USER MANUAL EXPLORER 2014
Contents
1. Alinear las ruedas Cambiar disco Verificar circuitos de freno Cambiar los que esten da ados o rotos Vaciar fluido de freno y reponer con uno nuevo recomendado por el constructor Reponer el pist n de la bomba Ajustar los frenos AM In the event of breakdown always take the motorcycle to a specialist mechanic A 54 User manual Standardisation components User manual 55 Standardisation components OSSA Your Ossa Explorer is standardised in compliance with UE regulations It adheres to all standardisation requirements EURO 3 regula tions 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 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 56 User manual Standardisation components m y cm IN d 2 um M ze im Front headlight 9 Exhaust system 2 Front indicators 10 Speedometer 3 Rear indicators 11 Pinion output A Rear pilot 12 Lock 5 License plate support 13 Horn 6 Reector 14 Kickstand Mirrors 15 Throttle limiting bolt 8 Manufacturer s plate 16 Handle 17 Passenger footrests in the bike homologated for 2 people Each of the registered elements should be part of the v2. USER MANUAL EXPLORER 2014 2 User manual OSSA Introduction For 2014 the Explorer receives multiple internal and external im provements The engine has been thoroughly revised to improve reliability and further refine its operation while in the cycle have polished practical details that make the experience even better to ride an Explorer OSSA motorcycles have been designed assembled and tested by experts and each of its parts has been produced under the su pervision of OSSA engineers 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 on research and design for each item We at OSSA Motor would like to thank you for purchasing one of our products When designing the Explorer OSSA engineers and designers were based on the following approach create a bike that was easier to reach the most difficult places Its extreme lightness and trials qualities combined with its enhanced ergonomics make it possi ble to enjoy both tours real quiet as trial areas User manual 3 Important OSSA Read this manual thoroughly and keep it in a safe place This information manual provides technical information necessary for keeping your new Explorer motorcycle in full working condition It provides in formation on common aspects for the motorcycle s upkeep and fine tuning In the
3. 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 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 atthis 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 OSSA Control Pad Control Pad The control pad is located on the left handlebar within reach of the thumb This control pad can be used to
4. 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 User manual DR EY 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 up to 12 000 rom 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 Multi function box 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
5. it will be presumed that it is the same fault 4 f 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 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 User manual 63 Warranty OSSA PERIOD OF WARRANTY OSSA is answerable for faults that appear over a two year period from the product 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 de
6. 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 18 User manual pm NI NI A KM H DBOBOH SNS nnn 00 8 50005 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 l repeatedly To move to the next digit press button 3 Con firm the selection by pushing button 2 Adjustment of the revolution pulse PPR Note This step must only be fo llowed 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 l repea tedly 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 elec tric pulse each time the engi ne turns PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pres sing button l repeatedly 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 im pleme
7. control the lights indicators horn and engine stop 088 AIR MAX 4 iin 3 2 ws aara 088888 4 OC 8088 RPM DST 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 See the image with information about the control pad Position lights 2 Cross lights 3 Long range lights 4 Lights for changing direction left right 5 Horn 6 Button to switch off engine User manual 23 Suspension The front suspension is made up of a fork that fixes the wheel and the front brake system in place This fork is formed by the suspen sion bars that contain the shock absorber spring and the suspension mechanism They are connected to the upper part where the di rection 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 sus pension 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 The fork contains oil SAE 5 with 230 cc in the left bar C and 130 cc in
8. 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 Giro na 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 the warranty without limitation except for those that are listed in this manual The main tenance 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 Whe
