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Summary of Contents for VOGE 525R
- Page 1 Far & Beyond Q uality MOTORCYCLE OPERATION MANUAL 525R...
- Page 2 VOGE keeps standard of high safety and quality due to constant research and improvement, which may lead to difference with your manual, but VOGE distributor is glad to give you correct guide at any time.
- Page 3 Issues need pay attention to When you saw the warning symbols below, please follow the driving and maintenance procedure This means potential danger may lead to heavy injury or death Danger Warning This means possible damage on motorcycle This means more efficient and convenient driving essentials Caution Danger This motorcycle suits rational and careful driving in the person with corresponding...
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Page 4: Table Of Contents
Contents Adjustment for front brake lever ......Vehicle identification............1 Adjustment for gearshift pedal ........ Motorcycle head..............2 Adjustment for rear brake pedal ......Left side ...................3 Adjustment for throttle grip ........Right side ................4 Adjustment for clutch lever ........ower part of seat ............... Adjustment for rear shock absorber ...... - Page 5 Trouble shooting .............. Brake pads................59 Engine starting failure...........38 Replace the fuel filter.............60 Difficult engine starting ..........39 Replace the signal lights..........61 Powerless engine..............39 Storage and cleaniness ..........62 Checking and maintenance ........40 Refit and accessories............64 Maintenance for air filter ..........43 Motorcycle parameters..........65 Maintenance of engine oil...........44 Maintenance plan ............67 Check oil level ..............44...
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Page 6: Vehicle Identification
Vehicle identification Vehicle Identification Number( )and Motorcycle Brand Plate Engine type and Identification number Motorcycle Brand Pla te Engine type and Identification Vehicle Identification Number （VIN number... -
Page 7: Motorcycle Head
Motorcycle head 1. Clutch lever 2.Lef t switch assy. 3.Meter 4.Fuel tank cap 5.Ignition switch 6.Front brake master cylinder 7.Right switch assy. 8.Front brake lever... -
Page 8: Left Side
Left side 9.Coolant filling-up por t 10.Front disc brake pump 11.Thermostat 12.Gearshift arm 13.Side stand 14.Engine oil drainage bolt... -
Page 9: Right Side
Right side 15.Speed sensor 16.Oil pressure sensor 17.Heat radiator water port 18.Oil element 19.Water temperature sensor 20 Rear brake oil cup 15 19... -
Page 10: Lower Part Of Seat
Lower part of seat 21.Fuse box 22.Batter y 23.Air filter 24.ABS controller（Match-select） 25.Diagnosis joint 26.Seat cable 27.Tools 28. Star ting relay 29.ECU 30.Dumping switch... -
Page 11: Loading And Accessories
Caution The equipment and accessories of VOGE are specially designed or verified, in this case, we strongly suggest you adopt OEM par ts or accessories we permitted. The change of weight has a large influence on power per formance, in this case, you have to accept... -
Page 12: Issues Need To Pay Attention To During Driving
Issues need to pay attention to during driving 1. Any passenger need know well the driving speciality, because unsuitable sitting position, for ex ample deviation of gravity center from central plane of motorcycle or sudden moving during driving may have influen ce on operation or control;... -
Page 13: Ignition Switch
Ignition switch The ignition switch is on the front of fuel tank , which including ignition and steering lock. This model equipped 2 pcs of keys, in which one is for spare. One key is for ignition, steering, seat, and fuel lock. Ignition switch has three positions: Position “... -
Page 14: Meters And Indicator
Meter and indicator 1.Indicating light for left turning signal light 2.Engine malfunction alarm light 3.Neutral indicating light 4.Driving speed 5.Low voltage alarm light of battery 6.ABS malfunction indicating light 7.Oil pressure indicating light 8.High beam indicating light 9.Indicating light of right turning signal light 10.Light sensor 11.Alarm light for fuel meter and... - Page 15 Turn the ignition key to " "，the instrument star ts its self-inspection： In case the self-inspection is on，and shows the motorcycle is under，the ABS malfunction alarm light " " and oil pressure alarm light " " are on. In case the kill switch on right switch assy. is not on "...
- Page 16 . In motorcycle driving, in case the indicating light" " goes on or flashing, please stop using, then contact the VOGE dealers. ABS malfunction indicating light" "...
