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SSR SR150 Owner's Manual - Service Maintenance,

Manual is about: PIT BIKE

Summary of SR150

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    Authorized dealer gokartsusa.Com 2442 estand way pleasant hill, ca (800) 603-1437 ( 925) 691-0330 sales, parts, service.

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    On the covers: sr150r at milestone ranch mx park (riverside, ca), ridden by professional racer jeff willoh, a member of the ssr motorsports competition team (800) 603-1437.

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    Congratulations on choosing an ssr motorsports pit bike, and welcome to our powersports family. Your new ssr motorsports pit bike is designed, engineered and manufactured to be the best in its class. We have prepared this manual to acquaint you with the proper procedures for operating, caring for an...

  • Page 4: Contents

    Forward................................................................................................................................................3 table of contents.............................................................................................................................4 com...

  • Page 5

    Engine oil.............................................................................................................................................21 fuel.................................................................................................................................................

  • Page 6: Contents        (Cont.)

    Contents (cont.) suspension inspection, front and rear...............................................................................................46 suspension adjustments, front and rear............................................................................................48 brakes, front a...

  • Page 7

    Being prepared for the unexpected general guidelines................................................................................................................................72 if your engine quits or won’t start.....................................................................................

  • Page 8: Compoment Locations

    (1) clutch lever (2) carburetor (3) fuel petcock (4) air filter (5) drive chain (6) rear sprocket (7) chain adjuster block (8) chain guide (9) chain slider (10) chain roller (11) foot peg (12) engine and stator cover (13) gearshift lever (14) engine skidplate (15) front brake caliper (16) front brak...

  • Page 9: Compoment Locations

    (1) rear brake rotor (2) rear brake caliper (3) muffler (4) fuel filler cap (5) breather tube and breather cap (6) throttle (7) front brake lever (8) front brake master cylinder (9) auxiliary oil cooler (10) exhaust pipe (11) rear brake pedal and lever (12) foot peg (13) oil filler cap and dipstick ...

  • Page 10: Controls, Brakes

    Front brake lever rear brake pedal the front brake lever is located on the right side of the handlebar and operates the front brake only. It is operated by the fingers of the right hand, by pull- ing the lever to the rear. The brake pedal, which is located on the right side a few inches forward and ...

  • Page 11: Controls, Clutch And

    The clutch lever is located on the left end of the handlebar and is operated by the fingers of the rider’s left hand. The clutch is disengaged by pull- ing the lever in against the handlebar grip. After shifting gears the clutch is re-engaged by slowly releasing the lever and allowing it to return t...

  • Page 12: Controls, Clutch And

    To start any “one down/three up” bike from a full stop, pull the clutch lever in against the grip and push the gearshift lever firmly all the way down. To upshift from 1st to 2nd, 2nd to 3rd, or 3rd to 4th, pull the clutch lever back against the grip, place the toe of the left boot beneath the shift...

  • Page 13: Controls, Handlebar &

    Controls, handlebar & miscellaneous kick-starter manual choke and fuel petcock all ssr pit bikes are kick-start only, with the excep- tion of the sr125-auto model, which is equipped with an electric start and continuously variable au- tomatic transmission. The kick-start lever is located on the righ...

  • Page 14: Controls, Handlebar &

    Controls, handlebar & miscellaneous (cont.) throttle throttle closed throttle open the throttle controls the engine speed (rpm) and is operated by rotating the hand grip on the right side of the handlebar. To increase engine speed, the grip is rotated rearward toward the rider; to reduce engine (and...

  • Page 15

    Engine on/off switches engine off (kill) switch two position on/off switch ssr pit bikes are equipped with one of two types of on/off or engine-off switches. The first is a simple momentary-style engine stop (ignition kill) switch, a button that is pressed to stop the engine. The second type of swit...

  • Page 16: Controls, Handlebar &

    Controls, handlebar & miscellaneous (cont.) side stand the side stand is used to support the bike in an upright, slightly leaning position while parked. The side stand is located on the left side of the bike either directly behind or, on select models, below the left foot peg. The side stand is rais...

  • Page 17: Operation

    Operation before riding before each ride be certain that both you and your ssr pit bike are ready to ride. Make sure that you are in good physical and mental condition, that you are not under the influence of alcohol or drugs, and that you are wearing proper safety gear. We want to keep you as a cus...

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    Operation (cont.) a safe and enjoyable ride begins with good plan- ning and preparation. It’s safest – and usually the most fun – to ride with at least one other person. If one of you has a problem the other person can help. Always let someone know where you’re going and when you expect to return. B...

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    Tires. Use a quality tire pressure gauge to check the air pressure when the tires are cold (before riding) and add or remove air as necessary to meet the manufacturer’s recommended cold tire air pres- sure. Also inspect both tires for any sign of exces- sive wear or damage. If a tire is damaged or e...

