Ownersmanual - HANSAPOST · 2019. 6. 4. · 12 SAFETYTEST Checklist...

Owners manual

We cannot be held liable for any conseque-ntial damage caused by accessories not a-pproved by the factory.

The scope of delivery and version of the sc-ooter is solely determined by the purchaseagreement concluded with the dealer.

This operating manual includes important instructions for handling your light scooter. R-ead it carefully, because professional hand-ling combined with regular care and mainte-nance helps to maintain the scooter,s valueand is one of the requirements for warrantyclaims.

We wish you at all times a safe journey.

Yours

You have purchased a our scooter,con-gratulations and thank you for puttingyour trust in us.

This model is a sturdy scooter in modern d-esign.

Its sound construction, the meticulous sele-ction of materials, the advanced manufact-uring techniques and conscientious work ofdedicated employees provides the scooterwith all the characteristics such as econom-ical operation, quality, reliability and its last-ing value.

Safety symbols and notes

Please observe the following:

WARNINGPrecautionary measures against the risk ofaccidents, injury and /or death.

FIRE HAZARD

CAUTION

NOTE

The vehicle is equipped with a catalyst,thisresults in extremely high temperatures on t-he exhaust system(risk of burning)

Important instructions and precautionary ru-les to avoid damage to the vehicle.Nonobs-ervance can lead to the warranty becomingvoid.

Special instructions for better handling duri-ng operation, inspection adjustments and s-ervice activities.

PREFACE

1

CONTENTS

OVERVIEW AND OPERATIONIdentification number, engine number.........................................3

View of vehicle..........................................................................4-5

Instrument, handlebar instrument.................................................6

Ignition lock and fork-column lock................................................7

Storage box, luggage hooks.........................................................8

Fuel, fuel tank...............................................................................9

Tank cap.....................................................................................10

Side stand, parking stand...........................................................11

SAFETY TEST

Checklist.....................................................................................12

Load and lights...........................................................................13

Ride safely..................................................................................13

RIDING INSTRUCTIONSRide economically and environmentally.....................................14

Running-in instructions...............................................................15

Starting..................................................................................16-17

Brakes...................................................................................18-19

Stopping the engine...................................................................19

SERVICE INSTRUCTIONS

Servicing the scooter / cleaning agents.................................20-21

Winter operation and corrosion protection..................................21

Repairing paint damage / servicing the tyres.............................22

Lay-up commission....................................................................22

Technical modifications, accessories and spare parts...............23

2

CONTENTS

NOTES ON MAINTENANCEEngine oil

Transmission oil

Checking steering bearing, telescopic fork

Tyres

Front wheel brake

Rear wheel brake

Adjusting the play of the twist grip throttle control

Cleaning the air filter

Cleaning the spark plug

Fuse

Battery

Changing the light bulbs

Adjusting the headlight

...............................................................................24-26

..........................................................................26

.................................27

...........................................................................................28

..................................................................29-30

........................................................................31

.......................32

...................................................................33

..............................................................34

............................................................................................35

...................................................................................36-37

........................................................38-41

................................................................42

TECHNICAL DATA

WARRANTY AND SERVICE DATA

Warranty conditions

List of wear items

Inspection items

Proof of maintenance

....................................................................47

...................................................................48-49

.....................................................................50-52

.............................................................53-54

Engine

Power transmission

Chassis

Lubricants and operating fluids

Electrical equipment

Dimensions and weights

.........................................................................................43

....................................................................44

.......................................................................................44

...................................................45

....................................................................45

.............................................................46

3

SUMMARY AND OPERATION

Identification number Chassis number Engine number

NOTEThe description for right hand side is view-ed from the driver

The identification number is located onthe rear part of the frame below the rightunderside cover

-

.

.

(1)

The chassis number is located on the fra-me behind the cover (2).

The engine number (3) is located on the fr-ont part the left crankcase.

KeyWith the scooter you get two separate inde-finite keys for:

Keep the spare key at a safety place.

- Ignition lock, storage box and seat.

21

3

OVERVIEW AND OPERATION

Right-hand side view1 Storage box with tool kit

2 Luggage hook

3

4 Battery box and fuse

5 Ignition and fork-column lock

6 Brake fluid container for front

wheel brake

7 Handbrake lever for front brake

Engine oil filter cap

2

3

4

15

4

6

7

Left-hand side view

14

13

9

11

10 12


5

8 Handbrake lever for rear brake

9 Instrument

Kick starter

Parking stand

Transmission oil filler screw

Air filter

Side stand

10

11

12

13

14

8


Instrument Handlebar instrument, left Handlebar instrument, right

1 Fixed grip2 Handbrake lever for rear brake3 Direction-indicator switch

Switch to leftLeft indicator onSwitch to rightRight indicator onPush button for switch off

4 Push-button:horn56 High beam indicator

high beamlow beam

Hazard warning lamp switch

2

3

45

2

34

64

5

1 Speedometer km/h/mph

2 Odometer km

3 Fuel indicator

4 Left and right directionindicator green

5 High beam indicator bl eu

6 Malfunction indicator lamp oranger

Instrument lights

7 Handbrake lever for front brake

8 Throttle

switch

When the switch on" " position,

it has electric power, the engine c-

an be start.

10 Starter button

9 Engine off

When the switch on" " position,

it is not power, the engine can not

be start.

6

1

1

7

8910

6


Ignition and fork-column lock

NOTEKeysWith the scooter you get two indefinite ignit-ion keys. Keep the spare key at a safety pl-ace.

(1) Operating positionIgnition and all circuits activated.

WARNINGWhile riding do not switch the ignition off,

!

NOTEThe key can be removed in positionsand .

Key positions

(2) Ignition offFork column not locked (handle-bars can be freely turned to theleft or right).

(3) Fork column locked andgnition offi

Turn the handlebar to the left asfar as to the stop.Push and turn the key to the leftuntil it is in the LOCK position.The fork column is now locked.

