MadAss 125 Owners Manual GB

8/8/2019 MadAss 125 Owners Manual GB

1/84


2/84

125 owners manual


3/84


4/84

PREFACE

Reprinting, reproduction and translation,even of excerpts, without our expressconsent is not permitted. All rights stipula-ted in the copyright law remain expresslyreserved.

Technical changes to the standard motor-cycles can cause the EC type approval tobecome invalid. Therefore before imple-menting a change, ask a specialized dealerwhether this is allowed.

We cannot be held liable for any conse-quential damage caused by accessoriesnot approved by the factory.

The scope of delivery and version of the mo-torbike is solely determined by the purchase

agreement concluded with the dealer.

This operating manual includes importantinstructions for handling your light motor-cycle. Read it carefully, because professi-onal handling combined with regular careand maintenance helps to maintain themotorbikes value and is one of the require-ments for warranty claims.

We wish you at a ll times a safe journey.

YourSACHS Fahrzeug- und Motorentechnik GmbH

You have purchased a Sachs MadAss,congratulations and thank you forputting your trust in us.

The MadAss is a sturdy motorcycle in mo-dern design.

Its sound construction, the meticulousselection of materials, the advanced ma-nufacturing techniques and conscientiouswork of dedicated employees provides themotorcycle with all the characteristics thatare typical of Sachs, such as economicaloperation, quality, reliability and its lastingvalue.

Sachs GmbH is continuously involved inthe further development of all types andmodels. We therefore ask you for your kindunderstanding that we reserve the right tochange the scope of delivery with respectto appearance, equipment and technology.

No claims can thus be derived from thedata and descriptions contained in thisinstruction manual.


5/84

1

CONTENTS

RIDING INSTRUCTIONSRide safely ............................................................................... 22Ride economically and be aware of the environment .............. 23Running-in instructions ............................................................ 24Side stand ................................................................................ 25Starting .................................................................................... 26Starting with kick star ter .......................................................... 27Starting with electric starter ..................................................... 28Riding, Shifting gears .............................................................. 29Braking ............................................................................... 30-31Stopping the engine ................................................................. 32

Steering lock ............................................................................ 32

SERVICE INSTRUCTIONSServicing the motorbike / cleaning agents .......................... 33-34Operation in winter and anti-corrosion protection .................... 35Repairing paint damage / servicing the tyres .......................... 35Lay-up / commission ................................................................ 36Technical changes, accessories and spare par ts .................... 37

OVERVIEW AND OPERATIONSafety symbols .......................................................................... 3Chassis number, engine number ............................................... 3Side view ................................................................................ 4-5Engine ....................................................................................... 6Handlebar ttings ....................................................................... 7Cockpit ....................................................................................... 8Ignition lock ................................................................................ 8Speedometer set-up, time adjustment ....................................... 9Speedometer battery change .................................................. 10

SAFETY TESTChecklist .................................................................................. 11Clutch ...................................................................................... 12Fuel, fuel tank .......................................................................... 13Fuel tap .................................................................................... 14Engine oil ................................................................................. 15Checking the oil level ............................................................... 16Brakes ................................................................................ 17-18Drive chain ............................................................................... 19Tyre prole, tyre pressure and size .......................................... 20Load / lights ............................................................................. 21


6/84

2

CONTENTS

NOTES ON MAINTENANCEChecking steering bearing .......................................................38Checking the telescopic fork and shock absorber ...................38Adjusting the shock absorber ..................................................39Removing the front wheel ........................................................40Installing the front wheel ..........................................................41Removing the rear wheel .........................................................42Installing the rear wheel ...........................................................43Checking, adjusting the drive chain ....................................44-45Front wheel brake ....................................................................46Rear wheel brake ...............................................................46-47Adjusting the clutch lever .........................................................48Cleaning the air lter ................................................................ 49Cleaning the fuel lter ..............................................................50Adjusting the play of the twist grip throttle control ...................50Spark plug ............................................................................... 51Battery ................................................................................52-53Cheching the fuse .................................................................... 54Changing the bulbs ............................................................55-57

Adjusting the headlamps ......................................................... 58

TECHNICAL DATAEngine ..................................................................................... 59Power transmission ................................................................. 60Chassis .................................................................................... 61Lubricants and operating uids ............................................... 62Electrical Equipment ................................................................ 63Dimensions and weights .......................................................... 64

WARRANTY AND SERVICE DATAWarranty conditions ................................................................. 65

List of wear par ts ................................................................ 66-67Inspection plan ................................................................... 68-70Maintenance conrmation .................................................. 71-75Motorbike data / Rating plate ................................................... 77


7/84

3


8/84

4

2

5

1

7

43

6

89

Right-hand side view

1 Brake uid reservoir rear brake

2 Brake uid reservoir front brake

3 Chassis number and rating plate4 Fork column lock

5 Footbrake lever, rear brake

6 Footrest

7 Kick starter

8 Battery and fuse

9 Pillion footrest, fold-up

OVERVIEW AND OPERATION


9/84

5

11

10

12

13

1516 141718

10 Cockpit

11 Handlebar ttings

12 Tank cap13 Adjustment shock absorber

14 Pillion footrest, fold-up

15 Side stand

16 Footrest

17 Gear shift pedal

18 Air lter housing

Left-hand side view



10/84

6

5 4

7

32

1

6

11 10

8

9

1 Intake valve adjuster cover2 Exhaust valve adjuster cover

3 Spark plug connector

4 Electric starter

5 Oil drain plug

6 Clutch cover

7 Oil ller cap

Engine right-hand side view

8 Carburetor9 Fuel tap

10 Engine number

11 Gear shift pedal

Engine left-hand side view



11/84

7

89

1012

111

2

6

3 54

7

A

B

8 Emergency off switchengine will not startengine starts

9 Handbrake lever

10 Throttle

11 light switch

off

position light

driving light

12 Starter button

Right-handle handlebar ttingsLeft-handle handlebar ttings

1 Fixed grip2 Clutch lever3 Head light switch

High beam

Low beam4 Head light signal

5 Choke lever ( )Operating positions:

A Cold startB Warm start

6 Direction-indicator switch

Switch to the left:Left indicator onSwitch to the right:Right indicator onPush button for switch off

7 Push-button: horn



12/84

8

1

22

1

4 5

637

Ignition-lock

NOTEThe ignition-lock as well as the tank cap areoperated with the same key.Key positions

1 Operating position: ignition and allcircuits activated.

2 Ignition off.

WARNINGWhile riding, do not switch the ignition

off !

NOTEActivate the parking light only for a limitedperiod. Take into account the charge of thebattery.The key can be removed in positions .

