the locknut 1 on the T P ter of motorcycle then distribute crank case the weight evenly from side to side durability and safe operation of your motorcycle note the following points regarding the specified tires The tire air pressure should be 1 Tire tread depth min 1 6 mm checked and adjusted before each 2 Tire sidewall 2 Turn the adjusting bolt 2 in or out to meet the requirements of clutch free play 3 The free play should be 10 20 mm on the clutch lever 4 Tighten the lock nut 1 after This will ensure proper handling of the vehicle Tire inspection adjusting the nut 2 10 20 mm ride The tire air pressure must be checked and adjusted on cold tires Tire air pressure Driver only Front 2 1 bar Rear 2 2 bar With passenger and max payload Front 2 1 bar Rear 2 5 bar WARNING Do not over load your motorcycle instead the tire pressure will decrease Allocation of your cargo and the total weight of your vehicle is very important for your own safety and vehicle performance When you do not load your cargo firmly on vehicle it may lead to an accident 3 Tire wear indicator The tires must be checked before each ride If a tire tread shows crosswis
26. ed coolant CASTROL MOTORCYCLE COOLANT CHECKING MAINTAINING ECU Engine Control Unit The ECU is installed on top of the air box under the front cover According to the pre set control procedures and parameters ECU controls fuel injection ignition timing precisely enabling the engi ne working optimally under various working condition at the same time minimizing the tailpipe emissi ons and fuel consumption When the system detects fault s the ECU also provides diagnosis when system malfunctions occur by outputting trouble code according to EOBD 32 The ECU is one of the most important parts of the vehicle and it is adjusted properly during manufacturing If you have any problem please contact a dealer for consultation Each ECU is identified with a product label for traceability it should not be defaced or soiled or the manufacturer shall not be hold responsibility of investigation and replacement Keep the ECU clean by a dry cloth Keep the ECU and connectors away from water fuel or other corrosive liquid which may damage the housing of the ECU Adjust the idling If the idle is not correct consult a dealer to check it The minimum speed of the engine idling must be approxemately 1700 100 rev min 779 the throttle cable free 1 Release the locknut 1 2 Rotate the adjusting screw 2 to adjust the clearance 3 Tighten the lock nut 1 after adjusting the nut 2 Th
27. f 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 49 50 1000 km 1 Month Stamp Signature 7000 km or 12 Month Stamp Signature 13000 km or 24 Month Stamp Signature 19000 km Stamp Signature Stamp Signature 4000 km or 6 Month Stamp Signature 10000 km or 18 Month Stamp Signature 16000 km Stamp Signature Stamp Signature Stamp Signature SERVICEPLAN From 13000 km maintenance should place every 3000 km or annually The warranty can be granted only when the vehice has been serviced in accordance with this Service plan
28. he can firmly hold grip at operator and with feet on footrest e Driving after drinking alcohol or drug consumption or influen cing medicaments Is strictly pro hibited e This motorcycle is designed for on road use only It is not sui table for off road use Protective clothing Proper adequate clothing will keep yourself safe from potential acci dents e Always wear an approved helmet with face shield to protect your eyes e The wearing of proper jacket shoes gloves reduce the degree of injury from unexpected accident e Never wear loose fitting clo thes otherwise they could catch on the control levers or wheels and can cause injury or accidents e Never touch the engine or ex haust system during or after driving as they become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Modifications Modifications on the motorcycle which have not been approved by the producer or the removal of ori ginal parts may result in an unsafe vehicle condition and entail severe accidents and injuries Not appro ved modifications make your mo torcycle illegal Loading and accessories The adding loading of acces sornes or cargo on to your motor cycle will influence the stee rng amp balance of the vehicle It may cause an accident so please be extremely carefully and consider the limitation when you equip it with accessories Here are some guide lines referring lo
