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Sachs Bikes MadAss 50 Owner's Manual

Summary of MadAss 50

  • Page 1

    Your sfm dealer sfm gmbh strawinsky-straße 27b · d-90455 nürnberg phone: +49 (0)9122 60 39- 0 · fax +49 (0)9122 60 39- 332 e-mail: info@sachs-bikes.De · www.Sachs-bikes.De 2008 10 002.

  • Page 2: Owners Manual

    50 owners manual.

  • Page 3

    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...

  • Page 4

    1 contents riding instructions ride safely ............................................................................... 24 ride economically and be aware of the environment .............. 25 running-in instructions ............................................................ 26 side stand ..........

  • Page 5

    2 contents notes on maintenance checking steering bearing ....................................................... 40 checking the telescopic fork and shock absorber ................... 40 adjusting the shock absorber .................................................. 41 removing the front wheel .......

  • Page 6

    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 in fl am ma ble materials (such as hay, lea...

  • Page 7

    4 5 1 7 3 6 8 9 4 2 right-hand side view 1 brake fl uid reservoir rear brake 2 brake fl uid 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 illustr...

  • Page 8

    5 11 10 12 13 15 16 14 17 10 cockpit 11 handlebar fi ttings 12 tank cap 13 adjustment shock absorber 14 pillion footrest, fold-up 15 side stand 16 footrest 17 gear shift pedal left-hand side view overview and operation illustration, 4- gear model.

  • Page 9

    6 5 4 7 3 2 1 6 10 8 9 11 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 fi ller cap 8 carburetor 9 air fi lter housing 10 fuel tap 11 engine number overview and operation right hand view of engine, 4-gear ...

  • Page 10

    7 9 8 10 6 7 3 2 1 5 4 overview and operation right-hand view of engine, automatic model 1 service cover, intake valve 2 service cover, exhaust valve 3 spark plug socket 4 starter 5 oil drain plug 6 oil level inspection glass 7 oil fi ller plug left-hand view of engine, automatic model 8 carburettor...

  • Page 11

    8 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 fi ttings left-handle handlebar fi ttings 1 fixed grip 2 clutch lever 3 head light switc...

  • Page 12

    9 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 li...

  • Page 13

    10 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 fro...

  • Page 14

    11 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)....

  • Page 15

    12 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 spe cial ized sfm dealer to do so. This will provide you with the cer tain ty that your mo- torcycle cor re sponds t...

  • Page 16

    13 1 a 2 3 safety test 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 (2). - t...

  • Page 17

    14 1 3 2 safety test warning fuel is highly infl ammable and can ex- plode. Do not smoke or bring a naked fl ame near the fuel tank. Fuel expands under the infl uence of heat and the sun. Therefore, never fi ll the tank to the brim. Never fi ll the tank while the engine is running. Never bring a glo...

  • Page 18

    15 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- er wise, fuel could enter the engine and this could make starting diffi cult or lead to se ri ous engine damage. We cannot be held liable under the guarantee for damage caused by n...

  • Page 19

    16 -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 sup ple ment ed with fric- tion modifi ers (such energy-con serv ing oils can lead to the ...

  • Page 20

    17 max . Min . 1 safety test caution checking the oil while the engine is cold will lead to a wrong measurement and therefore the wrong oil quan ti ty. In order to avoid engine damage, never ex ceed the maximum oil level nor let it drop below the minimum level. - stop the warmed-up engine, wait for ...

  • Page 21

    18 2 min. Max. 1 safety test caution checking the oil on a cold engine will lead to misinterpretation and thus to an incorrect oil level! In order to avoid engine damage: do not exceed the maximum level! Do not allow to drop below the minimum level! - shut the engine down at operating temperature, w...

  • Page 22

    19 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. Im me di ate ly consult a sfm dealer. Check the brake-fl uid level ...

  • Page 23

    20 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...

  • Page 24

    21 a mm 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 tension...

  • Page 25

    22 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 prop er ties of the motorbike and the l...

  • Page 26

    23 safety test load / lights warning for the sake of your safety, use only original sfm accessories or prod ucts released by sfm. Sfm cannot judge for each third-part prod- uct whether it can be safely used in combi- nation with your sfm mo tor cy cle. Nor can a of fi cial approval give such a guar ...

  • Page 27

    24 riding instructions ride safely caution riding safety is largely also de ter mined by the manner of riding. Therefore: – put on a tested/approved safety hel met and correct close the buckle. – wear suitable protective clothes. – rest your feet on the footrests. – do not ride if your riding abilit...

