Neon Owners manual v.11.07_EN
Contents
1. 27 Fuel Pipes _ Carburettor idle speed _ Throttle function _ Braking system pads fluids 28 Clutch weights Brake switch _ Transmission belt Transmission system check for leakage Engine check for leakage Fasteners bolts screws nuts Headlight beam setting Suspension Wheels tyres Steering stem bearings 23 SERVICE AND MAINTENANCE Note The filter element should be cleaned or replaced with greater frequency when driving in a dusty environment In such cases it is recommended to clean it every 500 km The vehicle must be serviced according to the maintenance and service schedule The symbols in the schedule chart stand for l Inspect or clean A Adjust C Clean R Replace Engine oil This scooter should use 2 stroke engine oil FC There is no need to use any additives Do not use common oil vegetable oil or castor oil The 2 stroke engine consumes the lubricant so you should inspect the level of the engine oil frequently The oil tank is behind the centre cover and has a capacity of 1 2L When you unlock the centre cover you can reach the tank and refill if necessary SERVICE AND MAINTENANCE 24 F AITIENIION After the engine has been running the oil temperature is high Exercise care to avoid injury from burning Gear transmission oil Use gear oil for 2 stroke gasoline engines Reco2. Fuel is flammable When draining and refilling the fuel tank the engine should be switched off CARE AND STORAGE GUIDE Long term storage When stored for a long time your scooter must be protected against moisture sunlight and rain Before storing the following steps should be taken 1 Replace the engine oil 2 Drain the fuel completely out of fuel tank and carburettor and fill the fuel tank with anti rust fluid 3 Disconnect and remove the battery and put it in a cool place 4 After cleaning your scooter apply a colour fixing or preserving agent on coloured parts and grease on moving metal parts 5 Inflate tyres to specified pressure and then lift the scooter onto blocks to keep the wheels off the ground 6 Finally cover your scooter s Use after storage 1 Take the cover off and clean your scooter If the scooter has been stored for more than 4 months replace the engine oil 2 Recharge the battery and install it 3 Drain the anti rust fluid from the fuel tank then refill with fuel 4 Pre operation inspection should be carried out before riding see page 17 34 AIIENIION m Washing with high pressure water may damage some parts The following parts should not be washed in this 5 9 faghion EARD SEORAGE GUIDE compartment main switch and speedometer Cleaning Cleaning the scooter periodically will help keeping the painting coat bright 1 The scooter should be washed after it is stored in o
3. a clock The time can be set by the two buttons one on each side of the screen Controls Main lgnition switch 1 The main switch is located at the upper right part of the frame body It is used to control the ignition and electrical systems and to lock the steering wheel To use it insert the ignition key The switch can then be turned to the following positions 12 gt WARNING p Mdven tackitigetheysted 25 4dlebsitionushibe drimeg asifulldgftaussi onaeridaihe key should be pressed 5 9 MAIN COMPONENTS iiir iade im at ee SESS ee ee ge ON The engine and the electrical system are on and the key cannot be removed Ij OFF The engine and the electrical system are off and the key can be removed Steering lock The steering is locked and cannot be turned the engine and the electrical system are off and the key can be removed Steering lock To lock the steering turn the handlebars all the way to the left and insert the key in the main switch 1 Then press down and while pressing turn to 3 position to lock To unlock the steering insert the key and turn it to position To prevent from theft always lock the steering when parked Start button 2 To start the engine using the start button make sure to raise the side stand and hold the front or rear brake Then press the start button to start the engine 13 MAIN COMPONENTS Light switch 3 It
