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PREFACE You have purchased a SFM MadAss, congratulations and thank you for putting your trust in us. This operating manual includes important Reprinting, reproduction and translation, The MadAss is a sturdy light motorcycle in even of excerpts, without our express instructions for handling your light motor- modern design.
CONTENTS OVERVIEW AND OPERATION RIDING INSTRUCTIONS Ride safely ................24 Safety symbols ................3 Ride economically and be aware of the environment ....25 Chassis number, engine number ..........3 Side view ................4-5 Running-in instructions ............26 Side stand ................27 Engine ..................
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CONTENTS NOTES ON MAINTENANCE TECHNICAL DATA Checking steering bearing ............40 Engine ..................61 Checking the telescopic fork and shock absorber ....40 Power transmission ..............62 Adjusting the shock absorber ..........41 Chassis ..................63 Removing the front wheel ............42 Lubricants and operating fl...
OVERVIEW AND OPERATION Safety symbols and notes Chassis number Engine number Observe the following: WARNING Precautionary measures against the risk of accidents, injury and/or death. FIRE HAZARD The bike is supplied with a catalyst. The exhaust system becomes very hot. While riding, idling or parking, make sure that no easily in fl...
OVERVIEW AND OPERATION Left-hand side view 10 Cockpit 11 Handlebar fi ttings 12 Tank cap 13 Adjustment shock absorber 14 Pillion footrest, fold-up 15 Side stand 16 Footrest 17 Gear shift pedal Illustration, 4- gear model...
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OVERVIEW AND OPERATION Right hand view of engine, 4-gear model Left hand view of engine, 4-gear model 1 Intake valve adjuster cover 8 Carburetor 2 Exhaust valve adjuster cover 9 Air fi lter housing 3 Spark plug connector 10 Fuel tap 4 Electric starter 11 Engine number 5 Oil drain plug...
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OVERVIEW AND OPERATION Right-hand view of engine, automatic model Left-hand view of engine, automatic model 1 Service cover, intake valve 8 Carburettor 2 Service cover, exhaust valve 9 Air fi lter housing 3 Spark plug socket 10 Engine number 4 Starter 5 Oil drain plug 6 Oil level inspection glass 7 Oil fi...
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OVERVIEW AND OPERATION Left-handle handlebar fi ttings Right-handle handlebar fi ttings 6 Direction-indicator switch Switch to the left: Left indicator on Switch to the right: Right indicator on Push button for switch off Push-button: horn 1 Fixed grip 8 Emergency off switch engine will not start 2 Clutch lever engine starts...
OVERVIEW AND OPERATION Cockpit Ignition-lock WARNING While riding, do not switch the ignition NOTE Activate the parking light only for a lim it ed period. Take into account the charge of the battery. The key can be removed in positions 1 Speedometer NOTE 2 KM/H -odometer...
OVERVIEW AND OPERATION Speedometer time adjustment Speedometer set-up 12 : 00 Button M press untill the clock time (CLK) NOTE appears The display is only visible when the ignition is on. Button S press once, the hour value fl ashes Mode for: DST = total distance (km) The hour value can be set by...
OVERVIEW AND OPERATION Speedometer battery change Replace the batteries (6) by using new Remove the screws (3 + 4) and take off NOTE batteries, type AG 13. the cover (5). If the ignition is turn off the clock is supplied Set-in the batteries with the plus termi- by the battery power.
SAFETY TEST Checklist Before each ride, carry out a safety – Lights Important notes for the operation with a catalyst. check using the checklist. – Clutch operation The catalyst. is designed for a optimal Take the safety check seriously. Carry out –...
SAFETY TEST Clutch, 4-gear model Adjustment: - Remove the rubber cap (1). - Release the lock nut (2). - Turn setting screw (3) as appropriate. - Tighten up the lock nut (2). - Check the play. NOTE Clutch lever play If this adjustment is not suffi...
SAFETY TEST Fuel, fuel tank Opening: - Tilt up the cover (2) in the direction of the arrow. - Insert the ignition key (3), turn the cover (2) to the left and open the tank cap (1). Closing: - Close the tank cap (1) by turing the cover (2) to the right and pull out the ignition key.
SAFETY TEST Fuel tap Fuel tap (4) CAUTION Fuel tap positions: When you stop the engine, always set = OPEN the fuel tap to position CLOSE. Oth- fuel tank will empty down to a er wise, fuel could enter the engine and reserve quantity of approx.