29. he vehicle fixed at autho rized dealer before operate it If it failed to be corrected by yourself please contakt your retailer 22 PRE OPERATION CHECK Pre operation check list Fuel Check the fuel level in the fuel tank Refill fuel if it is necessary Check the fuel line for leakage Final transmission Check vehicle for oil leakage Front brake e Check operation f the brake feels soft or spongy have a dealer to check the system e Check brake pads for wear and replace it if it is necessary Check the fluid level in reservoir and add brake fluid to if it is necessary Check hydraulic system for leakage Brake lever e Make sure that it works operates smoothly Lubricate the lever pivoting points if necessary Throttle grip Make sure that operation is smooth Check cable free play Lubricate cable and grip housing Wheels and tires Check for damage e Check tire condition and tread depth Check air pressure Chasis fasteners Make sure that all nuts and bolts and screws are properly tightened Tighten it if it is necessary Instruments and lights Check operation 23 OPERATION AND IMPORTANT POINTS Starting the engine 1 Turn on the ignition 2 Switch the gear to N neutral 3 Actuating one of the brakes 4 Operate the starter button without accelerating 5 Let the side stand raise up WARNING Do not start the engine and allow it to idle in a cl
30. ll be subjected to unnecessary stress resulting in early wear and even chain breakage 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 wheel or damage the engine In either case the operator is likely to lose control of the motorcycle Adjust the chain Tension 1 Loosen collar nut 1 2 Loosen counter nuts 2 3 Turn right and left adjusting screws 3 equally far 4 Tighten counter nuts 2 Before tightening the wheel spindle verify that the chain adjusters are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 with 0 Nm Shock absorber shock absorber is equipped with a preload adjuster The shock 5 preload adjuster is infini tely variable This allows the shock absorber to be adapted to match your body CHECKING MAINTAINING Adjust the preload Turn the adjusting ring 1 e clockwise to increase the preload e counterclockwise to decrease the preload WARNING The shock absorber is filled with high density nitrogen Do not disassembly the shock Absorber This may lead to injury Battery The battery is installed under the seat inside of the air filter box For any replacement please re lease the screws form 1 2 and 3 on On both sides of the vehicle and screw 4 an
31. nproven items or poor instal lation may cause a dangerous loss of electricity or short circuit or cable fire Gasoline and exhaust gas e GASOLINE IS HIGHLY FLAMMABLE e Always turn off the engine when refueling e care not to spill any gasoli ne on the engine or exhaust system when refueling e Do not smoke or use mobile pho ne while refueling e Never start the engine or let it run for any length of time in a closed area SAFETY INFORMATIONS The exhaust fumes are poisonous and may cause loss of conscious ness and death within a short time e Always turn the engine off before leaving the motorcycle and remove the key from the main switch When parking the motorcycle please note the following e n case of swallowing any gaso line or gasoline getting into your eyes please consult a doctor im mediately Keep away the gasoline from your skin e he engine and exhaust system remain hot Therefore park the mo torcycle in a place where pedest rians or children are not likely to touch these hot areas e Do not park the motorcycle on a slope or a soft ground otherwise it can fall over e Do not park the motorcycle close to open or camp fire e Pay attention to the environment Gasoline is not environmentally friendly Other safe driving points e Turn the signal before making turns e When raining or driving across slippery area keep your speed slow Take care while braking to avoid slipping or e