4. has three positions and amp Headlight rear light position light and license plate light off Turn the light switch to this position after the engine has started to turn on EE the position light rear light and license plate light In this position the headlight is off It is recommended for afternoon use Yr Turn the light switch to this position after the engine has started to turn on the headlight position light rear light and license plate light It is recommended for use while driving at night in reduced visibility conditions Dimmer switch 4 This switch controls the headlight beam with the light switch in position o High beam 45 Low beam Turn signal switch 5 Push this switch to position to signal a left hand turn or to gt position to signal a right hand turn Then return the switch to the centre position To turn off the signal lights press the button in the centre of the switch Horn button 6 Press this button to sound the horn 14 NUIE m Bheavefusigihaleswasth ntpes urotchore off atte rstatiagBycOfoparntumse press ytgdet swatch off after turning otherwise 5 9 it WPAPNPCONIPONENTSI storage compartment To open the seat first unlock it from the seat lock turning the key clockwise and then lift it up To close the seat lower it down and push the rear part of the seat until you hear a clicking so
5. the brake amp m move pus reservoir cap Only use DOT3 or brake fluid from a sealed container Do not mix pollutants such as oil mud or water with the brake fluid in the reservoir Inspect that the fluid level is above the MIN mark when resting the motorcycle in a vertical position he brake fluid can cause soreness and inflammation to the skin Do not allow it to come into contact with pur skin and eyes If contact is made with the skin wash it thoroughly with water If contact is made with the es wash out with plenty of water and consult a doctor immediately Do not mix different types of brake fluid Brakes inspection You should check the braking system for breakages and leaks before riding 1 Depress the brake lever several times to determine whether there is a leak 2 Check the wear condition of the brake pads SERVICE AND MAINTENANCE 30 Wear condition of brake pads varies according to the use of the vehicle riding style and road conditions Generally speaking the brake pads may wear faster when driving on wet and dirty roads Brake pad wear should be checked at every scheduled maintenance In a hydraulic brake system the thickness of brake disk and brake pad must be checked Check the wear mark 1 on each brake pad if one of the two brake pads is worn to the wear mark replace both pads If the thickness of brake disk is worn to its limit the disk must be replaced at once Battery This model uses a 1
6. 2 2 25 bar 2 30 bar Note 1 bar 1 kg cm 100 kPa Driving with worn tyres is very dangerous The tyres must be replaced before the tread is worn to the wear mark 1 Brakes This scooter is equipped with hydraulic disk type front brake and rear brake Periodic maintenance and adjustment of the braking system should be performed to prevent accidents SERVICE AND MAINTENANCE 28 1 screws 2 Reservoir cap 3 Reservoir pad l 4 Reservoir seal 9 5 Reservoir E u B 1 5 Ey r Hydraulic brake fluid inspection Frequently scheduled inspections of hydraulic fluid level and wear condition of brake pads must be carried out If the free play of the brake lever is excessive gt 2 3cm and the brake pad wear is within its specified limits air may be trapped in the braking system It must be expelled Take your scooter to an authorized Nipponia service point for brake maintenance When the hydraulic fluid level has fallen to the MIN mark refill the fluid in the reservoir 1 Remove the handlebar cover reservoir cap pad and seal 2 3 and 4 2 Add DOT3 or DOT4 brake fluid from a sealed closed container into the reservoir until the fluid level is at the MAX mark 3 Reinstall the reservoir pad reservoir cap and handlebar cover and tighten the screws 1 SERVICE AND MAINTENANCE 29 AUIS ION m sd pain
7. 2V 7Ah maintenance free sealed battery The battery will be prepared for use before you take delivery of the scooter Please note the following 1 If the motorcycle is stored for a long time the battery must be removed and charged fully then stored in a cool dry place If the battery is left on the vehicle remove the negative cable from the battery pole 2 When removing the battery the ignition switch should be in position and the negative cable removed When installing connect the positive cable first then the negative 3 Battery poles erode easily Brush them clean with a needle brush then apply a film of Vaseline or grease 4 When installing the battery terminal bolts must be screwed tightly 31 ROMENENBAG cover screw and open the battery case ver EAA edplasive gashkertp tovyns ie at a time Alternatively the ye Take the out of the battery case Battery removal Electric fuse The fuse is located at the battery and can withstand up to 15A The fuse can be rendered useless due to overloading of the electrical system or short circuiting Switch off the main switch turn to position in advance to avoid a short circuit when replacing and or inspecting a fuse 32 WARNING Use of fuses of rating other than specified may result in damage to the electrical system loss of engine power 5 9 OSERVICE AND MAINTENANCE 33 WARNING