- Page 17 High beam indicating light" " When pushed the headlight switch on left switch assy. upwards，the indicating light " "gets on. When pressed the over taking light switch on left switch assy the indicating light" "gets on un til you release the switch.
- Page 18 Negative display instrument The instrument is on he screen shows you the information mode of last setting. The back light of instrument: The instrument shif t the strength of light mode of Light/Dark according to surrounding light. Rotation speed: The engine rotation speed. (r min rotation circles minute —...
- Page 19 Caution The fuel in its tank is easy to wave during driving, so when the residual fuel is not much, it may lead to the indicating strip goes flashing, which is normal, when the fuel alarm light gets yellow, the residua l fuel is about 2L.
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Page 20: Fuel Filling Up
This indicator reminds you fill-up the fuel Caution: Insufficient fuel may lead to engine star ting failure, in case ignition continued, the engine may be damaged. Use up all the fuel is not allowed, keep the minimum fuel is necessar y. Fuel filling up Turn the ignition key clockwise for opening fuel tank cap. -
Page 21: Insufficient Oil Pressure
Insufficient oil pressure This indicator is on means too low the oil pressure. In this case, stop and cease the engine. Performance requirement for lubricant. The only way for confirm the oil level is viewing through oi l view window. Oil indicator on means too low the level. -
Page 22: Emergency Indicator
This indicator is on means EFI system failure, going on driving may lead to ignition or fuel supplying failure. Please turn off the engine and ignition switch, and then re-star t, in case the indicator goes off, go on the driving; In case the indicator is still off, go for trouble shooting in specialized ser vice station nearby. -
Page 23: Usb Power Interface
USB Power interface " " This meter equipped with integrated USB power interface with output specification of ： 5V 1A. The water proof cap of USB power interface is with mark " ". Use the USB power interface from left to right. Warning Use self prepared charging line when this function is needed,After used, well cover the water-proof cap for preventing water or dust enter the USB power inter face to decrease working-life. - Page 24 Headlight dimmer switch When turned the dimmer to " "，the high beam is on，while the corresponding indicator" " th e meter is on. When turned the dimmer to" "，the low beam is on，while the high beam and its indicator" " a re off. Warning Headlight could be on before engine star ting, which depends on batter y.
- Page 25 Overtaking indicator button" PPAS" When pressed down button" PPAS "，the high beam is on，while its corresponding indicator " " on meter is also on and restored after released. ， Warning button " " When pressed down button " "， all the turning signals and their indicator on meter are flashing. In case there is emergency or accident use the warning indicator ，...
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Page 26: Gearshift Pedal
Gearshift pedal The speed transmission of this model is Rear brake pedal Step down the pedal ， Rear wheel brakes while its light is on. with 6 gears and gears change as below： Step for ward Pick for ward Rear brake pedal Gearshift pedal Side stand The parking system of this motorcycle is designed... - Page 27 Warning 1 In case the parking ground is rough or soft, the motorcycle is unable to steadily park , so, parking shall be on solid and flat road. In case parking on inclined way could not be avoided, put the head face to uphill, and lay the engine on 1st gear for decrease the possibility of motorcycle turnover due to side stand turning.