9. event of questions or queries on aspects not mentioned in this manual you should consult the OSSA official Never overload the motorcycle distributor or a specialist engineer Any additional weight could destabilise the mo u torcyclewhich may cause accidents that incur se Follow each stage of the instructions provided below for obtaining rious injury or even death good results These instructions are accompanied by icons to make reading quicker and easier A ATTENTION This symbol indicates that special attentionmust be paid 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 This manual has been put together with the OSSA Explorer current layout However OSSA Motor reserves the right to make changes tothis layout without prior notification to consumers In the event of this taking place your dealer will provide you with the relevant 4 User manual OSSA 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 his motorcycle is designed to be used in both urban and rural areas It should be used however while respecting other pe
10. 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 turn 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 User manual 17 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 repeatealy To move to the next digit
11. the right bar R 24 User manual The rear suspension is formed by a single shock absorber spring The preloadof this spring can be adjusted by turning the toothed rings that dictate its direction 5 A special key is needed to adjust these toothed rings Adjustable rings for the spring pre charge OSSA In order to access some parts of the engine or the wiring you must previously remove the seat 1 First you must open the rear seat lock with the ignition key 2 Then you must pull the back of the seat upwards and then bac kwards as in figure 2 3 To put the seat back on the bike repeat the process in inverse order T i A zx Ab DA K p 3 LS B Ke CS Y 4 Vus f fi af y il go ELLE t n A Fy M os NS x G Se WI ARS wc NE x SS ee Z Fig 1 Seat Fig 2 User manual 25 Anti theft immobilizer The Explorer 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 IMPORTANT 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 regis tration page and series number of this manual 26 User manual Before starting the motorcycle you must ensure that the key switch at the right hand side of the headlight i
12. 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 When the set rate is near to be ing reached the right hand war ning light will flash indicating that the engine is turning at an excessive rate Default value 10 000 rpm En ter the value by pressing button l repeatedly To move on to the next digit press button 3 Con firm the selection by pressing button 2 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 a DESEES SH FE aan LIDL gt mgpe I E PERCHE NCC T gli a w gg 88 88 88 ET s DELL 6888 Multi function box 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 CLOSE RESET 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 t
13. using the motorcycle beyond those limits or specifications indicated by OSSA maximum load passenger capacity soeed 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 compound 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 deteriora tion 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 guarantee 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 User manual 65 Warranty OSSA Parts Spark plugs fuel and oil filters and their components transmission chains air filters engine sprockets back crown gears d
14. 0 EFI Kokusan Indirect injection Digital flywheel CDI Kokusan Hydraulic Battery assisted kickstart 6 speeds Primary transmission by gears final transmission by chain Mixture 10076 synthetic oil lubrication 0 9 450 cc of Gear Extreme type 75 W oll Made of CR MO steel tube with fuel tank and lower part made of forged aluminium Hydraulic fork 40 mm diameter adjustable in rebound and compression Variable progressive system with Oll mono shock absorber with adjustable spring preload 185 mm diameter disc with 4 piston brake caliper 180 mm diameter disc with 4 piston brake caliper 28 spokes with 2 75x21 wheel 28 spokes with 4 00 x 18 tubeless wheel Constructed in AA7075 T6 Forged aluminium Forged aluminium with retractable toe cap OSSA WEIGHTS AND MEASUREMENTS Wheelbase Seat height Ground clearance Fuel tank capacity Dry weight 1 328 mm 840 mm 340 mm 7 6 litres 2 6 5 I 74 Kg Technical specifications 0SSA Factory reserves the right to make modifications without prior notification Kokusan Marzocchi OHlins are registered trademarks and their use is licensed 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 t is important to run the engine for some minutes until it reaches the cor
15. AUSE POSSIBLE SOLUTION Cylinder damaged Replace the damaged cylinder The motorcycle makes abnormal Supports screws or nuts are not pro Check and adjust using suitable torque wrench noises perly fastened Tyres wear swing arm or its needle Change worn parts for new parts bearings wear Wheel rim not centred Centre wheel rim Wheel not centred Check the tension of the spokes and readjust Lack of engine oil Check and add engine oil Steer axle with excessive tolerance Tighten the handlebar support and the steer axle nut using suitable torque wrenches The handlebar vibrates Handlebar support loose steer axle nut Tighten the handlebar support and the steer axle nut loose using suitable torque wrenches AN In the event of breakdown always take the motorcycle to a specialist mechanic A User manual 53 Troubleshooting PROBLEM La moto tiende a inclinarse a un lado Los frenos no act an correctamente POSSIBLE CAUSE POSSIBLE SOLUTION Chasis torcido Direcci n mal ajustada Eje de direcci n torcido Horquilla delantyera torcida Ruedas mal alineadas Disco desgastado Fluido del freno deteriorado P rdida del fluido de freno Pist n de la bomba roto Frenos mal ajustados Cambiar el chasis Ir a un taller especializado Ajustar direcci n Ir a un taller especializado Cambiar eje direcci n Ir a un taller especializado Cambiar horquilla delantera