8. Owner s manual Neon 50 Nipponia S A OWBOO1 EN INTRODUCTION This Owner s Manual contains basic instructions on how to operate inspect and maintain your scooter Please read it carefully and thoroughly Correctly operating maintaining and repairing your scooter will minimise any possible risks and result in its best performance The authorised Nipponia service points will be glad to provide you with more detailed instructions Important information contained in this manual is marked using the following symbols NOTE Important information or instructions t ATTENTION Important information or instructions Failure to follow these instructions may result in damage to your scooter or minor injury t WARNING Important information or instructions Failure to follow these instructions may result in heavy damage to your scooter serious injury or even death This manual is an integral part of the scooter and must always accompany it even in the event of a resale If you have any questions concerning the contents of this manual or need further information regarding the operation of your scooter do not hesitate to contact your local Nipponia dealer This booklet is compiled with the latest available information However due to constant improvements modifications or alterations may be made without prior notification Updated versions can be downloaded from the Nipponia website www nipponia com Introduction Cont
9. and warn vehicles from behind 3 When the vehicle stops switch off the turn signal light 4 Turn the main switch to Z position to stop the engine 5 Rest the scooter on the main stand 6 To prevent from theft always lock the steering when parking main switch on position and remove the ignition key 21 WARNING Park the scooter on a flat and stable surface to prevent it from falling DWRN CINSTRUETION S the scooter facing upwards to prevent it from falling S Engine Break In Breaking in your scooter is very important as it helps to prolong the life of the engine The break in period is the first 1000km with the following speed variation During the period from 0 to 500km driving speed should not exceed 20km h while from 500 to 100km it should not exceed the maximum speed according to the engine version 25 30 45km h During the engine break in period do not put heavy loads on the scooter and avoid driving at full throttle or constant speed for a long time 22 SERVICE AND MAINTENANCE Maintenance Schedule Period of maintenance in km First Every Every Every Every Reference 500 1000 3000 6000 12000 pages First replacement at 300km and then every 2000km Check the oil level Engine oil 2 24 every 500km refill engine oil when it is not enough Gearbox oil R Replace every 4000 km 25 Air filter element C R 26 Spark plug
10. ents Safety Information Safe riding Protective clothing Vehicle modifications Loading Accessories Vehicle Identification Vehicle Description Left view Right view Instruments and controls Main Components Instrument panel Speedometer Odometer Fuel gauge Turning signal indicator Oil level indicator High beam indicator OO OO 1 Q1 BN PP PrP N PP PEP PP P RP O Clock and regulation buttons Controls Main lgnition switch Steering lock Start button Light switch Dimmer switch Turn signal switch Horn button Seat Storage compartment Fuel Tank Fuel Driving Instructions Pre operation Inspection Starting the Engine Kick starting Driving Braking Parking Engine Break in 12 12 12 13 13 14 14 14 14 15 15 16 16 17 17 18 19 20 20 21 22 Service and Maintenance 23 Maintenance Schedule 23 Engine oil 24 Gear transmission oil 25 Gear oil replacement 25 Air Cleaner 26 Spark Plug 27 Spark plug inspection and replacement 27 Tyres 28 Brakes 28 Hydraulic brake fluid inspection 29 Brakes inspection 30 Battery 31 Battery removal 32 Electric Fuse 32 Care and Storage Guide 34 Long term storage 34 Use after storage 34 Cleaning 35 Specifications 36 Wiring Diagram 37 SAFETY INFORMATION Safe riding 1 Always perform the pre operation inspection before driving 2 The scooter should not be used by anyone who does not hold a valid d
