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Kove 800X Rally 2024 Instruction Manual

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ZF800LS
西藏新珠峰摩托车有限公司
两轮摩托车使用说明书

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  • Page 1 ZF800LS 西藏新珠峰摩托车有限公司 两轮摩托车使用说明书...
  • Page 3 To the owner Instruction Manual for The Two-wheeled Motorcycle 800X RALLY 1st Edition (January 2024) First of all, congratulations on your purchase of a brand new KOVEMOTO! If you choose products of KOVEMOTO, you will become a member of the KOVEMOTO family. This Instruction Manual introduces the main specifications, basic structure, adjustment method and maintenance knowledge of the motorcycle.

  • Page 4: Safety Precautions

    Safety Precautions The safety of you and others is very important, and the safe driving of this motorcycle is an important responsibility. To help you make an informed decision about your safety, we provide steps and other information on the safety label and in the Instruction Manual to remind you.

  • Page 5: Table Of Contents

    Content Motorcycle safety Operating instructions Maintenance Troubleshooting Relevant information Technical parameters...

  • Page 6: Motorcycle Safety

    Motorcycle safety This section contains important information about the safe riding of motorcycles, please read this section carefully. Safety instructions Safety precautions Riding precautions Spare parts and modifications Loading guide...

  • Page 7: Safety Instructions

    Safety instructions To enhance your driving safety, please follow these guidelines: ● Perform all routine and routine inspections as specified in the Instruction Manual. ● Before filling the tank, turn off the engine and keep away from sparks and open flames. ●...
  • Page 8 Make yourself easier to see Especially at night, wear bright reflective clothing to make yourself more eye-catching, stop so that other drivers can see you, turn on the signal light before turning or changing the lane, and when necessary, use the horn to remind pedestrians. Don't drink and ride Alcohol and driving are not compatible.

  • Page 9: Carbon Monoxide Hazard

    Carbon monoxide hazard The exhaust gas contains toxic carbon monoxide, a colorless and odorless gas, and inhaling higher concentrations of carbon monoxide can cause people to lose consciousness and may even be fatal. Do not start the engine for long periods of time in a garage or other enclosed space. Warning ●If the engine is started for a long time in a closed or semi-closed space, it may cause a rapid accumulation of toxic carbon monoxide gas.

  • Page 10: Safety Precautions

    Safety Precautions ● Be careful when riding, always keep your hands on the throttle grips and your feet on the pedals. ● Always pay attention to driving safety, keep a safe distance from other vehicles, avoid pedestrians, and slow down. ●...

  • Page 11: Riding Precautions

    Riding precautions Run-in period Follow these guidelines during the first 500 km of driving to ensure the motorcycle's later reliability and performance. ● Avoid starting with a heavy throttle or rapid accelerating. ● Avoid emergency braking and rapid downshifting. ● Ride carefully. Brake Follow the following guidelines: ●Avoid excessive emergency braking and downshifting...

  • Page 12: Anti-Lock Brake System (Abs)

    Anti-lock brake system (ABS) This model is equipped with an anti-lock braking system to prevent tire lock-up during emergency braking. ● When the vehicle speed is less than 10 km / h, the anti-lock braking system does not work. During braking, after ABS intervention, the brake handle or Foot brake lever may slightly rebound, which is a normal phenomenon. ●...
  • Page 13 Stop the motorcycle with the side support 1. Extinguish engine. 2. Lower side support. 3. Tilt the motorcycle slowly to the left until its weight is concentrated on the side bracket. 4. Turn the steering handle completely to the left. If the steering handle is turned to the right, it will reduce stability and may cause the motorcycle to fall.

  • Page 14: Spare Parts And Modifications

    Spare parts and modifications We strongly recommend that you do not use any accessories other than KOVEMOTO, and do not modify the original design of the motorcycle, which will cause the motorcycle to be unsafe. Unauthorized modifications to your motorcycle will void your warranty service and result in your motorcycle being unable to legally drive on public roads and highways.

  • Page 15: Operating Instructions

    Operating instructions This section contains important information about the operation of the motorcycle, please read this section carefully. Component location diagram Instruments Switch Ignition switch Start the engine Gear shift Oiling...

