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Ossa Explorer 2012 User Manual

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Summary of Contents for Ossa Explorer 2012

  • Page 1 User manual 2012...
  • Page 2 2 User manual...

  • Page 3: Introduction

    We at OSSA Motor would like to thank you for purchasing one of our products. In response to the wishes of motorcycling enthusiasts, Ossa laun- ches an extraordinary model: the new Ossa Explorer 2012.

  • Page 4: Important Warning

    This manual has been put together with the OSSA Explorer current layout. However, OSSA Motor reserves the right to make changes tothis layout without prior notification to consumers. In the event...

  • Page 5: Saferty

    Safety Both your safety and the safety of others are very important when - Never drive if you have consumed alcohol or any type of subs- riding a motorcycle. tance (medication, drugs) that might affect your driving capability. Some important advice for using your motorcycle correctly is de- tailed below.
  • Page 6 6 User manual...

  • Page 7: Table Of Contents

    Contents Introduction Tension adjustments Important warning Lubriction of moving parts 42-44 Saferty Tyres Contents Pressure and condition Technical specifications Control of crankcase oil Recommendations Filling up and draining Brakes Section 1 - Components Torque wrenches Location 12-14 Storage Multi-function box 15-22 Troubleshooting 50-54...

  • Page 8: Technical Specifications

    Technical specifications ENGINE Cylinder size 272,2 cc Type 2 stroke inverted monocylinder with reed box admission Cooling Liquid cooled Bore x Stroke 76x60 mm Injection EFI Kokusan Indirect injection Ignition Digital flywheel CDI Kokusan Clutch Hydraulic Start Battery-assisted kickstart TRANSMISSION Gearbox 6 speeds Transmission...
  • Page 9 340 mm Fuel tank capacity 7,6 litres (2,6 + 5 l.) Dry weight 78 Kg OSSA Factory reserves the right to make modifications without prior notification. Kokusan, Marzocchi, OHlins are registered trademarks and their use is licensed. User manual 9...

  • Page 10: Recommendations

    Recommendations It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order. - 12 hours of running-in is recommended to ensure that the engine works correctly and for a long-lasting time period. - It is important to run the engine for some minutes until it reaches the correct temperature to work correctly.

  • Page 11: Section 1 - Components

    Section 1 - Components User manual 11...

  • Page 12: Location

    Location of elements 1 Front mudguard 2 OSSA multi-function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide 7 Front tyre 8 Front fork bottles 9 Front fork stanchions 10 Shift pedal 11 Chain 12 Chain slider...
  • Page 13 Location of elements 15 Rear break caliper and anti-theft immobilizer 16 Exhaust 17 Kick-start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear brake lever 22 Crankcase protector 23 Front brake caliper 24 Front brake disc 25 Air filter 26 Rear footrests (depen- ding on version)

  • Page 14: Location

    Location of elements 27 Front brake lever 28 Throttle grip 29 Throttle control 30 Front brake pump 31 Front fork servicing cap 32 OSSA multi-function box 33 Clutch pump 34 Lights control pad 35 Clutch lever 36 Headlights 37 Ignition key...

  • Page 15: Multi-Function Box

    Multi-function box The OSSA Explorer multi-function box and the indicator lights next OSSA Multifunction Display to it provide very useful information at all times. The multi-function box is a power box system with an LCD screen controlled by a con- sole with indicator lights, located in the centre of the handlebars.
  • Page 16 Multi-function box Technical features Functions Technical features Symbol Increasess Accuracy Current speed SDP0 4 - 399,9 Km/h o M/h ,1 Km/h o M/h+ /- 0,1% Tachometer 0 - 19999 rpm 10 rpm+ /- 0,1% Tachometer bar 0 - 12000 rpm Variable+ /- 0,1% Maximum speed...
  • Page 17 Multi-function box Functions ODO: Mileage counter It records the distance or total accumulated mileage for the ve- RPM: Bar hicle. The data is stored in the memory, even when the device is Bar graph tachometer. The tachometer bar graph displays up to switched off.
  • Page 18 Multi-function box Adjustment of the multi-function box settings After confirming each value, the multi-function box will move straight on to the next screen adjustment until the process is complete. If no button is pressed, the multi-function box will return to the initial screen after 15 seconds. Activation of the adjustment mode Select the speed unit To activate the adjustment mode...
  • Page 19 Multi-function box Adjustment of the revolution pulse Time adjuster (PPR) Set the time by pressing button The indicator receives an elec- 1 repeatedly. To move to the tric pulse each time the engi- next digit, press button 3. Con- ne turns (PPR). Default value firm the selection by pushing for 2 and 4 stroke engines: 1 button 2.
  • Page 20 Multi-function box Temperature selector Warning temperature selector select unit Note: temperature,either ºC or ºF, This stage should only be imple- press button 1. Confirm the mented for those vehicles that selection by pressing button 2. have an optional temperature sensor. When the motorcycle temperature exceeds the set va- lue, the left-hand warning light comes on.
  • Page 21 Multi-function box Dangerous turn rate selector Setting the whole multi-function box to zero When the set rate is near to be- Press the RESET button by using a suitable object. The indicator ing reached, the right-hand war- will boot again, excluding data that corresponds to total accumu- ning light will flash, indicating lated that the engine is turning at an...

