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Related Manuals for Sachs Bikes MadAss
Summary of Contents for Sachs Bikes MadAss
- Page 1 Your Sachs dealer SACHS Recommends Sachs Fahrzeug- und Motorentechnik GmbH Nopitschstraße 70 • D-90441 Nürnberg Telefon: +49 (0)911 4231 400 • Telefax +49 (0)911 4231 332 e-Mail: info@sachs-bikes.de • www.sachs-bikes.de Printed in Germany Nr. P00 649 008 00 02 000 2004 ..
- Page 2 owners manual...
- Page 3 PREFACE You have purchased a Sachs MadAss Congratulations – and thank you for putting your trust in us. The MadAss is a sturdy light motorcycle in Technical changes to the standard motor- This operating manual includes important modern design. cycles can void the EC operating license.
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Page 4: Table Of Contents
CONTENTS Summary and operation Riding instructions Safety symbols ................3 Right-hand side view ..............4 Ride safely................21 Engine ..................5 Ride economically and be aware of the environment ..22-23 Left-hand handlebar fittings ............6 Running-in instructions ............24 Right-hand handlebar fittings............. - Page 5 CONTENTS Maintenance Technical Data Maintenance activities ............. 39 Engine ..................58 Checking the fork-column bearings ......... 40 Power transmission ..............59 Removing the front wheel............41 Chassis..................60 Installing the front wheel............42 Lubricants and operating fluids ..........61 Removing the rear wheel............43 Electrical Equipment..............
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Page 6: Summary And Operation
SUMMARY AND OPERATION Safety symbols and notes Observe the following: WARNING CAUTION NOTE Precautionary measures against the risk of Important instructions and precautionary Special instructions for better handling accidents, injury and/or death. rules to be followed in order to prevent during operation and inspection and when the motorbike from being damaged. -
Page 7: Right-Hand Side View
SUMMARY AND OPERATION Right-hand side view 1 Fuel tank cap 2 Handlebar fittings 3 Brake fluid reservoir front brake 4 Speedometer 5 Chassis number and rating plate 6 Fork column lock 7 Side stand 8 Battery and fuse 9 RH pillion footrest, fold-up SFM 649 051.1... -
Page 8: Engine
SUMMARY AND OPERATION Engine left-hand side view Engine right-hand side view SFM 649 013.1 SFM 649 012.1 7 Spark plug connector 1 Carburattor 8 Electric starter 2 Air filter 9 Footbrake lever 3 Fuel cock with filter 10 RH footrest 4 Engine number 11 Oil filler cap 5 LH Foot rest... -
Page 9: Left-Hand Handlebar Fittings
SUMMARY AND OPERATION Left-handle handlebar fittings Right-handle handlebar fittings Choke lever right SFM 649 024.1 SFM 649 025.1 SFM 649 017.1 1 Clutch lever 4 Emergency off switch 9 Choke lever ( 2 Head light switch engine will not start Operating positions: engine starts Push button upwards for... -
Page 10: Ignition Lock
SUMMARY AND OPERATION Ignition-lock Key positions NOTE Activate the parking light only for a limited Operating position: ignition and all period. Take into account the charge of the circuits activated. battery. The key can be removed in positions Ignition off. WARNING While riding, do not switch the ignition SFM 649 015.1... -
Page 11: Cockpit
SUMMARY AND OPERATION Cockpit Speedometer set-up Speedometer time adjustment 11 : 55 SFM 649 059_2 Botton B press once Seedometer the clock (CLK) appears 1 KMH - odometer or switchable on the time can be set. 12 : 00 MPH - speedometer (in miles) Botton B press once the hour signal is 2 DST - total distance (km) flashing... -
Page 12: Speedometer Battery Change
SUMMARY AND OPERATION Speedometer battery change SFM 649 058.1 Remove the screws (2) and take off the Remove the batteries (4) and replace NOTE cover (3). against new once, type AG 13. If there is no reading on the display or very Set-in the batteries with the plus termi- poor change the batteries. -
Page 13: Safety Test Checklist
SUMMARY AND OPERATION SAFETY TEST Important notes for the operation with Checklist a catalyst. – Total weight Before each ride, carry out a safety The catalyst. is designed for a optimal – Lights check using the checklist. performance and lifetime.Note the –... -
Page 14: Clutch
SAFETY TEST Clutch SFM 649 016.1 Clutch lever play Adjustment: - Remove the rubber cap (1). CAUTION If you drive with no clutch lever play, the - Release the lock nut (2). clutch will be damaged. - Turn setting screw (3) as appropriate. Checks: - Pull the lever until there is discernable - Tighten up the lock nut (2). -
Page 15: Fuel
SAFETY TEST Fuel 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. - Page 16 SAFETY TEST Fuel WARNING Fuel expands under the influence of heat and the sun.Therefore, never fill the tank to the brim. Never fill the tank while the engine is running. Never bring a glowing cigarette or naked flame near an open tank, because fuel vapour could suddenly ignite.