3

2 1

7


Storage box Luggage hooks

2

- Do not store valuables in the box.

- Make sure that the seat has been lockedcompletely after it was pressed down.

- Take out valuables before washing to av-oid wetting these objects.

- Do not place thermal sensitive objects inthe box because of engine

,s heat and hi

gh temperature.-

Unlock- Insert the ignition key (1) into the lock and

turn the key to the right.

WARNINGAfter the seat is closed check if it waslocked firmly.

Maximun load capacity: 10 kg

CAUTIONMaximum load capacity kgDo not transport bulky loads.

: 1.5

Use the hooks (3) only for small baggagepieces.

Lock- Press down the seat (2) until the lock is

engaged.- Pull out the ignition key.Never leave the key in the storage box.

13

8

Malfunction Indicator Lamp- When the fault light (2) flashes, indicating

that the electronic control system failure,please check with the local dealer.


Fuel, fuel tank

WARNINGFuel is highly inflammable and can expl-ode. Do not smoke or bring a naked fla-me near the fuel tank.

Fuel expands under the influence of heatand the sun. Therefore,never fill the tankto the brim. Never fill the tank while theengine is running.

Never bring a glowing cigarette or nakedflame near an open tank, because fuelvapour could suddenly ignite.

NOTEThe fuel indicator (1) is active when the ign-ition is turned on.

The scale with the tank symbol remem-bers for a tank stop.

Don,t run down the fuel tank until it is empty.

- Use only premium lead-free fuel (min.95octane)

E = EmptyF = Full

Filling up with fuel

Fuel stock, tanking

1 2

9


Tank cap

3

NOTEThe tank cap is designed with ventilation.Do not make any changes to the cap.

Unlock:- Insert ignition key (2) into the lock and turn

the key to the right, open the seat (1).

- Turn the tank cap(3) counter-clockwisedand open the tank cap

LOCK:- ,

-

-

Align A to B press the tank cap and turnit clockwised

Press down the seat until the lock isengaged

Pull out the key

.

.

.

AB

21

10


Side stand and parking stand

2

3

WARNINGAlways make sure that the stand is resti-ng on firm ground. On sloping roads, al-ways park the scooter facing uphill.It is essential that the side stand is fold-ed up before starting off ! -Risk of accid-ents!

Propping up the scooter on the sidestand.

Side stand

NOTEThe scooter is equipped with a side standswitch. If the side stand is folded up the en-gine is shut off and will not start.

- Switch off the engine.- Put your left hand on the left-hand handle-

bar grip.- Hold with your right hand the holder grip

(3).- Fold out the arm fo the side stand(1)as far

forward as it will go and stop by foot.- Slowly tilt the scooter to the left until its w-

eight is supported.

Parking stand- Switch off the engine.- Put your left hand on the left-hand handle-

bar grip.- Hold the holder grip(3)with your right hand.- Push the parking stand (2) down until the

two skids are on the ground.- Put you full body weight on the perating

mandrel of the main standard.- Pull the scooter towards the rear and sim-

ultaneously upwards onto parking stand.- Check that the scooter is standing firmly.

o

1

11

12

SAFETY TEST

Checklist

Before each ride,carry out a safety checkusing the checklist.Take the safety check seriously. Carry outmaintenance activities before you start yourride or ask a specialized dealer to do so.This will provide you with the certainty thatyour motorcycle corresponds to traffic regu-lations. A technically faultless motorcycle isa basic requirement for the safety of bothyourself and other road users.

Before starting your ride, check the followi-

ng:

- Steering (smooth and free play)

- Engine oil quantity

- Fuel quantity

- Front brake

- Rear brake

- Tyres (profile and pressure)

- Telescopic fork

- Load / lights

- Total weight

- Lights

- Brake fluid (lever)

- Brake (operation)

In case of problems or difficulties, contact a

dealer, who will do everything possible to

assist you.

WARNINGWhile the engine is running or the igniti-on is on , do not touch the ignition syst-em.

FIRE HAZARDThe exhaust system becomes very hot.While riding,idling or parking,make surethat to inflammable materials (e . g . hay,leaves, grass, coverings or luggage,etc.)can come into contact with it!

WARNINGFor the sake of your safety, use only ori-ginal accessories or products releasedby us.We cannot judge for each third-part productwhether it can be safely used in combinatio-n with your scooter.Nor can a official approval give such a gua-rantee in all cases, since the test scope isnot always sufficient.

SAFETY TEST

Load / lights

Correctly loadedMake sure that the left-right weight distrib-ution is balanced.

- Check that fastenings are correct and tight.- Do not transport bulky loads.- Do not cover the lights.

-

NOTEOur accessories and approved products aswell as qualified advice are available fromall specialized dealers.

WARNINGThe total allowable weight may not be e-xceeded.Check the tyre pressure.

Checking the lights

WARNINGBefore any ride, check the operation ofall lighting components.

- Check that the headlamps and lenses areclean.

Ride safely

CAUTIONRiding safety is largely also determinedby the manner of riding.

Therefore:- Put on a tested / approved safety helmet

and correct close the buckle.- Wear suitable protective clothes.- Rest your feet on the footrests.- Do not ride if your riding ability has been

compromised.

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

- Strictly observe all traffic regulations.- Always adapt your riding speed to the tra-

ffic and road conditions.

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

13

RIDING INSTRUCTIONS

Ride economically and be aware of the environment

Fuel consumption , environmental pollutionand wear of engine, brakes and tyres depe-nd on various factors.Your personal riding style is highly determi-nant for economical fuel consumption andexhaust gas and noise generation.While idling, the engine takes a long time towarm up to operational temperature. In thewarm-up phase,however,the wear level andpollutant emissions are very high. It is ther-efore best to start riding immediately afterstart-up.