  • Page 22: Multi-Function Box

    Multi-function box Screen Options When it is connected to the 12V vehicle installation, the illumina- The multi-function box displays all information on three different tion will be brighter and will remain constant for 20 minutes after screens. While on, it is possible to see screens 1 or 2. Screen 3 is the vehicle has stopped.

  • Page 23: Control Pad

    Control Pad Control Pad The control pad is located on the left handlebar, within reach of the thumb. This control pad can be used to control the lights, indicators, horn and engine stop. See the image with information about the control pad. 1 –...

  • Page 24: Air Bleed

    Suspension The front suspension is made up of a fork that fixes the wheel and The rear suspension is formed by a single shock absorber the front brake system in place. This fork is formed by the suspen- spring. The preloadof this spring can be adjusted by turning the sion bars that contain the shock absorber spring and the suspension toothed rings that dictate its direction.

  • Page 25: Seat

    Seat In order to access some parts of the engine or the wiring, you must previously remove the seat. 1: First, you must open the rear seat lock with the ignition key. 2: Then you must pull the back of the seat upwards and then bac- kwards, as in figure 2.

  • Page 26: Anti-Theft Immobilizer

    Anti-theft immobilizer The Explorer has an immobilization system for protection against IMPORTANT: this key has a code which is needed for theft. making duplicate copies of the key. This code should be written down in the indicated space on the regis- This system consists of a lock situated in the area of the brake tration page and series number of this manual.

  • Page 27: Start Lever

    Kick start pedal Before starting the motorcycle, you must ensure that the key If the motorcycle has been inactive for a long period of time, switch at the right hand side of the headlight is activated. Also, its recommended that the kick-start pedal is activated gently it must be in neutral gear.

  • Page 28: Fuel Tank

    Fuel tank The engine of this motorcycle works with a mix- ture of unleaded petrol and 2S oil, 100% syn- thetic in a 0.9 proportion. Filling lid The Explorer has two fuel tanks, one forms a struc- tural part of the chassis and is located on the front Upper fuel tank inside part.
  • Page 29 Fuel tank In order to access some parts of the engine or the wiring, you must previously lift the upper fuel tank. 1: First you must remove the seat. (see page 25, Seat) 2: Unscrew only the four upper screws of the side tank pannels. 3: Disconnect the air hose located in the front of the upper fuel tank.
  • Page 30 Fuel tank In operation No. 2 (Unscrew only the four When performing the operation No. 4 (Disconnect upper screws of the side tank pannels) never the connector that connects the two fuel tanks), You release the screws that attach the pannels to must mind the existence of residual fuel in the quick the radiator, as it could pierce it or eventually connector.

  • Page 31: Section 2 - Maintenance And Basic Operations

    Section 2 – Maintenance and basic operations User manual 31...

  • Page 32: Maintenance Grid

    Maintenance grid – Engine Item Replace / Change Grease / lubricate Check / Inspect Adjust Clean When damaged Air filter Each use Each useE ach wash Transmission oil 30 Hours 60 horas Refrigerant Each use Each year 60 Hours Sparkplug Each use 30 Hours 15 Hours...
  • Page 33 Maintenance grid - Cycle Item Replace / Change Grease / lubricate Check / Inspect Adjust Clean Rear shock absorber Each year Every 2 years Front suspension Each year When necessary Every 2 years 60 Hours Front suspension lubricant Brakes Each useW When necessary hen damaged Swing arm and linkage arms...

  • Page 34: Adjustments To The Motorcycle Controls

    Adjustments to the motorcycle controls The clutch lever is located on the left handlebar grip and is used to activate the clutch mechanism to change gear. The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake. min.

