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- Owner's Manual
Sachs Bikes MadAss 125 Owner's Manual
Summary of MadAss 125
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Your sachs dealer sachs uses and recommends sachs fahrzeug- und motorentechnik gmbh ernst-sachs-straße 6 • d-90441 nürnberg phone: +49 (0)911 4231 400 • fax +49 (0)911 4231 332 e-mail: info@sachs-bikes.De • www.Sachs-bikes.De nr. P00 646 008 00 02 000 2006 04 005.
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125 owners manual.
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125.
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Preface reprinting, reproduction and translation, even of excerpts, without our express consent is not permitted. All rights stipula- ted in the copyright law remain expressly reserved. Technical changes to the standard motor- cycles can cause the ec type approval to become invalid. Therefore before...
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1 contents riding instructions ride safely ............................................................................... 22 ride economically and be aware of the environment .............. 23 running-in instructions ............................................................ 24 side stand ..........
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2 contents notes on maintenance checking steering bearing ....................................................... 38 checking the telescopic fork and shock absorber ................... 38 adjusting the shock absorber .................................................. 39 removing the front wheel .......
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3 2 1 observe the following: warning precautionary measures against the risk of accidents, injury and/or death. Fire hazard the bike is supplied with a catalyst. The exhaust system becomes very hot. While riding, idling or parking, make sure that no easily inflammable materials (such as hay, leaves, ...
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4 2 5 1 7 4 3 6 8 9 right-hand side view 1 brake fluid reservoir rear brake 2 brake fluid reservoir front brake 3 chassis number and rating plate 4 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.
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5 11 10 12 13 15 16 14 17 18 10 cockpit 11 handlebar fittings 12 tank cap 13 adjustment shock absorber 14 pillion footrest, fold-up 15 side stand 16 footrest 17 gear shift pedal 18 air filter housing left-hand side view overview and operation.
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6 5 4 7 3 2 1 6 11 10 8 9 1 intake valve adjuster cover 2 exhaust valve adjuster cover 3 spark plug connector 4 electric starter 5 oil drain plug 6 clutch cover 7 oil filler cap engine right-hand side view 8 carburetor 9 fuel tap 10 engine number 11 gear shift pedal engine left-hand side view overvie...
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7 8 9 10 12 11 1 2 6 3 5 4 7 a b 8 emergency off switch engine will not start engine starts 9 handbrake lever 10 throttle 11 light switch off position light driving light 12 starter button right-handle handlebar fittings left-handle handlebar fittings 1 fixed grip 2 clutch lever 3 head light switch hi...
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8 1 2 2 1 4 5 6 3 7 ignition-lock note the ignition-lock as well as the tank cap are operated with the same key. Key positions 1 operating position: ignition and all circuits activated. 2 ignition off. Warning while riding, do not switch the ignition off ! Note activate the parking light only for a ...
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9 s m 0 kmh 0 dst s m 0 kmh 12 : 00 clk s m 0 kmh 11 : 55 clk s m speedometer set-up note the display is only visible when the ignition is on. M mode for: dst = total distance (km) trip = trip odometer clk = clock time s set for clock time and to clear trip odometer button m press once changing from...
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10 3 4 5 6 7 7 1 1 2 3 4 speedometer battery change note if the ignition is turn off the clock is supplied by the battery power. Always replace both batteries. After disconnecting and reconnecting the battery the clock time needs to be reset. - remove the screws (1) and take off the speedometer (2)....
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11 before each ride, carry out a safety check using the checklist. Take the safety check seriously. Carry out maintenance activities before you start your ride ( maintenance) or ask a specialized sachs dealer to do so. This will provide you with the certainty that your mo- torcycle corresponds to tr...
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12 1 a 2 3 safety test clutch clutch lever play caution if you drive with no clutch lever play, the clutch will be damaged. Checks: - pull the lever until there is discernable resistance. - measure the play. Required value: a = 3-4 mm adjustment: - remove the rubber cap (1). - release the lock nut (...
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13 1 3 2 safety test warning fuel is highly inflammable and can ex- plode. Do not smoke or bring a naked flame near the fuel tank. Fuel expands under the influence of heat and the sun. Therefore, never fill the tank to the brim. Never fill the tank while the engine is running. Never bring a glowing cigar...
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14 r a z 4 r a z safety test fuel tap caution when you stop the engine, always set the fuel tap to position close. Oth- erwise, fuel could enter the engine and this could make starting difficult or lead to serious engine damage. We cannot be held liable under the guarantee for damage caused by non- o...
