USER MANUAL TRi
Contents
1. USER MANUAL TRi We at OSSA Motor would like to thank you for purchasing one of our products It is very important that you read this User s Guide to ensure the correct functioning and maintenance of your new TR As the owner of an OSSA motorcycle you are the member of an exclusive group You have just acquired a unique model the first model to be produced since the relaunching of OSSA The TR is the visiting card for our new OSSA Factory It marks the co meback after a 25 year interval of the legendary brand with the clover logo which in the 1960s and 1970s earned itself a solid international reputation outside the frontiers of the motorcycling world This is a really special article that will form part of the his tory of the brand of trial racing and of motorcycling as a sport Introduction The TR is a motorcycle that has been conceived for competition and then adapted to traffic regulations for use on public roads It has been specifically designed for trial competitions which means that its features are ideal for such conditions It is extremely light in weight both its gears and transmission systems and the dis tribution of its component parts have been arranged with careful attention and make it a revolutionary machine that is technically extremely advanced OSSA motorcycles have been designed assembled and tested by experts and each of its parts has been produced under the su pervision of OSSA eng2. User manual ww 9 0 S O LEID SAN N DB Le ON The transmission chain transmits the engine s movement to the rear wheel To ensure that is works correctly it should be checked OSSA TRi User manual Extend Shorten Lubrication of moving parts Lubrication of moving parts Cleaning the motorcycle and lubricating the mobile parts will help protect the motorcycle and guarantee that it works better If using a high pressure hose to clean the motorcycle bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle Take care NOT to accidentally lubricate the brake caliper or brake pads If this happens clean off the lubricant and carry out controlled braking until the brakes work correctly again OSSA TRi User manual Lubricate using specific products 1 Transmission chain 2 Clutch and brake lever joints 3 Gear lever joints 4 Rear brake pedal joints and bearings 5 Footrest brackets and springs 6 Engine kick start pedal joints 7 Gas handle right grip Use specific lubricants for each part of the motorcy cle Clutch and brake lever joints The chain drive should always be well lubricated Check it each time the motorcycle is used and apply lubrication when necessary The chain must be lubricated using special oil for chain 1 Chain drive Rear brake pedal Chain drive
3. medication drugs that might affect your driving capability Moderate speed Do not exceed 63 KPH 40 MPH Do not cross water areas Do not release your hands from the handlebars Do not perform risky maneuvers and stunts Do not use your motorcycle for transporting or towing loads In the event of needing to carry loads always use the box under the seat This load may be light weight and small in volume so that driving is not affected Ensure that there are no loose leashes or other elements that might get caught inside a mechanism Never apply additional weight to the handlebars fork or mudguards Be specially careful when transporting any type of load Do not clean the motorcycle with pressurized water equipment since this may damage the parts OSSA TRi User manual 5 Contents 6 OSSA TRi User manual Introduction 3 Important warning 4 Saferty 5 Contents 7 Technical specifications 8 9 Recommendations 10 Section 1 Components 11 Location 12 14 Multi function box 15 22 Control pad 23 Front suspension Settings 24 Air bleed 24 Rear suspension Settings 25 Air bleed 25 Anti theft immobilizer 26 Start lever 27 Fuel tank 28 Upper section 29 Section 2 Maintenance and basic operations 31 Maintenance grid 32 33 Adjustments to the motorcycle controls 34 Electric connections 35 Simplified lighting wiring diagram 36 Simplified i
4. 4 The measurement obtained corresponds to the measurement of the wheel circumfe rence Method 2 On a smooth and flat surface put a mark on the side of the tyre and in the area where it is touching the ground Move forward with the vehicle until the wheel has tuned completely once and the mark is on the lowest part again Put a new mark on the ground at this point Measure the distance between the two marks on the ground If necessary convert the measurement in mm by multi plying the figure obtained by 25 4 The measurement obtained corresponds to the wheel circumference To obtain a more accu rate measurement the rider should remain on the vehicle when the measurement is taken Control Pad The control pad is located on the left handlebar within reach of the thumb This control pad can be used to control the lights indicators horn and engine stop EN E o See the image with information about the control pad 1 Position lights 2 Cross lights 3 Long range lights 4 Lights for changing direction left right 5 Horn 6 Button to switch off engine EIC SAN HBBBE SS mmm mmi S DDD cess o See the image with information about the control pad 1 Pilot lamp for change of direction left right 2 Pilot lamp for cross lights 3 Pilot lamp for long range lights 4 Pilot lamp for footrest OSSA TRi User manual Front suspension The front sus
5. D Use a funnel to add the oil NEVER filling above the Maximum level Replace the cap If you fill above the Maximum level oil must be removed To remove oil from the hood place a receptacle under the motorcycle and remove the lid B located on the side of the hood and the screw E and lean the bike over in both directions to ensure that no oil remains inside the hood OSSA TRi User manual The crankcase has a 450cc oil capacity 2T 100 synthetic oil should always be used Clutch cover D The brakes permit precise and controlled riding It is necessary to check them in order to ensure that they work correctly OSSA TRi User manual Tightening torques Storing the bike 3 These grids show the tightening torques of different parts FRAME na Engine fixation Rear brake pump fixation 70 40 50 2 12 22 F 30 R 48 OSSA TRi User manual ENGINE 2 m unn 8 9 et 8 3 DE TI 8 9 mamcwernam 8 9 ye ida eta 89 DITES 8 9 Storage If the motorcycle is to be stored for a long period of time the following procedure should be followed to ensure that it is stored correctly Clean the motorcycle as much as possible because dirt can cause the deterioration of components Turn on the engine for a few minutes to warm up the transmission fluid and then drain see section on draining fluid F