  • Page 35: Electrical Connections

    Electrical connections Check the condition of the motorcycle’s electrical connections in order to ensure they are maintained in good working order. As seen in the image on the right, these are located at the left side of the cylinder, between the steering bar and the front headlight, and in the fuel system apparatus.

  • Page 36: Simplified Lighting Wiring Diagram

    Simplified diagram of the lights wiring 36 User manual...

  • Page 37: Simplified Injection Wiring Diagram

    Simplified diagram if the injection installations User manual 37...

  • Page 38: Air Filter

    Air filter Air filter. Cleaning and maintenance The air filter should be controlled periodically. Lift the upper fuel tank, as you can see in the image on page 29, in order to access the filter box. Remove the sensor on the filter base and the clamp. Then remove the filter, according to the illustration.

  • Page 39: Radiator

    Radiator The radiator contains the engine coolant. To fill up with or add To fill the radiator, special coolant should be used coolant to the radiator, locate the tank lid. To locate this lid, -30ºC. lift the upper fuel tank (see pag. 29, Fuel tank). Once the tank is lifted the radiator lid is visible.

  • Page 40: Sparkplug

    Sparkplug To access the sparkplug detach the right side cover (see fig. 1). Once the cover has been removed, the motorcycle’s electrical sys- tem can be accessed. Carefully but firmly, pull away the hood that provides current, leaving the upper part of the sparkplug exposed. Using a special sparkplug tool, unscrew it and take it out from the right side of the motorcycle (see fig.

  • Page 41: Tension Adjustments

    Cadena - Reglajes de tensión The transmission chain transmits the engine’s movement to the rear wheel. To ensure that is works correctly, it should be checked. The axle has easily adjustable eccentrics for ten- sing the chain and centring the wheel. The chain hook should be positioned in an oppo- site direction to the gear, as can be seen in the photo.

  • Page 42: Lubrication Of Moving Parts

    Lubrication of moving parts Cleaning the motorcycle and lubricating the mobile parts will help protect the motorcycle and guarantee that it works better. If using a high pressure hose to clean the motorcycle, bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle.
  • Page 43 Lubrication of moving parts The chain drive should always be well lubricated. Check it each time the motorcycle is used and apply lubrication when necessary. The chain must be lubricated using special oil for chain Gear change lever joints Chain drive Rear brake pedal Chain drive joints and bearings User manual 43...
  • Page 44 Lubrication of moving parts Footrest bracket and springs Chain drive and tension adjuster springs Engine kick-start pedal joints Gas handle (right grip) 44 User manual...

  • Page 45: Tyres

    Tyres Pressure and condition To ensure that the motorcycle works correctly, it’s very important to check the tyre pressure and that the wheels are in good working condition before each use. Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability.
  • Page 46 Checking the crankcase oil Filling and draining the crankcase IMPORTANT: Clean the plug and change the sealing washer each time the oil is changed. Crankcase oil is used for lubricating the change pedal and the clutch. Check the oil level with the indicator located on the lower The crankcase has a 375cc oil capacity.

  • Page 47: Brakes

    Brakes The brakes permit precise and controlled riding. It is necessary to check them in order to ensure that they work correctly. Wear on the front and rear brake pads must be periodically controlled so that the brakes work effectively. The oil level can be checked using the indicator on the front handle and on the rear pump tank.

  • Page 48: Torque Wrenches

    Torque wrenches These grids show the pressure that should be used to tighten parts. CHASSIS ENGINE Part N-mN Part Front wheel axle 40 - 50 Sparkplug 70 - 80 7 - 8 40 - 50 7 - 8 40 - 50 40 - 50 7 - 8 Handles...

  • Page 49: Storage

    Storage Storage Starting the motorcycle again If the motorcycle is to be stored for a long period of time, the fo- To start up the motorcycle after a period of inactivity, the following llowing procedure should be followed to ensure that it is stored co- procedure should be followed: rrectly.