SAFETY TEST Engine oil Recommended grade: - 20° -10° 0° 10° 20° 30°40° C CAUTION Per API: SG or higher or also with ad di tion al release status: ACEA A3/96 (CCMC G5). Do not use additives. Since the oil also SAE 10W/30 serves to lubricate the clutch, do not use Recommended viscosity:...
SAFETY TEST Checking the oil level, 4-gear model - Stop the engine and remove the oil fi ller cap (1) on the lower right of the crank- case. - Clean the oil fi ller cap at the MIN-MAX aera with a clean rag. CAUTION For checking the oil level only insert the oil fi...
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SAFETY TEST Checking the oil level, automatic model - Shut the engine down at operating temperature, wait approx. 5 minutes and hold the vehicle in level position. NOTE MAX. Keep the motorbike in level position throug- hout the oil level chack. Even the slightest inclination towards the side will lead to MIN.
SAFETY TEST Brakes Front brake-fl uid tank Rear brake-fl uid tank WARNING Sudden changes in play or a spongy feel of the brake lever can be caused by UPPER LOWER faults in the hydraulic system. Do not ride on when in doubt about the oper- UPPER ability of the brake system.
SAFETY TEST Front brake Rear brake Checking the brake linings WARNING The brake disks and brake linings must be free of oil and grease. Brake linings (1) are subject to wear. In order to guarantee the operability of the brake system, the wear limits of the brake linings must not have been reached.
SAFETY TEST Drive chain Check the chain tension CAUTION - Shift the gear to neutral. The chain setting affects the wear on the - Prop the motorbike up on the side drive chain and sprocket as well as the stand. spring excursion of the rear wheel.
SAFETY TEST Tyre profi le Tyre pressure Tyre size Checking the tyre pressure The standard motorbike is provided with the following tyre sizes: WARNING Front 90/80-16 M/C 45P Rear 120/70-16 M/C 57P Adjust the tyre pressure according to the total weight load. Never exceed the All tyres are tubeless.
SAFETY TEST Load / lights Correctly loaded Checking the lights WARNING - Make sure that the left-right weight For the sake of your safety, use only WARNING distribution is balanced. original SFM accessories or prod ucts Before any ride, check the operation of - Check that fastenings are correct and released by SFM.
RIDING INSTRUCTIONS Ride safely Your reactions can be adversely af fect ed On smooth, slippery roads take into ac count CAUTION not only by alcohol, but also by drugs and that your riding stability and brak ing power medicines. are limited by the grip of the tyres on the Riding safety is largely also de ter mined road top.
RIDING INSTRUCTIONS Ride economically and be aware of the environment Turn the engine off when waiting in Fuel consumption is also affected by Fuel consumption, environmental pol lu tion traf fi c. conditions that are out of your control, for and wear of engine, brakes and tyres de- Different riding conditions affect fuel con- instance, poor road condition, hills, riding...
RIDING INSTRUCTIONS Running-in instructions running-in instructions for engine and Maximum top speed in the individual gears Running-in new tyres during the running-in period: gearbox WARNING CAUTION New tyres have a smooth surface. They 4-gear model must therefore be roughened by care- Exceeding the running-in speeds incre- km/h in the individual fully running them in at various slanted...
RIDING INSTRUCTIONS Side stand - Switch off the engine. - Left hand on the left-hand handle- bargrip. - Right hand on the seat. - Fold out the arm of the side stand as far forward as it will go and stop by foot. - Slowly tilt the motorbike to the left until its weight is supported.
RIDING INSTRUCTIONS Starting Before starting - Turn the ignition key (2) to its operating 4-gear model: - Shift the gear pedal (3) to neutral. position - Put the motorcycle it in a vertical position and fould up the side stand. NOTE - Turn the fuel chock (1) to position WARNING...
RIDING INSTRUCTIONS Starting with kick starter CAUTION CAUTION CAUTION Avoid high engine-speed counts af ter After starting the engine, check that The EMERGENCY OFF switch (4) is a a cold start. the kick starter lever is returned to its safe ty device and should normally be normal position.
RIDING INSTRUCTIONS Starting with electric starter CAUTION If the engine won’t start im me di ate ly, release the start button, wait a few sec- onds and push it again. Each time, push the start button for just a few seconds in order to save the battery.