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Page 17: Engine Oil
SAFETY TEST Engine oil - Stop the engine and remove the oil filler cap (1) on the lower right of the crankcase. - Clean the oil filler cap at the MIN-MAX aera with a clean rag. CAUTION For checking the oil level only insert the MAX. -
Page 18: Engine Oil
SAFETY TEST Engine oil � ��� ���� �� ��� ��� ������ � CAUTION Engine oil: Do not use additives. Since the oil Recommended grade: also serves to lubricate the clutch, do Per API: SG or higher or also with additional ���... -
Page 19: Front Brake
SAFETY TEST Front brake Checking the brake linings Check the brake-fluid level WARNING WARNING MIN. The brake disks and brake linings must Every two years, the brake fluid must be free of oil and grease. be changed by a Sachs dealer. The level must not drop below the MIN Brake linings are subject to wear. -
Page 20: Rear Brake
SAFETY TEST Rear brake Checking the brake linings WARNING The brake disks and brake linings must be free of oil and grease. Brake linings 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. -
Page 21: Drive Chain
SAFETY TEST Drive chain Check the chain tension - Shift the gear to neutral. - Prop the motorbike up on the side stand. - Let the motorbike rear end drop to the limit imposed by the suspension. - Push in the drive chain from the top half 30 - 35 mm way between the sprocket and pinion. -
Page 22: Tyre Profile, Tyre Pressure And Size
SAFETY TEST Tyre profile, tyre pressure and size WARNING - While the tyres are cold: Never ride without valve caps. Firmly - Twist off the valve caps. tightened valve caps prevent the tyre - Check/adjust the tyre pressure. from suddenly losing pressure. - Twist on the valve caps. -
Page 23: Load / Lights
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 Sachs accessories or products Before any ride, check the operation of - Check that fastenings are correct and released by Sachs. -
Page 24: Riding Instructions
RIDING INSTRUCTIONS Ride safely CAUTION Your reactions can be adversely affected On smooth, slippery roads take into account Riding safety is largely also determined not only by alcohol, but also by drugs and that your riding stability and braking power by the manner of riding. -
Page 25: Ride Economically And Be Aware Of The Environment
RIDING INSTRUCTIONS Ride economically and be aware of the environment Avoid rapid acceleration Unnecessary acceleration and hard Fuel consumption, environmental pollution braking cause high fuel consumption and wear of engine, brakes and tyres de- Open the throttle not further than needed, and increased pollution levels. -
Page 26: Ride Economically And Be Aware Of The Environment
RIDING INSTRUCTIONS Ride economically and be aware of the environment Fuel consumption is also affected by Observe the following aspects for eco- Low tyre pressure increases rolling conditions that are out of your control, for nomical fuel consumption: resistance. This increases fuel consumption instance, poor road condition, hills, riding –... -
Page 27: Running-In Instructions
RIDING INSTRUCTIONS Running-in Running-in new tyres Running-in instructions for engine Maximum speed of the gears during running-in period: and transmission CAUTION CAUTION New tyres have a smooth surface. km/h of each Excessive revs while running-in the They must therefore be roughened by Kilometer gear engine increases the wear of the engine. -
Page 28: Side Stand
RIDING INSTRUCTIONS Side stand Propping up the motorbike on the side stand. WARNING Always make sure that the stand is resting on firm ground.On sloping roads, always park the motorbike facing uphill and in 1st gear.When you kick the stand in, do not stand within the pivoting arc of the stand. -
Page 29: Starting
RIDING INSTRUCTIONS Starting SFM 649 015.1 SFM 649 010.1 SFM 649 003.1 Before starting - Shift the foot-operated gear lever (3) to - Turn the ignition key (2) to its operating neutral. - Put the motorcycle it in a vertical position position and allow the side standard to tilt up. -
Page 30: Starting With Kick Starter Lever
RIDING INSTRUCTIONS Starting with kick starter SFM 649 017.1 SFM 649 018.1 SFM 649 031.1 WARNING CAUTION CAUTION Never allow the engine to run in an en- Avoid high engine-speed counts after After starting the engine, check that closed space. Exhaust gases are highly a cold start. -
