SWM VAREZ Operation And Maintenance Manual
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SWM VAREZ Operation And Maintenance Manual

SWM VAREZ Operation And Maintenance Manual

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  • Page 1 Manual - Operation - Maintenance...

  • Page 2: Table Of Contents

    SUMMARY CAUTION ........................26 PRESENTATION ......................3 CLUTCH CONTROL ..................... 27 IMPORTANT NOTICES ....................3 REAR BRAKE CONTROL ..................... 27 IMPORTANT ........................4 GEAR SHIFT CONTROL ....................27 PRECAUTIONS FOR CHILDREN .................. 4 FUELLING ........................28 SAFE RIDING AND MOTORCYCLE SAFETY .............. 5 SIDE STAND ........................
  • Page 3 TYRES ..........................42 WIRING DIAGRAM......................53 FRONT BRAKE FLUID LEVEL CHECK ................ 43 BATTERY ......................... 55 REAR BRAKE FLUID LEVEL CHECK ................43 BATTERY CHARGER ..................... 55 BRAKE PAD WEAR CHECK ..................44 FUSES..........................57 PAD CLEANING ......................44 CAUTION ........................57 PAD INSTALLATION ....................

  • Page 4: Presentation

    IMPORTANT NOTICES Welcome to the SWM motorcycling Family! The VAREZ model is a motorcycle for ROAD use, guaranteed and free of de- Your new SWM motorcycle is designed and manufactured to be the best in its fects and covered by legal warranty provided that the STANDARD category.

  • Page 5: Important

    • Park the vehicle where it cannot be easily and maintenance manual by having scheduled bumped or damaged. After a fall, inspect the motorcycle carefully. maintenance carried out at authorised SWM Make sure that the throttle, brake, clutch and workshops. Even slight or involuntary bumps can cause the all other systems and controls are undamaged.

  • Page 6: Safe Riding And Motorcycle Safety

    SAFE RIDING AND MOTORCYCLE - Always assess the road conditions and adjust crease the braking action through engine com- SAFETY your speed accordingly. pression; using only brakes when going downhill Here are some basic principles for riding your - Reduce speed if it is raining and especially if could cause the brake pads to overheat and re- motorcycle safely.
  • Page 7 order to keep the motorcycle under control. Anti-lock braking system -ABS Risks related to carbon monoxide - The passenger must always hold on to the rider The ABS is an electromechanical braking-aid sys- Exhaust gas contains carbon monoxide, a color- or the passenger handle with both hands and tem: less and odorless gas.

  • Page 8: Identification Data

    IDENTIFICATION DATA ENGINE NUMBER The engine identification number is stamped at the top of the crankcase, while vehicle serial number or Vehicle Identification Number is stamped on the steer- B20M????? ing tube of the frame. Always quote the number stamped on the frame when ordering spare parts or （...

  • Page 9: Views Of Motorcycles

    VIEWS OF MOTORCYCLES RIGHT-HAND SIDE VIEW 1) Fuel tank cap 2) Fuel tank 3) Instrument panel 4) Headlight 5) Taillight 6) Front turning indicators 7) Rear turning indicators 8) Rear brake disc 9) Rear brake calliper 10) Combined braking control pedal 11) Rear brake pump 12) Engine oil filter 13) Engine oil dipstick...
  • Page 10 LEFT-HAND SIDE VIEW 1) Side stand 2) Front brake disc 3) Front brake calliper 4) Gear shift pedal 5) Horn 6) Fuse control unit 7) Rider seat 8) Passenger seat/Storage compartment 9) Transmission chain 10) Coolant radiator. 11) Plate lighting device 12) Passenger handle 13) Cooling fan 9- EN...
  • Page 11 CONTROLS AND INSTRUMENTS 1) Left-hand rear-view mirror 2) Right-hand rear-view mirror 3) Instruments 4) Ignition/steering lock block 5) Clutch control lever 6) Left-hand switch 7) Right-hand switch 8) Throttle twist grip 9) Front brake control lever 10) Front brake fluid reservoir EN-10...