Open the throttle not further than needed,inorder to reduce fuel consumption as well aspollution and wear levels.Do not use excessive revs; change up as s-oon as possible and do not change down u-ntil it is necessary to do so.

Unnecessary acceleration and hard brakingcause high fuel consumption and increasedpollution levels.

Avoid rapid acceleration

Ride as evenly as possible and look ahe-ad as far as possible.

Turn the engine off when waiting in traffic.

-

Different riding conditions affect fuel consu-mption. The following conditions are unfav-ourable for fuel consumption:- High traffic density, especially in big cities

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

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

speed, meaning riding with relatively highrevs.

Plan rides ahead of time in order to avoidheavy traffic.

Fuel consumption is also affected by condi-tions that are out of your control, for instan-ce, poor road condition, hills,riding in winter.

Observe the following aspects for economi-cal fuel consumption:- The planned inspection intervals must be

closely observed.- Regular service by a specialized.

dealer will guarantee not only continuedoperability, but also economical fuel cons-umption, low environmental pollution anda long lifespan.

-Check the tyre pressure every two weeks.

Low tyre pressure increases rolling resista-nce. This increases fuel consumption andtyre wear and adversely affects riding beh-aviour.- Continually check fuel consumption.- Frequently check the engine-oil level.

14

Running-in instructions for engine andtransmission.

Running-in

- During the first 500 km:

- Up to 1,000 km:

Less than 1/2 throttle.

Less than 3/4 throttle.

NOTEDuring the running-in period, ride in freque-ntly changing load and rpm ranges. Selectwinding and slightly hilly routes. Avoid con-stantly low rpm counts and full throttle und-er load. WARNING

New brake linings must be run-in and w-ill 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.

Running-in new tyres

CAUTIONNew tyres have a smooth surface. Theymust therefore be roughened by careful-ly running them in at various slanted po-sitions.Only then will the surface obtain its fullgrip!

Running-in new brake linings

RIDING INSTRUCTIONS

CAUTIONExcessive revs while running-in the eng-ine increases the wear of the engine.Engine faults during the running-in peri-od must be immediately reported to a s-pecialized dealer. CAUTION

The first inspection must be carried outimmediately after the first 1.000 km.

You can save yourself delays by making anappointment with a specialized dealer in ad-vance.

15

CAUTIONIf the engine won,t start immediately, re-lease the start button,wait a few secondsand push it again. Each time,push the st-art button for just a few seconds in orderto save the battery. Never push the startbutton for more than 10 seconds.

Starting with the electric starter

3

RIDING INSTRUCTIONS

NOTE WARNINGNever allow the engine to run in an encl-osed space. Exhaust gases are highly t-oxic and can kill.

2

WARNINGPropping up the scooter with the parkingstand. Operate the rear handbrake leverto avoid a moving of the scooter.Avoid high engine rpm,s while the vehic-le is standing still , otherwise the clutchwill engage.

Before starting- Propping up the scooter with the parking

stand.- Turn the ignition lock (1) with the ignition

key to its operating position .- Do not open the throttle (3).- Pull and hold the handbrake lever (2).- Operate the start button (4).- If the engine can not be started after the

starter motor is running for 3-5 seconds,open the throttle(3)1/8-1/4 turns and startagain.

- Push the scooter off its parking stand.- Mount the scooter.- Release the brake before riding.

4

1

Every scooter is equipped with side standswitch. When the side stand is fold up, canstart the engine. When the side stand is released, can't start the engine.

-

16

CAUTIONAfter starting the engine , check that thekick starter lever (3) is returned to its no-rmal position.

Starting with kick starter

3

RIDING INSTRUCTIONS

NOTEUse the kick starter from time to time to ma-intain its function.

- Propping up the scooter when operatingthe kick starter.

- Turn the ignition lock (1) with the key to itsoperating position .

- Do not open the throttle (2).- Depress the kick starter lever(3)quick and

the engine will start.- After the engine is running return the kick

starter lever to its normal position.

" "

17

2

1

Wet brakesWashing the scooter or riding through wateror rain can delay the braking effect due towet or ( in winter ) ice-covered brake discsand linings.

Braking

NOTEMake sure you practice braking for emerge-ncy situations, but do so where you will notpose a risk to yourself or others(e.g.a dese-rted parking area).

WARNINGOperate the brakes to grind off the saltdeposited on the brake discs.

Dirty brakesWhen riding on dirty streets, the braking ef-fect can be delayed due to dirty brake discsand linings.

Oil and grease

RIDING INSTRUCTIONS

WARNINGThe brakes must first be operated untilthey are dry.Salt film on the brakesWhen riding on salted streets without braki-ng for a while, the full braking effect may bedelayed.

WARNINGThe brake discs and linings must be freeof oil and grease!

If the scooter is not used for a while , arust film may form on the brakes and th-us increase the braking effect. A thick r-ust film can cause the brakes to lock up.When setting out on a ride after a long l-ay-up period, carefully operate the brak-es several times until they work normal-ly.

WARNINGOperate the brakes until they are clean.Lining wear is increased by dirty brakes!

18

2

Braking

RIDING INSTRUCTIONS

On tight curves, sandy / dirty streets, wet a-sphalt and icy roads,use the front brake ca-refully: if the front wheel locks , the bike willslide sideways.Brake with care.Locked wheels do not havemuch braking effect and can lead to skiddi-ng / crashing. In principle,do not brake on acurve, but before the curve.Braking on a curve increases the danger ofsliding.

3

Stopping the engine

Braking

both

The front b ake and rear brake are operate-d independently from each other.The front brake is operated via the right-ha-nd brake lever(1)on the handlebars,and therear brake is operated via the left-hand bra-ke lever(2).

When stopping or slowing down,release thethrottle gas and operate brakes at thesame time.

r- Turn the ignition lock (3) with the ignition

key to the position .- Pull out the ignition key.

" "

19

1

CAUTIONRubber and plastic parts will be damagedby caustic or penetrating cleaning agentsor solvents.