  • Page 50: Troubleshooting

    Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The engine won’t start - Long period of engine inactivity - Change the old petrol for new petrol - Sparkplug dirty or wet - Dry / clean or change the sparkplug - General fuse damaged - Change general fuse - Bad electrical connection - Check electrical connections and position correctly...
  • Page 51 Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION - Move wire or loosen it a bit - Wire makes it difficult for the han- dlebar to turn - Loosen the steer axle screw The motorcycle is unstable - Steer axle screw is very tight - Replace steering bearings - Steering bearings are damaged or with wear...
  • Page 52 Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION - Too little oil in front fork - Add oil to the fork until it reaches a sufficient level The shock absorption is too soft - Front fork oil not sufficiently viscous - Drain fork oil and fill up with suitably viscous oil - Front fork bent - Change the front fork.
  • Page 53 Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION - Replace the damaged cylinder - Cylinder damaged - Check and adjust using suitable torque wrench - Supports, screws or nuts are not pro- The motorcycle makes abnormal perly fastened noises - Change worn parts for new parts - Tyres wear, swing arm or its needle bearings wear - Centre wheel rim...
  • Page 54 Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION -Chasis torcido. -Cambiar el chasis. Ir a un taller especializado. -Dirección mal ajustada. -Ajustar dirección. Ir a un taller especializado. La moto tiende a inclinarse a un lado -Eje de dirección torcido. -Cambiar eje dirección. Ir a un taller especializado. -Horquilla delantyera torcida.

  • Page 55: Registration, Series Number And Key

    Standardisation components User manual 55...
  • Page 56 Standardisation components Your Ossa Explorer is standardised in compliance with UE regulations. It adheres to all standardisation requirements EURO-3 regula- tions. The obligatory elements to be registered for driving on public roads and for passing the vehicle’s MOT are listed below.
  • Page 57 2 people). Each of the registered elements should be part of the vehicle. In the event of breakages, loss or bad functioning, it is recommended that you go to an official OSSA mechanic to remedy the problem. User manual 57...
  • Page 58 Standardisation components Element Homologation identification 1. Front headlight 11/12-e9*97/24*97/24/*4367*00 Front position lamp R55.00.14839 Driving beam R113.00.14839 Passing Beam R113.00.14839 2. Front indicators 11001200e94367 3. Rear indicators 11001200e94367 4. Rear pilot e13*50 R00*50R00*12448*00 5. License plate support 6. Reflector IA.E9.02.01269 7. Mirror L-e9*80/780*80/780*0143*01 8.
  • Page 59 Standardisation components Manufacturer’s plate Serial number User manual 59...
  • Page 60 Standardisation components El número de llave se encuentra marcado debajo del tapón rojo, se debe retirar para ver el número. Engine number Key number 60 User manual...

  • Page 61: Warranty Conditions

    Warranty User manual 61...
  • Page 62 The warranty is associated to the product indicated in the “CERTIFICATE OF DELIVERY AND INSPECTION”, which shall be filed out by authorised staff in OSSA FACTORY, SL (hereinafter referred to as OSSA). It is valid for those countries indicated on page 33. The warranty is only applicable to motorcycles that have been initially imported via the official OSSA importer for your country, meeting all the regulatory requirements and authorisations of each country.
  • Page 63 Warranty The repair is disproportionate when it is uneconomic, or when the reparation is more expensive than the value of the product. If this oc- curs, the purchaser can choose between a price reduction or contract resolution. Resolution is not permitted when the non-compliance is insignificant.
  • Page 64 WARRANTY FOR SPARE PARTS AND/OR ACCESSORIES This warranty covers the repair or exchange, at the discretion of OSSA, of any original part due to faulty material or fabrication. The ma- terials and/or labour will be free of charge. Other damages are not included in the warranty, nor are repairs included that appear due to the replacement of the original part.
  • Page 65 OSSA (maximum load, passenger capacity, speed of motor and others) Damages due to the use of parts that are not original or not recommended by OSSA, or the use of fuel, lubricant and compound liquids with specifications that are different to those indicated in the Owner’s Manual.
  • Page 66 Any part replaced under warranty will become the legitimate property of OSSA. The parts replaced during the period of warranty will be guaranteed for the time remaining for the substituted part. OSSA reserves the right to introduce modifications and improvements it deems appropriate for all its models.
  • Page 67 This means that your motorcycle will receive all the benefits of the OSSA warranty. It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was purchased, where both you and your motorcycle are known.
  • Page 68 Procedure for obtaining repairs under warranty If your motorcycle needs a repair to be carried out under warranty, it should be taken to your official OSSA dealer where the repair will be made (YOU ARE RESPONSIBLE FOR THE TRANSPORT COSTS TO AND FROM THE DEALER).

  • Page 69: Final Considerations

    Final information We recommend that you stay in contact with your OSSA dealer so that you can receive help, advice and information about your new motorcycle, as well as information about the new products laun- ched by OSSA Factory, SL.
  • Page 70 Ossa Motor Carretera antiga d’Amer, nau 12 17007 Girona, Spain tel 0034 972 107 107 fax 0034 972 117 899 70 User manual...

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