  • Page 12: Technical Data

    TECHNICAL DATA ENGINE FUEL SYSTEM Type ....................single cylinder, 4 stroke Type..................Electronic injection feed Cooling…………………………………………………………………………… liquid with electric fan PRIMARY DRIVE Water radiators ......................n° 1 Drive pinion gear-Clutch ring gear ............Z 20-Z 67 Bore........................58.0 mm. Transmission ratio...................... 3.35 Stroke ........................47.2 mm. CLUTCH Displacement......................
  • Page 13 SECONDARY DRIVE Transmission sprocket …………………………………………………………………………………Z 14 Cold tyre pressure Rear wheel sprocket ……………………………………………………………………………………Z 53 Front Transmission ratio ………………………………………………………………………………………3.786 Rider only …………………………………………………………………………………………………2.0 bar Transmission chain dimensions. ………………………………………………………4/8" x 7/20" Rider and passenger …………………………………………………………………………………2.0 bar CHASSIS Rear Type …………………trellis perimeter frame made of high-resistance steel tubes Rider only …………………………………………………………………………………………………2.2 bar FRONT SUSPENSION Rider and passenger …………………………………………………………………………………2.4 bar...
  • Page 14 TABLE FOR LUBRICATION, SUPPLIES Engine, gearbox and primary drive lubricating oil MOTUL 10W 40 Brake system fluid MOTUL DOT 4 Grease lubrication MOTUL GREASE 100 Final drive chain lubrication MOTUL CHAIN LUBE Front fork oil MOTUL FORK OIL LIGHT 5W Oil for rear shock absorber MOTUL SHOCK OIL FL Electric contact protection MOTUL EZ LUBE...

  • Page 15: Instruments

    INSTRUMENTS The motorcycle is equipped with a combined instrument divided into the following areas: 1) Signal lights (see “Warning and signal lights”) 2) Multifunction display (see “Multifunction Display”) 3) Tachometer: Indicates engine rpm. WARNING Maintain the engine speed lower than 10500 rpm. If this speed is ex- ceeded, the engine may be damaged.
  • Page 16 The indicator lighting up warns that the engine overheated reaching an alarm temperature. -Stop and turn off the engine; -Wait for the engine to cool down and then restart the engine. If the problem occurs again, it is necessary to refer to the nearest SWM’s dealer for a check. 15- EN...
  • Page 17 ABS braking system: -Stop and turn off the engine. -wait for a few minutes and restart the engine. If the light turns on again, see the closest SWM dealer to check the ABS system. MULTIFUNCTION DISPLAY 1) Speedometer Indicates motorcycle speed.
  • Page 18 CLOCK SETTINGS -Press the “Set” key (1) and set the tenths of minutes; to confirm settings, press -Press the “Set” key (1) until “CLOCK” appears. the “Set” key (1) and hold for more than 3 seconds until the minutes flash on the display.
  • Page 19 In the event of a fault, the relevant error code is indicated on the display (1); more than 3 seconds to reset the value and return the count to 0 km or Find the nearest SWM dealer to check the fault. miles.

  • Page 20: Abs Malfunction List

    ABS MALFUNCTION LIST Malfunction Possible Causes Possible Impact Recommended Measures C1101 ECU Voltage supply: high voltage Poor connect of battery terminal. ABS alarms and not working. Clean the terminal. C1102 ECU Voltage supply: low voltage Poor connect of battery terminal. ABS alarms and not working.
  • Page 21 Malfunction Possible Causes Possible Impact Recommended Measures ECU error (hardware, Micro-controller er- C1604 ABS Internal damange ABS internal damange and not working. Replace ABS ror) C2308 Valve fault, inlet valve front ABS Internal damange ABS internal damange and not working. Replace ABS C2312 Valve fault, outlet valve front...

  • Page 22: Appendix: Dtc List

    APPENDIX: DTC LIST System or component Error code Error description Driver behavior Coolant/Oil Sensor P0118 Coolant/Oil Temperature Sensor Circuit High Volt- age or Open Stop the engine and check whether the cylinder P0117 Coolant/Oil Temperature Sensor Circuit Low Volt- temperature sensor is connected effectively. If the error still persist ask for assistance.
  • Page 23 System or component Error code Error description Driver behavior Front Oxygen Sensor P2A00 Front oxygen sensor signal activate failure Check if the front oxygen sensor is connected effec- tively. If the error still persist ask for assistance. P00D1 Front oxygen sensor heating circuit low current Fuel Pump Relay (FPR) P0232 FPR Coil Circuit High Voltage...
  • Page 24 System or component Error code Error description Driver behavior Intake Temperature P0114 Intake temperature sensor signal error fluctuation Sensor Intake Air Temperature P0113 IAT Circuit High Voltage or Open Check if the intake air temperature sensor is con- Sensor (IAT) nected effectively.
  • Page 25 System or component Error code Error description Driver behavior Vehicle Speed Sensor P0500 VSS No Signal Check if the vehicle speed sensor is connected ef- fectively. Use multimeter to check the voltage (12V- 14.7V normally). If the error still persist ask for assis- tance.