Page 31: Starting Withelectric Starter
RIDING INSTRUCTIONS Starting with electric starter - When the operating temperature is increasing, turn back the CHOKE all the way in the opposite direction to the arrow "B". WARNING Never allow the engine to run in an enclosed space. Exhaust gases are highly toxic and can kill. -
Page 32: Riding, Changing Gears
RIDING INSTRUCTIONS Riding, shifting gears Starting / shifting up Shifting down - Pull in the clutch lever - Close the throttle - Push down on the foot-operated gear - Pull in the clutch lever lever (without opening the throttle) - Push down on the foot-operated gear - Carefully engage the clutch lever - Simultaneously slightly open the throttle... -
Page 33: Braking
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 braking 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. - Page 34 SFM 649 019.1...
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Page 35: Stopping The Engine / Fork-Column Lock
RIDING INSTRUCTIONS Stopping the engine Fork- column Lock SFM 649 015.1 SFM 649 021.1 SFM 649 010.1 Stopping the engine Safeguard the steering assembly against CAUTION - Turn the ignition key to the position unauthorized use. Turn the fuel chock (2) to the OFF (1). -
Page 36: Service Instructions
SERVICE INSTRUCTIONS Servicing the motorbike / cleaning agents WARNING NOTE Always carry out a brake test after Regular, expert service will help maintain cleaning and before starting a ride! the value of your motorcycle and is a condition for guarantee claims for corrosion CAUTION and other such damage. - Page 37 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 commercially available anti-corrosion agent. Preservation agents Cleaning When necessary, the motorcycle must - To wash the motorcycle, use a soft...
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Page 38: Operation In Winter And Anti-Corrosion Protection
SERVICE INSTRUCTIONS Operation in winter and anti-corrosion protection Winter operation / anti-corrosion NOTE CAUTION protection Protect the environment by using only en- Do not use hot water, which would in- Use of the motorcycle in the winter can crease the effect of the salt. vironmentally friendly preservation agents, cause considerable damage due to the and use them frugally. -
Page 39: Repairing Paint Damage / Servicing The Tyres
SERVICE INSTRUCTIONS Repairing paint damage / servicing the tyres Repairing paint damage Servicing tyres Minor paint damage should be immediately If the motorcycle is not used for a longer repaired. Major damage must be repaired period, it is recommended to support the by a Sachs dealer. -
Page 40: Lay-Up / Commission
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 - Remove the battery. outside Sachs dealer change the engine oil. Observe the maintenance instructions. - Clean the motorcycle. -
Page 41: Technical Changes, Accessories And Spare Parts
SERVICE INSTRUCTIONS Technical changes, accessories and spare parts For approved Sachs accessories and origi- WARNING CAUTION nal Sachs spare parts, see a specialised Technical changes to the motorcycle can We recommend using only approved Sachs dealer. lead to cancellation of the EC operating Sachs accessories and original Sachs He will also ensure that they are profes- license. -
Page 42: Maintenance
MAINTENANCE Maintenance activities Checking the fork-column bearing Before carrying out any maintenance Front brake activities, read the relevant section of Removing the front wheel Rear brake this operating manual. Installing the front wheel Adjusting the clutch lever play Removing the rear wheel Spark plug Installing the rear wheel Battery, fuse... -
Page 43: Checking The Fork-Column Bearings
MAINTENANCE Checking the fork-column bearings - Jack up the machine on a sturdy NOTE installation jack. The telescopic fork must not stick when - Take hold of the lower fork tubes and try turned, and at both limit positions it must to move them to and fro in the direction easily tilt back. -
Page 44: Removing The Front Wheel
MAINTENANCE Removing the front wheel SFM 649 027.1 SFM 649 026.1 - Support the motorcycle so that the front CAUTION wheel can move freely and the motorcycle Take care not to damage the brake discs is standing securely. and linings while removing them. - Loosen the axle nut (1). -