6. Front fork spring weak or broken Replace front fork spring Brake pads badly positioned or Change position of brake pads or replace crystallised them OSSA TRi User manual OSSA TRi User manual 53 Troubleshooting In the event of breakdown always take the motorcycle to a specialist mechanic POSSIBLE CAUSE POSSIBLE SOLUTION Bent chassis Change chassis Go to specialist me The motorcycle tends to lean to one chanic side Steering badly adjusted Adjust steering Go to specialist me chanic Steer axle bent Change steering axle Go to specialist mechanic Standardisation components Wheels badly centred Align wheels The brakes don t work correctly Loss of brake fluid Check brake circuits Change if dama ged or broken Brake fluid in bad condition Drain brake fluid and replace with new fluid recommended by a mechanic Pump piston broken Replace the pump piston Brakes badly adjusted Adjust brakes OSSA TRi User manual OSSA TRi User manual Standardisation components Standardisation components Each of the registered elements should be part of the vehicle In the event of breakages loss or bad A Each of the registered elements should be part of the vehicle In the event of breakages loss or bad functioning it is recommended that you go to an official OSSA mechanic to remedy the problem functioning it is recommended that you go to an official OSSA mechanic to remedy the probl
7. and radiator 17 Kick start pedal 4 Cylinder 18 Fuel tank f 5 Sparkplug 19 Rear brake disc 6 Chain guide 20 Swing arm 7 Front tyre 21 Rear brake lever 8 Front fork bottles 2 a a ss ee 9 Front fork stanchions Q 2 da rake caliper 10 Shift pedal ront brake disc 11 Chain 12 Chain slider 13 Rear sprocket protector 14 Rear tyre OSSA TRi User manual OSSA TRi User manual Location of elements Multi function box 25 Front brake handle 26 Throttle grip 27 Throttle grip mechanism 28 Front brake pump 29 Right fork stanchion regulator 30 OSSA multi function box 31 Left fork stanchion regulator The OSSA TR multi function box and the indicator lights next to it provide very useful information at all times The multi function box is a power box system with an LCD screen controlled by a console with indicator lights located in the centre of the handle bars The information displayed on the multi function box includes the number of revolutions made by the engine speed distance covered total distance covered time average speed maximum speed environmental temperature running time and uptime This device has an internal memory unit that stores data like total Km and total running time even when it is switched off Temperature warning LED OSSA Multifunction Display LED warning of excessive motor rotation 32 Clutch pump 33 Lights control pad 34 Clutch handle 35 Headlights 36 Air
8. the motorcycle to a specialist mechanic PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The shock absorption is too soft level The motorcycle makes abnormal Supports screws or nuts are not properly Check and adjust using suitable torque fastened wrench Front fork oil not sufficiently viscous Drain fork oil and fill up with suitably viscous ROSES oll Tyres wear swing arm or its needle Change worn parts for new parts Front fork bent Change the front fork Contact an officially bearings wear registered mechanic Wheel rim not centred Centre wheel rim Rear shock absorber badly adjusted Adjust the rear shock absorber Wheel not centred Check the tension of the spokes and Chain badly adjusted Adjust chain readjust The motorcycle makes abnormal Change chain and sprockets Lack of engine oil Check and add engine oil noises Rear sprocket teeth wear Change rear sprocket Steer axle with excessive tolerance Tighten the handlebar support and the steer Insufficient chain lubrication Lubricate chain The handlebar vibrates axle nut using suitable torque wrenches Rear wheel badly adjusted Align rear wheel Contact an officially regis Handlebar support loose steer axle nut Tighten the handlebar support and the steer tered mechanic loose axle nut using suitable torque wrenches Front fork with insufficient oil Add oil to the fork until it reaches a sufficient level
9. the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR Note This step must only be followed for those vehicles that change the PPR pulse type to a specific turn rate If you don t know this value press button 2 to move on to the next screen Enter the value by pressing button 1 re peatedly To move on to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR The indicator receives an electric pulse each time the engine turns PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pressing button 1 re peatedly To move on to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR Note This stage must only be imple mented if in the previous stage the value O was entered Default value 1 0 If you don t know this value press button 2 to move on to the next screen To move on to the next digit press button 3 Confirm the selection by pres sing button 2 OSSA TRi User manual 2 CSSCSSZ N pp Multi function box Multi function box Temperature selector To select the unit of temperature either C or F press button 1 Confirm the se lection by pressing button 2 Danger temperature selector Note This stage should only be imple mented for those vehicles that have an opti
10. up to 12 000 rpm The tachometer signal is received from the sparkplug wire SPD Speedometer The speedometer information appears on the centre of the screen It displays up to 399 9 km hour or miles hour MS Maximum speed meter It displays the maximum speed reached during the last operation after having set the counter at zero DST Distance covered It appears on the right side on the second line of the screen The TRIP function records the mileage accumulated by the vehicle since the last RESET ODO Mileage counter It records the distance or total accumulated mileage for the ve hicle The data is stored in the memory even when the device is switched off ART Running time controller It calculates the total running time It begins counting as soon as the engine is switched on RT Total running time controller It calculates the vehicle s running time from the last RESET It begins to count from when the vehicle starts to move The data is stored in the memory even when the device is switched off 12 24 hour clock It displays the current time in 12 or 24 hour clock It indicates the temperature of the environment and engine The display screen on the upper left shows the environmental temperature Using an optional temperature sensor the screen displays the engine tem perature If excessive the yellow light comes on Indicator that engine turn rate is excessive Warning of gear change due to rpm If the engine tur