  • Page 16: Component Location Diagram

    Component location diagram 1. Instrument 2. Left combination switch 3. Fuel tank filler cap 4. Clutch lever 5. Side stand 6. Shift lever 7. Rider footrests 8. Chain 9. Link fork...
  • Page 17 Component location diagram 1.Rearview mirror 2. Emergency OFF switch/electric starter button 3. Fuel tank 4. Hand brake lever 5. Engine 6. Rider footrests 7. Foot brake lever 8. Muffler 9. Seat...
  • Page 18 Instrument - civil version Current driving Mobile projection Instrument main interface Simple navigation interface information interface navigation interface Light-sensitive hole Press and hold the ENT button on the left handlebar switch to switch the right- side interface Display check When the ignition switch is turned to “○” (ON), the instrument is powered on to play the start-up animation, and then self-test is performed, and all functional modules and symbols are displayed.
  • Page 19 Main interface function description - civil version -1...
  • Page 20 Main interface function description - civil version -2...
  • Page 21 Menu description - civil version - 1...
  • Page 22 Menu description - civil version - 2...
  • Page 23 Instrument - competitive version Simple navigation Mobile projection Current driving Instrument main interface interface navigation interface information interface Light-sensitive hole Press and hold the ENT button on the left handlebar switch to switch the right- side interface Display check When the ignition switch is turned to “ ○” (ON), the instrument is powered on to play the start-up animation, and then self-test is performed, and all functional modules and symbols are displayed.
  • Page 24 Main interface function description - competitive version -1...
  • Page 25 Main interface function description- competitive version-2...
  • Page 26 Menu description - competitive version - 1...
  • Page 27 Menu description - competitive version - 2...
  • Page 28 The instrument functions are as follows: Instrument button: Short press the SET key to enter the menu setting: long press the SET key to enter the display interface setting.Press the up and down keys to conduct page turning. Information viewing: When the mobile phone is connected with Bluetooth, the message display panel will reflect the information pushed by the mobile phone.

  • Page 29: Hazard Warning Light Switch

    Switch Left combination switch Menu switch: This combination button is used to set the functions of the instrument. Instrument combination button Hazard warning light switch : Select to switch up and down BACK: Back button SET: Set instrument function button Hazard warning light switch: After the emergency button is pressed, the left and right turn signal lamps flash at the same time.

  • Page 30: Electric Starter Button

    Right combination switch Emergency OFF switch: When the switch is in the “ ” (run) position, the engine can be started; Emergency OFF switch, electric starter button When the switch is in the “ ” (stop) position, the engine cannot be started. In case of emergency, switch to the “...
  • Page 31 Gnition and steering lock When the key is in the " " position, turn the direction handle to the leftmost, press the key, and rotate it counterclockwise to the " " position, and the direction can be locked; if users need to unlock, rotate the key clockwise. Location Function Note...

  • Page 32: Start The Engine

    Start the engine Whether the engine is hot or cold, please follow the instructions below to start the engine. 1. Turn the ignition switch to the “ ” (ON) position. 2. Verify that the engine shutoff switch is in the “ ”...

  • Page 33: Gear Shift

    Gear shift Your motorcycle has 6 forward gears and adopts 1 down 5 up shift mode. Method of shift: Warm up the engine for normal operation. 1. When the engine is idling, disengage the clutch and press down on the shift pedal to move the transmission into the low (1st) gear position. 2.
  • Page 34 Fill up with oil Open the fuel tank cover: Turn over the lock cover, insert the ignition key, and turn clockwise Filler neck to open the fuel tank cover. Fuel tank filler Close the tank cap: 1. After refueling, press the fuel tank cover down until it locks. 2.

  • Page 35: Maintenance

    Maintenance Please read “Maintenance” and “Maintenance Specifications” carefully before prepar-ing for maintenance. For maintenance data, please refer to “Technical Parameters”. Maintenance Maintenance schedule Check list of torque cycles at off-weight position Maintenance specifications Replacement part Remove and install body component Engine oil Coolant Brakes...