16. No 4 Disconnect In operation No 2 Unscrew only the four the connector that connects the two fuel tanks You upper screws of the side tank pannels never must mind the existence of residual fuel in the quick release the screws that attach the pannels to the radiator as it could pierce it or eventually connector damage the threads 30 User manual far Su Y Section 2 Maintenance and basic operations User manual 31 Maintenance grid Engine Item Check Inspect Adjust Replace Change Clean Grease lubricate me p mem tes FE emma on p o99 aem INTE oem LL mea ore win me em reste overs oen meme _ fom eo mm o s oe mmm L aas I EC mmm Y nn na A na JA pesas wwe rer if Tone onen ome mem iP 32 User manual OSSA Maintenance grid Cycle Item Check Inspect Adjust Replace Change Clean Grease lubricate User manual 33 Adjustments to the motorcycle controls EEES 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 L min 3 mm Vv Z min 3 mm Front brake lever Clutch lever ww SE Y Sti N It s important that the levers and rear brake pedal have a 2 3 mm give It s important that the levers can be e
17. To fill up with petrol open the upper fuel tank lid situated on the upper part by unscrewing in an anti clockwise direction Its recommended that a hose or funnel is used to fill up to avoid spilling the petrol This is es N pecially important if the motorcycle is hot DO li Lower fuel tank NOT fill up with petrol when the motorcycle is 28 User manual OSSA In order to access some parts of the engine or the wiring you must previously lift the upper fuel tank 1 First you must remove the seat see page 25 Seat 2 Unscrew only the four upper screws of the side tank pannels 3 Disconnect the air hose located in the front of the upper fuel tank see fig 2 4 Disconnect the conector that connects both fuel tanks 5 Unscrew the upper tank central screw which is located where indicated with number 5 6 We proceed to lift the tank from the front pivoting backwards fig b2 VICO Fuel tank User manual 29 Fuel tank A UN EN mm eg mE r x f v En i P4 pns um Ti 7 BE A S AHF A HA z3 am A HA p t Ade a r d i P y N EIS T g A Nub A Sy Win 4 EN Us Y RT gt y c NE y 1 Ye a a Wwies f 3 2 7 X N A i LA f A 5 AX N VES y 3 a LLANA M IE M Aes ATA u 5 Ir ws 8 pr 1 1 o hU f WA onem Ae LE ase EDS Rp cs E Pl oM D Ge E AA Sen lg NEC AV ie i 1 y When performing the operation
18. anty 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 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 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 68 User manual 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 Thank you and we hope you enjoy your new motorcycle Final information User manual 69 WWW OSsamotor es Ossa Motor Carretera antiga d Amer nau 12 1 007 Girona Spain tel 0034 972 107 107 fax 0034 972 117 899
19. asily activated by the rider while he she is riding the bike using the index and middle fingers 34 User manual OSSA Electrical connections 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 and in the fuel system apparatus 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 User manual 35 Simplified diagram of the lights wiring EN ES BREF SD Ge 36 User manual Simplified diagram if the injection installations Jj 2 User manual 3 Air filler Air filter Cleaning and maintenance Carry out regular and thorough maintenance of The air filter should be controlled periodically Lift the upper fuel your motorcycle Always use original spare parts tank as you can see in the image on page 29 in order to access and top quality products to ensure that it works the filter box Remove the filter rubber cap unscrew the upper part correctly 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 outlined previously but in reverse Make sure that the par
20. e sparkplug should be carried at all times in case it co mes off The sparkplug can accumulate charcoal and dirt with use For this reason it can be removed and cleaned so that it lasts longer Right side panel Fig 1 Observe the distance between the electrode and the arch This distance should be 0 7 mm NOTE The sparkplug should not be handled if the motorcycle is hot 40 User manual To extract the side cover 1 bend it slightly until releasing one of the fixing snaps 2 move the cover laterally without turning it to release the other fixing snap 3 pull the cover out Fig 1 3 2 ges gt The transmission chain transmits the engine s movement to the rear wheel To ensure that is works correctly it should be checked The axle has easily adjustable eccentrics for ten sing the chain and centring the wheel The chain hook should be positioned in an oppo site direction to the gear as can be seen in the photo The chain tension should permit 2 cm of oscilla tion in the chain tension adjuster gt pb Cadena Reglajes de tensi n User manual 41 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 Lubricat