11. B sedis Setting the indicator functions to zero after each use of the vehicle After each use of the vehicle it s possible to set the following functions to zero simultaneously Maximum speed Distance Chronometer Maximum temperature Maximum turn rate Confirm that you want to set these functions to zero by simulta neously pressing buttons 1 and 2 Setting the whole multi function box to zero Press the RESET button by using a suitable object The indicator will boot again excluding data that corresponds to total accumu lated distance and time Internal battery The multi function box works with a 3V internal battery type CR2032 When the battery tension falls beneath 2 45V the screen displays the LO indicator To change the battery open the lid on the bottom of the indicator by unscrewing it as is indicated in the image using a coin Ensure that the positive side of the battery is facing upwards OSSA TRi User manual Multi function box Control Pad Screen Options The multi function box displays all information on three different screens While on it is possible to see screens 1 or 2 Screen 3 is displayed for three seconds and then returns to screen 1 To move from one screen to another repeatedly press button 2 Mode To edit the distance covered DST hold down button 3 Screen 1 Screen 1 displays the following information Speed distance covered time environmental temperatu
12. Front brake lever Carry out a regular and thorough maintenance of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly Clutch lever min 3 mm 4k 4k min 3 mm OSSA TRi User manual OSSA TRi User manual Simplified diagram of the lights viring 3 3 Simplified diagram of the injection viring OSSA TRi User manual OSSA TRi User manual Air filter Radiator Air filter Cleaning and maintenance The air filter should be controlled periodically Lift the upper fuel tank as you can see in the image on page 29 in order to access the filter box Remove the filter rubber cap unscrew the upper part of the filter not necessary to use tools and take out To clean use water and detergent leave to dry and then lubricate with a special liquid for filters Reassemble using the steps outli ned previously but in reverse Make sure that the parts areput in their correct positions Carry out regular and thorough maintenance of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly OSSA TRi User manual The radiator contains the engine refrigerant To fill up with or add refrigerant to the radiator locate the tank lid To locate this lid detach the air filter l
13. If one of the afore mentioned terms is invalid due to regional or federal laws all other terms stipulated in this warranty continue to be valid Thank you and we hope you enjoy your new motorcycle OSSA TRi User manual OSSA TRi User manual WWW Ossamotor es Ossa Motor Carretera antiga d Amer nau 12 17007 Girona Spain tel 0034 972 107 107 fax 0034 972 117 899
14. MPORTANT this key has a code which is needed for making duplicate copies of the key This code should be written down in the indicated space on the registration page and series number of this manual OSSA TRi User manual Before starting the motorcycle you must ensure that the key switch at the right hand side of the headlight is activated Also it must be in neutral gear DO NOT try to start in a gear The kick start pedal is part of the mechanism that is used to kick start the motorcycle mechanically To kick start the motorcycle the kick start pedal must be sepa rated from the bike and moved outwards Once separated place your foot on top and press strongly to turn it counter clockweise It is necessary to ensure that the light signals are working properly that the tire pressure is correct and the security and control ele ments brakes and controls are in good condition If the motorcycle has been inactive for a long period of time its recommended that the kick start pedal is activated gently 3 or 4 times without actually kick starting the motorcycle This will enable the engine to o move which will help when kick starting it If the motorcycle has been inactive for a very long period of time change the oil and petrol because they might have become degraded This could affect the motorcycle s performance Kick start pedal OSSA TRi User manual Fuel tank Upper section To access different
15. SIBLE SOLUTION Long period of engine inactivity Change the old petrol for new petrol e uh makes it difficult for the handlebar Move wire or loosen it a bit i e motorcycle is unstable o turn The engine won t start Sparkplug dirty or wet Dry clean or change the sparkplug y Steer axle screw is very tight Loosen the steer axle screw General fuse damaged Change general fuse 7 e Steering bearings are damaged or with Replace steering bearings Bad electrical connection Check electrical connections and posi wear tion correctly Take the motorcycle to a specialist Steer axle bent Change the steer axle Contact an mechanic officially registered mechanic Lack or deterioration of petrol Fill the fuel tank with new petrol MP Excessive oil on front fork Remove surplus oil until it reaches the The engine starts and then stops Take the motorcycle to a specialist The shock absorption is too hard correct level mechanic Oil too viscous on front fork Drain fork oil and fill up with viscous Front fork bent Change the front fork Contact an officially registered mechanic Rear shock absorber badly adjusted Adjust the rear shock absorber Iyre pressure too great Check the pressure of the tyres OSSA TRi User manual OSSA TRi User manual Troubleshooting Troubleshooting In the event of breakdown always take the motorcycle to a specialist mechanic A In the event of breakdown always take
