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- Owner's Manual
Sachs Bikes madass Owner's Manual
Summary of madass
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Your sachs dealer sachs recommends sachs fahrzeug- und motorentechnik gmbh nopitschstraße 70 • d-90441 nürnberg telefon: +49 (0)911 4231 400 • telefax +49 (0)911 4231 332 e-mail: info@sachs-bikes.De • www.Sachs-bikes.De printed in germany nr. P00 649 008 00 02 000 2004 .. ....
Page 2: Owners Manual
Owners manual gb.
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The madass is a sturdy light motorcycle in modern design. Its sound construction, the meticulous selection of materials, the advanced ma- nufacturing techniques and conscientious work of dedicated employees provide the motorcycle with all the characteristics that are typical of sachs: economical ope...
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1 contents summary and operation safety symbols .......................................................................... 3 right-hand side view ................................................................. 4 engine ..................................................................................
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2 3 contents maintenance maintenance activities ............................................................. 39 checking the fork-column bearings ......................................... 40 removing the front wheel........................................................ 41 installing the front whe...
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2 3 summary and operation note special instructions for better handling during operation and inspection and when carrying out adjustment procedures and service activities. Observe the following: warning precautionary measures against the risk of accidents, injury and/or death. Fire hazard the bike i...
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4 5 1 2 3 4 5 6 7 8 9 sfm 649 051.1 summary and operation right-hand side view 1 fuel tank cap 2 handlebar fittings 3 brake fluid reservoir front brake 4 speedometer 5 chassis number and rating plate 6 fork column lock 7 side stand 8 battery and fuse 9 rh pillion footrest, fold-up.
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4 5 sfm 649 012.1 11 7 9 8 10 12 sfm 649 013.1 6 1 3 2 5 4 1 carburattor 2 air filter 3 fuel cock with filter 4 engine number 5 lh foot rest 6 gear lever summary and operation engine left-hand side view 7 spark plug connector 8 electric starter 9 footbrake lever 10 rh footrest 11 oil filler cap 12 k...
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6 7 sfm 649 017.1 a b 1 2 3 sfm 649 024.1 5 6 4 7 8 sfm 649 025.1 9 1 clutch lever 2 head light switch push button upwards for the upper low beam push button downwards for the below low beam 2 direction-indicator switch push to the left: left-hand direction indicators are activated push to the right...
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6 7 1 2 sfm 649 015.1 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 ...
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8 9 sfm 649 059_2 1 4 3 2 a b 5 0 kmh 0 dst b a 0 kmh 0 trp b a 0 kmh 11 : 55 clk b a 0 kmh 12 : 00 clk b a summary and operation cockpit seedometer 1 kmh - odometer or switchable on mph - speedometer (in miles) 2 dst - total distance (km) trp - trip odometer clk - time announcement instrument light...
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8 9 sfm 649 058.1 4 summary and operation speedometer battery change note if there is no reading on the display or very poor change the batteries. Always replace both batteries. Remove the speedometer for battery change. - remove the screws (1) and take off the speedometer. - remove the batteries (4...
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10 11 summary and operation checklist 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 ...
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10 11 2 1 3 a sfm 649 016.1 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 = min. 3-4 mm adjustment: - remove the rubber cap (1). - ...
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12 13 sfm 649 007.1 1 2 sfm 649 011.1 3 safety test fuel warning fuel is highly inflammable and can explode. Do not smoke or bring a naked flame near the fuel tank. Tank cap (1) note for opening the tank cap (1) only insert the ignition key (3) and do not turn. Open by using the cover (2). The fuel-...
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12 13 res off on sfm 649 010.1 4 sfm 649 063.1 off res on safety test fuel caution when you stop the engine, always set the fuel cock to off. Otherwise, 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 f...
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14 15 max. Min. Sfm 649 005.1 sfm 649 006.1 1 safety test engine oil 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 bel...
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14 15 safety test engine oil caution do not use additives. Since the oil also serves to lubricate the clutch, do not use car engine oils supplemented with friction modifiers (such energy- conserving...
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16 17 max . Min. Sfm 649 022.1 safety test front brake 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 operability of the brake system. Immediately consult a sachs dealer. Check the brake-fluid...
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16 17 1 20 mm sfm 649 035.1 safety test rear brake warning check the play of the footbrake lever (1) before riding. Target value 20 mm. Adjusting the footbrake lever play: maintenance checking the brake linings warning the brake disks and brake linings must be free of oil and grease. Brake linings a...