32. or dusty area 27 CHECKING MAINTAINING SERVICE INTERVALS The inspection intervals are required 1000 km or 4000 km or 7000 km or 10000 km or 13000 km or Par O 7 jAirfiter __ E wv v e 4 Steering bearing Conovcieam wbrioate v Screws Coverparts comovtomen v v v v Brake system Controcleanvexchange v v v _ 4 2 2 2 5 2 mme _ _ ome fon LL 7z Teese eee LE Driven chain sprokets Control clean exchange Clutch __ v _ lt IS lt m SIS m lt m m M lt 4 414 4 lt 4 tt lt 4 4 4 ISIS SIS n iMi m lt lt 28 CHECKING MAINTAINING SERVICE INTERVALS lt lt Cable bowden Control clean lubricate ov v _ Throttle Control adjust lubrica Ff lt 4 lt Lights switches Fuel line fuel filter dle speed Exhaust system Important Information Th mit n Tu iin Brake lines have to be exchanged at least every 4 years Brake liquid has to be exchanged at least every 2 years otarting at 13000 km the maintenance should be done every 3000 km or annually The vehicle must be constantly checked for rust owner himself is re
33. osed room Exhaust fu mes are poisonous and can cause loss of consciousness and death Provide always adequate ventilati on while the engine is running e Maximum period for continuous starting is 5 seconds Wait at least 5 seconds before trying it again e Dont ride your motorcyle with full load and dont over rev the engine while it is cold as the piston warming up faster than the water will cool the cylinder 24 e Always keep in mind that the en gine should be warmed up with medium R P M and small load Stop the Engine 1 Reduce the throttle to 0 position 2 Pull the clutch lever 3 Switch the gear to N neutral 4 Operate the brakes 5 After the vehicle is stopped turn off the ignition Before starting off allow the engi ne to warm up otherwise the spark plug and engine can be damaged early Starting off 1 Pull the clutch lever 2 Shift the engine to the first gear 3 Slowly release the clutch lever and open the throttle at the same time Shifting and riding a Shifting gears upwards 1 Release the throttle 2 Pull the clutch lever 3 Lift the gear lever upwards to change to the higher gears 4 Slowly release the clutch lever and open the throttle at the same time b Shifting gears downwards 1 Release the throttle 2 Operate the brakes and reduce the speed to a appropriate speed 2 Pull the clutch lever 3 Lift the gear lever down wards to change to the lower gears 4 Slowly
34. ow beam position move the switch down wards to use the high beam light The switch will not return automati cally to the low beam position 2 Turn signal switch Move the switch from the center position to the right to activate the right flasher light or move the switch to the left to activate the left flasher light The switch will not return au tomatically to the center position 3 Horn switch horn is sounded with this but ton 4 Clutch lever clutch lever is fitted on the left side of the handle bar OPERATION INSTRUMENTS oi 2 otarter switch 5 Starter switch Use the starter switch to operate the electric starter 6 Hand front brake lever hand brake lever is fitted on the right side of the handle bar and refers to the front brake 7 Throttle grip The throttle grip can be used for the acceleration and the deceleration of the vehicle 18 Rear foot brake pedal The rear brake pedal is located on the right side of the vehicle and re fers to the rear brake Press down the brake pedal to activate the rear brake Shift pedal The shift pedal is located on the left side of the engine The position of the gears is shown in the illustrati on The neutral gear is located between the first and the second gear E Fuel tank filler cap The fuel tank and the filler cap are located under the seat bench To reach the filler cap you mus
35. pe 95 octane unleaded mm gasoline Overall Width mm 845 plumber or cylinders Overall 1120 60 44 Wheelbase mm 1385 124 4 Vehi Rear ehicle Weight kg 76 kg Cooling mode Water cooled Total 139 kg Lubricating mode Force feed and splash lubrication Front External Oil tank capacity 1 2 L Oil change 1 L Wheel 100 80 17 Specification Rear External Air cl Fil 130 80 17 ir cleaner ilter sponge Fuel tank capacity T5Ltz0 2L Wet multi plate friction Top speed 110 km h un Maximum climbing lt angle is not less than 5 pattern Manual 6 gear 20 degrees Idle speed 1700 100 rpm min Drive Train Clutch type 3 zi Max torque 12 18 Nm 7500 r min m dea i Max power 11 Kw 9000 r min capacity type YUASATT27SL up Alternating current Generator type permanent Compression ratio 12 0 1 magnetic motor Pressure of Spark plug NGK CR8E 12 5 13 5 bar Spark plug 0 7 0 8 mm Diameter of front 280 mm clearance mM 395 brake disc e gt Ignition type CDI 2 2 240 47 WIRING DIAGRAM EFIINDICATOR HIGH BEAM LIGHT 2W SPEEDOMETER LIGHT 2W TURN SWITCH FLAMEOUT SWITCH TURN SIGNAL LIGHT 3W LEFT TURN SIGNAL LIGHT HORN SWITCH fal STARTOR SWITCH WATER TEMPERATURE LIGHT RIGHT em SWITCH 3 a DJ Ga m oo oo ud