11. es Inspect condition of the brake pads Check the brake fluids and refill to the specified level if necessary Inspect the hydraulic system for any leakage Wheels and tyres Check tyre condition and tyre wear Check for any potential damage to the wheels or tyres Inspect the air pressure and adjust if necessary 17 WARNING If any item the Pre operation inspection list is not functioning properly have it inspected and repaired amp I tNSTROCTIONS Item Inspection Throttle grip Check operation of the throttle grip It should be able to turn smoothly and be fully opened and closed Inspect condition and free play of the cable Brake levers Check whether the brake levers operate smoothly and lubricate the joints if necessary Lights and Inspect operation of the headlight rear light brake light turn signal lights horn instruments and panel instruments If you need assistance on how to perform any of the above mentioned tasks do not hesitate to contact an authorised Nipponia service point Starting the Engine Before starting the engine make sure to raise the side stand You can rest the scooter on the main stand 1 Turn the main switch to O position 2 Close the throttle completely and do not turn it 3 Press the start button while holding the rear brake lever to start the engine 18 NUN TION Kick starting Make sure to rai
12. mmended oil type SAE 80W 90 Gear oil replacement 1 Set the scooter on the main stand on a level surface 2 Remove the filling bolt 1 and the drain bolt 2 3 It is better to replace the gear oil when the engine is warm as it will be MI easier to drain out the residue of the gear oil m 4 After the gear oil has been drained out completely clean the drain bolt and tighten it 5 Pour about 100ml of new gear oil 6 Tighten the filling bolt to prevent the gear oil from flowing out 7 For a new scooter replace the gear oil after the first 500 km After that replace every year or every 6000 km SERVICE AND MAINTENANCE 25 AITENITION Miswuotlshusdsl a pbplee Wippo aleairvicerge high pressure air and not oil type solvent amp p Rethacaitictegaer ailnobilesthebechgoneeictlyadusa drwithstrekedaditertigti mro d heven gur acgitwl ens dist had caeusie drains out completely Replace the gear oil more frequently than recommended in the following conditions 1 Frequent use in wet weather 2 Prolonged riding time 31 Riding with a loaded scooter Air cleaner The air cleaner must be maintained periodically Especially after driving in a dusty environment maintenance must be enhanced 1 Remove air cleaner fixing bolts 2 Remove air cleaner tightening bolts take the air cleaner out 3 Clean or replace filter element Re install the air cleaner in re
13. n as it can cause burns Vehicle modifications Making any modifications to the scooter or replacing the original components can affect its performance and safety and or render it illegal for use Observe applicable laws and all national and local regulations concerning vehicle equipment Additionally such modifications will cancel the warranty Loading Adding accessories or cargo to your scooter can adversely affect stability and handling if the weight distribution of the scooter is changed Use extra care when riding a scooter with extra load Here are some general guidelines to follow when loading cargo or adding accessories to your scooter 1 All accessories must be fastened securely on the vehicle in order to minimise vibration that could cause instability 2 Any extra load should be placed as close to the gravity centre as possible and must be equally SAFETY INFORMATION distributed on both sides of the scooter to avoid imbalance and instability 3 The tyre pressure must be adapted to the weight of the load and road conditions 4 Make sure that extra load is securely attached to the vehicle to prevent it from falling and being lost 5 Do not hang any load on the handlebars or the suspension 6 The total weight of the driver passenger accessories and cargo must not exceed the maximum load limit of the scooter 170kg Accessories When installing accessories not approved by Nipponia attention should be paid to the followi