RIDING INSTRUCTIONS Start-up 4- gear model shifting gears - Simultaneously slightly open the throt tle Start-up, automatic model (2). - Release the hand brake lever (3). CAUTION - Accelerate after engaging the clutch. - Slightly open the twist grip throttle control Avoid: Shifting up to gears 2, 3 and 4 is done (2) to accelerate the motorbike.
RIDING INSTRUCTIONS Braking Wet brakes Oil and grease WARNING Washing the motorcycle or riding through WARNING Operate the brakes to grind off the salt water or rain can delay the brak ing effect deposited on the brake discs. The brake discs and linings must be free due to wet or (in winter) ice-covered brake of oil and grease! discs and linings.
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RIDING INSTRUCTIONS Braking Brake with care. Locked wheels do not have much braking effect and can lead to skid- ding / crashing. In prin ci ple, do not brake on a curve, but before the curve. Braking on a curve increases the dan ger of sliding.
RIDING INSTRUCTIONS Stopping the engine Steering lock Safeguard the steering against unautho- Stopping the engine CAUTION rized use. - Turn the ignition key to the po si tion Lock: Turn the fuel chock (2) to the OFF (1). po si tion (Z). In the ON (A) or RES (R) Turn the handlebar fully to the left.
SERVICE INSTRUCTIONS Servicing the motorbike / cleaning agents WARNING Always carry out a brake test after NOTE cleaning and before starting a ride! Regular, expert service will help main tain the value of your motorcycle and is a CAUTION condition for guarantee claims for cor ro sion Do not use steam or high-pressure jet and other such damage.
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SERVICE INSTRUCTIONS Servicing the motorbike / cleaning agents CAUTION Never use paint-polishing agents on plastic parts. - After a longish ride, thoroughly clean the chassis and the aluminium parts and preserve them with a com mer cial ly available anti-cor ro sion agent. Cleaning - To wash the motorcycle, use a soft sponge and clean water.
SERVICE INSTRUCTIONS Operation in winter and Repairing paint damage Servicing tyres anti-corrosion protection If the motorcycle is not used for a long er period, it is recommended to support the motorcycle so that its weight is not on the NOTE tyres.
SERVICE INSTRUCTIONS Lay-up / commission Lay-up Commission NOTE - Clean the motorcycle. - Remove the preservation agents from the Before laying up the motorcycle, have a outside. - Remove the battery. SFM dealer change the engine oil. Observe the maintenance in struc tions. - Clean the motorcycle.
SERVICE INSTRUCTIONS Technical changes, accessories and spare parts For approved SFM accessories and original WARNING CAUTION SFM spare parts, see a specialised SFM dealer. Technical changes to the mo tor cy cle can We recommend using only ap proved lead to cancellation of the EC op er at ing SFM accessories and original SFM spare He will also ensure that they are pro fes sion al ly in stalled.
NOTES ON MAINTENANCE Checking the steering bearings Checking the telescopic fork Checking the shock absorber - Pull the hand brake to block the front Check the fastenings (2) of the spring NOTE wheel brake. strut for tight fi t. The telescopic fork should not jam up when turned and it should swing back lightly to - Now pump the fork girders several times - Check the spring strut for oil leaks.
NOTES ON MAINTENANCE Adjusting the shock absorber Adjusting the spring preload CAUTION The spring strut is manufactured with NOTE a gas fi lling. The spring preload can be infi nitely ad- justed. Do not open the valve cap (3) and do not make any changes.
NOTES ON MAINTENANCE Removing the front wheel - Support the motorcycle so that the front CAUTION wheel can move freely and the motor- Take care not to damage the brake discs cycle is standing securely. and linings while removing them. - Loosen the shaft-clamping screws (1).
NOTES ON MAINTENANCE Installing the front wheel - Grease the full fl oating axle (3) and push CAUTION it in with the spacer bushing (5) as far as it will go. Take care not to damage the brake discs and linings (4) while installing them. - Attach the axle nut (2) and screw tight.
NOTES ON MAINTENANCE Removing the rear wheel - Prop up the motorbike so that the rear CAUTION NOTE wheel can turn freely and that the Do not damage brake disc and linings motorbike is secure. When taking off the rear wheel, make sure during removal! that the bush (3) to the left of the wheel - Hold the full fl...
NOTES ON MAINTENANCE Installing the rear wheel - Insert right chain adjuster (2) and CAUTION NOTE reassemble with axle nut (1). Do not damage brake disc and linings Insert brake support into the guide (9) of during installation! Have a SFM dealer rear suspension.