36. r 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 document by the seller and that he has registered your vehicle correctly in our system Please also mind the fol lowing 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 one of our 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 o
37. release the clutch lever and open the throttle at the same time WARNING Always switch one gear only otherwise the transmission can be damaged OPERATION AND IMPORTANT POINTS Acceleration and deceleration The speed can be adjusted by ope ning and closing the throttle To in crease the speed turn the throttle grip in direction a To reduce the speed turn the throttle grip in direc tion b lt 7 E ee LN 1 Release the throttle A 2 Apply the front and rear brake at the same time 3 Apply the clutch lever gradually increasing the pressure Braking A WARNING eAvoid hard or sudden braking especially when cornering otherwise the motorcycle may skid eRailroad crossings street car rails iron plates on road cons truction sites and manhole co vers become extremely slippery when wet Therefore slow down when approaching such areas and cross them with caution eKeep in mind that braking on a wet road is much more difficult eRide downhill slowly because braking downhill can be very difficult eWhen you brake the brake discs brake pads and the brake fluid heat up The hotter these parts get the weaker the bra king effect In extreme cases the entire braking system might malfunction eTake time to become familiar with the braking system Engine break in period For the first 1500km driving do not rev the engine or make it exceed 80 of the maximum spee
38. rm water and a mild detergent WARNING Before operating the motorcycle test the brake performance and tires Storage Always store your motorcycle in a cool dry place and protect it against dust with a motorcycle cover Please store the motorcycle in a well air flow room with dry air A storage with high humidity will cause rust prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemicals are stored Follow all the instructions in the Cleaning section of this chapter Fill the tank and pour some additive in The quality of the fuel will stay constant Lubricate all cables and the pivoting points of all levers and pedals Check and if necessary correct the tire air pressure and then lift the motorcycle so that both wheels are off the ground Cover the muffler outlet with a plastic bag to prevent moisture entering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month If the machine is to be stored in a humid or salt air environment coat all exposed metal surfaces with a film of light oil Do not apply oil to rubber parts or the seat cover Make any necessary repairs before storing the motorcycle Recommended maintenance products CASTROL GREENTEC BIKE CLEANER CASTROL BIKE POLISH CASTROL CHAIN SPRAY O R CASTROL MOTORCYCLE DWF 46 SPECIFICATION TR 125 Mode TR 125 Engine type QU160MI A Overall Length 2030 Fuel ty
39. sponsible for rust protection The drive chain must be cleaned and lubricated regulary The air filter needs more frequently service If you ride in unusually wet or dirty area Recommended Supplies and maintenance products Fuel Unleaded gasoline 95 Octane or higher Engine oil SAE 10W 40 Castrol Power 1 4T Capacity is 1 2L Coolant Castrol Motorcycle coolant Brake fluid DOT 4 Castrol Motorcycle brake fluid Multi purpose lubricant Castrol Motorcycle DWF Chain Spray Castrol chain spray O R 2 CHECKING MAINTAINING 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 maintenance and lubrication chart In addition the condition of the Spark plug can reveal the condition of the engine Spark plug type CR8ES Tightening torque 10 15Nm Spark plug gap 0 6 0 7mm lt 30 Air filter The air filter element 1 should be cleaned and replaced regarding the service intervals Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Open the seat bench 2 Remove the left and right front coverparts 3 Dismantle the screw of the air DOX 4 Remove the air filter element 9 Blow out the air filter carefully with compressed air 5 Reassemble in reverse order