21. e 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 motorcycle caliper or brake pads If this happens clean off the lubricant and carry out controlled braking until the brakes work correctly again A Take care NOT to accidentally lubricate the brake 42 User manual Clutch and brake lever joints OSSA Lubrication of moving parts 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 drive Rear brake pedal Chain drive joints and bearings User manual 43 Lubrication of moving parts Footrest bracket and springs Chain drive and tension adjuster springs Engine kick start pedal joints Gas handle right grip 44 User manual OSSA lyres 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 efficient Tyre in good working condition Front
22. ehicle In the event of breakages loss or bad functioning it is recommended that you go to an official OSSA mechanic to remedy the problem User manual 57 Standardisation components Element 1 Front headlight Front position lamp Driving beam Passing Beam 2 Front indicators 3 Rear indicators 4 Rear pilot 5 License plate support 6 Reflector 7 Mirror 8 Manufacturer plaque 9 Exhaust system 10 Speedometer 11 Pinion output 12 Lock 13 Horn 14 Kickstand 15 Throttle limiting bolt 16 Passenger handle 17 Passenger footrests in the bike homologa ted for 2 people 56 User manual Homologation identification 11 12 e9 97 24 97 24 4367 00 R55 00 14839 R113 00 14839 R113 00 14839 11001200e94367 11001200e94367 e13 50 ROO 50R00 12448 00 IA E9 02 01269 L e9 80 780 80 780 0143 01 Fell e13 28RO00 28RO00 0037 00 Manufacturer s plate Serial number Standardisation components User manual 59 Standardisation components OSSA El n mero de llave se encuentra marcado debajo del tap n rojo se debe retirar para ver el n mero Engine number Key number 60 User manual Warranty User manual 61 Warranty OSSA 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
23. eive 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 your 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 sur faces to deteriorate User manual 67 Warranty OSSA Procedure for obtaining repairs under warranty If your motorcycle needs a repair to be carried out under warr
24. he hood leaning the bike over in both directions to wer ensure that no oil remains inside the hood zr B 46 User manual OSSA The brakes permit precise and controlled riding It is necessary to check them in order to ensure that they work correctly gt DD Wear on the front and rear brake pads must be periodically controlled so that the brakes work effectively The oil level can be checked using the indicator on the front handle and on the rear pump tank The oil level should be situated between the min and max values MAX MIN To remove surplus air from the break circuit the calipers are equipped with air bleeds See image Brakes User manual 47 lorque wrenches These grids show the pressure that should be used to tighten parts CHASSIS Front wheel axle am Tom Fontana os Front wing bridge section Break pedal 2 32 Silencer fixing 18 25 Rear brake pump fixing 48 User manual 40 50 7 10 ENGINE Sparkplug Clutch fixing Cylinder clasp fixing Cylinder reed fixing Pressure plate fixing Clutch mass fixing Crankcase half fixing Water pump cover fixing Clutch cover fixing Steering fixing Water separator Ignition cover Engine drain plug Kick start pedal screw Transmission pedal screw Cylinder block screws Cylinder nuts pe n 1 i 29 40 0 m 7 8 7 8 m 7 8 3 4 7 8 7 8 m 7 8 HEE goss Az Storage If the mo
25. he positive side of the battery Confirm that you want to set these functions to zero by simultaneously is facing pressing buttons 1 and 2 User manual 21 Multi function box 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 temperature 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 22 User manual OSSA
26. isk 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 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 during 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 guarantee repairs for noise vibration oil filtrations and other elements that don t affect the product quality functioning and performance 66 User manual OSSA Warranty 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 servi ces are correctly registered This means that your motorcycle will rec
27. livery 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 ma terials 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 64 User manual OSSA Warranty EXCEPTIONS TO THE WARRANTY The OSSA warranty does not cover the following 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
28. n the pro duct 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 disproportionate 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 account 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 62 User manual OSSA Warranty The repair is disproportionate when it is uneconomic or when the reparation is more expensive than the value of the product If this oc curs the purchaser can choose between a price reduction or contract resolution Resolution is not permitted when the non compliance is insignificant Regulations 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