Servicing the scooter / cleaning agents


NOTERegular, expert service will help maintain t-he value of your scooter and is a conditionfor guarantee claims for corrosion and oth-er such damage.

WARNINGAlways carry out a brake test after clea-ning and before starting a ride!

CAUTIONDo not use steam or high-pressure jet de-vices!Such devices can damage seals, the hyd-raulic braking system and the electricalsystem.

CLEANING- To wash the motorcycle,use a soft sponge

and clean water.- Afterwards,dry off with a polishing cloth or

chamois.- Do not wipe off dust or dirt with a drycloth,

to avoid scratching the paint or covering.

20

PRESERVATION AGENTSWhen necessary, the scooter must be pres-erved with commercially available preservingand cleaning agents.

- By way of precaution (especially in winter),regularly treat parts liable to corrosion withpreservation agents.

Servicing the scooter / cleaning agents


NOTEProtect the environment by suing only envi-ronmentally friendly preservation agents, a-nd use them frugally.

Use of the motorcycle in the winter can ca-use considerable damage due to the prese-nce of salt on the roads.

CAUTIONNever use paint-polishing agents on pla-stic parts.

- After a longish ride,thoroughly clean the ch-assis and the aluminium parts and preservethem with a commercially available anti-co-rrosion agent.

Operation in winter andanti-corrosion protection

CAUTIONDo not use hot water, which would incre-ase the effect of the salt.

- At the end of each ride, wash the motorcy-cle with cold water.

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

ne anti-corrosion agents.

21

Minor paint damage should be immediatelyrepaired.

Repairing paint damage


NOTECombine lay-up / commission activities withan inspection by a dealer.

- Remove the preservation agents from theoutside.

- Clean the motorcycle.- Install the charged battery.- Preserve the battery terminals with termi-

nal grease.- Check / adjust the tyre pressure.- Check the brakes.- Carry out activities according to the inspe-

ction plan.- Carry out the safety checks.

Commission

Servicing tyres

If the scooter is not used for a longer period,it is recommended to support the scooter sothat its weight is not on the tyres.You can prevent the tyres from becoming dr-y and brittle by spraying them with a silicone-rubber treatment. First thoroughly clean thetyres.Do not store the scooter or the tyres in hot s-paces (such as a boiler room) for longer per-iods.

Lay-up / commission

Lay-up- Clean the scooter.- Remove the battery.

Observe the maintenance instructions.- Spray suitable lubricants onto the brake-

lever and clutch-lever joints and the side-standard and main-standard bearings.

- Rub bright / chromium-plated parts with ac-id-free grease(Vaseline).

- Store the scooter in a dry room and jack itup so that its weight is not on the wheels.

WARNINGA minimum tyre-profile depth of 2.0 mmmust be maintained at all times.

22

Technical changes, accessories and spare parts


For approved accessories and original spa-re parts, see a specialised dealer.He will also ensure that they are professio-nally installed.

CAUTIONWe recommend using only approved ac-cessories and original spare parts for ourscooter.

This is in your wn interests : the safety,suitability and reliability f these access-ories and parts will have been tested spe-cifically for the scooter.

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 certificate of ac-ceptance from an officially recognised te-chnical testing / supervision agency, or alicense issued by the authorities.

oo

WARNINGTechnical changes to the scooter can le-ad to cancellation of the EC operating li-cense.

Should you want to make technical change-s, observe our guidelines. This will serve toprevent the scooter from being dam-agedand the traffic and operational safety beingretained. A specialised dealer can carry outthese activities with meticulous care.

Always consult a dealer before buying acc-essories or making any technical changes.

23

Engine oil

2

NOTES ON MAINTENANCE

NOTEMake sure that the scooter during oil-levelchecks stands level in all respects.Even theslightest inclination towards the side will pr-oduce measurement errors.

- Stop the warmed-up engine, wait for app-rox. 5 minutes and hold the scooter up-rig-ht.

- Propping up the scooter on the parking st-and.

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

- Clean the oil filler cap at the MIN-MAX ae-ra with a clean rag.

CAUTIONChecking the oil while the engine is coldwill lead to a wrong measurement and t-herefore the wrong oil quantity. In orderto avoid engine damage, never exceed t-he maximum oil level nor let it drop belo-w the minimum level.

Checking the oil level

CAUTIONFor checking the oil level only insert theoil filler cap and don,t screw in!Otherwise there will be a wrong measur-ement in order to avoid engine damage.

- The oil level must be between the minimu-m and maximum marks.

- Tighten the oil filler cap by hand.

If required, replenish the engine oil SAE 15W/40 via the oil level up to the MAX levelmark.

- When change new engine oil, open the oilhole screw (2), till all engine oil is flow out,then tighten the screw (2) and add new oilvia the oil level up to the MAX. level mark.

- Tighten the oil filler cap (1).

24

1

Engine oil

1


25

2

3

4

Clean oil filter element

Install torque:32 N.m

If the oil filter element is also to be replacedor cleaned, perform the following procedure.- Remove the oil strainer cover (1), spring (3)

and oil filter element(2).- Replace the O-ring (4) new.- Install the new or clean oil filter element and

the oil strainer cover.

CAUTIONDo not use additives . Since the oil alsoserves to lubricate the clutch, do not usecar engine oils supplemented with frictio-n modifiers (such energy-conserving oilscan lead to the clutch slipping). Use a su-itable, light engine oil for scooters , suchas Motorex SAE 15W/40 mineral oil API(SJ or higher).

- If required, replenish the engine oil(for clas-sification and viscosity, see the table) via theoil-filler opening up to the maximum level m-arking.

Engine oil

Checking the transmission oil level- Stop the warmed-up engine, wait for appr-

ox. 5 minutes.- Propping up the scooter on the parking st-

and.- Remove the oil filler screw (1)and check if

the oil level is below the oil-filler opening.- If required, replenish transmission oil Hyp-

oid SAE 80W-90 via the oil-filler opening.- When change new transmission oil, open

the oil hole screw(2),till all transmission oilis flow out, then tighten the screw (2) andadd new oil via the oil-filler opening.