  • Page 28

    25 riding instructions ride economically and be aware of the environment fuel consumption, environmental pol lu tion and wear of engine, brakes and tyres de- pend on various factors. Your personal riding style is highly de ter - mi nant for economical fuel con sump tion and exhaust gas and noise gen...

  • Page 29

    26 riding instructions running-in instructions running-in instructions for engine and gearbox caution exceeding the running-in speeds incre- ases the wear of the engine! In case of engine problems during the running-in period you should immediately consult your specialized sfm-dealer. Note during th...

  • Page 30

    27 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...

  • Page 31

    28 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, ...

  • Page 32

    29 1 a b 5 4 2 3 riding instructions starting with kick starter caution avoid high engine-speed counts af ter a cold start. - turn the choke (1) in the direction of the arrow "a" for cold start. - do not open the throttle (2). Automatic model: - pull the hand brake lever (3) and hold it. Then operat...

  • Page 33

    30 1 a b 2 6 3 4 5 riding instructions starting with electric starter 4- gear model caution avoid high engine-speed counts af ter 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). ...

  • Page 34

    31 1 2 3 4 3 2 n 1 start-up riding instructions 4- gear model shifting gears caution avoid: – crashing the gears – changing gear without operating the clutch – changing down at high rpm's – too low and too high rpms (un nec - es sary wear and fuel con sump tion). Starting / shifting up - pull in the...

  • Page 35

    32 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 fi lm may form on the brakes and thus increase the braking effect. A thick rust fi lm can cause the brakes to lock up. When setting out ...

  • Page 36

    33 1 2 riding instructions braking braking the front brake and rear brake are op er at ed independently from each other. The front brake is operated via the handbrake lever (1) on the han dle bars, and the rear brake is operated by step ping on the footbrake lever (2) with the right foot. When stopp...

  • Page 37

    34 r a z 2 1 1 riding instructions stopping the engine - turn the ignition key to the po si tion (1). - pull out the ignition key. Caution turn the fuel chock (2) to the off po si tion (z). In the on (a) or res (r) position, fuel could enter the engine, leading to se ri ous damage when start- ing th...

  • Page 38

    35 service instructions servicing the motorbike / cleaning agents note regular, expert service will help main tain the value of your motorcycle and is a condition for guarantee claims for cor ro sion and other such damage. Caution rubber and plastic par ts will be dam aged by caustic or penetrating ...

  • Page 39

    36 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...

  • Page 40

    37 service instructions repairing paint damage minor paint damage should be im me di ate ly repaired. If the motorcycle is not used for a long er period, it is recommended to support the motorcycle so that its weight is not on the tyres. You can prevent the tyres from be com ing dry and brittle by s...

  • Page 41

    38 service instructions lay-up / commission lay-up - clean the motorcycle. - remove the battery. Observe the maintenance in struc tions. - spray suitable lubricants onto the brake- lever and clutch-lever joints and the side- standard and main-stan dard bearings. - rub bright / chromium-plated parts ...

  • Page 42

    39 service instructions technical changes, accessories and spare parts warning technical changes to the mo tor cy cle can lead to cancellation of the ec op er at ing license. Should you want to make technical chang- es, observe our guidelines. This will serve to prevent the motorcycle from being dam...

  • Page 43

    40 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...

  • Page 44

    41 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 infi nitely ad- justed. Slacken the locking nut (...

  • Page 45

    42 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...

  • Page 46

    43 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 sfm 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 direc...

  • Page 47

    44 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...

  • Page 48

    45 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 sfm dealer check the tightening torques. - clean and grease the full fl oating axle (4). - introduce full fl oating axle (4), chain adjuster (7), brake support (8) with brake calip...

  • Page 49

    46 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...

  • Page 50

    47 2 1 3 a mm 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 way betw...

  • Page 51

    48 ! ! ! ! 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 sfm deal er. Front wheel brake - visually inspect the brake calliper (1). - check the thickness of the brake li...

  • Page 52

    49 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 bled ...

  • Page 53

    50 1 a 2 3 4 5 7 6 adjusting the clutch lever 4-gear model 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). - rele...

  • Page 54

    51 8 2 4 3 1 1 5 7 7 6 cleaning the air fi lter notes on maintenance clean for the fi rst time after 1.000 km replace every 4.000 km removing the air fi lter - remove screws (1) from the intake ma- nifold and take off the carburettor with the air fi lter. - loosen the clamp (2) and pull the air fi l...