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15 -10° 0° 10° 20° 30°40° c - 20° sae 10w/30 sae 10w/40 10w/50 sae 15w/40 15w50 sae 20w/50 engine oil caution do not use additives. Since the oil also serves to lubricate the clutch, do not use car engine oils supple- mented with friction modifiers (such energy-conserving oils can lead to the clutch...
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16 max . Min . 1 safety test checking the oil level caution checking the oil while the engine is cold will lead to a wrong measurement and therefore the wrong oil quantity. In order to avoid engine damage, never exceed the maximum oil level nor let it drop below the minimum level. - stop the warmed-...
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17 1 upper lower lower upper 2 safety test warning sudden changes in play or a spongy feel of the brake lever can be caused by faults in the hydraulic system. Do not ride on when in doubt about the oper- ability of the brake system. Immediately consult a sachs dealer. Check the brake-fluid level warn...
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18 1 1 safety test front brake checking the brake linings warning the brake disks and brake linings must be free of oil and grease. Brake linings (1) are subject to wear. In order to guarantee the operability of the brake system, the wear limits of the brake linings must not have been reached. Check...
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19 a safety test drive chain caution the chain setting affects the wear on the drive chain and sprocket as well as the spring excursion of the rear wheel. Regularly clean and lubricate the drive chain. Check the chain setting and the drive chain for damage before each run. Check the chain t...
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20 2 1 safety test checking the tyre pressure warning adjust the tyre pressure according to the total weight load. Never exceed the rated total weight or the bearing capacity of the tyres. Incorrect tyre pressure will have a con- siderable effect on the riding properties of the motorbike and the lif...
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21 safety test load / lights warning for the sake of your safety, use only original sachs accessories or products released by sachs. Sachs cannot judge for each third-part product whether it can be safely used in combination with your sachs motorcycle. Nor can a official approval give such a guarante...
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22 riding instructions ride safely caution riding safety is largely also determined by 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 h...
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23 riding instructions ride economically and be aware of the environment fuel consumption, environmental pollution and wear of engine, brakes and tyres de- pend on various factors. Your personal riding style is highly deter- minant for economical fuel consumption and exhaust gas and noise generation...
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24 riding instructions running-in running-in instructions for engine and transmission caution excessive revs while running-in the en- gine increases the wear of the engine. Engine faults during the running-in period must be immediately reported to a specialized sachs dealer. Note during the running-...
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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 far forward as it will go and stop by foot. - slowly tilt the motorbike to the left until its weight is supported. Caution the mo...
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26 r a z 1 2 3 riding instructions before starting - put the motorcycle it in a vertical position and fould up the side stand. - turn the fuel chock (1) to position a = on or r = reserve - mount the motorcycle. - turn the ignition key (2) to its operating position . Warning before beginning a ride, ...
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27 1 a b 3 2 4 riding instructions starting with kick starter caution avoid high engine-speed counts after a 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. Caut...
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28 5 3 4 1 a b 2 riding instructions starting with electric starter caution avoid high engine-speed counts after a cold start. The starter is active only with pulled clutch lever. - turn the choke (1) in the direction of the arrow "a" for cold start. - do not open the throttle (3). - pull in the clu...
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29 2 1 riding, shifting gears riding instructions caution avoid: – 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 o...
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30 riding instructions braking oil and grease warning the brake discs and linings must be free of oil and grease! If the motorcycle is not used for a while, a rust film may form on the brakes and thus increase the braking effect. A thick rust film can cause the brakes to lock up. When setting out on a...
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31 1 2 riding instructions braking braking the front brake and rear brake are operated independently from each other. The front brake is operated via the handbrake lever (1) on the handlebars, and the rear brake is operated by stepping on the footbrake lever (2) with the right foot. When stopping or...
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32 r a z 2 1 1 riding instructions stopping the engine - turn the ignition key to the position (1). - pull out the ignition key. Caution turn the fuel chock (2) to the off position (z). In the on (a) or res (r) position, fuel could enter the engine, leading to serious damage when start- ing the engi...
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33 service instructions servicing the motorbike / cleaning agents note regular, expert service will help maintain the value of your motorcycle and is a condition for guarantee claims for corrosion and other such damage. Caution rubber and plastic parts will be damaged by caustic or penetrating clean...
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34 service instructions servicing the motorbike / cleaning agents 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 dry cloth, to avoid scratching the paint or covering. Preservation ag...