16. TX OHlins mono shock absorber adjustable in extension and compression Oll mono shock absorber adjustable in spring preload depending on version 185 mm diameter disc with 4 piston brake caliper 150 mm diameter disc with 2 piston brake caliper 2 5x21 wheel 4 00 x 18 tubeless wheel Constructed in AA7075 T6 WEIGHTS AND MEASUREMENTS Wheelbase Seat height Ground clearance Fuel tank capacity Dry weight Kick start pedal Shift and brake pedal 1 328 mm 655 mm 340 mm 2 6 litres 64 5 Kg Forged aluminium Forged aluminium with retractable toe cap OSSA TRi User manual 9 Recommendations It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order 12 hours of running in is recommended to ensure that the engine works correctly and for a long lasting time period It is important to run the engine for some minutes until it reaches the correct temperature to work correctly The engine lubrication is a mixture of petrol oil with a 0 9 oil proportion Always use synthetic oil When the motorcycle is new the oil must be changed for the first time after 5 hours of use and for the second time after 12 hours of use OSSA TRi User manual Section 1 Components OSSA TRi User manual Location of elements Location of elements 1 Front mudguard 15 Rear break caliper and anti theft immobilizer 2 OSSA multi function box 16 Exhaust 3 Fan
17. arantee for parts or fluids that have deteriorated due to use The parts or elements mentioned below are not covered by the warranty except when it is necessary to replace them during a repair carried out under warranty OSSA TRi User manual Warranty Warranty Parts Spark plugs fuel and oil filters and their components transmission chains air filters engine sprockets back crown gears disk brake and break pads clutch disks light bulbs except for those that are sealed fuses belts tyres and inner tubes wires and other rubber and or tire parts specified by OSSA Fluids Lubricants such as oil grease etc and fluids for functioning for example refrigerant liquid for the radiator break and gear fluids transmission fluids suspension oil etc 1 Cleaning inspection adjustments and other elements of periodical maintenance m Additional costs on top of warranty service including notifications accommodation maintenance and other costs due to breakdowns in isolated places Compensation for wasted time commercial losses or hire costs of a substitute product du ring the adjustment period n Any part replaced under warranty will become the legitimate property of OSSA The parts replaced during the period of warranty will be guaranteed for the time remaining for the substituted part OSSA reserves the right to introduce modifications and improvements it deems appropriate for all its models 0 OSSA does not gu
18. arantee repairs for noise vibration oil filtrations and other elements that don t affect the product quality functioning and performance OSSA TRi User manual MAINTENANCE AND SERVICE It is your responsibility to ensure that the services are carried out on your motorcycle within the specified time periods and that the services are correctly registered This means that your motorcycle will receive all the benefits of the OSSA warranty It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was purchased where both you and your motorcycle are known Under normal circumstances periodical revisions reduce overall maintenance costs If you need to use the warranty service please contact your authorised OSSA dealer immediately and make an appointment so that the necessary work can be carried out It is recommended that periodical motorcycle services are planned in advance LOOKING AFTER YOUR MOTORCYCLE Inspect your motorcycle on a daily basis before driving The Owner s Manual contains a list of things to be checked These inspections will help avoid problems Remember that minor adjustments are made more easily at home rather than on the road As well as improving the motorcycle s appearance thorough cleaning take care when using pressure or steam cleaning equipment as it can damage the paint and lacquer of the product s finish provides the perfect opportunity for inspecting yo
19. em Your OssaTR is standardised in compliance with UE regulations It adheres to all standardisation requirements EURO 3 regulations The obligatory elements to be registered for driving on public roads and for passing the vehicle s MOT are listed below The elements to be registered among others are identified with a specific mark and registration 1 Front headlight 9 Exhaust system 2 Front indicators 10 Speedometer 3 Rear indicators 11 Pinion output 4 Rear pilot 12 LOCR 5 License plate support 13 Horn 6 Reector 14 Kickstand 7 Mirrors 15 Throttle limiting bolt 8 Manufacturer s plate OSSA TRi User manual OSSA TRi User manual Standardisation components Standardisation components Hmm II 1 Front headlignt 11 2 e9 97 24 97 24 4367 00 P Front position lamp R55 00 14839 png beam Ras Passing Beam R113 00 14839 O 2 Front indicators 1101200094867 3 Rearindicatos fo 4 Rear pilot e13 50 R00 50R00 12448 00 5 license plate support 6 Rettector DA 020 0 ZM L e9 80 780 80 780 0143 01 8 Manufacturer paue ES Exnaustsysem PP HO Speedometer PP 11 Pinion output f o n E NEN eee O p 1 NENNEN 12 Lock e13 28R00 28R00 0037 00 cS ES CE Manufacturer s plate Serial number 14 Kickstand 15 Throttle limiting bolt OSSA TRi User manual 58 OSSA TRi User manual Standardisation components The key number can be found under the red cove
20. filter Some features may be personalised the device can measure in kilometres or miles The wheel circumference value can also be changed N ST MUS RY pa A temperature sensor warns us with a yellow light 1 when the engine temperature is excessive Another sensor provides a warning with a red light 2 when the Left bufon Right button rate at which the engine turns is excessive Right button OSSA TRi User manual OSSA TRi User manual Multi function box Multi function box Technical features Functions sm eheu 1 Km h o M h 0 1 Km h o M h O 999 hours 59 minutes 1 minute me SL em Input voltage 9 400 V CA CC Speed sensor magnetic non contact sensor Tachometer input electrical pulse sensor Wheel circumference adjuster 1 mm 3 999 mm increases of 1 mm Running temperature storage from 0 C to 60 C from 32 F to 140 F from 20 C to 80 C from 4 F to 176 F Battery Life 3V CR2032 1 year approx 16 OSSA TRI User manual 0 196 pus Functions RPM Bar Bar graph tachometer The tachometer bar graph displays up to 12 000 rpm RPM Digital tachometer The RPM appear on the right side on the second line The digital tachometer displays up to 12 000 rpm The tachometer signal can be captured from the sparkplug wire Warning of gear change due to rpm The rpm appear on the right side on the second line The digital tachometer displays