Cockpit

1 Speedometer2 KM/H -odometer

3 DST - total distance (km)TRIP- trip meter

Instrument lights4 left direction indicator green

5 right direction indicator green

6 high beam blue7 Change-over gear Neutral green



13/84

9

S M

0KMH

0DST

S M

0KMH

12 : 00CLK

S M

0 KMH

11 : 55CLK

S M

Speedometer set-up

NOTEThe display is only visible when the ignitionis on.M Mode for:

DST = total distance (km)TRIP = trip odometerCLK = clock time

S Set for clock time and to clear tripodometer

Button M press once changing from DSTto TRIP or to CLK

Button S press in TRIP Mode to clear thetrip odometer to zero

Button M press untill the clock time (CLK)appears

Button S press once, the hour valueashesThe hour value can be set bypressing button M

Button S press once the minute valueashes

The minute value can be set bypressing button M

Button S press once, the time is set and( : ) ashes.

Speedometer time adjustment



14/84

10

3

45 6

7 7

1 1

2

3

4

Speedometer battery change

NOTEIf the ignition is turn off the clock is suppliedby the battery power. Always replace bothbatteries.After disconnecting and reconnecting thebattery the clock time needs to be reset.

- Remove the screws (1) and take off thespeedometer (2).

- Remove the screws (3 + 4) and take offthe cover (5).

-

Replace the batteries (6) by using newbatteries, type AG 13.

- Set-in the batteries with the plus termi-nal (+) showing upwards.

- Insert the O-rings (7) and close thecover proper ly.

DISPOSALTake a dead battery to a collection point.Never dispose of one with householdrefuse.



15/84

11

Before each ride, carry out a safetycheck using the checklist.Take the safety check seriously. Carry outmaintenance activities before you startyour ride ( MAINTENANCE) or ask aspecialized Sachs dealer to do so. This willprovide you with the certainty that your mo-torcycle corresponds to trafc regulations.A technically faultless motorcycle is a basicrequirement for the safety of both yourselfand other road users.

Before starting your ride, check the fol-

lowing: Steering (smooth and free of play)

Clutch lever play

Fuel quantity

Engine oil (level)

Front brake

Rear brake

Tyres (prole and pressure) Telescopic fork

Load / lights

Total weight

Lights

Clutch operation

Brake uid (level) Brakes (operation)

In case of problems or difculties, contact aSachs dealer, who will do everything pos-sible to assist you.

WARNINGWhile the engine is running or the ig-nition is on, do not touch the ignitionsystem.

FIRE HAZARDThe exhaust system becomes very hot.While riding, idling or parking, make surethat no inammable materials (e.g. hay,leaves, grass, coverings or luggage, etc.)can come into contact with it!

Important notes for the operation witha catalyst.The catalyst. is designed for a optimal

performance and l i fet ime.Note thefollowing:

- Operate a catalyst. bike only with leadfree fuel.

- Dont turn off the ignition if the bike stillrolls.

- Dont drive on at misring, decline inperformance and poor engine run.

- In case of problems, contact the nextSachs dealer.

- Longer starting tests by moving the bikein cold or warm operating state should berefrained.

At the mentioned operating states unburnedfuel can reach the catalyst., burn and causeoverheating of the exhaust system.

SAFETY TEST

Checklist


16/84

12


17/84


18/84

14

R

A

Z4

R

A

Z

SAFETY TEST

Fuel tap

CAUTIONWhen you stop the engine, always setthe fuel tap to position CLOSE. Oth-erwise, fuel could enter the engine andthis could make starting difcult or leadto serious engine damage.We cannot be held liable under theguarantee for damage caused by non-observance of this caution.

Fuel tap (4)Fuel tap positions:A = OPEN

fuel tank will empty down to areserve quantity of approx.0,35 litres

R = RESERVEfuel tank is drained. There is aremaining quantity which can

not be used.

Z = CLOSEDfuel supply closed.


19/84

15

-10 0 10 20 3040 C- 20

SAE 10W/30

SAE 10W/40 10W/50

SAE 15W/40 15W50

SAE 20W/50

Engine oil

CAUTIONDo not use additives. Since the oil

also serves to lubricate the clutch,do not use car engine oils supple-mented with friction modifiers (suchenergy-conserving oils can lead to theclutch slipping). Use a suitable, lightengine oil for motorcycles, such asMotorex SAE 15W/40 mineral oil API (SGor higher).

Recommended grade:Per API: SG or higher or also with additionalrelease status: ACEA A3/96 (CCMC G5).

Recommended viscosity:

Viscosity depends on the outside tem-perature. For short while, the temperaturemay exceed or fall short of the limits of theSAE grades.

The recommended viscosity grade SAE15W/40 covers the ambient temperaturerange 15 C to +40 C and thereforerepresents the optimum for our latitudes.

SAFETY TEST

- If required, replenish the engine oil(for classification and viscosity, seethe table) via the oil-filler openingup to the maximum level marking.


20/84

16

MAX.

MIN.

1

SAFETY TEST

Checking the oil level

CAUTIONChecking the oil while the engine is coldwill lead to a wrong measurement andtherefore the wrong oil quantity. In orderto avoid engine damage, never exceedthe maximum oil level nor let it dropbelow the minimum level.

- Stop the warmed-up engine, wait for ap-prox. 5 minutes and hold the motorcycleupright.

NOTEMake sure that the motorcycle during oil-level checks stands level in all respects.Even the slightest inclination towards theside will produce measurement errors.

- Stop the engine and remove the oil llercap (1) on the lower right of the crank-case.

- Clean the oil ller cap at the MIN-MAXaera with a clean rag.

CAUTIONFor checking the oil level only insert theoil ller cap and don't screw in!Otherwise there will be a wrong mea-surement in order to avoid enginedamage.

- The oil level must be between the mini-mum and maximum marks.

If required, replenish the engine oil SAE15W/40 via the oil-ller opening of the oilller cap.

- Tighten the oil ller cap by hand.


21/84

17

1

UPPER

LOWER

LOWER UPPER

2

SAFETY TEST

WARNINGSudden changes in play or a spongy

feel of the brake lever can be caused byfaults in the hydraulic system. Do notride on when in doubt about the oper-ability of the brake system. Immediatelyconsult a Sachs dealer.

Check the brake-uid level

WARNINGEvery two years, the brake uid must

be changed by a Sachs dealer. Thelevel must not drop below the MIN mark.Use only brake uid of the DOT 4 clas-sication.If air bubbles can be seen, check thebrake linings for wear; if necessary,replenish the brake uid.

CAUTIONDo not spill any brake uid on painted

or plastic surfaces as it will demage thesurface severely.

- Turn the handlebars until the brake-uidtank (1) is level.

- The brake uid level should be betweenthe minimum (MIN) and the maximummarking (MAX).

Front brake-uid tank Brakes Rear brake-uid tank

- Park the motorbike horizontally.

- The brake uid level should be betweenthe minimum (MIN) and the maximummarking (MAX) on the brake uid tank(2).