29. not clean the motorcycle with pressurized water equipment since this may damage the parts User manual 5 OSSA Introduction Important warning Saferty Contents Technical specifications Recommendations Section 1 Components Location Multi function box Control pad Front suspension Settings Air bleed Seat Anti theft immobilizer Start lever Fuel tank Section 2 Maintenance and basic operations Maintenance grid Adjustments to the motorcycle controls Electric connections Simplified lighting wiring diagram Simplified injection wiring diagram Air filter Radiator Spark plug Chain Tension adjustments Lubriction of moving parts Tyres Pressure and condition Control of crankcase oil Filling up and draining Brakes Torque wrenches Storage Troubleshooting Registration series number and key Warranty conditions Final considerations Contents 41 42 44 45 User manual 7 Technical specifications ENGINE Cylinder size Type Cooling Bore x Stroke Injection Ignition Clutch otart TRANSMISSION Gearbox Transmission Lubrication Gearbox and clutch lubrication FRAME Type Front suspension Rear suspension Front brake Rear brake Front wheel Rear wheel Engine protector Kick start pedal shift pedal 8 User manual 247 7 cc Explorer 250 272 2 cc Explorer 280 2 stroke inverted monocylinder with reed box admission Liquid cooled 2 5x60 mm Explorer 250 76x60 mm Explorer 28
30. nted 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 pressing button 2 Multi function box User manual 19 Multi function box Temperature selector To select the unit of temperature either C or F press button 1 Confirm the selection by pressing button 2 Danger temperature selector Note This stage should only be im plemented for those vehicles that have an optional tempera ture sensor When the motor cycle temperature exceeds the set value right hand warning light comes on Default value 110 C 250 Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pressing button 2 20 User manual Pu x FAS dAnGEr X MODE 22 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 l 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
31. oo great Check the pressure of the tyres Rear shock absorber badly adjus Adjust the rear shock absorber ted A In the event of breakdown always take the motorcycle to a specialist mechanic A User manual 51 Troubleshooting PROBLEM Too little oil in front fork Front fork oil not sufficiently viscous Front fork bent The shock absorption is too soft Rear shock absorber badly adjusted The motorcycle makes abnormal i Chain badly adjusted noises Chain wear Rear crow teeth wear Insufficient chain lubrication Rear wheel badly adjusted Front fork with insufficient oil Front fork spring weak or broken Brake disc wear Brake pads badly positioned or crystallised POSSIBLE CAUSE POSSIBLE SOLUTION Add oil to the fork until it reaches a sufficient level Drain fork oil and fill up with suitably viscous oil Change the front fork Contact an officially registered mechanic Adjust the rear shock absorber Adjust chain Change chain rear crown and secondary transmission pinion Change rear crown Lubricate chain Align rear wheel Contact an officially registered mechanic Add oil to the fork until it reaches a sufficient level Replace front fork spring Replace brake disc Change position of break pads or replace them AM In the event of breakdown always take the motorcycle to a specialist mechanic A 22 User manual Troubleshooting PROBLEM POSSIBLE C
32. ople 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 Safely Never ride if you have consumed alcohol or any type of substance 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
33. rect temperature to work correctly The engine lubrication is a mixture of petrol oil with a 0 976 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 10 User manual Section I Components User manual 11 Location of elements Front mudguard 2 OSSA multi function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide Front tyre 8 Front fork bottles 9 Front fork stanchions 10 Shift pedal 11 Chain 12 Chain slider 13 Rear sprocket protector 14 Rear tyre 12 User manual 15 Rear break caliper and anti theft immobilizer 16 Exhaust 1 Kick start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear brake lever 22 Crankcase protector 23 Front brake caliper 24 Front brake disc 25 Air filter 26 Rear footrests depen ding on version 2 Passenger handle Location of elements User manual 13 Location of elements Dee 2 Front brake lever 28 Throttle grip 29 Throttle control 30 Front brake pump 31 Front fork servicing cap 32 OSSA multi function box 33 Clutch pump 34 Lights control pad 35 Clutch lever 36 Headlights 3 Ignition key UTER gt LAZO e a EA Cs ay Na me ea 14 User manual The OSSA Explorer multi function box and the indicator lights next to it provide very useful information at all times The multi f
34. s 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 se parated 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 elements brakes and controls are in good condition Kick start pedal 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 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 per formance User manual 27 Fuel tank A The engine of this motorcycle works with a mix N ture of unleaded petrol and 25 oil 10076 syn thetic in a O 9 proportion The Explorer has two fuel tanks one forms a struc cli Filling lid 5 tural part of the chassis and is located on the front N Upper fuel tank inside part The other one is made of polyamide plastic and is located in the classic position on the frame