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18 19 sfm 649 009.1 30 - 35 mm 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...
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18 19 sfm 649 008.1 1 2 safety test checking the tyre profiles warning observe the minimum profile depth prescribed by law. - measure the profile depth at the centre (1) of the tyre’s tread. Recommended minimum profile depth: front 2.0 mm rear 2.5 mm checking the tyre pressure warning adjust the tyr...
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20 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 guar...
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20 21 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 abilit...
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22 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 generat...
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22 23 riding instructions ride economically and be aware of the environment fuel consumption is also affected by conditions that are out of your control, for instance, poor road condition, hills, riding in winter. Observe the following aspects for eco- nomical fuel consumption: – the planned inspect...
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24 25 riding instructions running-in running-in instructions for engine and transmission caution excessive revs while running-in the engine 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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24 25 sfm 649 049.1 riding instructions side stand propping up the motorbike on the side stand. Warning always make sure that the stand is resting on firm ground. On sloping roads, always park the motorbike facing uphill and in 1st gear. When you kick the stand in, do not stand within the pivoting a...
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26 27 2 sfm 649 015.1 sfm 649 003.1 3 res off on sfm 649 010.1 1 riding instructions before starting - put the motorcycle it in a vertical position and allow the side standard to tilt up. - turn the fuel chock (1) to on or res. - mount the motorcycle. - turn the ignition key (2) to its operating pos...
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26 27 sfm 649 018.1 2 3 sfm 649 031.1 sfm 649 017.1 a b 1 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. - push down the emergency-off switch ...
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28 29 sfm 649 018.1 2 3 sfm 649 017.1 1 a b riding instructions starting with electric 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. - push down the emergency-off switch (2) to pos...
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28 29 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 (unnecessary wear and fuel consumption). Starting / shifting up - pull in the clutch lever - push down on the fo...
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30 31 riding instructions braking oil and grease warning the brake discs and linings must be free of oil and grease! Warning 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 set...
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30 31 sfm 649 019.1 1 sfm 649 035.1 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 t...
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32 33 1 sfm 649 015.1 sfm 649 021.1 3 res off on sfm 649 010.1 2 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. In the on or res position, fuel could enter the engine, leading to s...
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32 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 dam- aged by caustic or penetrating ...
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34 35 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...
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34 35 service instructions operation in winter and anti-corrosion protection winter operation / anti-corrosion protection use of the motorcycle in the winter can cause considerable damage due to the presence of salt on the roads. Note protect the environment by using only en- vironmentally friendly ...
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36 37 service instructions repairing paint damage / servicing the tyres repairing paint damage minor paint damage should be immediately repaired. Major damage must be repaired by a sachs dealer. Servicing tyres if the motorcycle is not used for a longer period, it is recommended to sup...
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36 37 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 ...
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38 39 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 ...
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38 39 maintenance maintenance activities before carrying out any maintenance activities, read the relevant section of this operating manual. - checking the fork-column bearing - removing the front wheel - installing the front wheel - removing the rear wheel - installing the rear wheel - checking , a...
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40 41 sfm 649 048.1 maintenance checking the fork-column bearings note the telescopic fork must not stick when turned, and at both limit positions it must easily tilt back. - jack up the machine on a sturdy installation jack. - take hold of the lower fork tubes and try to move them to and fro in the...
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40 41 sfm 649 026.1 1 sfm 649 027.1 2 3 maintenance 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 motorcyc...
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42 43 sfm 649 027.1 2 3 1 sfm 649 026.1 4 maintenance 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 (3) (o...
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42 43 sfm 649 030.1 4 2 5 sfm 649 029.1 3 1 2 maintenance 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....
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44 45 5 7 2 4 sfm 649 032.1 sfm 649 030.1 4 2 5 sfm 649 029.1 3 1 2 6 maintenance 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 (1). - introduce full floating axl...
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44 45 sfm 649 033.1 1 2 3 30 - 35 mm a 4 maintenance checking, adjusting the drive chain - release the axle nut (4). - evenly adjust the setting nuts (3) on both sides of the chain adjuster (rear wheel must be aligned with the front wheel). - let the motorbike rear end drop to the limit imposed by t...
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46 47 sfm 649 014.1 sfm 649 047.1 3 4 maintenance 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 brake - visually inspect the brake calliper ...
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46 47 sfm 649 034.1 maintenance rear brake 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. - visually inspect the brake calliper (1) on the right mo...