22/84

18


23/84

19

A

SAFETY TEST

Drive chain

CAUTIONThe chain setting affects the wear on thedrive chain and sprocket as well as thespring excursion of the rear wheel.Regularly clean and lubricate the drivechain.Check the chain setting and the drivechain for damage before each run.

Check the chain tension- Shift the gear to neutral.

- Prop the motorbike up on the sidestand.

- Let the motorbike rear end drop to thelimit imposed by the suspension.

- Push in the drive chain from the top halfway between the sprocket and pinion.Measure the travel.

Required value: A =30-35 mm

- Adjust the drive chain is necessary.

MAINTENANCE


24/84

20

2

1

SAFETY TEST

Checking the tyre pressure

WARNINGAdjust the tyre pressure according tothe total weight load. Never exceed therated total weight or the bearing capacityof the tyres.Incorrect tyre pressure will have a con-siderable effect on the riding propertiesof the motorbike and the lifespan of thetyres.

- While the tyres are cold:- Twist off the valve caps.- Check/adjust the tyre pressure.- Twist on the valve caps.

Tyre pressure Solo Withpassenger

Front 2.2 bar 2.2 barRear 2,5 bar 2.7 bar

Tyre prole

The standard motorbike is provided with thefollowing tyre sizes:

Front 90/90-16 48J

Rear 120/80-16 60J

WARNINGUse only tyres approved by the manu-facturer. The use of non-approved tyrebrands, types or sizes leads to the op-erating permit of the vehicle becomingnull and void. Use only pairs of tyresproduced by the same manufacturer.

Tyre pressure Tyre size

Checking the tyre proles

WARNINGObserve the minimum profile depthprescribed by law.Never ride without valve caps (2) . Firmlytightened valve caps prevent the tyrefrom suddenly losing pressure.

- Measure the prole depth at the centre(1) of the tyres tread.

Recommended minimum profile depth:Front 2.0 mmRear 2.5 mm


25/84

21

SAFETY TEST

Load / lights

WARNINGFor the sake of your safety, use only

original Sachs accessories or productsreleased by Sachs.Sachs cannot judge for each third-partproduct whether it can be safely used incombination with your Sachs motorcycle.Nor can a ofcial approval give such aguarantee in all cases, since the test scopeis not always sufcient.

NOTESachs accessories and Sachs-approvedproducts as well as qualied advice areavailable from all specialized Sachsdealers.

Correctly loaded- Make sure that the left-right weight

distribution is balanced.

- Check that fastenings are correct andtight.

- Do not transport bulky loads.- Do not cover the lights.

WARNINGThe total allowable weight of 300 kg maynot be exceeded.Adjust the telescopic forks and tyre

pressures to the total weight.

Checking the lights

WARNINGBefore any ride, check the operation ofall lighting components.- Check that the headlamps and lenses are

clean.

Adjusting the headlamps

MAINTENANCE.


26/84

22

RIDING INSTRUCTIONS

Ride safely

CAUTIONRiding safety is largely also determined

by the manner of riding.

Therefore:

Put on a tested/approved safety helmetand correct close the buckle.

Wear suitable protective clothes. Rest your feet on the footrests. Do not ride if your riding ability has been

compromised.

On smooth, slippery roads take into accountthat your riding stability and braking powerare limited by the grip of the tyres on the

road top.

Your reactions can be adversely affectednot only by alcohol, but also by drugs andmedicines.

Strictly observe all trafc regulations. Always adapt your riding speed to the

trafc and road conditions.


27/84

23

RIDING INSTRUCTIONS

Ride economically and be aware of the environment

Fuel consumption, environmental pollutionand wear of engine, brakes and tyres de-pend on various factors.

Your personal riding style is highly deter-minant for economical fuel consumptionand exhaust gas and noise generation.While idling, the engine takes a long timeto warm up to operational temperature. Inthe warm-up phase, however, the wear leveland pollutant emissions are very high. It istherefore best to start riding immediatelyafter start-up.

Avoid rapid accelerationOpen the throttle not further than needed,in order to reduce fuel consumption as wellas pollution and wear levels.Do not use excessive revs; change up assoon as possible and do not change downuntil it is necessary to do so.

Ride as evenly as possible and look ahead as far as possible.Unnecessary acceleration and hard brakingcause high fuel consumption and increasedpollution levels.

Turn the engine off when waiting intrafc.Different riding conditions affect fuel con-

sumption. The following conditions areunfavourable for fuel consumption:- High trafc density, especially in big cities

with many stops for trafc lights.- Frequent short rides with repeated starts

and warm-ups of the engine.- Riding in a column of motor cycles at low

speed, meaning riding with relatively highrevs.

Plan rides ahead of time in order to avoidheavy trafc.

Fuel consumption is also affected byconditions that are out of your control, forinstance, poor road condition, hills, riding

in winter.

Observe the following aspects for eco-nomical fuel consumption:- The planned inspection intervals must be

closely observed.- Regular service by a specialized Sachs

dealer will guarantee not only continuedoperability, but also economical fuelconsumption, low environmental pollutionand a long lifespan.

- Check the tyre pressure every twoweeks.

Low tyre pressure increases rolling resis-tance. This increases fuel consumptionand tyre wear and adversely affects ridingbehaviour.- Continually check fuel consumption.- Frequently check the engine-oil level.


28/84

24

RIDING INSTRUCTIONS

Running-in

Running-in instructions for engineand transmission

CAUTIONExcessive revs while running-in the en-gine increases the wear of the engine.Engine faults during the running-inperiod must be immediately reported toa specialized Sachs dealer.

NOTEDuring the running-in period, ride in fre-quently changing load and rpm ranges.Select winding and slightly hilly routes.Avoid constantly low rpm counts and fullthrottle under load.

Running-in new tyres

CAUTIONNew tyres have a smooth surface. Theymust therefore be roughened by care-fully running them in at various slantedpositions.Only then will the surface obtain its fullgrip!

Running-in new brake linings

WARNINGNew brake linings must be run-in andwill not have their full friction power untilafter 500 km.The slightly reduced braking effect canbe compensated for by an increase inthe pressure on the brake lever.During this period, avoid unnecessaryhard braking actions!

- During the rst 800 km:Less than 1/2 throttle.

- Up to 1.600 km:Less than 3/4 throttle.

CAUTIONThe rst inspection must be carried outimmediately after the rst 1.000 km.

You can save yourself delays by makingan appointment with a specialized Sachsdealer in advance.

- 800 to 1.600 km:Slowly increase the revs. Up to 1.600 km,avoid longer rides under full load.


29/84

25

RIDING INSTRUCTIONS

Side stand

- Switch off the engine.

- Left hand on the left-hand handle-

bargrip.- Right hand on the seat.

- Fold out the arm of the side stand as farforward as it will go and stop by foot.

- Slowly tilt the motorbike to the left until itsweight is supported.