14. ng points 1 The installation of the accessories must not affect the suspension travel the light position and the steering angle 2 Do not obstruct the ventilation duct to ensure cooling of the engine 3 Avoid installing any accessories that could hinder your access to vehicle controls and movement of your hands and feet as it could impair your reaction in an emergency event 4 Do not install a bulb with higher power than that specified It could burn the fuse or cause problems to the electrical system due to low voltage 5 Do not add a sidecar to the scooter NUIE Please make a note of your scooter s VIN and Engine number so you can place your orders quickly when s PYERICLEIDENFIFICATION The Frame label 1 is located at the right side of the main stand bracket The Vehicle identification number VIN 2 is located on the main front bar of the scooter frame and is covered by the VIN cap The Engine number 3 is engraved on the upper left part of the engine case You can write your scooter s identification numbers here Vehicle identification number nennen Engine number o ee VEHICLE DESCRIPTION Left view NIPPONIA Se by e 1 9 9 1 Side stand 2 Battery cover 3 Seat 4 Handgrip 5 Seat lock 6 Pillion footrest 7 Kick Starter 8 Main Stand 9 Air filter VEHICLE DESCRIPTION Right view 4 1 Exhaust muffle
15. r 2 Rear fender 3 Rear light 4 Fuel tank 5 Storage compartment 6 Oiltank 7 Front turn signal light 8 Headlight VEHICLE DESCRIPTION Instruments and controls 1 9 10 11 12 re N C2 1 Horn button 2 Turn signal switch 3 Rear brake lever 4 Left rear view mirror 5 Dimmer switch 6 Instrument panel 7 Light switch 8 Right rear view mirror 9 Front brake lever 10 Throttle grip 11 Start button 12 Main Ignition switch 10 MAIN COMPONENTS Instrument Panel Speedometer 1 This meter displays the current driving speed in km h and mph Odometer 2 This meter displays the accumulated mileage of the scooter in km Fuel gauge 3 This gauge indicates the amount of fuel left in the fuel tank When the pointer of the gauge reaches the F Full mark there are 5L in the tank When it reaches the red area there are about 1 2L left in the tank and the fuel tank needs to be refilled Turning signal indicator 4 This indicator flashes when left or right turn signal light is on 11 MAIN COMPONENTS JAWTTENTIGN H A di preise sts during normal engine operation it is advisable to check the engine oil level In TAH PHU aal OA GET AREA iif ela val RINE Pate igh Beam indicator 6 This indicator lights when the dimmer switch is in the high beam position Clock and set buttons 7 This mini screen functions as
16. rder to wash out the accumulated dust The plastic parts should be cleaned with a cloth or sponge using a neutral cleaning agent 2 After drying let the engine run at idle for several minutes 3 Before riding the brakes should be inspected carefully 35 SPECIFICATIONS Neon 50 Overall length mm Displacement ml Overall width mm Ignition type Seas Max power 25 or 30km h speed limit 2 2 6500 KW rpm 45km h speed limit 3 1 7500 When Max torque 25 or 30km h speed limit 3 2 5500 Nm rpm 45km h speed limit 4 0 6500 Weight with oil and fuel kg Idling speed rpm 1800 180 Man load Ke Fuel consumption at 30km h speed L 100km lt 2 0 m driver Front Fronttyre 120 70 12 12 Spark plug BPR7HS Climbing ability Engine oil capacity L 1 2 Braking distance m lt linitial speed 40 km h lt 21m Fuel tank capacity L 5 0 12V 7Ah 15A 180 180 Battery High low beam light Position light Taillight brake light license plate light Turn signal lights Fuse Front disc brake mm Rear disc brake mm 12V 35W 35W 12V 5W 12V 5W 21W 5W 12V 10W x 4 Note All data obtained under laboratory conditions in accordance with relevant standards 36 WIRING DIAGRAM starting motor ignition switch turning switch E T brake switch
17. relay i gt gt Mos IA 11 PEL wre II gt starting switch flasher Gr 5 0 D L 03 k fuel meter battery horn CP taillight ap ads al lighting switch gt F gE left winkers T BBB eL bx horn 3 w OR position light 9 oil sensor fuel sensor meter light j D ClO oil warning light 7 Tiurning indicator Dimmer switch TEE i amp high beam 8 i right winkers indicator enrichment ie ae ol il iis ignitor ignition coil spark plug headlight M magnetor GD GP 37
18. riving license 3 Many accidents involve motorcycles not seen by other drivers so please pay attention to the following Wear bright coloured clothes Do not drive too close to other vehicles or in another driver s blind spot Avoid overtaking 4 Always follow local traffic regulations Driving above the speed limit is the reason for many accidents Driving speed must not exceed the limit specified by traffic regulations and allowed by road conditions Always signal when turning or changing lanes in order to attract the attention of the other drivers 5 Never drive under the influence of alcohol or other drugs it dramatically increases the risk of accidents 6 Exercise special attention when driving over crossroads or parking area exits 7 When driving you must hold the handlebars with both hands and place your feet on the footboard The passenger should hold the handgrips or the driver and place his feet on the footrests 8 This scooter is designed for on road use only It is not suitable for off road use SAFETY INFORMATION Protective clothing 1 For your safety the driver and passenger should both wear helmets Use of additional safety apparel gloves glasses protective wear is recommended 2 Do not wear loose clothing as it may be caught by the handle levers the kick starter or the wheels and could lead to an accident 3 During or after operation the muffler s temperature is very high Exercise extreme cautio