- Tighten the oil filler screw(1).


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

Recommended viscosity:

Viscosity depends on the outside temperat-ure. For short while, the temperature mayexceed or fall short of the limits of the SAEgrades.

The recommended viscosity grade SAE 15W/40 covers the ambient temperature ran-ge -15 to +40 and therefore representsthe optimum for out latitudes.

℃ ℃

SAE W/10 30

SAE W/ W/10 40 10 50

SAE W/ W/15 40 15 50

SAE W/20 50

-10° 0° 10°20°30° C-20° 40°

2

1

26

Checking the steering bearings


NOTEThe telescopic fork should not jam up whenturned and it should swing back lightly to b-oth end positions.

- Pull the hand brake to block the front whe-el brake.

- Hold the handlebar with both hands and t-ry to move the handle bar(1)back and forth.

If the fork column bearing shows noticeableplay, it must be adjusted by a specialised d-ealer.

Checking the telescopic fork

- Pull the hand brake to block the front whe-el brake.

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

- The suspension should respond perfectly.

- Check the fork girders for oil leaks.

NOTEIf damage to the telescopic fork or the spri-ng strut is found have the motorbike exami-ned by a professional dealer.

1

27

Tyre profile


Checking the tyre pressureChecking the tyre profiles

WARNINGObserve the minimum profile depth pre-scribed by law.Never ride without valve caps(1) . Firmlytightened valve caps prevent the tyre fr-om suddenly losing pressure.

- Measure the profile depth at the centre (2)of the tyre,s tread.

Recommended minimum profile depth:2.0 mmObserve the wear marks(3).

WARNINGAdjust the tyre pressure according to t-he total weight load. Never exceed the r-ated total weight or the bearing capacityof the tyres.Incorrect tyre pressure will have a consi-derable effect on the riding properties ofthe scooter and the lifespan of the tyres.

Tyre sizeThe standard scooter is provided with thefollowing tyre sizes:

FrontRear

All Tyres are tubeless.

120/70-12 56J P J120/70-12 56J P J

or 51 or 51or 51 or 51

WARNINGUse only tyres approved by the manufa-cturer. The use of non-approved tyre br-ands, types or sizes leads to the operati-ng permit of the vehicle becoming null a-nd void.Use only pairs of tyres producedby the same manufacturer.

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

Front: 1.75Kg/cm Rear: 2.00Kg/cmFront: 2.00Kg/cm Rear: 2.25Kg/cm

2 2

2 2

1

2

3

28

Front wheel brake


CAUTIONDo not spill any brake fluid on painted orplastic surfaces as it will demage the su-rface severely.

- Turn the handlebars until the brake-fluid t-ank (2) is level.

- The brake fluid level(3)should be betweenthe minimun (MIN) and the maximum mar-king (MAX).

- If air bubbles can be seen,check the brakelinings for wear; if necessary, replenish thebrake fluid by a dealer.

Front brake-fluid tank

WARNINGSudden changes in play or a spongy feelof the brake lever (1) can be caused byfaults in the hydraulic system.Do not ride on when in doubt about theoperability of the brake system. Immedi-ately consult a dealer.

Checking the brake-fluid level

WARNINGEvery two years, the brake fluid must bechanged by a dealer. The level must notdrop below the MIN mark.Use only brakefluid of the DOT 4 classification.

1

29

MIN

2

3

Front wheel brake


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

- Check the thickness of the brake lining.

Minimum thickness:

- If the lining thickness is below the minimu-m,

A = 2.0 mm

have the brake lining (1) replaced bya dealer.

Checking the brake linings

CAUTIONThe minimum lining thickness must bemaintained

Checking the disc brake

- Visually inspect the disc (2).

- Check the thickness of the disc.

Minimum thickness:

- If the disc thickness is below the minimum,

B = 3.0 mm

have the disc (2) replaced by a dealer.

2

B

30

Rear wheel brake

2


NOTEAfter a longer period of operation, adjustm-ent of the brakes is essential due to naturalwear of the brake-shoe linings.

Checking

Adjusting

- An external sign of the brakes needing a-djustment is the constantly increasing freetravel (A) of the handbrake lever (1) 10-20mm.

- Screw the nut (2) on the rear-wheel b akeonto the brake rod until the handbrake lev-er reach a free travel of 10-20 mm.

- After this measurement is attained, the br-ake shoes should be heard brushing agai-nst the brake drum.

r

CAUTIONFor your own safety, we recommend ha-ving activities to the brake system carri-ed out by a dealer.

Adjusting the rear wheel brakeCAUTION

Have a dealer check the adjustment.Checking the brake linings.

CAUTIONThe thickness of the brake lining may no-t be lower than the minimum value.Operate the handbrake lever(1) and visu-ally inspect it.Check the thickness of the lining:The extension of the wear indicator (3) atthe brake lever must be in front of the mi-nimun mark of the scale(4)when the rearbrake is depressed.If the thickness of the lining has fallen b-elow the minimum, have a specialised d-ealer replace it.

A

1

3

4

31

Adjusting the play of the twist grip throttle control


Check:

A = 3-5 mm

- Check the throttle cable for light move-me-nt by turning the twist grip(1)from closed toopen position.

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

- Check whether the throttle cable is obstru-cted by other parts.

- Open the twist grip throttle control until re-sistance can be felt.

- Measure the play.Nominal value:

42A

Adjustment:- Push back the protective cap (2).- Slacken the lock nut (3) on the handlebar.- Turn the setscrew (4) accordingly.- Tighten the lock nut (3).- Check the play.- Push over the protective cap (2).

NOTEIf the play cannot be corrected this way, ha-ve the scooter checked by your dealer.