21. for repairs product replacement price reduction or contract resolution 1 It will be free for the purchaser 2 It will be carried out in a reasonable time period 3 In the six months following delivery of the repaired product the seller will be answerable for those faults which necessitated the repair When defects occur of the same origin as those initially repaired it will be presumed that it is the same fault 4 If after the product has been repaired the product still has faults while the warranty is in force the purchaser can choose between a replacement a price reduction or refund If the purchaser selected a product replacement they can request a repair always while the cost of this repair is not disproportionate a price reduction or refund 5 The seller is not obliged to replace fungible or second hand goods 6 The price reduction will be proportional to the difference between the value that the product would have had on delivery if the fault did not exist and the value that the product had at the time of delivery 7 In the event of it being impossible for the purchaser to address the seller for the product s non compliance with the purchase agree ment they will be allowed to claim directly to the manufacturer in order to obtain a replacement or product repair OSSA TRi User manual Warranty Warranty PERIOD OF WARRANTY OSSA is answerable for faults that appear over a two year period from the produc
22. id see page 36 Air Filter Once the filter lid is detached the radiator lid is visible Unscrew the lid and pour in refrigerant ATTENTION Use gloves Do not open the lid if the engine is hot This could cause burns Avoid contact of the liquid with the eyes mouth or nasal passage Do not ingest In the event of this happening follow the product instructions and consult a doctor The radiator has an electric fan to force air through it as can be seen in the image belovv To fill the radiator special coolant should be used 30 C To ensure that the motorcycle works correctly periodic controls must be carried out to check the coolant levels This will ensure that the motorcycle is running at an optimum temperature o Always use special refrigerant for light alloy engines OSSA TRi User manual Chain tension Sparkplug To access the sparkplug detach the upper section of the motor cycle see page 29 Once the upper cover has been removed the motorcycle s electrical system can be accessed Carefully but firmly pull away the hood that provides a current leaving the upper part of the sparkplug exposed Using a special sparkplug key unscrew it The sparkplug should be checked regularly and a spa re sparkplug should be carried at all times in case it o comes off The sparkplug can accumulate charcoal and dirt with use For this reason it can be removed and cleaned so that it lasts longer OSSA TRi
23. ill up with new transmission fluid Empty the fuel tank petrol degrades over time Lubricate the chain and all wires Apply oil to non painted metal surfaces to prevent rust Avoid putting oil on the brakes and rubber parts Wrap the outside of the exhaust pipe in a plastic bag to prevent rust Position the motorcycle so that the wheels don t touch the ground to prevent possible tyre deformation If this is not pos sible cardboard can be placed underneath the wheels Place a cover over the motorcycle such as canvas plas tic or material This will protect the motorcycle from dust and other external factors Avoid storing the motorcycle outside or in direct sunlight Starting the motorcycle again To start up the motorcycle after a period of inactivity the fo llowing procedure should be followed Remove the plastic covers that were placed over the motorcycle before storing including the exhaust pipe and those parts that had special protection Tighten the sparkplug Fill up the fuel tank with new petrol Carry out general lubrication Check tyre pressure Leave the engine running for some minutes to warm up the engine oil OSSA TRi User manual Troubleshooting Troubleshooting In the event of breakdown always take the motorcycle to a specialist mechanic A In the event of breakdown always take the motorcycle to a specialist mechanic PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION PROBLEM POSSIBLE CAUSE POS
24. ineers so as to obtain the best possible re sults and the best possible performance At OSSA Motor we know that each motorcycle model is unique and has its own features which is why we dedicate so much time to the research and design for each item OSSA TRi User manual 3 Important Read this manual thoroughly and keep it in a safe place This manual provides technical information necessary for keeping your new OSSA TR motorcycle in full working condition It provides information on common aspects for the motorcycle s upkeep and fine tuning In the event of questions or queries on aspects not mentioned in this manual you should consult the OSSA official distributor or a specialist engineer Follow each stage of the instructions provided below for obtaining good results These instructions are accompanied by icons to make reading quicker and easier ATTENTION This symbol indicates that special attention must be paid o INFORMATION Informative note advice Some of the indications specified in this manual are to prevent possible harm from being inflicted on people or material Not following the instructions may result in serious consequences which could put people s lives at risk 4 OSSA TRi User manual This manual has been put together with the OSSA TR current layout However OSSA Motor reserves the right to make changes tothis layout without prior notification to consumers In the event of this taking p