Page 45: Installing The Front Wheel
MAINTENANCE Installing the front wheel SFM 649 027.1 SFM 649 026.1 CAUTION Take care not to damage the brake - Grease the full floating axle (2) and push - Before tightening the screws, stand the discs and linings (4) while installing it in from the right as far as it will go. -
Page 46: Removing The Rear Wheel
MAINTENANCE Removing the rear wheel SFM 649 029.1 SFM 649 030.1 NOTE CAUTION When taking off the rear wheel, make sure Do not damage brake disc and linings - Prop up the motorbike so that the rear that the bush (3) to the left of the wheel during removal! wheel can turn freely and that the hub is not lost. -
Page 47: Installing The Rear Wheel
MAINTENANCE Installing the rear wheel SFM 649 032.1 SFM 649 030.1 SFM 649 029.1 NOTE CAUTION Insert brake support into the guide (7) of Do not damage brake disc and linings - Adjust the drive chain (s. adjusting drive rear suspension. during installation! chain page 45). -
Page 48: Checking, Adjusting The Drive Chain
MAINTENANCE Checking, adjusting the drive chain 30 - 35 mm SFM 649 033.1 Checking the chain for wear Adjusting the chain - Release the axle nut (4). - Evenly adjust the setting nuts (3) on both CAUTION CAUTION sides of the chain adjuster (rear wheel The chain, sprocket and pinion must be How the chain is adjusted affects the must be aligned with the front wheel). -
Page 49: Front Brake
MAINTENANCE Front brake � � � � SFM 649 047.1 SFM 649 014.1 Brake light switch Checking the brake linings - Visually inspect the brake calliper (1). NOTE CAUTION The minimum lining thickness must be The brake light switch (3) is placed in the - Check the thickness of the brake lining: maintained. -
Page 50: Rear Brake
MAINTENANCE Rear brake � � � � SFM 649 034.1 Checking the brake linings CAUTION - Visually inspect the brake calliper (1) on The minimum lining thickness must be the right motorbike side. maintained. NOTE - Check the thickness of the brake lining: minimum thickness: A = 1,5 mm For your own safety, we recommend having activities to the brake system carried out by... -
Page 51: Rear Brake
MAINTENANCE Rear brake 20 mm SFM 649 036.1 SFM 649 052.1 SFM 649 035.1 Setting the footbrake pedal position Adjusting the foot brake Adjusting the brake light switch NOTE NOTE NOTE The footbrake pedal position can be adjusted After a longer period of operation, adjustment By correct adjustment of the brake light with the setting screw (1). -
Page 52: Adjusting The Clutch Lever Play
MAINTENANCE Adjusting the clutch lever play SFM 649 016.1 SFM 649 037.1 SFM 649 038.1 CAUTION NOTE If you drive with no clutch lever play, the If the clutch play cannot be corrected with - Remove screws (4) and take off the clutch clutch will be damaged. -
Page 53: Sparkplug
MAINTENANCE Spark plug ��� � ��� �� ��� ��� ����� SFM 649 040.1 Check and change CAUTION - Insert new spark plug NGK CR7 HSA Check or change the spark plug only and tighten up. when the engine is cold. Torque 20 Nm. - Page 54 SFM 649 042.1 SFM 649 041.1...
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Page 55: Fuse
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, battery. The charging current (in amperes) Keep children away from acids and immediately flush the eye for several must not exceed 1/10 of the battery... - Page 56 MAINTENANCE Battery SFM 649 036.1 SFM 649 041.1 SFM 649 060.1 Removing and installing the - Remove the screw (4) with the splint pin CAUTION and hang out the brake rod (1). battery The battery may only be connected - Remove three screws (5) and lift off cover or disconnected while the ignition is (2) to the left side.
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Page 57: Changing The Bulbs
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 fingers. Hold bulbs with a clean, dry cloth when installing or removing them. - Page 58 MAINTENANCE Tail / brake light bulb SFM 649 043.1 SFM 649 045.1 Tail / brake light bulb The tail light is not fitted with a replaceable - Push back the cable protection (2) light bulb (diode light). underneath the seat. Check the cable connections (3) green/ yellow, green If the tail light does not work you should and black.