31

32

Cleaning the air filter


NOTEThe scooter is attached with a oil foam airfilter. In case of heavy dirtiness the foam(3)has to be replaced.

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

- Remove the foam (3).- Clean the foam with Motorrex air cleaner.- Afterward soak and wring out the foam wi-

th air filter oil.

Disassembly and cleaning

Installation- Clean the hole (4) before installation.- Usually the installation takes place in rev-

erse order to disassembly.

CAUTIONNever run the engine without air filter.- Dust depsit is one of the major causes of

reducing output horsepwer and increasingfuel consumption.

- Change the air cleaner element more fre-quently to prolong the engine

,s service life

if the scooter is ride on dusty roads veryoften.

- Check for properly installation of the foamhousing in the filter case.

- Otherwise the engine runs poorly or leadto serious engine damage.

- Be careful not to soak the air cleaner wh-en washing the scooter. Otherwise it willcause engine hard to start.

4

3

The air inlet of oil-gas separator connectswith cylinder breath pipe, air outlet connectswith air filter port, oil discharge outlet shouldface to the ground. If there's too muchoil inthe oil discharge pipe, please release the oiland check the oil measure tape if the engineoil is enough.

(5)

5

33

1

2

1 1

11

1

Checking the spark plug


- Remove screw(1), take down the maintaincover (2).

- Pull the spark plug connector (3).- Unscrew the spark plug with the spark wr-

ench from the on-bord toolkit.- Check the electrode gap (0.6-0.7mm) rep-

lace the spark plug if it is severely burnt a-way.

- Use a new spark plug andtighten up.

NGK CR7 HSA

CAUTIONCheck or change the spark plug only wh-en the engine is cold.

Check and change - Screw in the spark plug by hand and thentighten up with the spark wrench.

- Plug in the spark plug connector (3).

Torque 11 Nm.

0.7-0.8mm

2

34

1

35

Checking the fuse


- Turn off the ignition.- Remove the two screw (1) and open the

battery cover (2).- Open the fuse case (3) and remove the

fuse.- A faulty or blown fuse must be replaced

by a new one with 15 A.- Check the fuse for correct contact. Loose

fuse will blow.

Installation takes place in reverse order todisassembly.

CAUTIONNever install a fuse with a larger rating,since this could destroy the entire elect-rical system.

The fuse is located behind the inspectioncover.

1

23

1

Battery

Charging the battery

Maintenance

After a long lay-up(3-4 months), charge thebattery. The charging current (in amperes)must not exceed 1/10 of the battery capac-ity (Ah).The battery must not be fast-charged. Thebattery may only be charged using a speci-al charger approved for MF batteries.

Although the battery is maintenance-free.Never leave the battery discharged. Keep t-he battery clean and dry and make sure th-at the connection terminals are firmly seat-ed.

th

FIRST AIDIf acid comes into contact with an eye,imme-diately flush the eye for several minutes withfresh water. Then immediately visit / call a d-octor.Acid on the skin or clothing must immediate-ly be neutralised using acid converter or so-ap suds, and the spots must be flushed withplenty of water.If acid is swallowed, immediately visit / call adoctor.

WARNINGAlways wear safety glasses.Keep children away from acids and batt-eries.


EXPLOSION DANGERA battery being charged produces a highly explosive gas which is why firesparks naked flames and smoking areprohibited

-, ,

,.

FIRE HAZARDAvoid generating sparks and electrostaticdischarges when handling cables and elec-trical devices.Avoid short circuits.

Battery acid is highly caustic, so alwayswear safety gloves and glasses.Do not tilt the battery as acid can leak fr-om the ventilation openings.

DANGER-CAUSTIC ACTION

CAUTIONDo not expose batteries to direct sunlig-ht. Discharged batteries can freeze, so t-hey must be stored in a place where thetemperature remains above 5°- 15 .Professional maintenance,charging andstorage will increase the lifespan of thebattery and are a condition for the hono-uring of guarantee claims.

℃

WARNINGTake a dead battery to a collection pointNever dispose of one with household ref-use

.

.

36

Removing and installing the battery


- Turn off the ignition.- Remove the four screw(1)and open the in-

spection cover (2).

CAUTIONThe battery may only be connected or di-sconnected while the ignition is inactive.

First disconnect the minus terminal ( 3,black cable ).

When installing the battery,first connectthe plus terminal (4, red cable).

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

- Disconnect the battery.- Remove the battery.Installation takes place in reverse order todisassembly.

1

2

41

3

37

38

Headlight


Changing the bulb

NOTEUse only tested,incandescent bulbs with th-e ‘

bulb:

E’ designation. Use of non-approved bul-bs will void the operating license. Do not to-uch the bulbs with bare fingers. Hold bulbswith a clean, dry cloth when installing or re-moving them.

Low beam-high beam12V 35W/35W

- Turn off the ignition.- Remove the screws and bolts (1).- Take off the headlight cover (2).

- Remove the rubber cover (4).- Disconnect the holder clamp (5)


- Disconnect the plug (3).

.- Press the indicator bulb and turn counter-

clockwised, take off the bulb (6).

5

6A

1

NOTEWhile installation, align A to B.

1 1

1

1

B

3

3

3

5

42

39

Front indicator


Changing the bulbs Front indicator- Remove the screws and bolts (1).- Take off the headlight cover (2).

Disconnect the plug (3).

Bulbs:

-- Press the indicator bulb and turn counter-

clockwised, take off the bulb(4).


12V 10W

NOTEDo not touch the bulbs with bare fingers.Hold bulbs with a clean, dry cloth when ins-talling or removing them.

1 1

1 1

1

3

3

3

4 4

NOTEWhile installation, align A to B.

B

2

40


Rear indicator and Tail / brake light

Rear indicator-

-

Remove two bolts with washers (1).- Remove four bolts with washers (2) and

take off the handle holder (3).- Open the seat.

Remove four bolts (4) and two nuts withwashers from the storage.