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35 service instructions repairing paint damage minor paint damage should be immediately repaired. If the motorcycle is not used for a longer period, it is recommended to support the motorcycle so that its weight is not on the tyres. You can prevent the tyres from becoming dry and brittle by spraying...
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36 service instructions lay-up / commission lay-up - clean the motorcycle. - 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 wit...
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37 service instructions technical changes, accessories and spare parts warning technical changes to the motorcycle can lead to cancellation of the ec operating license. Should you want to make technical changes, observe our guidelines. This will serve to prevent the motorcycle from being damaged and...
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38 1 1 2 2 checking the steering bearings checking the telescopic fork checking the shock absorber notes on maintenance note the telescopic fork should not jam up when turned and it should swing back lightly to both end positions. - pull the hand brake to block the front wheel brake. - hold the hand...
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39 b a 2 3 1 adjusting the shock absorber notes on maintenance warning before taking a ride adjust the spring preload of the spring strut according to the total weight! A = harder b = softer adjusting the spring preload note the spring preload can be infinitely ad- justed. Slacken the locking nut (1)...
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40 2 1 3 3 removing the front wheel caution take care not to damage the brake discs and linings while removing them. Do not operate the handbrake lever after the wheel has been removed. Protect the wheel bearings from dirt and moisture. - support the motorcycle so that the front wheel can move freel...
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41 2 3 5 1 3 4 installing the front wheel caution take care not to damage the brake discs and linings (4) while installing them. Have a sachs dealer check the tightening torques. - roll the front wheel in between the fork tubes and insert the spacer bush (4) (on the right as seen from the riding dir...
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42 3 4 2 5 2 1 8 6 removing the rear wheel caution do not damage brake disc and linings during removal! Protect the wheel bearings from dirt and moisture! Note when taking off the rear wheel, make sure that the bush (3) to the left of the wheel hub is not lost. - raise the rear wheel, remove the ful...
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43 3 4 7 5 2 1 6 9 8 installing the rear wheel caution do not damage brake disc and linings during installation! Have a sachs dealer check the tightening torques. - clean and grease the full floating axle (4). - introduce full floating axle (4), chain adjuster (7), brake support (8) with brake caliper...
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44 1 checking the chain for wear caution the chain, sprocket and pinion must be changed as one unit. - prop the motorbike up on the side stand. - hold the chain (1) at the furthest rear point of the sprocket and pull it off. - with correct chain tension, it should not be possible to lift the chain h...
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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 wheel must be in line with the front wheel). - let the rear end of the motorbike drop to the suspension limit. - push in the drive chain up half wa...
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46 checking the brake linings caution the minimum lining thickness must be maintained. Note for your own safety, we recommend having activities to the brake system carried out by a sachs dealer. Front wheel brake - visually inspect the brake calliper (1). - check the thickness of the...
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47 3 rear wheel brake adjusting the footbrake pedal position warning check the play on the footbrake pedal and ensure that the brake is functioning properly. A soft and spongy feel when operating the foot brake indicates that there is air in the brake system. You should have the brake system...
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48 1 a 2 3 4 5 7 6 adjusting the clutch lever caution if you drive with no clutch lever play, the clutch will be damaged. Check: - pull the lever until there is discernable resistance. - measure the play. Required value: a = min. 3-4 mm adjustment: - push back protective cap (1). - release the lock ...
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49 6 6 6 7 5 2 4 3 1 8 9 cleaning the air filter - clean the foam with motorrex air clean- er. - afterward soak and wring out the foam with air filter oil. Caution check for properly installation of the foam housing (9) and the manifold pipes (5) in the filter case. Otherwise the engine runs poorly or ...
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50 1 1 a 2 3 cleaning the fuel filter note we recommend to have the fuel filter (1) cleaned by a sachs-dealer. Clean for the first time after 1.000 km clean every 4.000 km notes on maintenance check: - check the throttle cable for light move- ment by turning the twist grip (1) from closed to open posit...
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51 1 2 spark plug check and change caution check or change the spark plug only when 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 burnt away. - insert new spark plug ngk c...
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52 battery warning always wear safety glasses. Keep children away from acids and batteries. Explosion danger a battery being charged produces a highly explosive gas, which is why fire, sparks, naked flames and smoking are prohibited. Fire hazard avoid generating sparks and electrostatic discharges whe...
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53 5 4 3 1 1 2 removing and installing the battery caution the battery may only be connected or disconnected while the ignition is inactive. First disconnect the minus terminal (4, black cable). When installing the battery, first connect the plus terminal (5, red cable). The battery is maintenance-fr...