  • Page 55

    52 1 a 2 3 1 cleaning the fuel fi lter note we recommend to have the fuel fi lter (1) cleaned by a sfm-dealer. Clean for the fi rst 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 p...

  • Page 56

    53 mm 1 2 checking the 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. - use a new new spark plug...

  • Page 57

    54 battery warning always wear safety glasses. Keep children away from acids and bat ter ies. Explosion danger a battery being charged produces a highly explosive gas, which is why fi re, sparks, naked fl ames and smoking are prohibited. Fire hazard avoid generating sparks and elec tro stat ic disch...

  • Page 58

    55 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 in stall ing the bat tery, fi rst connect the plus terminal (5, red cable). The battery is main te n...

  • Page 59

    56 1 1 1 2 3 4 checking the fuse caution never install a fuse with a larger rat ing, since this could destroy the en tire 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 ...

  • Page 60

    57 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 fi ngers. Hold bulbs with a clean, dry cloth when installing or re mov ing them. Headlight 1 = low beam...

  • Page 61

    58 1 the tail / brake light (1) is not fi tted with a replaceable light bulb (diode light). If the tail light does not work you should fi rst check, whether a cable connection is interrupted. Tail / brake light if this is not the case, the tail light must be replaced by a sfm dealer. Notes on mainte...

  • Page 62

    59 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...

  • Page 63

    60 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...

  • Page 64

    61 technical data engine engine type: 4-gear model: fy139fmb automatic model: fy139fmb-b design: single cylinder 4-stroke petrol engine valve control: 1 overhead cam with rocker arms valves: 2 valves valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm displacement: 49.5 cm 3 bore: ø 39 mm stro...

  • Page 65

    62 technical data power transmission 4-gear model automatic model clutch: wet multi-disk clutch multi-disk automatic splashing oil- clutch gear shifting: 4-gear claw dog-clutch engage- ment pedal gear shifting 2- gear transmission with permanent engagement gear ratios: 1. Gear = 36/11 (3,273) 2. Gea...

  • Page 66

    63 technical data chassis motorbike version: 4-gear model: type 649 003 automatic model: type 649 004 frame: tube-type centre frame front suspension: telescopic fork ø 37 mm, hydraulic shock absorber, spring travel 100 mm rear suspension: mono shock absorber, travel 65 mm wheels: light metal (alu) f...

  • Page 67

    64 technical data lubricants and operating fl uids 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...

  • Page 68

    65 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...

  • Page 69

    66 technical data dimensions and weights overall length: 1840 mm width across handlebars 760 mm without rear view mirror maximum height: 1035 mm without rear view mirror wheel base: 1235 mm seat height: 835 mm weight empty: 85 kg weight in running order: 89,5 kg max. Transport weight allowed: 190,5 ...

  • Page 70

    67 warranty warranty conditions in case of an occurring fault the company sfm gmbh will provide the customer with the following performances through the authorized sfm-dealer (seller) within the scope of its statutory warranty obligations: 1. Within a period of 24 months after the de- livery of the ...

  • Page 71

    68 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...

  • Page 72

    69 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...

  • Page 73

    70 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 confi rm them on the guarantee certifi cate. - use only origin...

  • Page 74

    71 inspection plan components assembly work to be performed (*only by an authorised sfm dealer) before start- up 1. Service after 1000 km every 4.000 km / 4 months every 8.000 km / 8 months valves check valve clearance, adjust if necessary (cold)* x x x spark plugs check condition, if necessary clea...

  • Page 75

    72 inspection plan component assembly servicing tasks (*only by an authorised sfm 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 c...

  • Page 76

    73 workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date maintenance confirmation.

  • Page 77

    74 maintenance confirmation workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date.

  • Page 78

    75 km .................................. Date................................. Km .................................. Date................................. Km .................................. Date................................. Km .................................. Date..............................

  • Page 79

    76 km .................................. Date................................. After 44.000 km/44 months dealer stamp km .................................. Date................................. After 40.000 km/40 months dealer stamp km .................................. Date............................

  • Page 80

    77 new brake fl uid yes no km ..................................... Date .................................. Stamp, signature new brake fl uid yes no km ..................................... Date .................................. Stamp, signature new brake fl uid yes no km .............................

  • Page 81

    78.

  • Page 82

    79 motorbike data (fill in on purchase) model designation: ...................................................... Vehicle identity no: ...................................................... (chassis no.) key no.: ...................................................... ...................................

  • Page 83

    80