  • Page 36: The Importance Of Maintenance

    Maintenance The importance of maintenance The safety of maintenance It is important to keep your motorcycle in good condition of Please read the maintenance instructions before each maintenance, which is essential for your safety, as well as maintenance to ensure that you have the necessary tools, protecting your property, getting the best performance, components and skills.

  • Page 37: Maintenance Schedule

    Maintenance schedule The motorcycle should be maintained within the specified time. In order to ensure safety, it can only be repaired by a special repair shop of KOVEMOTO. The symbols in the table have the following meanings: I: Carry out inspection, cleaning and adjustment R: Change A: Adjust L: Lubrication...

  • Page 38: Check List Of Torque Cycles At Off-Weight Position

    Check list of torque cycles at off-weight position...

  • Page 39: Maintenance Specifications

    Maintenance specifications In order to ensure safety, it is your responsibility to conduct a pre-ride inspection and ensure that any problems you find have been resolved. A pre-ride inspection is required.
  • Page 40 RReplace part Battery Check Check and replace the battery 1. Before installing the battery, if the electrode is dirty, please wipe it clean and then install it, otherwise the function may fail due to poor contact. 2. In the process of use, if the battery is deformed, abnormal heat, smoke and other abnormal phenomena, please immediately stop using, and timely handed over to the special repair shop of KOVEMOTO for inspection.

  • Page 41: Blown Fuse

    Fuse Fuses protect the electrical circuit of your motorcycle. If some electrical parts of your motorcycle stop working, check and replace the blown fuses. Check and replace fusess Turn the ignition switch to the “ ” (OFF) position to take out and check the fuse. If the fuse is blown, please replace it with a fuse of the same specification, and refer to “Technical Parameters”...

  • Page 42: Brake Fluid

    Brake fluid Engine oil The consumption of engine oil and the decline in oil quality Do not add or replace brake fluid unless in an emergency. Only use the brake fluid newly removed from the sealed will vary depending on the driving conditions and the use time. The container.If you add the brake fluid, please go to the special repair higher the operating speed, the faster the oil consumption rate.
  • Page 43 Cleaning and lubricating DDrive chain After checking the sag, turn the rear wheel and clean the drive chain must checked regularly chain and sprocket at the same time. Use dry cloth, oil seal lubricated. If you often drive in poor road conditions, high chain special cleaning agent or neutral detergent.
  • Page 44 Tyres (check / replace) Tyre size Front： Cover tire: 90/90-21M/C 54S Inner tube: 2.75/3.00-21 Pad belt: Liner belt or TWI 21×30mm tyres：140/60R17 Cover tire: 140/80-18M/C 70S Inner tube: 4.50/4.75/5.10-18 Pad belt: Liner belt 18×30mm Wear indication Abnormal wear check position mark Check the contact surface of the tire for signs of abnormal wear.
  • Page 45 Whenever changing tyres, follow the following guidelines: ● Use recommended tyres or equivalent products of the same size, construction, speed class and load capacity. Warning Warning ● The use of excessively worn or improperly inflated tyres can lead to accidents and serious casualties. Please follow the relevant tyre inflation and maintenance guidelines in the instruction manual.

  • Page 46: Air Cleaner

    Air cleaner This motorcycle is equipped with an air filter element made of paper, please do not maintain it by yourself. It should be cleaned or replaced by a special repair shop of KOVEMOTO. The oil collection tube of the air filter is located on the Air filter element lower left side of the air filter.Check whether there is water or oil in the oil collecting tube every 1 month, especially check...
  • Page 47 Remove and install body component Battery Remove Confirm that the ignition switch is turned to the “ ” (OFF) position. 1. Remove the left fuel tank guard plate. 2. Remove the battary box cover. 3. Disconnect the negative (-) terminal of the battery. 4.
  • Page 48 Seat Remove Insert the ignition key into the seat cushion lock, turn the key clockwise, pull up the rear end of the rear seat cushion assembly to disengage from the lock, and then remove the rear seat cushion assembly with a slight force to the rear. Install 1.
  • Page 49 Engine oil Check engine oil Check and add engine oil 1. Idle for 3-5 minutes, turn the ignition switch to the “ ” (OFF) position, and wait for 2-3 minutes. Oil filler cap 2.Place the motorcycle vertically upward on a stable and flat ground, and check whether the oil level is between the upper and lower limit mark from the engine oil inspection window.
  • Page 50 Replace the engine oil and the secondary oil filter 1.If the engine is cold, please idle for 3-5 minutes, turn the ignition switch to the "○" (OFF) position, and then wait for another 2-3 minutes. 2.Park the motorcycle on a firm and flat level. 3.Remove the lower guard plate of the engine and place an oil pan under the oil drain bolt.
  • Page 51 Precautions for replacing the engine oil and the secondary oil filter: 1.Using the wrong engine oil and secondary oil filter can seriously damage the engine. 2.Check and clean the oil strainer every time the engine oil is changed, and replace it in time if any damage is found. 3.When replacing the engine oil, replace the secondary oil filter.