CAUTIONThe motorbike is equipped with a sidestand switch.If the side stand is folded up and a gearis shifted the ignition will be discon-nected.The engine is shoot off and will notstart.

Propping up the motorbike on the sidestand.

WARNINGAlways make sure that the stand isresting on rm ground. On sloping roads,always park the motorbike facing uphilland in 1st gear.

It is essential that the side stand isfolded up before starting off! -Risk ofaccidents !


30/84

26

R

A

Z12

3

RIDING INSTRUCTIONS

Before starting- Put the motorcycle it in a vertical positionand fould up the side stand.

- Turn the fuel chock (1) to positionA = ON orR = RESERVE

- Mount the motorcycle.

- Turn the ignition key (2) to its operatingposition .

WARNINGBefore beginning a ride, the side standmust be tilted up all the way (danger ofcrashing).

Starting

- Shift the foot-operated gear lever (3) toneutral.

NOTEOnce you have shifted to neutral, the greenneutral indicator light must become active.


31/84

27

1

A

B

3

2

4

RIDING INSTRUCTIONS

Starting with kick starter

CAUTIONAvoid high engine-speed counts aftera cold start.- Turn the CHOKE (1) in the direction

of the arrow "A" for cold start.- Do not open the throttle (2).- Depress the kick starter lever (4) quickly

and the engine will start.

CAUTIONAfter starting the engine, check thatthe kick starter lever is returned to itsnormal position.

- As soon as the engine is no longer run-ning smoothly, turn back the CHOKE (1)in position "B".

- When the operating temperature is in-creasing, turn back the CHOKE all theway in the opposite direction to the arrow"B".

WARNINGNever allow the engine to run in an en-

closed space. Exhaust gases are highlytoxic and can kill.

CAUTIONThe EMERGENCY OFF switch (3) is asafety device and should normally bein position .

ON:Switch downwards. The engine will startwhen the kick starter lever is used.

OFF:

Switch upwards. The engine will not start.


32/84

28

5

34

1

A

B

2

RIDING INSTRUCTIONS

Starting with electric starter

CAUTIONAvoid high engine-speed counts after acold start. The starter is active only withpulled clutch lever.

- Turn the CHOKE (1) in the direction ofthe arrow "A" for cold start.

- Do not open the throttle (3).

- Pull in the clutch lever (2).

- Operate the start button (4).

CAUTIONIf the engine wont start immediately,release the start button, wait a few sec-onds and push it again. Each time, pushthe start button for just a few seconds inorder to save the battery. Never push thestart button for more than 10 seconds.

- As soon as the engine is no longer run-ning smoothly, turn back the CHOKE (1)in position "B".

- When the operating temperature is in-creasing, turn back the CHOKE all theway in the opposite direction to the arrow"B".

WARNINGNever allow the engine to run in an en-closed space. Exhaust gases are highlytoxic and can kill.

CAUTIONThe EMERGENCY OFF switch (5) is asafety device and should normally bein position .

ON:Switch downwards. The engine will startwhen the electric starter is used.

OFF:Switch upwards. The engine will not start.


33/84

29

2

1

Riding, shifting gears

RIDING INSTRUCTIONS

CAUTIONAvoid: Crashing the gears Changing gear without operating the

clutch Changing down at high rpm's Too low and too high rpms (unnec-

essary wear and fuel consumption).

Starting / shifting up- Pull in the clutch lever (1).

- Push down on the foot-operated gearlever (without opening the throttle).

- Carefully engage the clutch.

- Simultaneously slightly open the throttle(2).

- Accelerate after engaging the clutch.

Shifting up to gears 2, 3 and 4 is donesimilarly.

Shifting down- Close the throttle.

- Adapt your riding speed.

- Pull in the clutch lever.

- Push down on the foot-operated gearlever.

- Accelerate after engaging the clutch.

- When stopping, change into neutral (con-trol light N in cockpit lights green).


34/84


35/84

31

1

2

RIDING INSTRUCTIONS

Braking

BrakingThe front brake and rear brake are operatedindependently from each other. The frontbrake is operated via the handbrake lever(1) on the handlebars, and the rear brake isoperated by stepping on the footbrake lever(2) with the right foot.

When stopping or slowing down, releasethe throttle gas and operate both brakesat the same time.On tight curves, sandy / dirty streets, wetasphalt and icy roads, use the front brakecarefully: if the front wheel locks, the bikewill slide sideways.

Brake with care. Locked wheels do not havemuch braking effect and can lead to skid-ding / crashing. In principle, do not brake

on a curve, but before the curve.Braking on a curve increases the dangerof sliding.


36/84

32

R

A

Z2

1

1

RIDING INSTRUCTIONS

Stopping the engine- Turn the ignition key to the position

(1).- Pull out the ignition key.

CAUTIONTurn the fuel chock (2) to the OFFposition (Z). In the ON (A) or RES (R)position, fuel could enter the engine,leading to serious damage when start-ing the engine.

Non-observance of this caution will leadto the guarantee becoming null and voidfor any damage attributable to such.

Stopping the engine Steering lock

Safeguard the steering against unautho-rized use.Lock:- Turn the handlebar fully to the left.- Insert key (1) into the lock and turn it in

clockwise direction.- Pull out the key.Unlock:- Insert key (1) into the lock and turn it in

anti-clockwise direction.

- Pull out the key.

CAUTIONAlways remove the key before settingoff.


37/84

33

SERVICE INSTRUCTIONS

Servicing the motorbike / cleaning agents

NOTE

Regular, expert service will help maintainthe value of your motorcycle and is acondition for guarantee claims for corrosionand other such damage.

CAUTIONRubber and plastic parts will bedamaged by caustic or penetratingcleaning agents or solvents.

WARNINGAlways carry out a brake test aftercleaning and before starting a ride!

CAUTIONDo not use steam or high-pressure jetdevices!Such devices can damage seals, thehydraulic braking system and theelectrical system.


38/84


39/84

35


Repairing paint damage

Minor paint damage should be immediatelyrepaired.

If the motorcycle is not used for a longerperiod, it is recommended to support themotorcycle so that its weight is not on thetyres.You can prevent the tyres from becomingdry and brittle by spraying them with asilicone-rubber treatment. First thoroughlyclean the tyres.Do not store the motorcycle or the tyresin hot spaces (such as a boiler room) forlonger periods.

WARNINGA minimum tyre-profi le depth of2.0 mm must be maintained at alltimes.

Servicing tyresOperation in winter andanti-corrosion protection

NOTEProtect the environment by using only en-vironmentally friendly preservation agents,and use them frugally.

Use of the motorcycle in the winter cancause considerable damage due to thepresence of salt on the roads.

CAUTIONDo not use hot water, which would in-crease the effect of the salt.

- At the end of each ride, wash the motor-cycle with cold water.

- Thoroughly dry the motorcycle.- Treat parts liable to corrosion with wax-

borne anti-corrosion agents.