- Take off the storage box (5) with the seat.- Remove the screws (6) and take off rear

center cover (7).

1 1

2

NOTEDo not touch the bulbs with bare fingers.Hold bulbs with a clean, dry cloth when ins-talling or removing them.

2 2

3 4

5

6 7

Changing the bulb

4

41

8 8

9 9

Rear indicator and Tail / brake light


Rear indicator


- Remove the bolts (8) screws(9) andtake off left/ right rear side cover (10).

- Press the indicator bulb and turn counter-clockwised, take off the bulb.

Bulbs: 12V 10W

8 8

10 10

NOTEDo not touch the bulb with bare fingers.Hold bulbs with a clean, dry cloth when ins-talling or removing them.

Bulbs:Tail / brake light

12V 21W/5W

42

Check the headlamps


- Start the scooter and run the engine.

- Activate the dipped beam.

- Use a screwdriver to adjust the screws (1)for the vertical and horizontal angle of theilluminated surface area of the road top forthe headlamp.

NOTEIf you have problems adjusting the head-lamps, see a specialised dealer.An incorrect adjustment is punishable bylaw. Remember, you are responsible forthe correct adjustment of the motorbike

,s

headlamp.

WARNINGDo not run the engine in an enclosed sp-ace (risk of asphyxiation).

Position the motorcycle on a level floor 5 m(measured from the headlamp) from a lightcoloured wall with a rider seated on the mo-torcycle and the tyres filled at the correct p-ressure.

- Measure the distance from the floor to thecentre of the headlamp and mark the heig-ht on the wall with a cross. Draw a secondcross 12 cm beneath the first cross.

Adjusting the headlamps

H

5mH

1 1

TECHNICAL DATA

Engine type

Pistion displacement:

Bore:

Stroke:Compression ratio:

Cooling:

Maximum net power output:

Maximum net torque:

Ignition system:

Construction: One cylinder stroke petrol engine-4

cm349.46

Fan air cooled

ECU

LJ1P37QMB

φ mm37

mm46

12:1

45km 2.9 kW / 8000rpm/h: 25km/h: 2.2 kW / 6500rpm

45km/h: 3.4 7500 25km/h: 3.3 Nm / 6000rpmNm / rpm

Spark plug:

Electrode gap:

Carburettor:Idle speed:

Air-filter:Type of starter:

NGK CR6HSA

0.7-0.8 mm

SVB18 18M

1900±100 /r min

Paper filter element

Electric starter and kick starter

LJ50QT-4B

43

Centrifugal type

CVT

Telescopic fork

Light metal (Alu) MT 2.75 12 or 3.00 12× ×

120/70-12 56J or 51P tubelessor 51J

Disc brakeφ mm190

Drum mmφ110

LJ50QT-4B

Unit swing, hydraulic shock absorption

Light metal (Alu) MT 2.75×12 or 3.00 12×

120/70-12 56J or 51P or 51J tubeless

One Rider: Two Rider:Front: 1.75Kg/cm Rear: 2.00Kg/cm Front: 2.00Kg/cm Rear: 2.25Kg/cm2 2 2 2

Power transmission

Transmission:

ChassisScooter version:Front suspension:

Rear suspension:

Wheels front:

Wheels rear:

Tires front:

Brakes, front:

Brakes, rear:

Clutch:

Tires rear:Tire pressure:

TECHNICAL DATA

LJ50QT-4B

44

TECHNICAL DATA

Lubricants and operating fluids

6.5 LitersFuel: Unleaded fuel min. 95 octane

Engine oil:

Filling quantity:

Transmission oil:

Filling quantity: 0.14 litresElectrical EquipmentGenerator:

Battery:

Fuse:

Head light:

Instrument lights Speedometer:

Control lights indicator and high beam:Brake/rear light:

Front / Rear turn signal light:

Fuel tank capacity:

SAE 15W/40 mineral oil API (SJ or higher)

litres0.8APIHypoid-oil SAE 80W-90 GL4

Front light:

LJ50QT-4B

12V 7Ah MF15A

Low beam/High beam 12V 35W/35W

12V 3W

12V 3W

12V 101W

12V 21W/5W

12V 10W

12V 5W / LED 12V 0.42W

45

TECHNICAL DATA

Dimensions and weights

Width across handlebars:

Maximum height:

Wheel base:

Seat height:Weight empty:

Weight in running order:

Max. permitted total weight:

Top speed:

Overall length: 1950 mm

695 mm without rear view mirror

97 kg

45 km/h or 25km/h

760mm

103 kg

263 kg

1385mm1145 mm without rear view mirror

LJ50QT-4B

46

Warranty conditions

In case of an occurring fault we will providethe customer with the following performanc-es through the authorized dealer (seller) wi-thin the scope of its statutory warranty obli-gations:

1. Within warranty period, we will rectify anydeficiencies caused by material or manu-facturing faults through the authorized d-ealer (seller) by repairing or replacing theaffected part according to the statutory w-arranty regulations. We may deny the re-quested repair or replacement of the fau-lty part if this would only be possible withdisproportionately high costs.In this casewe rectify the deficiency through the aut-horized dealer (seller) by applying the ot-her possible type of subsequent fulfillme-nt. If both types of subsequent fulfillmentare only possible with unproportionately

high costs, we deny the subsequent fulfi-llment all-together through the authorzieddealer (seller). The customer is then enti-tled to legal claims. Replaced parts passover into the possession of us.

r

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

3. The warranty does not cover normal we-ar and tear caused by normal use as we-ll as wear and tear caused by inappropri-ate handling and inappropriate use. Oxi-dation and corrosion are caused by envi-ronmental influences and are also not co-vered under warranty.