25. joints and bearings OSSA TRi User manual Lubrication of moving parts OSSA TRi User manual Cf ge ea DE O Bi S QS gt NG i Chain drive and tension adjuster springs Gas handle right grip Pressure and condition To ensure that the motorcycle works correctly it s very important to check the tyre pressure and that the wheels are in good working condition before each use Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability It also ensures that trial riding is safer and more effi cient Front tyre 2 75x21 Rear tyre 4 00x18 Front tyre pressure 0 45 bar normal Di 0 40 bar competition Rear tyre pressure 0 35 bar normal 0 30 bar competition NEVER forget to periodically chech the A tyre pressure to ensure that the tyres have a good grip Tyre in good working condition Tyre in bad working condition OSSA TRi User manual Checking the crankcase oil Filling and draining the crankcase Crankcase oil is used for lubricating the change pedal and the clutch Check the oil level with the indicator located on the lower part of the clutch cover which is on the right side of the engine The oil level should be lower than the indicated maximum level MAX C Optimum oil level MIN To add oil remove the cap A located on the top of the clutch cover
26. lace your dealer will provide you with the relevant information This motorcycle has been designed to carry one person only Never ride with passengers Do not carry loads Any additional vveight could destabilise the motorcycle which may provoke accidents that incur serious injury or even death Both your safety and the safety of others are very important when riding a motorcycle Some important advice for using your motorcycle correctly is de tailed below Always drive in a responsible way Always use a helmet This motorcycle is designed to be used in both urban and rural areas It should be used however while respecting other people and the environment If in your geographical area the use of motorcycles in rural areas is restricted you must respect the law Always wear appropriate clothing and protective accessories Gloves boots and thick trousers among others are recommen dable Do not wear baggy clothing that might get caught on a mechanism in the motorcycle Be careful with the exhaust system The exhaust system gets extremely hot during and after use of the motorcycle In the event of suffering burns see a doctor as soon as possible Take the time necessary to become familiar with your new mo torcycle Make sure your motorcycle is serviced regularly to avoid break downs while driving Never ride with passengers Never ride if you have consumed alcohol or any type of substance
27. llowing items a Damages that arise from not carrying out periodical revisions as stipulated by OSSA b Damages due to repairs or revisions carried out using methods that have not been specified by OSSA c Damages due to using the vehicle in races rallies or other similar competition sports d Damages due to the practice of functions that are not indicated in the Owner s Manual using the motorcycle beyond those limits or specifications indicated by OSSA maximum load passenger capacity speed of motor and others e Damages due to the use of parts that are not original or not recommended by OSSA or the use of fuel lubricant and com pound liquids with specifications that are different to those indicated in the Owner s Manual f Damages due to modifications that are not approved by OSSA motorcycle preparations modifications for increased vehicle performance light reduction increases and other changes g Damages due to the vehicle s aging natural decolouration of painted or chrome surfaces peeling and other types of deterio ration h The replacement or repair labour with non original OSSA parts or that are assembled by staff not authorised as part of the Official OSSA Post Sales Service or as OSSA dealers i Damages due to incorrect storage or transportation j Damages due to uses that disregard traffic regulations and damages due to accidents k Spare parts that need to be replaced frequently OSSA does not offer a gu
28. n rate is excessive a second red warning light will come on This function acts as a warning to change gear when a specific number of rpm is reached The red light flashes when the rpm reaches the established value and stops flashing when the gear is changed OSSA TRi User manual Multi function box Multi function box Adjustment of the multi function box settings After confirming each value the multi function box will move straight on to the next screen adjustment until the process is complete If no button is pressed the multi function box will return to the initial screen after 15 seconds Activation of the adjustment mode To activate the adjustment mode for the multi function box set tings push buttons 1 2 and 3 si multaneously for 3 seconds and then release them Select the wheel circumference Enter the wheel circumference by pushing button 1 repeatedly To move to the next digit press button 3 Confirm the selection by pushing button 2 Note If you don t know the whe el circumference consult the Measuring the wheel circumfe rence section OSSA TRi User manual Select the speed unit To select the speed unit between km h and m h press 1 Confirm your selection by pressing 2 Select the time format To select the time format change between the 12 and 24 press 1 Confirm your selection by pres sing 2 Time adjuster Set the time by pressing button 1 repeatedly To move to
29. njection wiring diagram 37 Air filter 38 Radiator 39 Spark plug 40 Chain Tension adjustments 41 Lubriction of moving parts 42 44 Tyres Pressure and condition 45 Control of crankcase oil Filling up and draining 46 Brakes 47 Torque wrenches 48 Storage 49 Troubleshooting 50 54 Registration series number and Rey 56 60 Warranty conditions 61 68 Final considerations 69 OSSA TRi User manual 7 Technical specifications Technical specifications ENGINE Cylinder size Type Cooling Bore x Stroke Injection Ignition Clutch Start TRANSMISSION Gearbox Transmission Lubrication Gearbox and clutch lubrication FRAME Type Front suspension Rear suspension Front brake Freno trasero Front wheel Rear wheel Engine protector 8 OSSA TRi User manual 294 1cc 272 2 cc 249 2 cc 124 9cc 2 stroke inverted monocylinder with reed box admission Liquid cooled 79x60 mm 76x60 mm 72 5x60mm 54x54 5 mm EFI Kokusan Indirect injection Digital flywheel CDI Kokusan Hydraulic Kickstart 6 speeds Primary transmission by gears final transmission by chain Mixture 10096 synthetic oil lubrication 0 996 450 cc of Gear Extreme type 75 W oil Made of CR MO steel tube with fuel tank and lower part made of forged aluminium Fork with aluminium bars 40 mm diameter Marzocchi depending on version adjustable in extension and compression Variable progressive system with T