40/84


41/84

37


Technical changes, accessories and spare parts

WARNINGTechnical changes to the motorcycle canlead to cancellation of the EC operat inglicense.

Should you want to make technicalchanges, observe our guidelines. This willserve to prevent the motorcycle from beingdamaged and the trafc and operationalsafety being retained. A specialised Sachsdealer can carry out these activities withmeticulous care. Always consult a Sachs dealer beforebuying accessories or making any technicalchanges.

CAUTIONWe recommend using only approvedSachs accessories and original Sachsspare parts for Sachs motorcycles. This is in your own interests: thesafety, suitability and reliability ofthese accessories and parts will havebeen tested specifically for Sachsmotorcycles.

Although we keep track of the market, wecannot evaluate nor be held liable for thequality of non-approved accessories andparts, even if they have a certicate ofacceptance from an ofcially recognisedtechnical testing/supervision agency, ora license issued by the authorities.

For approved Sachs accessories andoriginal Sachs spare parts , see aspecialised Sachs dealer.He wil l a lso ensure that they areprofessionally installed.


42/84

38

1

1

2

2

Checking the steering bearings Checking the telescopic fork Checking the shock absorber

NOTES ON MAINTENANCE

NOTEThe telescopic fork should not jam up whenturned and it should swing back lightly toboth end positions.

- Pull the hand brake to block the frontwheel brake.

- Hold the handlebar with both hands andtry to move the handle bar back and

forth.

If the fork column bearing shows noticeableplay, it must be adjusted by a specialisedSachs dealer.

- Pull the hand brake to block the frontwheel brake.

- Now pump the fork girders several timesup and down using the handlebar.

- The suspension should respond perfect-ly.

- Check the fork girders for oil leaks.

Checking the fastening of the handle-bar

- Check all four handlebar fastenings (1)for tight t.

- Check the fastenings (2) of the springstrut for tight t.

- Check the spring strut for oil leaks.

NOTEIf damage to the telescopic fork or the springstrut is found have the motorbike examinedby a professional Sachs dealer.


43/84


44/84

40

2

1

3

3

Removing the front wheel

CAUTIONTake care not to damage the brake discsand linings while removing them.Do not operate the handbrake lever afterthe wheel has been removed.Protect the wheel bearings from dirt andmoisture.

- Support the motorcycle so that the frontwheel can move freely and the motor-cycle is standing securely.

- Loosen the shaft-clamping screws (1).- Loosen the axle nut (2).

- Lift the front wheel and pull out the full-oating axle (3).

- Remove the front wheel downwards.



45/84

41

2

3

5

1

3

4

Installing the front wheel

CAUTIONTake care not to damage the brakediscs and linings (4) while installingthem. Have a Sachs dealer check thetightening torques.

- Roll the front wheel in between the forktubes and insert the spacer bush (4) (onthe right as seen from the riding direc-tion).

- Grease the full oating axle (3) and pushit in with the spacer bushing (5) as far asit will go.

- Attach the axle nut (2) and screw tight.

- Before tightening the screw (1) stand themotorbike on its wheels and push thetelescopic forks several times to preventtwisting of the fork struts.

TorqueAxle nut (2): 35-45 NmAxle locking screws (1): 10 Nm



46/84

42

3

4

2

5

2 1

8

6

Removing the rear wheel

CAUTIONDo not damage brake disc and liningsduring removal!

Protect the wheel bearings from dirt andmoisture!

NOTEWhen taking off the rear wheel, make surethat the bush (3) to the left of the wheelhub is not lost.

- Raise the rear wheel, remove the fulloating axle (4) with brake support (6)and brake caliper and take off the rear

wheel to the back.

- Prop up the motorbike so that the rearwheel can turn freely and that themotorbike is secure.

- Hold the full oating axle (4) and releasethe axle nut (1).

- Unscrew the lock nuts (2) on the left andright-hand sides of the chain adjuster allthe way.

- Remove the drive chain (5).



47/84

43

3

4

7

5

2 1

6

9

8

Installing the rear wheel

CAUTIONDo not damage brake disc and liningsduring installation! Have a Sachs dealercheck the tightening torques.

- Clean and grease the full oating axle(4).

- Introduce full oating axle (4), chainadjuster (7), brake support (8) with brake

caliper (6) into rear suspension.

- Insert right chain adjuster (2) andreassemble with axle nut (1).

- Adjust the drive chain (5).(see adjusting drive chain).

- Tighten axle nut (1).

TorqueAxle nut (1): 50-60 Nm

NOTEInsert brake support into the guide (9) ofrear suspension.

- Install the drive chain (5).

- Install rear wheel with spacer bush (3)and full oating axle (4).



48/84

44

1

Checking the chain for wear

CAUTIONThe chain, sprocket and pinion must bechanged as one unit.

- Prop the motorbike up on the sidestand.

- Hold the chain (1) at the furthest rearpoint of the sprocket and pull it off.

- With correct chain tension, it should notbe possible to lift the chain higher thanthe teeth of the sprocket.

- If the chain can be pulled higher, havechain, sprocket and pinion replaced byyour Sachs-dealer.

Checking the drive chain



49/84

45

2

1

3

A

Adjusting the drive chain

- Loosen the axle nut (1).- Adjust the setting nuts (2) evenly on both

sides of the chain tensioner (rear wheelmust be in line with the front wheel).

- Let the rear end of the motorbike dropto the suspension limit.

- Push in the drive chain up half waybetween sprocket and pinion. Measurethe travel.

Adjusting the chain

CAUTIONThe adjustment of the chain inuencesthe wear of chain and sprocket. It is essential to have the tighteningtorques checked by a Sachs-dealer.Too tight adjustment of the chain willcause bearing damage on engine andrear wheel and result in excessive wearof the chain.

Nominal value: A = 30-35 mm

- Tighten the axle nut (1).

- Tighten setting nuts (2) on both sides.

TorqueAxle nut (1): 50-60 NmSetting nuts (2): 22-35 Nm



50/84

46

Checking the brake linings

CAUTIONThe minimum lining thickness must bemaintained.

NOTEFor your own safety, we recommend havingactivities to the brake system carried out bya Sachs dealer.

Front wheel brake

- Visually inspect the brake calliper (1).

- Check the thickness of the brake lining.

Minimum thickness:Frontbrake A = 2,5 mmRear brake A = 1,5 mm

Rear wheel brake

- If the lining thickness is below the mini-mum, have the brake lining (2) replacedby a Sachs dealer.



51/84

47

3

Rear wheel brake

Adjusting the footbrake pedal position

WARNINGCheck the play on the footbrake pedaland ensure that the brake is functioningproperly. A soft and spongy feel whenoperating the foot brake indicates thatthere is air in the brake system. Youshould have the brake system bled by aSachs-dealer. Air in the brake system isa considerable safety risk!