  • Page 26: Controls

    CONTROLS STEERING LOCK RH HANDLEBAR SWITCH The motorcycle comes with a steering lock The right-hand switch features the following con- IGNITION SWITCH located on the ignition switch (1) Lock the steering trols: The ignition switch has three positions: as follows: Motorcycle start position (key not remova- 1) Engine start button -Turn the handlebar to the left.

  • Page 27: Caution

    LH HANDLEBAR SWITCH THROTTLE CONTROL FRONT BRAKE CONTROL The left-hand switch features the following con- The throttle twistgrip (1) is located on the right- The brake control lever (2) is located on the right- trols: hand side of the handlebar. hand side of the handlebar.

  • Page 28: Clutch Control

    CLUTCH CONTROL REAR BRAKE CONTROL GEAR SHIFT CONTROL The lever (1) is placed on the left-hand side of the The clutch control lever (1) is located on the left- The rear brake control pedal (1) is placed on the engine. hand side of the handlebar and is equipped with right-hand side of the motorcycle.

  • Page 29: Fuelling

    FUELLING SIDE STAND Recommended fuel: premium grade UNLEADED A side stand (1) is supplied with every motorcy- fuel (R.O.N 95). cle. WARNING Periodically check the side stand (see “Sched- uled Maintenance Chart”); make sure that the Fuel is extremely flammable and can be explo- springs are not damaged and the side stand sive under certain conditions.

  • Page 30: Storage Compartment

    Note*: Lower the stand with your right foot keep- STORAGE COMPARTMENT A storage compartment is present under the pas- ing the motorcycle balanced. When the stand has senger side seat. been lowered, make the bike rest on it. Once the To access the compartment, turn the key (1), lift motorbike has been brought from its rest position the passenger seat and remove it.

  • Page 31: Instructions For Using The Motorcycle

    INSTRUCTIONS FOR USING THE relative warning light comes on; MOTORCYCLE -Operate the turning indicators and check that -Apply both brakes several times to run-in the Note*: If you are not familiar with the motorcy- the warning light comes on; pads and the discs; cle operation, read paragraphs on “CONTROLS”...
  • Page 32 The engine has starting troubles -The cables on the voltage regulator are badly -Dirty or worn out spark plug: clean or replace; connected, or in short-circuit: correctly connect, The engine starts, but it is erratic or replace; -Dirty or worn out spark plug: clean or replace; -Faulty alternator coil: replace;...

  • Page 33: Mounting/Dismounting Of Rider And Passenger

    MOUNTING/DISMOUNTING OF RIDER AND The rider must be the first to get on and the last -Sit on the motorcycle and place both feet on the PASSENGER to get off the motorcycle and must control the ground. Balance the vehicle without putting all General stability of the motorcycle while the passengers your weight on the side stand.
  • Page 34 Mounting of passenger -Place your left hand on the rider's shoulder, your -Hold onto the special handles (2). Get the rider to mount first as described in the left foot on the footrest and then mount the mo- -Using your left leg, fully retract the stand. relevant section without starting the engine.

  • Page 35: Adjusting The Rear-View Mirrors

    Dismounting the motorcycle ADJUSTING THE REAR-VIEW MIRRORS -Stop the vehicle and switch off the engine. Sit on the motorcycle as described in the relative CAUTION paragraph. Make sure that the area where you want to Adjust both mirrors (1) so that you can clearly park the vehicle is stable and level.
  • Page 36 STARTING THE ENGINE started with the gear in neutral. After getting on the motorcycle as described in the relative paragraph, operate as follows to start the engine: -Place ignition key (1) to position (the buzz that you hear when you turn the key to caused by the fuel pump which puts the feeding system under pressure);...

  • Page 37: Important Note In Case Of Cold Starts At Low Temperatures

    IMPORTANT NOTE IN CASE OF COLD STOPPING THE MOTORCYCLE AND THE STARTS AT LOW TEMPERATURES ENGINE -Fully close the throttle twist grip (1) to decelerate It is recommended to briefly warm up at idle speed until you get a normal engine response to the motorcycle.

  • Page 38: Engine Emergency Stop

    WARNING ENGINE EMERGENCY STOP It can be useful to use the front brake inde- -Flick the red switch (7) to stop the engine pendently or to use the combined braking de- and then flick it back to position. pending on the situation. Be careful when using When the bike is off, place it on its side stand.