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54 1 1 1 2 3 4 checking the fuse caution never 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 of...
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55 1 2 3 4 4 5 6 7 changing the bulbs note use only tested, incandescent bulbs with the ‘e’ designation. Use of non-approved bulbs will void the operating license. Do not touch the bulbs with bare fingers. Hold bulbs with a clean, dry cloth when installing or removing them. Headlight 1 = low beam bul...
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56 1 the tail / brake light (1) is not fitted with a replaceable light bulb (diode light). If the tail light does not work you should first check, whether a cable connection is interrupted. Tail / brake light if this is not the case, the tail light must be replaced by a sachs dealer. Notes on maintena...
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57 2 1 1 2 3 changing the bulbs indicator lamps note for changing the bulbs an opening of the glass cover (1) is not required. Do not touch the bulbs with your bare hands. Use a clean, dry cloth for installation and removal. Indicator bulbs front/rear: 12 v/21w rear indicator front indicator - relea...
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58 12cm h 5m h 2 1 adjusting the headlamps adjusting the headlight - activate the dipped beam. - use the adjusting screw (1 and 2) on both sides to adjust the angle of the asymmetrically illuminated surface area of the road top. - release srews (1) and (2), adjust and tighten up. Note if you have pr...
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59 engine type: 4-speed model: ip52fmi construction: one cylinder 4-stroke petrol engine valve steering: 1 overhead cam with rocker arms valve: 2 valve valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm pistion displacement: 119.7 cm 3 bore: ø 52,4 mm stroke: 55,5 mm compression ratio: 9,3:1 ...
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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...
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61 technical data chassis motorbike version: 4-speed model: type 646 frame: center-type frame made of tubular steel front suspension: telescopic fork ø 37 mm , hydraulic shock absorption, travel 100 mm rear suspension: mono shock absorber, travel 65 mm wheels: light metal (alu) front rim size: = 1,8...
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62 technical data lubricants and operating fluids fuel tank capacity: 5,1 litres, including 0,35 litres reserve fuel: unleaded fuel min. 91 octane telescopic-fork oil: viscosity sae 10 w filling quantity per fork tube: 180 cm 3 engine oil: filling quantity: sae 15 w 40 mineral oil api (sg or higher) ...
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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 coc...
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64 technical data dimensions and weights overall length: 1840 mm width across handlebars without 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...
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65 warranty warranty conditions in case of an occurring fault the company sachs fahrzeug- und motorentechnik gmbh will provide the customer with the following performances through the autho- rized sachs-dealer (seller) within the scope of its statutory warranty obligations: 1. Within a period of 24 ...
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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 reached after only 1000 km or even earlier. Wheels, hubs depending on riding style, load and tire pressure the wear limit may already be reached af...
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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 cleane...
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68 inspection plan please observe the following: - during and after the warranty period all inspections should solely be performed by a specialised dealer approved by us. - observe the inspection intervals and have the specialised dealer confirm them on the guarantee certificate. - use only original s...
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69 inspection plan component assembly servicing tasks (*only by an authorised sachs dealer) before each trip 1st service after 1000 km every 4.000 km / 4 months every 8.000 km / 8 months valves check and adjust valves if necessary (cold)* x x spark plugs check condition and accordingly clean or repl...
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70 inspection plan component assembly servicing tasks (*only by an authorised sachs dealer) before each trip 1st service after 1000 km every 4.000 km / 4 months every 8.000 km / 8 months rear suspension check, retighten, replace if necessary or lubricate* every 24.000km / 2 years tyres check gereral...
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71 workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date maintenance confirmation.
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72 maintenance confirmation workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date.
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73 km .................................. Date................................. Km .................................. Date................................. Km .................................. Date................................. Km .................................. Date..............................
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74 km .................................. Date................................. After 44.000 km/44 months dealer stamp km .................................. Date................................. After 40.000 km/40 months dealer stamp km .................................. Date............................
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75 new brake fluid yes no km ..................................... Date .................................. Stamp, signature new brake fluid yes no km ..................................... Date .................................. Stamp, signature new brake fluid yes no km ...................................
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Page 81: Motorbike Data
77 db(a) min — sachs fahrzeug-und motorentechnik gmbh e1-0279 wsf 646a1061000101 82 3.750 rating plate (sample): motorbike data (fill out on purchase) model designation: ...................................................... Vehicle identily no: ...................................................... ...
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