30. nsion Each year Every 2 years PF Z TS sonos C Gees mm Clutch Eu When damaged DE Brake discs Each use When necessary Whendamged Front rear tyre Each use Each u Exhaust When damaged Silencer u When damaged se When use Screw nuts and fastenings When damaged Change kick start pedal Each use When necessary When damaged When necessary Each wash Radiator tube and connections Each use When necessary RI Secondary transmission Steering bearings Each wash Front rear spokes I ChassisE use Each use use Each OSSA TRi User manual OSSA TRi User manual Adjustments to the motorcycle controls Electrical connections The clutch lever is located on the left handlebar grip and is used to activate the clutch mechanism to change gear The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake It s important that the levers and rear brake pedal have a 3 mm give Check the condition of the motorcycle s electrical connections in order to ensure they are maintained in good working order As seen in the image on the right these are located at the left side of the cylinder between the steering bar and the front headlight N and in the fuel system apparatus WI It s important that the levers can be easily activated by the rider while he she is riding the bike using the index and middle fingers
31. onal temperature sensor When the motorcycle temperature exceeds the set value right hand warning light comes on Default value 110 C 230 F Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pres sing button 2 OSSA TRi User manual Warning temperature selector Note This stage should only be imple mented for those vehicles that have an optional temperature sensor When the motorcycle temperature exceeds the set va lue the left hand warning light comes on Default value 90 C 190 F En ter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Con firm the selection by pressing button 2 Gear change turn rate selector When the set rate is near to be ing reached the left hand war ning light will flash indicating the need to change gear Default value 6000 rpm Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pres sing button 2 Dangerous turn rate selector a When the set rate is near to be ing reached the right hand war SH ELS ning light will flash indicating HHHH that the engine is turning at an excessive rate a MODE c Default value 10 000 rpm En ter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Con firm the selection by pressing button 2 it i BB
32. parts of the motorcycle or the motorcycle s electrical system the upper section should be removed This section is made up of 2 parts that are screwed onto the chassis and fitted together The first part of this section is located on the front above the fuel tank Next is the second part of this section which corresponds to the seat area and rear mudguards The engine of this motorcycle works with a mixture of unleaded petrol and 2S oil 100 synthetic in a 0 9 proportion The fuel tank forms a structural part of the chassis o and is located on the front inside part To fill up with petrol open the fuel tank lid situated on the upper part by unscrewing in an anti clockwise direction It s recommended that a hose or funnel is used to fill up to avoid spilling the petrol This is especially important if the motorcycle is hot DO NOT fill up with petrol when the motorcycle is turned on Aa Remove the upper section Stage 1 Remove the upper section S OSSA TRi User manual OSSA TRI User manual Section 2 Maintenance and basic operations OSSA TRi User manual OSSA TRi User manual Maintenance grid Engine Maintenance grid Cycle Item Check Inspect Adjust Replace Change Clean Grease lubricate Item Check Inspect Adjust Replace Change Clean Grease lubricate Mw Rear shock absorber Each year S Every 2 years _ Air filter Each use When damaged Each useE ach wash Front suspe
33. pension is made up of a fork that fixes the wheel and the front brake system in place This fork is formed by the suspension bars that contain the shock absorber spring and the suspension mechanism They are connected to the upper part where the direction pipe is located a point of connection between the fork and the chassis A regulating screw and an air bleed are located on the upper part of each suspension bar see photo To regulate the extension use the screw located on the right sus pension bar Fig A To regulate the compression use the screw located on the left suspension bar Fig B Each of the suspension bars also has an air bleed to remove air that accumulates in the inside of the fork stanchion Fig C OSSA TRi User manual The rear suspension is formed by a single shock absorber spring The pre charge of this spring can be adjusted by turning the too thed rings that dictate its direction Li A special key is needed to adjust these toothed rings The compression C extension R and spring pre charge see Fig are adjustable in the rear shock absorber Rear suspension Adjustable rings for the spring pre charge OSSA TRi User manual Anti theft immobilizer The TR has an immobilization system for protection against theft This system consists of a lock situated in the area of the brake discs on the rear wheel It is a mechanism that is operated with a key and blocks the rear wheel I
34. r Engine number Key number E OSSA TRi User manual OSSA TRi User manual Warranty Terms and conditions of the warranty The warranty is associated to the product indicated in the CERTIFICATE OF DELIVERY AND INSPECTION which shall be filed out by authorised staff in OSSA FACTORY SL hereinafter referred to as OSSA It is valid for those countries indicated on page 33 The warranty is only applicable to motorcycles that have been initially imported via the official OSSA importer for your country meeting all the regulatory requirements and authorisations of each country This warranty does not limit or adversely affect consumers legal rights and guarantees by virtue of any obligatory national regulations It is independent of the legal warranty provided by the official dealer Name and address of guarantor The guarantor is the commercial organisation OSSA FACTORY SL Crta Antiga d Amer nave 12 Pol ind Domeny 17007 Girona Girona Consumer s rights as warranty holder With this document OSSA provides the final user with a guarantee that the motorcycle manufactured by OSSA is free from defects and that it has been manufactured in compliance with the strictest quality control regulations Therefore the warranty extends to both the parts and the labour costs in the event of any repair provoked by faulty materials or manufacture detected in a new motorcycle This is applicable for the time period stipulated within