NOTEThe footbrake pedal position can be adjus-ted with the setscrew (1).

WARNINGThe adjustment measurement A mustnot exceed 14 mm!

- Loosen lock nut (2) and adjust the footbrake pedal position (3) with setscrew (1).



52/84

48


53/84

49

66 6

7

5

2

43 1

8

9

Cleaning the air lter

- Clean the foam with Motorrex air clean-er.

- Afterward soak and wring out the foamwith air lter oil.

CAUTIONCheck for properly installation of thefoam housing (9) and the manifold pipes(5) in the lter case.Otherwise the engine runs poorly or leadto serious engine damage.

Usually the installation takes place in reverseorder to disassembly.

Remove the air lter- Loosen the clamp (1) and take off the

hose.

- Unscrew the screw (2).

- Pull out the lter case (3) from the guide(4) on both sides.

- Take off the manifold pipes (5) from thelter case on both sides.

Opening the air lter- Remove the screws (6) and take off thecover (7).

- Remove the screw (8) and take out thefoam housing (9).

NOTEThe motorbike is attached with a oil foamair lter. In case of heavy dir tiness the foam(9) has to be replaced.

Clean for the rst timeafter

1.000 km

Clean every 4.000 km

Replace every 8.000 km



54/84

50

1 1A23

Cleaning the fuel lter

NOTEWe recommend to have the fuel lter (1)cleaned by a Sachs-dealer.

Clean for therst time after

1.000 km

Clean every 4.000 km


CHECK:- Check the throttle cable for light move-

ment by turning the twist grip (1) fromclosed to open position.

- Move the handlebar to check whether thethrottle cable moves freely.

- Check whether the throttle cable isobstructed by other parts.

- Open the twist grip throttle control until

resistance can be felt.- Measure the play.

Nominal value: A = 1-2 mm

Adjusting the play of the twist grip throttle control

Adjustment:- Slacken the lock nut (2) on the handle-

bar.

- Turn setscrew (3) accordingly.

- Tighten lock nut (2).

- Check the play.

NOTEIf the play cannot be corrected this way,have the motorbike checked by your Sachsdealer.


55/84

51

1

2

Spark plug

Check and change

CAUTIONCheck or change the spark plug onlywhen the engine is cold.

- Pull the spark plug connector (1).

- Unscrew the spark plug (2).

- Check the electrode gap (0,7-0,8 mm),replace the plug if it is severely burntaway.

- Insert new spark plug NGK CR7 HSA and tighten up.

Torque 20 Nm.

- Plug in the connector (1).



56/84

52

Battery

WARNINGAlways wear safety glasses.Keep children away from acids andbatteries.

EXPLOSION DANGERA battery being charged produces ahighly explosive gas, which is why re,sparks, naked ames and smoking areprohibited.

FIRE HAZARD

Avoid generating sparks and electrostaticdischarges when handling cables andelectrical devices.Avoid short circuits.

DANGER - CAUSTIC ACTIONBattery acid is highly caustic, so alwayswear safety gloves and glasses.Do not tilt the battery as acid can leak from the ventilation openings.

FIRST AIDIf acid comes into contact with an eye, im-mediately ush the eye for several minuteswith fresh water. Then immediately visit / call a doctor.Acid on the skin or clothing must imme-diately be neutralised using acid converteror soap suds, and the spots must be ushedwith plenty of water.If acid is swallowed, immediately visit / calla doctor.

CAUTIONDo not expose batteries to direct sun-light. Discharged batteries can freeze, sothey must be stored in a place where thetemperature remains above 5 - 15C.Professional maintenance, charging andstorage will increase the lifespan of thebattery and are a condition for the hon-ouring of guarantee claims.

DISPOSAL

Take a dead battery to a collection point.Never dispose of one with householdrefuse.

Charging the batteryAfter a long lay-up (3-4 months), charge thebattery. The charging current (in amperes)

must not exceed 1/10th

of the battery ca-pacity (Ah).The battery must not be fast-charged. Thebattery may only be charged using a specialcharger approved for MF batteries.

MaintenanceAlthough the battery is maintenance-free.Never leave the battery discharged. Keepthe battery clean and dry and make sure

that the connection terminals are rmlyseated.



57/84

53

54

3

1

1

2

Removing and installing the battery

CAUTIONThe battery may only be connectedor disconnected while the ignition isinactive.

First disconnect the minus terminal (4,black cable).

When installing the battery, rst connectthe plus terminal (5, red cable).

The battery is maintenance-free . Do nottry to open it.

- Remove the screws (1) on both sides andtake off the cover (2).

- Disconnect the rubber band (3) on thebarttery case.

- Remove the battery.

Installation takes place in reverse order todisassembly.

Battery



58/84

54

1 1

1

2

3

4

Checking the fuse

CAUTIONNe ver install a fuse with a larger rating,since this could destroy the entire elec-trical system.

The fuse is located behind the cover (2).

Replace the fuse

- Turn off the ignition.

- Remove the lower battery cover.

- Remove the three screws (1) and take offthe cover (2) to the left side.

- Open the fuse case (3).

- A faulty or blown fuse (4) must be re-placed by a new one with 15 A.

- Check the fuse for correct contact. Loosefuse will blow.



59/84


60/84

56

1

The tail / brake light (1) is not tted with areplaceable light bulb (diode light).If the tail light does not work you shouldrst check, whether a cable connection isinterrupted.

Tail / brake lightIf this is not the case, the tail light must bereplaced by a Sachs dealer.



61/84


62/84

58

1 2 c m

H

5mH

2

1

Adjusting the headlamps

Adjusting the headlight

- Activate the dipped beam.

- Use the adjusting screw (1 and 2) onboth sides to adjust the angle of theasymmetrically illuminated surface areaof the road top.

- Release srews (1) and (2), adjust andtighten up.

NOTEIf you have problems adjusting theheadlamps, see a specialised Sachs dealer.An incorrect adjustment is punishable bylaw. Remember, you are responsible forthe correct adjustment of the motorbikesheadlamp.

WARNINGDo not run the engine in an enclosedspace (risk of asphyxiation).

Position the motorcycle on a level oor 5m (measured from the headlamp) from alight coloured wall with a rider seated onthe motorcycle and the tyres lled at thecorrect pressure.

- Measure the distance from the oor tothe centre of the headlamp and markthe height on the wall with a cross. Drawa second cross 12 cm beneath the rstcross.

- Start the motorcycle and run theengine.