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Page 28: Adjustment Before Driving
Adjustment of handle bar Adjust the handle bar to suitable position in relation to your stature and driving posture, in case adjustment is needed,ask VOGE dealer if possible. Loosen the bolt 1 Finely turn the handle bar to suitable position... -
Page 29: Adjustment For Front Brake Lever
Adjustment for front brake lever · Adjust distance between the lever and throttle grip by adjustment button. · This distance has 5 positions for adjusting shown as below ： – Push the lever for wards when adjusting. – Turn the adjustment button to the position you need. –... -
Page 30: Adjustment For Rear Brake Pedal
Adjustment for rear brake pedal ·Please keep the suitable height for rear brake pedal, too high the height may lead to step on the pedal and frequent friction between the pads and brake disc which damage them. ·For keeping the reliability of brake,the free travel of rear brake pedal shall be within 25-35mm, in case the travel is incorrect, adjust as below. -
Page 31: Adjustment For Throttle Grip
Adjustment for throttle grip · Throttle grip controls the engine rotation. · Turn the grip to driver direction is acceleration to opposite direction is deceleration. · Adjust the gap of throttle cable. –Remove the rubber jacket 1 – Loosen the locking nut 2 –... -
Page 32: Adjustment For Rear Shock Absorber
–Turn clockwise is adjusting the light beam to down. –Turn anticlockwise is adjusting the light beam to up. Caution Adjustmen t for spring of rear shock absorber may need specialized tools,wh ich could be supplied by VOGE deal ers. Danger Danger ·... -
Page 33: Running In Of New Motorcycle
Running in of new motorcycle Running-in period has a large influence on motorcycle working lief and fuel consumption so please ca refully read the user manual before driving(Correct using within initial 1000km may let you enjoy the driving). Grinding-in of engine ·... -
Page 34: Grinding In Of New Tire
Grinding in of new tire ·The sur face of new tire is ver y smooth, which makes danger driving in bending road or under high speed. For getting the strongest road holding, tire grinding-in is necessar y. ·During the initial 200km, grinding-in could be done in bending road under low speed until tire crown grinded in each angle. -
Page 35: Motorcycle Driving
Motorcycle driving Check before driving The accident may happen in case there is no check before driving so please check as below ·Horn – The tire is with correct air pressure. · Steering system – Depth of tire tread is enough without abrasion Handle bar turn freely without jamming –... -
Page 36: Engine Starting
Engine starting Danger The emission of motorcycle is with CO which is a The side stand is laid down. gas without smell and color but poisonous . Long idling in the place without sound ventilation Check to ensure the kill switch is on" ". -
Page 37: Driving On The Road
Driving on the road · Get on motorcycle from left side and ride on the seat. · Pick up the side stand · Adjust the motorcycle ver tical to ground, and upright the handle bar and let wheel for ward. ·... -
Page 38: Speed Transmission Device
Speed transmission device Step for ward Pick up for ward · Speed transmission device makes the engine steadily work during normal rotation speed. · Transmission ratio is designed in relation to engine performance, choose suitable gear according to driving conditions, high running speed in low gear position is not allowed. -
Page 39: Abs System
ABS system . 1 Under normal cases, when braking, loosen throttle grip first, then firmly hold handle bar, and the brake. When the running speed reduced, for avoiding engine off, grasp the clutch and get into low gear position. . 2 Reduce running speed and brake before passing the bending way. When passing bending way, keep even spee d, during which slight braking is permissible, but sudden braking is now allowed. - Page 40 Warning ·Af ter long driving, park the motorcycle in place the kids hard to close up for preventing scald du e to the high temperature of engine. ·Parking on sof t ground is not allowed for preventing falling down. ·In case parking on gentle slop, get into low speed gear position, and make the head face to uphill for preventing the side stand turn and falling down.
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Page 41: Fuel
Fuel ·The fuel consumption when you knew from purchasing is the least one under an even speed, which is largely different with the actual operation, in this case, you may found the actual fuel consumption is higher. ·The operations below may decrease fuel consumption under correction driving: –The driving shall be stable and soft, reduce the frequency of braking, and restar ting may use more fuel. -
Page 42: Fuel Evaporation
Fuel evaporation When the fuel evaporation system failed, please contact VOGE ser vice station. Refit the fuel evapor ation system is not allowed, or the fuel evaporation emission standard could not be met. After removal and maintenance, check the connection of pipeline for ensuring there is not or plug at the joint; Rubber tube is without squeezing, crack or damage. -
Page 43: Three-Way Catalyst
·Make periodic maintenance in relation to “Quality guarantee manual” ·When the engine worked unsteadily, contact VOGE dealer on time. ·When the fuel indicator is on, fill-up fuel on time, too low the fuel level may lead to poor fuel supplying. -
Page 44: Difficult Engine Starting
– Check if it is in high altitude area. · Incorrect checking or adjustment may damage your motorcycle and unable to find out the failure cause. This kind of damage is out of VOGE after-sales ser vice. In case operation is unknown, contact VOGE dealer. Warning Three-way catalyst is fragile, use unleaded gasoline, the gasoline with lead may damage three-way c atalyst and other impor tant parts. -
Page 45: Checking And Maintenance
Checking and maintenance Tool set Tool set is laid in its box under passenger seat, open the seat lock and remove the seat, the tool box could be seem. When used in bad conditions, such as after washed or in rain, make corresponding lubrication For dr iving safety, sound lubrication can prolong the working life. - Page 46 Power charging for batter y： In case the batter y voltage is lower than 12.6V, power charging is suggested. ·Power charging is by stable DC source. ·Charging voltage DC (14.5±0.3)V Charging current is not more than1.2A; ·Charging hours is within 6 to 8, charging current more than 1.2A is not allowed; ·Overcharging may shor ten the working life of batter y which is not allowed.