NOTES ON MAINTENANCE Checking the drive chain Checking the chain for wear - With correct chain tension, it should not be possible to lift the chain higher than CAUTION the teeth of the sprocket. The chain, sprocket and pinion must be - If the chain can be pulled higher, have changed as one unit.
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NOTES ON MAINTENANCE Adjusting the drive chain Adjusting the chain Loosen the axle nut (1). Nominal value: A = 30-35 mm Adjust the setting nuts (2) evenly on both CAUTION Tighten the axle nut (1). sides of the chain tensioner (rear wheel The adjustment of the chain infl...
NOTES ON MAINTENANCE Front wheel brake Rear wheel brake Checking the brake linings - Visually inspect the brake calliper (1). - If the lining thickness is below the mini- mum, have the brake lining (2) replaced - Check the thickness of the brake lining. by a SFM dealer.
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NOTES ON MAINTENANCE Rear wheel brake Adjusting the footbrake pedal position NOTE WARNING The footbrake pedal position can be adjus- Check the play on the footbrake pedal ted with the setscrew (1). and ensure that the brake is functioning properly. A soft and spongy feel when WARNING operating the foot brake indicates that The adjustment measurement A must...
NOTES ON MAINTENANCE Adjusting the clutch lever 4-gear model - Tighten up the lock nut (2). CAUTION NOTE - Remove screws (4) and take off the clutch If you drive with no clutch lever play, the If the clutch play cannot be corrected with cover (5).
NOTES ON MAINTENANCE Cleaning the air fi lter NOTE Before assembly check O-rings (7) and gasket (8) for damage and correct fi t. Installation takes place in reverse order to disassembly. Opening the air fi lter element Clean for the 1.000 km Unscrew three screws (4).
NOTES ON MAINTENANCE Cleaning the fuel fi lter Adjusting the play of the twist grip throttle control CHECK: Adjustment: NOTE - Slacken the lock nut (2) on the handle- - Check the throttle cable for light move- We recommend to have the fuel fi lter (1) bar.
NOTES ON MAINTENANCE Checking the spark plug - Use a new new spark plug NGK CR7 Check and change HSA. CAUTION - Screw in the spark plug by hand and than Check or change the spark plug only tighten up with a spark wrench 1/2 too 3/4 when the engine is cold.
NOTES ON MAINTENANCE Battery Charging the battery WARNING FIRST AID After a long lay-up (3-4 months), charge the Always wear safety glasses. If acid comes into contact with an eye, im- battery. The charging current (in amperes) Keep children away from acids and mediately fl...
NOTES ON MAINTENANCE Battery Removing and installing the battery - Remove the screws (1) on both sides and take off the cover (2). - Disconnect the rubber band (3) on the CAUTION barttery case. The battery may only be connected or disconnected while the ignition is - Remove the battery.
NOTES ON MAINTENANCE Checking the fuse Replace the fuse CAUTION Never install a fuse with a larger rat ing, - Turn off the ignition. since this could destroy the en tire elec- - Remove the lower battery cover. trical system. - Remove the three screws (1) and take off The fuse is located behind the cover (2).
NOTES ON MAINTENANCE Changing the bulbs NOTE Use only tested, incandescent bulbs with the ‘E’ designation. Use of non-approved bulbs will void the operating license. Do not touch the bulbs with bare fi ngers. Hold bulbs with a clean, dry cloth when installing or re mov ing them.
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NOTES ON MAINTENANCE Tail / brake light If this is not the case, the tail light must be replaced by a SFM dealer. The tail / brake light (1) is not fi tted with a replaceable light bulb (diode light). If the tail light does not work you should fi...
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NOTES ON MAINTENANCE Changing the bulbs Rear indicator Front indicator - Release the light case (2). - Push the bulb (3) back and release it by turning to the left. Take the bulb out. Indicator lamps NOTE Installation takes place in reverse order to For changing the bulbs an opening of the disassembly.
NOTES ON MAINTENANCE Adjusting the headlamps Adjusting the headlight - Activate the dipped beam. - Use the adjusting screw (1 and 2) on both sides to adjust the angle of the asymmetrically illuminated surface area of the road top. - Release srews (1) and (2), adjust and tighten up.
TECHNICAL DATA Chassis Motorbike version: 4-gear model: Type 649 003 Automatic model: Type 649 004 Frame: Tube-type centre frame Front suspension: Telescopic fork ø 37 mm, hydraulic shock absorber, spring travel 100 mm Rear suspension: Mono shock absorber, travel 65 mm Wheels: Light metal (Alu) Front rim size: = 1,85 x 16“...