  • Page 39: Periodic Maintenance And Adjustments

    PERIODIC MAINTENANCE AND OIL LEVEL CHECK ADJUSTMENTS Note*: Check the oil level when the engine has Carry out proper maintenance according to the just been turned off and is still hot. table given in Appendix A in this manual, which WARNING indicates the periodic maintenance intervals.

  • Page 40: Engine Oil And Filter Change

    ENGINE OIL AND FILTER CHANGE Note*: Carry out this operation with the engine hot. CAUTION Be careful not to touch the hot oil. - Remove the push rod by unscrewing the front retaining screw (1) and the two rear screws (2) -Remove the filter, check its condition and replace (one per side).

  • Page 41: Engine Coolant Level Check

    ENGINE COOLANT LEVEL CHECK AIR FILTER CHECK AND/OR REPLACEMENT - Remove the front fairing by unscrewing the re- The engine coolant level must be between the taining screws (2) (one per side) and the screws MIN and MAX notches on the clear reservoir (1). (1).

  • Page 42: Spark Plug Check

    CAUTION same rating. As this procedure is quite complex, it is advised to WARNING contact an SWM Dealer for spark plug check/re- A spark plug with heat rating too high can cause placement. pre-ignition and possible engine damage A spark plug with heat rating too low can cause a signifi- cant increase in carbon deposits.

  • Page 43: Tyres

    TYRES MINIMUM HEIGHT OF THE TREAD This motorcycle is equipped with tyres with inner FRONT 3 mm tube. REAR 3 mm WARNING -Check the tyre pressure which should be as in- The wheels have been designed to mount tyres dicated under TECHNICAL DATA. WARNING with inner tube It is prohibited to mount tubeless tyres.

  • Page 44: Front Brake Fluid Level Check

    Avoid contact with skin or eyes. In case of contact, motorcycle under such conditions, have the brake motorcycle under such conditions, have the brake system immediately checked by the SWM Dealer. flush thoroughly with water and call a doctor if system immediately checked by the SWM Dealer.

  • Page 45: Brake Pad Wear Check

    If the pads cannot be cleaned properly, replace of brake pads has to be replaced. them. CAUTION PAD INSTALLATION Contact an SWM dealer to have the brake pads Refit the pads following the removal procedure in replaced. FRONT reverse order.

  • Page 46: Combined Braking Pedal Position Adjustment

    BRAKE DISC WEAR COMBINED BRAKING PEDAL POSITION REAR BRAKE PEDAL FREE PLAY Measure the thickness of each disc in the point of ADJUSTMENT ADJUSTMENT The position of the rear brake pedal with respect maximum wear. Replace the disc if it wear exceeds The combined braking pedal (3) must have a free to the footrest may be adjusted according to the the limit provided.

  • Page 47: Air Vent From Forks

    AIR VENT FROM FORKS SINGLE REAR SHOCK ABSORBER SPRING WARNING Place the vehicle on a central stand, fully extend PRELOAD ADJUSTMENT the fork and loosen the valve (1) at the end of the The single rear shock absorber (1) spring pre- Be careful not to touch hot exhaust pipe while ad- operation tighten the valve, paying attention to load can be adjusted;...

  • Page 48: Fork Functionality Check

    -If you notice oil leaks and jamming, have it checked by an SWM dealer; 47- EN...

  • Page 49: Chain Cleaning And Lubrication

    CHAIN CLEANING AND LUBRICATION CHAIN /FRONT SPROCKET/REAR SPROCKET Note*: If worn, the pinion, crown and chain have The motorcycle is equipped with a chain (1) with WEAR CHECK to be replaced; using a new chain with a worn O-rings; to clean it, operate as follows; -Check the condition of the chain (1);...

  • Page 50: Chain Adjustment

    CHAIN ADJUSTMENT Preliminary Operations: 7. Make the adjusters rest on the sliding blocks Chain should be checked, adjusted and lubricated -Place the bike on a stand so as to have an ade- using the nut (4) (anticlockwise rotation), slightly as per the Maintenance Chart to ensure safety quate working space in the area of the rear wheel tighten.

  • Page 51: Throttle Control Cable Adjustment

    WARNING THROTTLE CONTROL CABLE ADJUSTMENT CLUTCH ADJUSTMENT To check proper adjustment of the throttle con- Normally, the clutch is adjusted by only stretching Using the motorcycle with a damaged throttle control cable considerably compromises safe rid- trol transmission, operate as follows: the cable using the adjusting unit positioned on ing.