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48 49 1 2 3 20 mm sfm 649 035.1 sfm 649 052.1 7 6 sfm 649 036.1 4 5 maintenance setting the footbrake pedal position note the footbrake pedal position can be adjusted with the setting screw (1). - release the lock nut (2). - adjust the foot brake pedal (3) position with the setting screw (1). Warnin...
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48 49 2 1 3 a sfm 649 016.1 sfm 649 038.1 4 4 5 sfm 649 037.1 7 6 maintenance adjusting the clutch lever play 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...
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50 51 sfm 649 040.1 1 2 maintenance 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 severel...
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50 51 sfm 649 042.1 3 sfm 649 041.1 2 2 1 maintenance 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 battery cover (1). Note the spare fuse is placed in the fuse case. Replace fuse - remove three screws ...
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52 53 maintenance 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 electrostat...
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52 53 sfm 649 036.1 4 1 1 2 sfm 649 060.1 3 5 5 2 sfm 649 041.1 maintenance removing and installing the battery caution for removing the battery hang out the brake rod (1) and remove the splint pin behind the srew (4). For installing use a new splint pin. For reasons of safety, the work should be do...
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54 55 sfm 649 046.1 5 6 7 sfm 649 044.1 3 1 2 4 maintenance 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...
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54 55 3 sfm 649 045.1 2 sfm 649 043.1 1 maintenance tail / brake light bulb the tail light 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 bulb - push back the cable prote...
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56 57 5 3 sfm 649 053.1 sfm 649 061.1 2 3 4 sfm 649 054.1 2 3 sfm 649 055.1 1 maintenance 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...
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56 57 sfm 649 045.1 sfm 649 044.1 1 2 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...
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58 59 type: fy139fmb 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: 49,5 cm 3 bore: ø 39 mm stroke: 41,4 mm compression ratio: 10:1 lubrication system: fo...
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58 59 technical data power transmission clutch: wet multi-plate type gear box: 4-seed constant mesh, foot operated gear ratios: 1. Gear = 36/11 (3,273) 2. Gear = 31/16 (1,938) 3. Gear = 27/20 (1,350) 4. Gear = 24/23 (1,044) primary transmission ratio: 4,059 chain pinion: 11 teeth sprocket: 53 teeth ...
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60 61 technical data chassis motorbike version: type 649 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: = 1,85 x 16" rear...
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60 61 technical data lubricants and operating fluids fuel tank capacity: 4,6 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 high...
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62 63 technical data electrical equipment generator: 12 v 80 w battery: 12 v 3 ah mf fuse: 15 a lights: - headlight: - position light: - instrument lights: - brake/rear light: - turn signal light: low beam 2x 12v 15w 12 v 3w direction-indicator 12v 3w change over gear 12 v 3w cockpit 12 v 3w 12 v di...
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62 63 technical data dimensions and weights overall length: 1830 mm width across handlebars without rear view mirror: 780 mm maximum height: 1010 mm without rear view mirror wheel base: 1235 mm seat height: 865 mm weight empty: 85 kg weight in running order: 89,5 kg max. Transport weight allowed: 19...
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64 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 authorized sachs-dealer (seller) within the scope of its statutory warranty obligations: 1. Within a period of 24...
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64 65 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 reache...
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66 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 cle...
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66 67 warranty 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 spa...
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68 69 warranty inspection plan type 649 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 acco...
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68 69 warranty inspection plan type 649 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 year...
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70 71 warranty maintenance confirmations workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date.
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70 71 warranty maintenance confirmations workshop activities carried out workshop activities carried out activities carried out km date activities carried out km date.
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72 73 warranty maintenance confirmations km .................................. Date................................. Km .................................. Date................................. Km .................................. Date................................. Km ...............................
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72 73 warranty maintenance confirmation km .................................. Date................................. After 44.000 km/44 months dealer stamp km .................................. Date................................. After 40.000 km/40 months dealer stamp km ..............................
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74 75 warranty maintenance confirmation new brake fluid yes no km..................................... Date .................................. Stamp, signature new brake fluid yes no km..................................... Date .................................. Stamp, signature new brake fluid yes ...
Page 78: Motorbike Data
74 75 db(a) min — sachs fahrzeug-und motorentechnik gmbh e1-0212*00 wsf 649b1040000101 69 3000 rating plate (sample): motorbike data (fill out on purchase) model designation: ...................................................... Vehicle identily no: ....................................................
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