4. Warranty claims lodged by the cuistomerwill be rejected in case of: Manipulationsto the motorcycle, installation of a differe-nt exhaust system, changes to the gear-box or secondary transmission ratio and

installation of accessories or spare partswhich have not been approved by us.Repairs carried out in workshops not au-thorized by us and the non-compliancewith the maintenance intervals in the wo-rkshop of an authorized dealer will alsocause the rejection of warranty claims.

5. When lodging a warranty claim the custo-mer must present the correctly filled in s-ervice book to the seller.

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

WARRANTY

47

WARRANTY

List of wear parts

Cleaning / inspection during every maintenance.

must be replaced during each maintenance interval to ensure proper function.

Wear limits

depending on riding style, load and tire pressure the wear limit may already bereached after only 500 km or even earlier.

depending on riding style, load and tire pressure the wear limit may already bereached after only 1500 km or even earlier. Check during each maintenance.Oxidation is a lack of maintenance!

during the first inspection, then with every maintenance interval(every 3000 km/6000 km).Check oil level before every ride.

depending on road conditions / unevenness of the road surface the lifetime will bereduced, this may already occur after 500 km.

depending on riding style and load these may already be worn after 1500 km,in cross-country operation even earlier.

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

depending on road conditions and care wear may start after 1500 km.Soiling of the wheel hub reduces the lifetime.Check during each maintenance interval, do not clean with a high pressure cleaner!

depending on load and care after 1500 km, check with every maintenance.

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

Plastic parts will be damaged by caustic or penetrating cleaning agents or solvents.

Tires, houses, rims

Wheels, hubs

Spring fork, spring strut

Sedal rings, sealants, O-rings

Wear parts

Oils, air filter, leakage inspection onengine

Lamps, incandescent bulbs, electricsystem

Barke linings, brake shoes, brake lines

Radial seals on engine, gearbox, fork andwheels

Wheel bearings, steering bearings

Swing arm bearing

Cables

Coverings

48

WARRANTY

List of wear parts

depending on use and care from the 6th month

Wear limitswith each maintenance interval.

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

Bowden cables,brake cables,throttle cables

Wear partsAir cleaner, oil filter

Mirror glasses

Self-locking nuts, cotter pins locking platesbonded screw connections

Spark plug

depending on ambient temperatures failures can be expected in the 6th month,when used for short rides even earlier.

Starter battery, batteries, fuses, starterbrushes

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

Variomatic, CVT, rolls, belts

Clutch linings / friction discs

depending on riding style and load these may be worn after 500 km.

depending on riding style and load these may be worn after 500 km.

Pistons, cylinders, crankshaft, conrods,engine bearings

depending on riding style, load and care these parts may be worn after 200 hours.When riding mainly with full throttle even earlier.

with each or every second maintenance interval.

depending on use and care from the 6th month, in winter and short distance operationeven earlier. Oxidation is a lack of maintenance!

Exhaust system, inspection of mountings

49

Please bserve the following:- During and after the warranty period all in-

spections should solely be performed by aspecialised dealer approved by us.

- Observe the inspection intervals and havethe specialised dealer confirm them on theguarantee certificate.

- Use only original spare parts.

o

INSPECTION PLAN

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 following in-spection intervals must be complied with:

At 1,000 km (1 service)Every 3,000 km / or after 6 months

st

Every 6,000 km / or after 12 months

After the warranty period the inspection int-evals specified in this manual must be app-lied as follows:

Every 3,000 km / 6 monthsEvery 6,000 km / 12 months

WARNINGFor safety reasons, do not carry out anyrepair or adjustment activities to the sc-ooter and chassis that exceed a closelyrestricted scope. Tinkering with safety-relevant parts could threaten the safetyof yourself and third parties.

This applied especially to the exhaust s-ystem, carburettor, ignition system, forkcolumn, brake system and lights.

Before starting work on the electrical sy-stem, disconnect the minus terminal ofthe battery.

50

INSPECTION PLAN

I = Inspection, cleaning, and adjustmentA = ReplacementR = Cleaning (replaced if necessary)S = LubricationComponentAssembly

Beforeeachtrip

1 st serviceafter

1000 km

Every3.000 km /6 months



Throttle cable adjustment

Transmission oil

Transmission check for leakage

Crankecase check for leakage

Crankecase vetilation

Driving belt, fight weight

Clutch discs

I

III

IIIII

I

AIIII I

IIA AIII

RRAIII

IIIIIIII I/A

I/AI

A

AA

Air cleaner foam

Oil filter (screen)

Engine oil

Fuel filter

Spark plug

Ignition time

Valve clearance

Compression check

Carburetor (Idle speed)

51

INSPECTION PLAN

ComponentAssembly

Beforeeachtrip

1 st serviceafter

1000 km




Brake function, brake pads

Brake fluid

Main-and side stand

Bolts and nuts (chassis)

I

IIIIIIIIII

I IIII

IIII I

IIIIII

III

III

I/SI

A / every 2 years

Bolts and nuts (engine)

Compression teat

Exhaust system

Fuel tank, fuel hoses

Battery

Stearing and bearings

Front and rear suspension

Shock absorption

Tire pressure

I = Inspection, cleaning, and adjustmentA = ReplacementR = Cleaning (replaced if necessary)S = Lubrication

I

52

1,000 km/1 months1 service

dealer stamp:

st

km......................................

date....................................

After 3,000 km/6 months

dealer stamp:

km......................................

date....................................

MAINTENANCE CONFIRMATION

km......................................

date....................................


dealer stamp:

km......................................

date....................................


dealer stamp:

km......................................

date....................................


dealer stamp:

km......................................

date....................................


dealer stamp:

km......................................

date....................................


dealer stamp:

km......................................

date....................................


dealer stamp:

53

MAINTENANCE CONFIRMATION

New brake fluidYes no

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

Stamp, signature


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

Stamp, signature


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

Stamp, signature


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

Stamp, signature

54

Date post:	25-Aug-2020
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

Ownersmanual - HANSAPOST · 2019. 6. 4. · 12 SAFETYTEST Checklist...

Documents