63/84

59

Engine type: 4-Speed model: IP52FMI

Construction: One cylinder 4-stroke petrol engine

Valve steering: 1 overhead cam with rocker armsValve: 2 valve

Valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm

Pistion displacement: 119.7 cm 3

Bore: 52,4 mm

Stroke: 55,5 mm

Compression ratio: 9,3:1

Lubrication system: forced oil lubrication

Cooling: air cooled

Maximum net power output: 6,0 kW at 8.400 1/min

Maximum net torque: 9,0 Nm at 5.400 1/min

Ignition system: transistorized ignition system with electronic ignition control (CDI)

Spark plug: NGK CR7 HSA or NHSP LD A7RTC electrode gap 0,7- 0,8 mm

Carburetor: TK Typ Z 22 PA

Air-lter: Foam air-cleaner

Idle speed: 1.600 +/- 200 1/min

Typ of starter: electric starter / kick starter

TECHNICAL DATA

Engine


64/84

60

TECHNICAL DATA

Power transmission

Clutch: Wet multi-plate type

Gear box: 4-gear claw dog-clutch engagement, pedal gear shifting

Gear ratios: 1. gear = 34/12 (2,832)2. gear = 29/17 (1,706)

3. gear = 26/21 (1,238)

4. gear = 23/24 (0,958)

Chain pinion: 16 teeth

Sprocket: 46 teeth

Drive chain: 428 O-ring, 112 links


65/84

61

TECHNICAL DATA

Chassis

Motorbike version: 4-speed model: Type 646

Frame: Center-type frame made of tubular steel

Front suspension: Telescopic fork 37 mm , hydraulic shock absorption, travel 100 mmRear suspension: Mono shock absorber, travel 65 mm

Wheels: Light metal (Alu)Front rim size: = 1,85 x 16" DOTRear rim size: = 2,50 x 16" DOT

Tires: Front = 90/90-16 48JRear = 120/80-16 60J

Tire pressure, solopillion driver

Front = 2,2 rear = 2,5 barFront = 2,2 rear = 2,7 bar

Brakes, front:Minumim lining thickness

Disc brake 260 mm, hydraulic two piston oating caliper2,0 mm

Brakes, rear:Minumim lining thickness

Disc brake 215 mm, mechanical two piston caliper1,5 mm


66/84

TECHNICAL DATA


67/84

63

TECHNICAL DATA

Electrical Equipment

Generator: 12 V 150 W

Battery: 12 V 6 Ah MF

Fuse: 15 A

Lights:

- Headlight:

- Position light:

- Instrument lights:

- Brake/rear light:

- Turn signal light:

Low beam 12V 55W E1, high beam 12V 55W E1

12 V 5W

Direction-indicator 12V 3W

Change over gear 12 V 3W

Cockpit 12 V 3W

12 V diode light

12V 21W

TECHNICAL DATA


68/84

64

TECHNICAL DATA

Dimensions and weights

Overall length: 1840 mm

Width across handlebarswithout rear view mirror:

760 mm

Maximum height: 1035 mm without rear view mirror

Wheel base: 1235 mm

Seat height: 835 mm

Weight empty: 100 kg

Weight in running order: 105,5 kg

Max. transport weight allowed: 194,5 kg

Max. permitted total weight: 300 kg

Top speed: 90 km/h

WARRANTY


69/84

65

WARRANTY

Warranty conditions

In case of an occurring fault the companySachs Fahrzeug- und MotorentechnikGmbH will provide the customer with thefollowing performances through the autho-rized Sachs-dealer (seller) within the scopeof its statutory warranty obligations:1. Within a period of 24 months after the

delivery of the motorbike to the endcustomer the company Sachs Fahrzeug-und Motorentechnik GmbH will rectifyany deciencies caused by material ormanufacturing faults through the autho-rized Sachs-dealer (seller) by repairingor replacing the affected part according

to the statutory warranty regulations.Sachs Fahrzeug- und MotorentechnikGmbH may deny the requested repairor replacement of the faulty part if thiswould only be possible with dispropor-tionately high costs. In this case SachsFahrzeug- und Motorentechnik GmbHmay rectify the deciency through theauthorized Sachs-dealer (seller) byapplying the other possible type ofsubsequent fulllment. If both types ofsubsequent fulfillment are only pos-sible with unproportionately high costs,Sachs Fahrzeug- und MotorentechnikGmbH may deny the subsequent fulll-ment alltogether through the authorizedSachs-dealer (seller). The customer is

then entitled to legal claims. Replacedparts pass over into the possession ofSachs Fahrzeug- und MotorentechnikGmbH.

2. The installation of spare parts within thescope of warranty does not extend thewarranty period that has started with thedate of delivery of the motorcycle.

3. The warranty does not cover normalwear and tear caused by normal use aswell as wear and tear caused by inap-propriate handling and inappropriateuse. Oxidation and corrosion are causedby environmental inuences and are also

not covered under warranty 4. Warranty claims lodged by the cuistomerwill be rejected in case of: Manipulationsto the motorcycle, installation of a dif-ferent exhaust system, changes to thegearbox or secondary transmission ratioand installation of accessories or spareparts which have not been approved bySachs Fahrzeugtechnik. Repairs car-ried out in workshops not authorized bySachs Fahrzeug- und MotorentechnikGmbH and the non-compliance with themaintenance intervals in the workshopof an authorized Sachs-dealer will alsocause the rejection of warranty claims.

5. When lodging a warranty claim the cus-

tomer must present the correctly lled inservice book to the seller.

6. The following table gives the customeran overview of the average limits of therespective wear parts:

WARRANTY


70/84

66

WARRANTY

List of wear parts

Wear parts Wear limits

Tires, hoses, rims depending on riding style, load and tire pressure the wear limit may already be reachedafter only 1000 km or even earlier.

Wheels, hubs depending on riding style, load and tire pressure the wear limit may alreadybe reached after only 2500 km or even earlier. Check during each maintenance.Oxidation is a lack of maintenance!

Oils, air lter, leakage inspection on engine during the rst inspection, then with every maintenance interval.Check oil level before every ride.

Spring fork, spring strut Cleaning / inspection during every maintenance.

Lamps, incandescent bulbs, electric system depending on road conditions / unevenness of the road surface the lifetime will be reduced,this may already occur after 500 km.

Brake linings, brake shoes, brake lines depending on riding style and load these may already be worn after 2500 km,in cross-country operation even earlier.

Sedal r ings, sealants, O-rings must be replaced during each maintenance interval to ensure proper function.

Radial seals on engine, gearbox,fork and wheels

depending on road conditions and care wear may start after 500 km.Dirt reduces the lifetime. Do not clean with a high pressure cleaner!

Wheel bearings, steering bearings depending on road conditions and care wear may start after 500 km.Soiling of the wheel hub reduces the lifetime.Check during each maintenance interval, do not clean with a high pressure cleaner!

Swing arm bearing depending on load and care after 2500 km, check with every maintenance.

Cables depending on care starting after 500 km. Check with every maintenance.

WARRANTY


71/84

67

WARRANTY

Wear parts Wear limits

Cleaning and lubrication of drive chain according of use and of every washing.

Drive chain, pinion, sprocket wheels,

chain guidance, chain pulley

depending on road conditions / ground and care, a wear is possible after 1500 km.