  • Page 52: Removing The Front Wheel

    REMOVING THE FRONT WHEEL REFITTING THE FRONT WHEEL Position the motorcycle in such a way that the Fit the LH spacer (D) on the wheel hub. front wheel is lifted from the ground. Fit the wheel between the fork legs. Unscrew the two screws (1) and remove the brake Fit the previously greased wheel shaft (5) from the calliper (2).

  • Page 53: Removing The Rear Wheel

    Note*: Do not operate the rear brake pedal when Fit the brake calliper on the disc assemble it on REMOVING THE REAR WHEEL Unscrew the nut (1) of the wheel pin and extract the relevant support and tighten the two screws the wheel has been removed;...

  • Page 54: Wiring Diagram

    WIRING DIAGRAM 53- EN...
  • Page 55 Cable Colour Coding O/Bk……………………………………………… Orange/Black KEY TO WIRING DIAGRAM B………………………………………………………………………Blue O/Gr……………………………………………… Orange/ Grey Electronic power unit B/Y ………………………………………………………Blue/Yellow O/W……………………………………………… Orange/ White OBD unit interface B/Gr ……………………………………………………Blue /Grey R…………………………………………………………………… Red Brake fluid filler Bk………………………………………………………………… Black R/ Bk ……………………………………………………Red / Black Starting motor Bk/R……………………………………………………...

  • Page 56: Battery

    (1) to access the battery compartment; If electrolyte leaks, or other failure of the electri- Flash relay -First remove the BLACK negative cable (2) and cal system, are detected, contact the SWM Horn then the RED positive cable (3) (when refitting, first Dealer.
  • Page 57 Using a battery charger with a constant voltage, WARNING WARNING first connect the RED positive cable to the battery The battery contains sulphuric acid Avoid contact If the battery is unused, it has to be in any case positive terminal then the BLACK negative cable with skin, eyes or clothing.

  • Page 58: Fuses

    FUSES F4) 15A fuse Fuse malfunction could cause problems to the motorcycle. F5) 15A fuse To access the fuse box, remove the side locking EFI system、instrument function display devices (1) and open the protective door (2). F6) 15Ause Before operating on the fuses, set the ignition EFI system switch to position and remove the key in or-...

  • Page 59: Projector Bulb Replacement

    PROJECTOR BULB REPLACEMENT PLATE LIGHT BULB REPLACEMENT WARNING Do not unscrew screws (2) and (4) -The front projector (1) is the LED type, replace it To replace the plate light, proceed as follows: if it does not work. -Remove the plate by releasing it from the side -Lift the cover (7) and remove the lamp holder fastening devices;...

  • Page 60: Headlight Adjustment

    HEADLIGHT ADJUSTMENT When checking the proper aiming of the head- light beam: inflate tyres at the right pressure, have a person sit astride the motorcycle and set the motorcycle perpendicular to its longitudinal axis. At 10 metres from a wall or screen, trace a hori- zontal line at the height of headlight centre and a vertical one, in line with vehicle longitudinal axis.

  • Page 61: Long Period Of Inactivity

    LONG PERIOD OF INACTIVITY To reactivate the motorcycle after storage, pro- CLEANING When the motorcycle is to be stored for a certain ceed as follows: Before washing the motorcycle, it is necessary to period, it should be prepared for storage as fol- -Make sure the spark plug is tightened;...

  • Page 62: Pre-Delivery Inspection

    PRE-DELIVERY INSPECTION  Hose clamps Check Check / Tighten  General lubricatio Description Operation Pre-delivery   General test Engine oil Check level  Spark plugs Check / Replace  Throttle body Check and adjust  Brakes / Clutch Check operation ...
  • Page 63 EN-62...
  • Page 64 VAREZ SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) ENGINE 1000 KM 5000 Km 10000 Km 15000 Km 20000 Km REPLACE IF NECESSARY VALVES C (*) C (*) C (*) VALVE SPRING VALVE CUP, VALVE HALF CONE CUVETTES, ROCKER ARM (INTAKE –EXHAUST)
  • Page 65 VAREZ SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) CHASSIS 1000 KM 5000 Km 10000 Km 15000 Km 20000 Km REPLACE IF NECESSARY COOLANT FOOTRESTS, FOOTRESTS PINS AND SPRINGS SEAT FRAME FASTENING BOLTS, ENGINE FASTENING BOLTS SIDE STAND...
  • Page 66 BOLTS AND NUTS TIGHTNESS GENERAL CHECK C: CHECK C (*): CHECK CLEARANCE S: CHANGE L: LUBRICATE R: OVERHAUL P: CLEANING NOTE: Upon every removal replace the gaskets Replace screws and nuts if worn General check after riding on mud or sand 65- EN...

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