  • Page 52: Check Coolant

    Coolant Check coolant Check the coolant level in the water reservoir while the engine is Compensating tank cooling. 1. Park the motorcycle on a stable, flat, and level surface. 2. Keep the motorcycle straight. 3. Check that the coolant level in the water reservoir is between the upper and lower limit marks.

  • Page 53: Change Coolant

    Add coolant Change coolant Unless you have the appropriate tools and have qualified mechanical technology, please go to special repair shop of KOVEMOTO to replace the coolant. If the coolant level is below the lower limit level mark, add the recommended coolant until the level reaches the upper limit level mark.

  • Page 54: Brakes

    Brakes Check brake fluid 1. Place the motorcycle vertically up on a stable flat ground. 2. Check whether the brake oil cup is level. Front brake fluid 3. Check the brake fluid level. If the brake fluid is below the Lower level mark reservoir window lower level mark, add it immediately.

  • Page 55: Check Brake Pads

    Check brake pads Check the condition of the brake pad wear indication mark. If the brake pads wear to the indicator mark, they need to be replaced. Check brake pads from under the brake caliper Check brake pads from the rear right of the brake caliper Front Rear Brake pad lining thickness: 4.8mm (indicated as wear...

  • Page 56: Side Support

    Side support Check side support 1. Check that the side supports are free to operate. If the side bracket operation is jammed or “squeaky”, clean the pivot area and grease the pivot bolt with clean grease. 2.Check the spring for damage or loss of elasticity.

  • Page 57: Drive Chain

    Drive chain Check the sag of the drive chain Check the sag at different points along the chain. If the sag at all points is not uniform, some links may have been bent and kinked. Please check the chain at the special repair shop of KOVEMOTO. 1.
  • Page 58 Adjust the sag of the drive chain When adjusting the sag of the drive chain: 1.Put the transmission into neutral and turn off the engine. 2.Place the motorcycle vertically on a firm and flat ground. 3.Loosen the rear wheel axle nut. 4.Loosen the locking nut and chain tension adjusting bolt with an open-end wrench.

  • Page 59: Clutch

    Clutch Free travel of clutch handle: 3-6mm Free travel Check the clutch cable for bending and damage. If necessary, please go to the special repair shop of KOVEMOTO for replacement. Lubricate the clutch cables with special cable oil to prevent premature wear and corrosion. Notes ●Incorrect adjustment of the free travel can cause premature clutch wear.

  • Page 60: Throttle

    Throttle Adjusting the hand brake lever Check throttle When the engine is off, check whether the throttle can be smoothly turned from the fully closed to the fully open position in all directions and the free stroke is correct. Adjusting If the throttle operation is not smooth, automatically closed screw or the cable is damaged, please go to the special repair shop of...

  • Page 61: Front Shock Absorber Adjustment

    Front shock absorber adjustment Air pressure adjustment When the shock absorber is working, it will generate air pressure inside, which is like a progressive spring and will affect the entire stroke of the motorcycle. During a long ride, the front shock absorber will become harder.

  • Page 62: Compression Damping Adjustment

    Compression damping adjustment The adjustment of the compression damping affects the speed at which the front shock absorber compresses. The compression damping adjuster of the front shock absorber is located on the top of the left and right front shock absorbers, with the word "COMP" engraved.