19. se the side stand and rest the scooter on the main stand 1 Turn the main switch to O position 2 Close the throttle completely and do not turn it 3 Step down the kick starter with force and the engine will start 19 DMARIING _ Bibrlginigiog ti etii tbe dinates heed to increase the speed and 5 9 c DRIVeENG TNSTRUCTIONS Driving 1 Start the engine as previously described 2 Push the vehicle off the main stand holding the rear brake lever 3 Get on the scooter keeping at least one foot on the ground to support and prevent it from falling 4 Adjust the rear view mirrors 5 Before taking off turn on the signal light and make sure it is safe to go 6 Release the brake and gradually turn the throttle grip open p Braking When you need to brake close the throttle grip and use both front and rear brakes Press the brake levers smoothly gradually increasing the pressure 20 o MAENIWON toed lolrankiing ache lili clog e she duri td e githa daesetbbtb brakes amp iternatively maintaining a low speed SI BREA ENS ERGOE ddathghasbitakiag cistanabristongewehatouhmbr kds c libeitiwwilngispebd b LI JU RRAK T d Did Lat i OW a MC Parking 1 Switch on the turn signal light in advance and check for approaching vehicles 2 Close the throttle grip and apply the brakes slowly so the brake light will turn on
20. und This indicates that the seat is locked Then you can remove the key from the lock Always make sure that the seat is securely locked before driving Storage compartment The storage compartment is located under the seat Its maximum loading capacity is 5kg 15 WARNING 1 Fuel tank cap G sotimaitctigie begging fg toe tart bdogegecie elie aie ME di En Fuel Tank The fuel tank is located under the seat To refuel lift the seat and turn the fuel tank cap 1 counter clockwise to open it After refuelling make sure to close the fuel tank tightly by turning the fuel tank cap clockwise Fuel Use only 90 97 octane unleaded gasoline 16 DRIVING INSTRUCTIONS Pre operation Inspection Always perform the pre operation inspection before driving your scooter Failure to do so may result in vehicle damage or an accident The time required to perform the necessary inspection is very short However it both ensures your safe driving and in the long term saves you time from vehicle repairs Make sure to inspect the following items Item Inspection Fuel Check the fuel level and refuel if necessary Inspect the fuel circuit for any fuel leakage Engine oil and gear oil Check the engine oil and the gear oil and refill to the specified level if necessary Inspect the scooter for any oil leakage Front and rear brakes Check operation of the brak
21. verse order SERVICE AND MAINTENANCE 26 WARNING 1 Electrode gap The spark plug must be screwed in fully Otherwise leakage from spark plug base and temperature increase amp I m paert Pilergilting in engine damage e eiecirode w Be Behind s pueden GEST eH AINE BERETS I t 9R TC RAN FAN PEed Spark plug inspection and replacement 1 Remove the dirt around the spark plug socket 2 Take the spark plug cap off and remove the plug with the spark plug wrench from the tool bag 3 Measure the gap between pole and electrode with a thickness gauge and adjust to 0 6 0 7 mm 4 When re installing the spark plug screw it in by hand and then tighten with the wrench 1 2 turn for a new plug 1 8 1 4 turn for a used one 5 Put on the spark plug cap Tyres The inflated tyre pressure must be checked daily and regulated according to the following table Cracks damage and wear on the tyres cause unsteady steering or even tyre blow out Note that tyre pressure is measured with cold tyres SERVICE AND MAINTENANCE 27 F AITEN ear mark If tyre F PSYIMG GAS tbe standard value the tyre can easily be damaged if tyre pressure is below the 5 u 2 standard value it may cause loss of control while driving the tyre being dislodged from the Tyre pressure in cold state Tyre specifications Rider and Rider only passenger Front wheel 120 70 12 1 75 bar 2 30 bar Rear wheel 120 70 1
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