35. re ta chometer bar Screen 2 Screen 2 displays the following information Speed digital tachometer running time uptime engine tempe rature tachometer bar Pantalla 3 Screen 3 displays the following information Maximum speed dangerous turn rate accumulated running time mileage counter maximum temperature optional Screen Illumination The multi function box works by using a 3V internal battery type CR2032 To change the battery open the lid on the bottom of the indicator by unscrewing it as indicated in the image using a coin Ensure that the positive side of the battery is facing upwards When the multi function box is powered exclusively by the inter nal battery the screen illumination is partially maintained for 3 seconds when the button is pressed OSSA TRi User manual When it is connected to the 12V vehicle installation the illumina tion will be brighter and will remain constant for 20 minutes after the vehicle has stopped Sleep Mode If the multi function box receives no information for 20 minutes wheel signal turn signal or pressed button the screen will turn off displaying only the time When the vehicle moves or by pres sing any button it will start up again Measuring the wheel circumference Method 1 Measure the diameter of the front wheel Multiply the diameter obtained by 3 14 If necessary convert the measurement into mm by multiplying the obtained figure by 25
36. t delivery but if the non compliance shows up after the sixth month the purchaser must demonstrate that the fault was present at origin and existed when the product was delivered Complaints made for the non compliance of that which is set out in the warranty must be done within a six month period from when the warranty ends Complaints will not be accepted after three years from the product delivery which is understood to have been made on the date that appears on the CERTIFICATE OF DELIVERY AND INSPECTION or on the invoice if a later date is shown ACTIVATING THE WARRANTY We request that you make an appointment with the OSSA sales representative that sold you the motorcycle or with any authorised OSSA sales representative providing this warranty manual The OSSA dealer is under obligation to repair or change at the discretion of OSSA any part that is faulty due to either the material used or manufacture process WARRANTY FOR SPARE PARTS AND OR ACCESSORIES This warranty covers the repair or exchange at the discretion of OSSA of any original part due to faulty material or fabrication The materials and or labour will be free of charge Other damages are not included in the warranty nor are repairs included that appear due to the replacement of the original part In any case you must certify that the attached table has been duly filled out OSSA TRi User manual EXCEPTIONS TO THE WARRANTY The OSSA warranty does not cover the fo
37. the warranty without limitation except for those that are listed in this manual The maintenance and service requirements indicated by OSSA must have been adhered to in compliance with the conditions herewith for the warranty to be valid OSSA is held responsible before the purchaser in the event of the product s non compliance at the time of product delivery When the product is non conforming the purchaser must decide whether they want the product to be repaired or replaced The purchaser s decision when notified to the seller is binding for both parties with one sole exception if the cost of reparation or replacement is dispro portionate to the product s value the most reasonable solution will be taken into account Rectification considered as disproportionate is that which implies costs for the seller which are not reasonable in contrast with the other means of rectification This takes into ac count the value the product would have if the non compliance did not exist as well as the relevance of the non compliance and if the alternative means of rectification could be carried out without any inconvenience OSSA TRi User manual Warranty The repair is disproportionate when it is uneconomic or when the reparation is more expensive than the value of the product If this occurs the purchaser can choose between a price reduction or contract resolution Resolution is not permitted when the non com pliance is insignificant Regulations
38. ur motorcycle The appearance and value of your motorcycle depends greatly on how it is looked after It is important to clean your motorcycle periodically during the winter because if not salt on the roads can cause uncovered metal surfaces to deteriorate OSSA TRi User manual Warranty Final information Procedure for obtaining repairs under warranty If your motorcycle needs a repair to be carried out under warranty it should be taken to your official OSSA dealer where the repair will be made YOU ARE RESPONSIBLE FOR THE TRANSPORT COSTS TO AND FROM THE DEALER Ossa recommends that you go to the dealer where your purchase was made However you can go to any Ossa dealer for repairs to be carried out under guarantee We recommend that you stay in contact with your OSSA dealer so that you can receive help advice and information about your new motorcycle as well as information about the new products laun ched by OSSA Factory SL We aim to provide full customer satisfaction If the service you have received is not adequate we would ask you to send us a written account stating specific instances with as much detail as possible about the incident concerning our dealer This will enable us to im prove the OSSA MOTOR customer service and services in general This guarantee provides you as a consumer with specific legal rights You may also have additional consumer rights that vary depen ding upon which country you are in
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