35. ssure Leave the engine running for some minutes to warm up the engine oil User manual 49 Troubleshooting OSSA PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The engine won t start Long period of engine inactivity Change the old petrol for new petrol Sparkplug dirty or wet Dry clean or change the sparkplug General fuse damaged Change general fuse Bad electrical connection Check electrical connections and position correctly ake the motorcycle to a specialist mechanic The engine starts and then stops Lack or deterioration of petrol Fill the fuel tank with new petrol ake the motorcycle to a specialist mechanic AN In the event of breakdown always take the motorcycle to a specialist mechanic A 50 User manual Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Wire makes it difficult for the han Move wire or loosen it a bit dlebar to turn The motorcycle is unstable Steer axle screw is very tight Loosen the steer axle screw Steering bearings are damaged or Replace steering bearings with wear Steer axle bent Change the steer axle Contact an officially registered mechanic The shock absorption is too hard Excessive oil on front fork Remove surplus oil until it reaches the correct level Oil too viscous on front fork Drain fork oil and fill up with viscous oil Front fork bent Change the front fork Contact an officially registered mechanic Tyre pressure t
36. torcycle is to be stored for a long period of time the fo llowing procedure should be followed to ensure that it is stored co rrectly 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 Fill 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 possi ble cardboard can be placed underneath the wheels Place a cover over the motorcycle such as canvas plastic or material This will protect the motorcycle from dust and other external factors Avoid storing the motorcycle outside or in direct sunlight Storage Starting the motorcycle again To start up the motorcycle after a period of inactivity the following procedure should be followed Remove the plastic covers that were placed over the mo torcycle 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 pre
37. ts areput in their correct po sitions 38 User manual OSSA Radiator coolant to the radiator locate the tank lid To locate this lid 30 C lift the upper fuel tank see pag 29 Fuel tank Once the tank is lifted the radiator lid is visible Unscrew the lid and pour in the coolant 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 ATTENTION Use gloves Do not open the lid if Always use special refrigerant for light alloy engines the engine is hot This could cause burns Avoid contact of the liquid with the eyes mouth or na sal passage Do not ingest In the event of this happening follow the product instructions and consult a doctor The radiator contains the engine coolant To fill up with or add To fill the radiator special coolant should be used The radiator has an electric fan to force air through it as can be seen User manual 39 Sparkplug To access the sparkplug detach the right side cover see fig 1 Once the cover has been removed the motorcycle s electrical sys tem can be accessed Carefully but firmly pull away the hood that provides current leaving the upper part of the sparkplug exposed Using a special sparkplug tool unscrew it and take it out from the right side of the motorcycle see fig 2 The sparkplug should be checked regularly and a spar
38. tyre 2 5x21 Rear tyre 4 00x18 Front tyre pressure 0 5 bars Tyre in bad working condition Rear tyre pressure y B 0 6 bars normal 0 9 bars with passenger NEVER forget to periodically check the tyre pres sure to ensure that the tyres have a good grip User manual 45 Checking the crankcase oil O Z CS Filling and draining the crankcase IMPORTANT Clean the plug and change the sealing washer each time the oil is changed 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 The crankcase has a 3 5cc oil capacity 2T 100 oil level should be lower than the indicated maximum level synthetic oil should always be used MAX O Optimum oil level MIN The oil level should be checked when the motor cycle is in an upright position and on a at surface The motorcycle should be cold If it is not cold wait some minutes until it goes cold Clutch cover D Indicator To add oil remove the cap A located on the top of the clutch cover D Use a funnel to add the oil NEVER fi ling above the Maximum level Replace the cap If you E Ta fill above the Maximum level oil must be removed To Ale SINE NN 3 remove oil from the hood place a receptacle under the SA Doy motorcycle and remove the lid B located on the side Ignition cover C of t
39. unction box is a power box system with an LCD screen controlled by a con sole with indicator lights located in the centre of the handlebars 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 envi ronmental 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 some features may be personalised the device can measure in kilo metres or miles The wheel circumference value can also be chan ged A temperature sensor warns us with a yellow light 1 when the engi ne temperature is excessive Another sensor provides a warning with a red light 2 when the rate at which the engine turns is excessive Multi function box OSSA Multifunction Display LED warning of Temperature warning LED Left buton Right button Function selection button User manual 15 Multi function box Technical features mem ION omms em om mew omm nee rn Upime 0 999 hours 59 minutes 999 hours 59 minutes minute o minute HO 1 0 1 Eu A 155 A pee me 2 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 O C to 60 C
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