Do not wash with high pressure cleaner! Control during every maintenance.Starter battery, batteries, fuses, starter brushes depending on ambient temperatures failures can be expected in the 6th month,

when used for short rides even earlier.

Mirror glasses depending on ambient temperatures and care failures can be expected in the 6thmonth, in winter operation even earlier. Oxidation is a lack of maintenance!

Bowden cables, brake cables, throttle cables depending on use and care from the 6th month.

Free-wheel sprockets, free-wheel of star ter depending on care from the 6th month.

Self-locking nuts, cotter pins locking platesbonded screw connections

during each maintenance interval or after unscrewing the nut or unlocking the lock.

Inspection, cleaning and adjustment of the carburetor after each cleaning and max. every 200 hours, at least 1x per year.

Clutch linings / friction discs depending on riding style and load these may be worn after 2500 km.

Pistons, cylinders, crankshaft, conrods, enginebearings

depending on riding style, load and care these parts may be worn after500 hours. When riding mainly with full throttle even earlier.

Spark plugs with each or every second maintenance interval, max. very 200 hours.

Exhaust system, inspection of mountings depending on use and care from the 6th month, in winter and short distanceoperation even earlier. Oxidation is a lack of maintenance!

List of wear parts

INSPECTION PLAN


72/84

68

INSPECTION PLAN

Please observe the following:- During and after the warranty period all

inspections should solely be performedby a specialised dealer approved by us.

- Observe the inspection intervals andhave the specialised dealer conrm themon the guarantee certicate.

- Use only original spare parts.

CAUTIONIn case of non-compliance the warrantywill become null and void.

The various activities carried out are listedon the inspection plan.During the warranty period the followinginspection intervals must be compliedwith:

At 1.000 km (1 st service)Every 4.000 km / or after 4 monthsEvery 8.000 km / or after 8 months

After the warranty period the inspectionintervals specied in this manual must beapplied as follows:

Every 4.000 km / 4 monthsEvery 8.000 km / 8 months

WARNINGFor safety reasons, do not carry out anyrepair or adjustment activities to the

motorcycle and chassis that exceed aclosely restricted scope . Tinkering withsafety-relevant parts could threaten thesafety of yourself and third parties.

This applies especially to the exhaustsystem, carburetor, ignition system,clutch, gears, fork column, brake systemand lights.

Before starting work on the electricalsystem, disconnect the minus terminalof the battery.

INSPECTION PLAN


73/84

69

INSPECTION PLAN

ComponentAssembly

Servicing Tasks(*Only by an authorised Sachs dealer)

Beforeeachtrip

1st serviceafter

1000 km

Every4.000 km / 4 months


Valves Check and adjust valves if necessary (cold)* x xSpark plugs Check condition and accordingly clean or replace x x

Replace x

Air lter Clean foam lter and housing.* x x

Replace foam lter* x

Carburetor Check and adjust idle and cold start* x x x

Throttle cable x x x

Fuel lter Clean x x

Fuel hoses Check and replace if necessary (change at leastevery 4 years)

x x x

Engine oil Change (operating temperature) x x

Exhaust system Check for leads and repair if necessary* x x

Brakes Check brake function and brake uid as well ashousing, correcting if necessary. Adjust rear brake*

x x x

Check and replace brake pads* x x

Brake uid Change* Every 24.000km / 2 YearsBrake hoses Check and renew* (min. every 4 years)* x x x

Clutch Check and adjust x x x

INSPECTION PLAN


74/84

70

INSPECTION PLAN

ComponentAssembly

Servicing Tasks(*Only by an authorised Sachs dealer)

Beforeeachtrip

1st serviceafter

1000 km



Rear suspension Check, retighten, replace if necessar y or lubricate* Every 24.000km / 2 YearsTyres Check gereral condition and prole depth and

replace if necessaryx x x

Wheels Check for damage, balance* x x x

Stearingand bearings

Check and adjust free play* x x x

Front forks Check general condition as well as for leaksand repair if necessary*

x x x

Chain Check adjustment and condidtion and grease,adjust and renew if necessary

inspect clean and lubricate every 1000 km

Side stand Check, grease, repair if necessary* x x x

Nut and bolttightness

Check that all bolts and nuts are tightened tothe correct torque settings*

x x

Cables Check the throttle, brake and clutch cabels for de-mage and smooth operation, if necessary replace*

x x

Headlight Check and adjust x x x

Battery Check, recharge if necessary x x x

General safetycheck

Check for trafc/operational safety:clutch, gear, idling speed, handbrake and footbra-ke, fork column, lighting and direction-indicatorsystem, check indicator lights, check tyre pressure

x x x

MAINTENANCE CONFIRMATION


75/84

71

Workshop activities carried out Workshop activities carried out

Activities carried out km date Activities carried out km date




76/84

72


Workshop activities carried out Workshop activities carried out

Activities carried out km date Activities carried out km date


77/84



78/84

74

km ..................................date.................................

After 44.000 km/44 months

dealer stamp

km ..................................date.................................


dealer stamp

km ..................................date.................................


dealer stamp

km ..................................date.................................


dealer stamp

km ..................................date.................................


dealer stamp

km ..................................date.................................

After56.000 km/56 months

dealer stamp

km ..................................date.................................

km ..................................date.................................


dealer stamp


dealer stamp



79/84

75

New brake uid

Yes no

Km .....................................Date ..................................

Stamp, signature

New brake uid

Yes no

Km .....................................Date ..................................

Stamp, signature

New brake uid

Yes no

Km .....................................Date ..................................

Stamp, signature

New brake uid

Yes no

Km .....................................Date ..................................

Stamp, signature


80/84

76


81/84

77

d B ( A ) min

Sachs Fahrzeug-undMotorentechnik GmbH

e1-0279

WSF 646A1061000101

82 3.750

Rating plate (sample): Motorbike data(ll out on purchase)

Model designation: ......................................................

Vehicle identily No: ......................................................(Chassis No)

Key No: ............................................................................................................

EC license: ......................................................

Owner: ..................................................................................................................................................................

ImportantIf you lose the operating license, immediately have amotor-vehicle approval agency write out a certicate of

approval.Send us the certicate along with the vehicle data. Youwill then receive from us a copy of the operating licensefor a fee.

EC-license :Federal Bureau for Motorised Vehicles (States Eagle)Frderstr. 16 D-24944 Flensburg

EC Operating LicenseAccording EWG 92/61EC license No: e1*2002/24 0279*00Motorcycle: (under 18 StVZO)Vehicle type: 646Holder of the EC operating license and manufacturer:Sachs Fahrzeug- und Motorentechnik GmbH90327 Nrnberg


82/84

78


83/84

79


84/84

MadAss 125 Owners Manual GB

Documents

Transcript of MadAss 125 Owners Manual GB