- Page 47 Assembly and disassembly of batter y： ·Turn off ignition key before assembly or disassembly. ·Remove the negative terminal before disassembling batter y, and then remove the positive terminal. ·When assembling batter y, install positive terminal first and then negative one. ·When the batter y re-installed, turn on ignition switch for 1 minute and then start engine for initialization of electric equipment.
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Page 48: Maintenance For Air Filter
Maintenance for air filter · Air filter located under fuel tank In case air filter is blocked the resistance of air inlet may increase and lead to power decrease and fuel consumption rise. · Driving under dusty condition need increase the element cleaning and replacement. -
Page 49: Maintenance Of Engine Oil
Maintenance of engine oil Oil ensures not only engine's internal lubrication but also cooling down, and helps its sealing, so the maintenance for oil is impor tant. Check oil level ·Oil filling-up and viewing are both on the right cover of engine, refer to figure 1. ·... - Page 50 ·Oil drainage： –In case too high the oil level, remove the oil drainage bolt by socket spanner whose position shown as below figure 1 which located on the lef t lower of engine. –Drain out suitable oil and screw up the oil bolt. Too low the oil level may damage the engine, which is the same to high level.
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Page 51: Replacement Of Engine Oil
Replacement of engine oil · Replace oil when maintenance period reached. ·Replace oil when the engine is hot for completely drain off the old oil. · Way for replacement ： – Make the motorcycle upright by auxiliar y parking rack. –... -
Page 52: Replace Oil Element
Oil element Warning Check the integrity of o-ring on element cover, replace for a new one if necessar y. Replace for wrong oil element may damage the engine, use OEM par ts of VOGE. -
Page 53: Filling Up Engine Oil
·The oil drainage bolt and the gasket are replaced and assembled. –Fill-up new “VOGE engine oil” by 2500ml. into the oil filling por t, and then screw up the cap. Star t the engine by various rotation speed and run for 5 minutes, when the engine is working, check the oil leakage on assembled or disassembled par ts. -
Page 54: Check And Maintain The Coolant
VOGE dealer for trouble shooting . Water tank Warning In case the coolant in expansion water tank is completely dried up, filling-up is not allowed, in this case, exhaust the air already entered water tank first, and this work shall be done by VOGE dealer. -
Page 55: Replace The Coolant
Replace the coolant · Drain off the coolant ： – Keep the motorcycle upright by special kick stand. – Lay a fluid plate under the engine – Remove the water drainage bolt Because the whole heat radiation system is connected, so all the coolant could be drained off. - Page 56 ·In the case of air temperature is lower than the mark label, use coolant with higher performance. ·Af ter VOGE tested, the coolant shall be the glycol one with ice point of -45℃. Please buy from VOG E dealer only.
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Page 57: Maintenance Of Brake Fluid
When the filling-up is needed, open the oil cup cap by yourself may result in water and air entering, which may largely reduce braking per formance, in this case, ask VOGE dealer for filling-up or replacing. Types of brake fluid Caution ·... -
Page 58: Maintenance For Transmission Chain
– attention to abrasion of sprocket – In case problems above were found contact VOGE dealer for trouble shooting. wheel, replace together if needed. Abrasion of chain may also wear out the sprocket wheel confirm problems below ·In case there is no chain oil for oil –... -
Page 59: Adjustment For Transmission Chain
Adjustment for transmission chain ·Too tight or loose the chain are incorrect. ·Too loose the chain may lead to drop off which result in accident. ·Too tight the chain may reduce its working life and increase resistance. Correct chain tightness is shown as below: 20-30mm In case your motorcycle failed meeting the demand above, the adjustment is needed, and do as below:... -
Page 60: Maintenance For Tires
Maintenance for tires The tires contact the ground which is impor tant. Incorrect specification and size may largely influence the performance. Danger Tire pressure Incorrect tire pressure may influence · Incorrect tire pressure may reduce the working life. driving and result in accident. ·... - Page 61 Repair the tire · Repair tiny hole on tubeless tire put a patch internally rather than externally because when it in high speed the centrifugal force may lead to patch outside flexible. · Driving speed more than 80km h within 24 hours after repaired is not allowed. ·...