TECHNICAL DATA Lubricants and operating fl uids Fuel tank capacity: 5,1 litres, including 0,35 litres reserve Fuel: Unleaded fuel min. 91 octane Telescopic-fork oil: Viscosity SAE 10 W Filling quantity per fork tube: 180 cm Engine oil: SAE 15 W 40 mineral oil API (SG or higher) Filling quantity: 0,8 litres Brake fl...
TECHNICAL DATA Electrical Equipment Generator: 12 V 150 W Battery: 12 V 6 Ah MF Fuse: 15 A Lights: - Headlight: Low beam 12V 55W E1, high beam 12V 55W E1 - Position light: 12 V 5W - Instrument lights: Direction-indicator 12V 3W Change over gear 12 V 3W Cockpit 12 V 3W...
TECHNICAL DATA Dimensions and weights Overall length: 1840 mm Width across handlebars 760 mm without rear view mirror Maximum height: 1035 mm without rear view mirror Wheel base: 1235 mm Seat height: 835 mm Weight empty: 85 kg Weight in running order: 89,5 kg Max.
WARRANTY Warranty conditions scope of warranty does not extend the service book to the seller. In case of an occurring fault the company warranty period that has started with the SFM GmbH will provide the customer with 6. The following table gives the customer date of delivery of the motorcycle.
WARRANTY List of wear parts Wear parts Wear limits Tires, hoses, rims depending on riding style, load and tire pressure the wear limit may already be reached after only 1000 km or even earlier. Wheels, hubs depending on riding style, load and tire pressure the wear limit may already be reached after only 2500 km or even earlier.
WARRANTY List of wear parts Wear parts Wear limits Cleaning and lubrication of drive chain according of use and of every washing. Drive chain, pinion, sprocket wheels, depending on road conditions / ground and care, a wear is possible after 1500 km. chain guidance, chain pulley Do not wash with high pressure cleaner! Control during every maintenance.
INSPECTION PLAN Please observe the following: WARNING CAUTION - During and after the warranty period all For safety reasons, do not carry out any inspections should solely be performed In case of non-compliance the warranty repair or adjustment activities to the by a specialised dealer approved by us.
INSPECTION PLAN Components Work to be performed before 1. Service every every Assembly (*Only by an authorised SFM dealer) Start- after 4.000 km / 8.000 km / 1000 km 4 months 8 months Valves Check valve clearance, adjust if necessary (cold)* Spark plugs Check condition, if necessary clean or replace Replace...
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INSPECTION PLAN Component Servicing Tasks Before 1st service Every Every Assembly (*Only by an authorised SFM dealer) each after 4.000 km / 8.000 km / trip 1000 km 4 months 8 months Rear suspension Check, retighten, replace if necessary or lubricate* Every 24.000km / 2 Years Tyres Check gereral condition and profi...
MAINTENANCE CONFIRMATION Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date...
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MAINTENANCE CONFIRMATION Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date...
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MAINTENANCE CONFIRMATION 1.000 km/1 months 4.000 km/4 months After 8.000 km/8 months After 12.000 km/12 months service dealer stamp: dealer stamp: dealer stamp: dealer stamp: km ........km ........km ........km ........date......... date......... date......... date......... After 16.000 km/16 months After 20.000 km/20 months After 24.000 km/24 months After 28.000 km/28 months...
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MAINTENANCE CONFIRMATION After 32.000 km/32 months After 36.000 km/36 months After 40.000 km/40 months After 44.000 km/44 months dealer stamp dealer stamp dealer stamp dealer stamp km ........km ........km ........km ........date......... date......... date......... date......... After 48.000 km/48 months After 52.000 km/52 months After56.000 km/56 months After 60.000 km/60 months...
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MAINTENANCE CONFIRMATION New brake fl uid New brake fl uid New brake fl uid New brake fl uid Km ........Km ........Km ........Km ........Date ........Date ........Date ........Date ........Stamp, signature Stamp, signature Stamp, signature Stamp, signature...
Rating plate (Sample): Motorbike data (Fill in on purchase) Model designation: ............Vehicle identity No: ............(Chassis No.) Key No.: ............WSF................... EC-approval: ............Owner: .................................. Important If the type approval should become invalid you should imme- diately contact a motor vehicle registration offi...
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