  • Page 63: Rebound Damping Adjustment

    Rebound damping adjustment The adjustment of rebound damping will affect the rebound speed of the front shock absorber. The rebound damping adjuster of the front shock absorber is located at the bottom of the left and right front shock absorbers, with the word "TEN" engraved. Adjust the slotted part of the stud center.

  • Page 64: Rear Spring Strut Adjustment

    Rear spring strut adjustment Airbag Spring preload adjustment The spring preload shall be adjusted when the engine is cooled, and the shock Compression damping adjuster absorber spring preload adjusting knob shall be rotated to adjust the spring Shock absorbing spring preload.
  • Page 65 Rebound damping adjustment The compression damping can be adjusted separately for the bolt to conduct high-speed compression damping and low-speed compression damping. You can adjust it according to your weight and riding conditions. Low-speed compression damping adjustment High-speed compression damping adjustment When it is necessary to adjust the compression damping of the When it is necessary to adjust the compression damping of the shock aborber at high speed, adjust the center slotted bolt part of the...
  • Page 66 Rebound damping adjustment Inspection of shock absorbers The rebound damping adjuster is located at the left lower Check and clean all parts of the shock absorber regularly to ensure optimum performance: end of the rear shock absorber. The rebound damping increases when the adjuster is rotated clockwise (H), and the rebound 1.

  • Page 67: Headlight

    Headlight Adjust the headlight beam You can adjust the angle of the headlight beam by rotating the adjusting screw, and the clockwise rotation is the overall decline of the headlight beam; The counterclockwise rotation is the overall rise of the headlight beam. Please comply with local laws and regulations. Adjusting screw 调节螺丝...

  • Page 68: Troubleshooting

    Troubleshooting Please read “Maintenance” and “Maintenance Specification” carefully before maintenance, and refer to “Technical Parameters” for maintenance data. The engine could not start The warning indicator lights up or blinks Puncture Remove wheel Electrical fault...

  • Page 69: The Engine Could Not Start

    The engine could not start The starter motor ran but the engine failed to start Overheating (water temperature alarm indicator light up) Check the following items: If the engine overheats when the water temperature alarm indicator is on and the speed increase is slow, please push the ●Check that the correct engine start sequence is used.

  • Page 70: The Warning Indicator Lights Up Or Blinks

    The warning indicator lights up or blinks Oil pressure indicator Electronic injection malfunction indicator light If the oil pressure indicator is on, push the motorcycle to a If the electronic injection malfunction indicator light up safe side of the road and turn off the engine, and take the during driving and riding, your electronic fuel injection system following measures: system may have serious problems.
  • Page 71 ABS (Anti-lock braking system) - civil version If any of the following conditions occurs in the ABS fault indicator, indicating that your ABS is faulty. The emergency brake will not be able to provide the anti-lock function, please send it to the special repair shop of KOVEMOTO as soon as possible. ●The ABS malfunction indicator is always on or flashing when riding.

  • Page 72: Puncture

    Puncture If the tire is punctured or damaged, please replace it instead of repairing it, since the repaired tire will not perform as well as a new tire. It may even break while you are riding. Special tools and skills are required for tire replacement. We recommend that such maintenance should be completed by special repair shop ofKOVEMOTO.

  • Page 73: Remove Wheel

    Remove wheel Front wheel If you need to remove the wheel to repair the tire tie, follow these steps. When you remove and install the wheel, be careful not to damage the wheel speed sensor and the ABS ring gear. Remove: Locking bolt - right 1.Firmly support your motorcycle with a service bracket or...
  • Page 74 Install 1.Place the front wheel in the middle of the front shock absorber, place the front wheel bushing (left and right) into the front wheel oil seal (the left bushing is equipped with wheel speed sensor mounting lugs), and clamp the brake discs into the brake caliper. 2.Pass the front wheel axle from right to left through the front wheel, tighten the front wheel axle nut (front wheel axle M16;...

  • Page 75: Rear Wheel

    Rear wheel Install 1.Install the rear wheels in the reverse order of removal to prevent the brake callipers from scratching the wheels during installation. Rear muffler 2. Align the rear wheel hole with the dowel pin on the rear wheel shaft, first install the rear wheel bushing (the bushing shall be coated with grease), and then insert the rear wheel shaft into the rear wheel assembly hole from left to right.