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Page 62: Fuse Link
Fuse link Electrical box Fuse box · Before replacing the fuse link check failure cause and remove the failure first. · This model adopted electrical box 1 with internal integrated relay) and 1 fuse box. Motorcycle power fuse ·All the specification and usage of fuse links are marked with explanation. EFI power fuse Spare fuse –... - Page 63 Af ter checked or replaced well cover its cap or the electrical failure may occur in rainy days or after washing. Caution In case the fuse link usually blows out, which indicates failure in electrical system, please timely contact VOGE dealer. Danger ·...
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Page 64: Brake Pads
Abrasion limit for rear pads ： The correct way for replacing brake pads need remove the wheels, this work shall be done by VOGE dealer. ·Both the front or rear pads need to be replaced as a set, in case replace 1 piece only, the imbalance brake may occur which result in accident. -
Page 65: Replace The Fuel Filter
Replace the fuel filter · Fuel filter is for cleaning impurities which reject it enter the fuel injector. · Nozzle of fuel injector is ver y precisely machined and easy to be blocked, in case it blocked,the engine is unable to be star ted, so please replace secondar y fuel filter timely. -
Page 66: Replace The Signal Lights
Replace the signal lights · You may in danger in case there is no light signals because it may help you to be easily found so please replace the broken light signals on time. ·Headlight, position lights, turning signal lights, rear position light, brake lights and registrati on plate light are all LED sealed light, in case damaged, go to ser vice station for replacing as a whole. -
Page 67: Storage And Cleaniness
·In case parking for a period is needed, the special maintenance is necessar y which need some speci al materials, equipments or technologies, in this case, these works shall be done by VOGE dealer. ·In case you prefer finish these works by yourself, do as below: –Totally replace the old oil. - Page 68 Protection for motorcycle ·Usually wash the motorcycle in relation to driving, and keep it dr y and clean. ·Timely wash up dirts on the sur face. ·Use cover cloth for motorcycle, under sun shine for long time may result in aged body kit and colo r fading. Cleaniness for motorcycle ·...
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Page 69: Refit And Accessories
Refit and accessories OEM par ts or accessories are permissible . · You are able to get OEM par ts accessories and other par ts from dealers with authorization, meanwhile, staff with specialization may introduce you the correct installation way and use. ·... -
Page 70: Motorcycle Parameters
Motorcycle parameters Motorcycle parameters Engine system L×W×H 2100mm×770mm×1090mm Engine type 2 cylinders in line/water cooling/8 valves/DOHC Wheel base 1445mm Bore×Stroke 68mm×68mm Seat height 785mm Displacement 494ml Ground clearance 165mm Compression ratio 11.5：1 Curb weight 198kg Air inlet clearance （0.16±0.03）mm Deadweight 180kg Air exhaust clearance （0.27±0.03）mm... - Page 71 Driving for long journey sand weather or in mud special maintenance is necessar y af ter travel finished. · The maintenance above shall be done by VOGE dealer. The waste from maintenance such as cleanser or oil shall be well disposed without pollution to the environment ·...
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Page 72: Maintenance Plan
Maintenance plan The table below shows the necessar y checking in each periodic maintenance, the inter vals is by the fir st coming of time and mileage. Each maintenance shall be done as below: Periodic maintenance table Item s Interval km×1000 Lubricant Lubrication elem ent... - Page 73 The VOGE key parts fastening daily inspection 525R Ref No Fastening par ts position Thread Numbers Torque N m （ . ） Front wheel axle Front wheel axle lock up Front disc brake caliper and shock absorber Rear fork axle...
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Page 74: Electrical Diagram
Electrical diagram Ther e a r e 6 br an ches f or mo to rc y cle power supp ly, whic h g et po wer fo r po sit ive po le of b at t er y a nd wit h 1 f use ea c h, w ho ar e indepen dent w itho ut int er fer enc e. 4 way fus e and control relay di a gra m Elec t r i c al sc hem atic diag ram in th e el ec tri ca l b ox F use pi ece spe c ific ati o n:... - Page 75 Maintenance download Facebook Facebook www.vogeglobal.com...
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Как снять водительское сиденье