40. st be checked as fol lows 1 Place the motorcycle ona level surface and hold it in an upright position 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly WARNING If any damage is found or the front fork does not operate smoothly contact a dealer to check or repair it Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the stee ring must be checked as follows at the intervals specified in the peri odic maintenance and lubrication chart Place a stand under the engine to raise the front wheel off the ground Hold the lower ends of the front fork legs and try to move them forward and backward If any free play can be felt contact a dealer to check or repair the steering WARNING Securely support the motorcycle so that there is no danger for it for falling over 37 CHECKING MAINTAINING Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic mainte nance and lubrication chart If there is free play in the wheel hub or if the wheel does not turn smoothly have a dealer check the wheel bearings Chain adjusting WARNING If the chain tension is too great parts within the secondary power 38 trasmission chain chain sprockets transmission and rear wheel bearings wi
41. t re lease the seatbench OPERATION INSTRUMENTS Fuel fuel tank Make sure that there Is all the time sufficient fuel in the tank To refuel the vehicle open the filler cap coun terclockwise Fill the fuel tank until the bottom of the filler tube Do not overfill the fuel tank otherwise may overflow Recommended fuel Unleaded gasoline 95 Octane or higher Fuel tank capacity 7 5 L 0 2L WARNING Itis not recommended to use E10 fuel This can damage the engine and fuel system Immediately wipe off spilled fuel with a clean and dry soft cloth because fuel may destroy pain ted surfaces or plastic parts In case of swallow any gasoline or gasoline get into your eyes please consult a doctor imme diately Keep away the gasoline from your skin Seat 1 To open the seat a Place the motorcycle on the stand b Insert the key into the seat lock and then turn it clockwise to open C Now you can realase the seat bench 2 close the seat a Fold the seat down and then push it down to lock it in place b Remove the key from the seat lock WARNING Make sure that the seat is pro perly secured before riding OPERATION INSTRUMENTS Engine oil The oil level should be measured between the upper and the lower li mit on the inspection glas 1 on the right side of the engine To check the engine oil place the motorcyc le in an upright position on a level surface
42. tact a dealer to inspect the brake system WARNING 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 CHECKING MAINTAINING Front brake free play adjustment 1 Loosen the locknut 1 2 Turn the adjusting bolt 2 until specified position 10 20 mm freeplay on the lever 3 Tighten the locknut again After adjusting make sure that the break pads do not drag When there is no free play on the lever the pressure in the brake system will increase and the system can over heat and fail If proper adjustment cannot be obtained as described contact a dealer to make this adjustment Rear brake There should be no free play at the brake lever end If there is free play contact a dealer to 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 Rear brake free play adjustment 1 Loosen the locknut 1 2 Turn the adjusting
43. ven fall down e Be careful when passing parked cars Inattention to other road users can cause accidents DESCRIPTION Location of labels You will find two different labels and the engine number on the vehicle The anti tampering plate 1 is located under the seat bench The VIN number plate 2 is located on the right side of the steering head tube The engine number 3 is stamped into the left engine cover DESCRIPTION Left view Front wheel Front brake caliper Front turn signal light Battery Rear turn signal light Rear wheel Chain tensioner 8 Air filter element 9 Shift pedal OND DESCRIPTION Right view 10 Tail brake light 11 Muffler 12 Fuel tank cap 13 Seat 14 Spark plug 15 Rear view mirror 16 Headlight 17 Rear brake pedal DESCRIPTION Operation instruments 18 Clutch lever 19 Left handlebar switches 20 Speedometer unit 21 Main switch steering 22 Right handlebar switches 23 Throttle grip 24 Front brake lever OPERATION INSTRUMENTS Main switch steering lock The main switch steering lock con trols the ignition and lighting sys tems and is used to lock the stee ring All electrical circuits supplied with power and the engine can be started key cannot be remo ved OFF 66 33 The electrical systems are off The key can be removed LOCK GG 33 The steering is locke
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