- Page 59 SFM 649 055.1 SFM 649 061.1 SFM 649 054.1 SFM 649 053.1...
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Page 60: Adjusting The Headlamps
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. -
Page 61: Technical Data Engine
TECHNICAL DATA Engine Type: FY139FMB Construction: One cylinder 4-stroke petrol engine Valve steering: 1 overhead cam with rocker arms Valve: 2 valve Valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm Pistion displacement: 49,5 cm Bore: ø 39 mm Stroke: 41,4 mm Compression ratio:... -
Page 62: Power Transmission
TECHNICAL DATA Power transmission Clutch: Wet multi-plate type Gear box: 4-seed constant mesh, foot operated Gear ratios: 1. gear = 36/11 (3,273) 2. gear = 31/16 (1,938) 3. gear = 27/20 (1,350) 4. gear = 24/23 (1,044) Primary transmission ratio: 4,059 Chain pinion: 11 teeth... -
Page 63: Chassis
TECHNICAL DATA Chassis Motorbike version: Type 649 Frame: Center-type frame made of tubular steel Front suspension: Telescopic fork ø 37 mm , hydraulic shock absorption, travel 100 mm Rear suspension: Mono shock absorber, travel 65 mm Wheels: Light metal (Alu) Front rim size: = 1,85 x 16"... -
Page 64: Lubricants And Operating Fluids
TECHNICAL DATA Lubricants and operating fluids Fuel tank capacity: 4,6 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: 800 cm Brake fluid:... -
Page 65: Electrical Equipment
TECHNICAL DATA Electrical Equipment Generator: 12 V 80 W Battery: 12 V 3 Ah MF Fuse: 15 A Lights: - Headlight: Low beam 2x 12V 15W - Position light: 12 V 3W - Instrument lights: Direction-indicator 12V 3W Change over gear 12 V 3W Cockpit 12 V 3W - Brake/rear light: 12 V diode light... -
Page 66: Dimensions And Weights
TECHNICAL DATA Dimensions and weights Overall length: 1830 mm Width across handlebars 780 mm without rear view mirror: Maximum height: 1010 mm without rear view mirror Wheel base: 1235 mm Seat height: 865 mm Weight empty: 85 kg Weight in running order: 89,5 kg Max. -
Page 67: Warranty
WARRANTY Warranty conditions In case of an occurring fault the company Sachs-dealer (seller). The customer is 5. When lodging a warranty claim the Sachs Fahrzeug- und Motorentechnik then entitled to legal claims. Replaced customer must present the correctly GmbH will provide the customer with parts pass over into the possession of filled in service book to the seller. -
Page 68: List Of Wear Parts
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. - Page 69 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.
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Page 70: Inspection Plan
WARRANTY 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 will become null and void. - Page 71 WARRANTY Inspection plan type 649 Component Servicing Tasks Before 1st service Every Every Assembly (*Only by an authorised Sachs dealer) each after 4.000 km / 8.000 km / trip 1000 km 4 months 8 months Valves Check and adjust valves if necessary (cold)* Spark plugs Check condition and accordingly clean or replace Replace...
- Page 72 WARRANTY Inspection plan type 649 Component Servicing Tasks Before 1st service Every Every Assembly (*Only by an authorised Sachs 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 profile depth and...
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Page 73: Maintenance Confirmations
WARRANTY Maintenance confirmations Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date... - Page 74 WARRANTY Maintenance confirmations Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date...
- Page 75 WARRANTY Maintenance confirmations 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...
- Page 76 WARRANTY 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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Page 77: Maintenance Confirmations
WARRANTY Maintenance confirmation New brake fluid New brake fluid New brake fluid New brake fluid Km........Km........Km........Km........Date ........Date ........Date ........Date ........Stamp, signature Stamp, signature Stamp, signature Stamp, signature... -
Page 78: Motorbike Data / Rating Plate
Rating plate (sample): Motorbike data (fill out on purchase) Model designation: ............Sachs Fahrzeug-und Motorentechnik GmbH Vehicle identily No: ............(Chassis No) e1-0212*00 WSF 649B1040000101 Key No: ......................3000 min — d B ( A ) EC license: ............Owner: ............