  • Page 76: Electrical Fault

    Electrical fault Blown fuse - competitive version Blown fuse - civil version Spare fuse Spare fuse Triode Triode Electrical fault 1.Remove the left fuel tank side guard plate 2.Open the cover of the fuse box, take out the fuse, and check whether the fuse is blown.If it melts, be sure to replace it with a fuse of the same specification.
  • Page 77 Run out of battery Please use the special charger for motorcycle lithium battery to charge the battery. Remove the battery from the motorcycle before charging. If the battery is not recovered after charging, please contact the special repair shop of KOVEMOTO. Notes It is forbidden to use car battery chargers or motorcycle lead-acid battery chargers for charging, which may cause battery damage or even fire.

  • Page 78: Relevant Information

    Relevant information Instruments, controls and other functions Maintenance of motorcycles Motorcycle storage Transport of motorcycles You and the environment Frame number, engine number, nameplate Catalytic converter...

  • Page 79: Ignition Key

    Ignition key The motorcycle has two ignition keys to start the engine. ●Do not bend the key or subject it to excessive pressure. ●Avoid prolonged insolation or exposure to high temperatures. ●Do not grind, punch or change its shape in any way. Notes ●...

  • Page 80: Instruments, Controls And Other Functions

    Instruments, controls and other functions Mileage meter, milometer (subtotal mileage) Ignition switch, engine OFF switch Ignition switch Odometer 1.In the parking state, please place the ignition switch in the “ ” When the reading exceeds 999,999, the display is locked at 999,999. or “...

  • Page 81: Maintenance Of Motorcycles

    Maintenance of motorcycles Regular cleaning and polishing ensure a long motorcycle lifespan. A clean motorcycle makes it easier to spot potential faults. It is particularly noteworthy that anti-icing seawater and salt scattered on the road can accelerate corrosion. Be sure to clean the motorcycle thoroughly after driving on the coastal or above-mentioned road..

  • Page 82: Cleaning Notes

    Cleaning notes ●Do not use high-pressure water guns: High-pressure water guns can damage moving parts and electrical components, making them impossible to repair. Moisture from the intake port may be sucked into the throttle body or into the air cleaner. ●Do not flush the muffler directly with water: Water ingress into the muffler may cause starting issues and muffler rust.

  • Page 83: Aluminium Components

    Aluminium components Muffler Aluminum will corrode after contact with dirt, mud or salt, The muffler is stainless steel, but it may also be dirty clean aluminum parts regularly, and follow the following because of mud or dust, you can use a wet sponge dipped in a guidelines to prevent scratches: cleaning agent to remove the mud or dust, and then carefully ●Do not use hard brushes, wire balls, or other abrasive...

  • Page 84: Motorcycle Storage

    Motorcycle storage If you leave your motorcycle outdoors, you should consider using a motorcycle full-body shield. If you do not ride for a long time, follow the following guidelines: ●Clean the motorcycle and wax all paint surfaces (except for matte paint surfaces) and apply anti-rust oil to all chrome-plated parts. ●Lubricate drive chain.

  • Page 86: Frame Number, Engine Number, Nameplate

    Frame number, engine number, nameplate When registering a motorcycle, you need to provide the frame number and engine number, which are unique and used to identify your motorcycle. When ordering replacement parts, record these numbers and keep them in a safe place. Engine number Nameplate Frame number...

  • Page 87: Catalytic Converter

    Catalytic converter The motorcycle is equipped with a three-way catalytic converter. Catalytic converters contain precious metals as high-temperature chemical reaction catalysts to convert hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) in the exhaust gas into a mixture that meets regulations.

  • Page 88: Technical Parameters

    Technical parameters Motorcycle related parameters Torque parameters Frame tightening torque...
  • Page 89 Motorcycle related parameters - 1...
  • Page 90 Motorcycle related parameters - 2...
  • Page 91 Torque parameters Notes ● In addition to the specified torque, the motorcycle adopts the standard torque values in the table above.
  • Page 92 Frame tightening torque...

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