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    Operation (cont.) pre-ride inspection (cont.) engine oil drain plug auxiliary oil cooler leaks. Inspect the engine/transmission case and the fuel tank for leaks. Look beneath the bike for signs of leaking fluids. If the bike has an auxiliary oil cooler check lines and fittings to be sure that there ...

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    Dipstick location engine oil. Check oil level using the dipstick on the right side of the engine/transmission case, and add oil if necessary. Be sure to use the correct type and weight oil as specified in this manual. Be sure the dipstick is properly and securely refitted into the engine/transmissio...

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    Operation (cont.) pre-ride inspection (cont.) filler neck & fuel cap fuel cap, breather tube & cap fuel. Check the fuel level and add more if neces- sary, filling to the bottom of the filler neck. Be sure to use 90 (or higher) octane unleaded pump gaso- line. Make certain that the fuel filler cap is...

  • Page 23

    Drive chain chain slider & roller drive chain. Check the chain for condition and correct tension (“slack”). The chain may break if too tight (not enough “slack”); excessive chain “slack” can cause accelerated wear, kinked or binding links, loose pins, and/or damaged rollers. Check the chain slider (...

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    Operation (cont.) pre-ride inspection (cont.) throttle cable clutch cable at transmission case clutch cable at handlebar cables. The clutch and throttle are actuated by cables from the handlebar levers. Check the cable housings for wear and the fittings for looseness, and replace or tighten as neces...

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    Spark plug spark plug spark plug and ignition wire. Make sure that spark plug is not loose in cylinder head; tighten if necessary. Be certain that the ignition wire terminals fit secure- ly onto the spark plug and ignition coil. Nuts and bolts. Using appropriate-size wrenches, be sure that all acces...

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    Throttle closed throttle open operation (cont.) pre-ride inspection (cont.) throttle. Check the throttle control for free play and adjust if necessary. 26.

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    Front brake control rear brake control brakes. Test front and rear brake controls for nor- mal operation. If either feels soft check the appro- priate master cylinder fluid reservoir and add dot 3 or 4 fluid as needed to fill. Adjust mechanical free play in front and rear levers and linkages, if nec...

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    Operation (cont.) starting and riding starting the engine. Be sure the transmission is in neutral and that (if applicable) the two-position on/off switch is in the ride (on) position. Turn the three position fuel petcock to the “on” position. If the bike’s engine is cold, lift the choke lever up to ...

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    If the air temperature is between 50- and 90-de- grees f, swing the kick-start lever’s foot peg out from its stored position and with your right foot ro- tate the lever down and to the rear until you feel re- sistance. Then, with a rapid and continuous motion, “kick” the lever down through its strok...

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    The instructions for a warm engine or high tempera- ture start. Warning! Do not start or run the bike in an en- closed area or any area without good ventilation. The exhaust contains carbon monoxide and other toxic gases which can collect quickly in confined areas and cause illness and even death. W...

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    All riders except those who are experienced, with expert-level skills, should reduce speed and finish braking before entering a turn. Riders should avoid braking or closing the throttle abruptly while turning; either action can cause one or both wheels to lose traction, and a loss of traction at eit...

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    Stopping and parking. After coming to a com- plete stop lower the side stand. Shut off the engine. Depending on how your specific bike is equipped this is accomplished by either pressing the button on the momentary-style engine stop (ignition kill) switch or, if equipped with a two-position, rocker-...

  • Page 33: Service Maintenance,

    Breaking-in the engine. While the engine in your new ssr pit bike does not require a formal “break- in” procedure, we recommend you follow the follow- ing tips to get the best performance and longevity from your bike. Note: none of the pit bikes covered in this manual are equipped with speedometers ...

  • Page 34: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) why proper maintenance is important (cont.) safety precautions read all instructions before beginning any mainte- nance or adjustment procedures. Be sure you have the necessary tools, skills and experience to suc- cessfully complete whatever w...

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    Recommended service & maintenance schedule a – adjust i – inspect and, if necessary, clean, correct, fill or replace l – lubricate r – change or replace t – tighten to proper torque x -- perform intervals* service operation** every 3 hours every 5 hours every 10 hours every 15 hours valve adjustment...

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    *inspect and service your ssr pit bike more frequently if ridden hard or in dusty, hot, or other extreme con- ditions. Regardless of hours of riding, always perform all service operations prior to storage or annually. **unless the owner is an experienced and skilled mechanic and has a good selection...

  • Page 37

    Use of a lower than recommended gasoline can cause “pinging,” which is also called “spark knock” or “pre-ignition,” (an occasionally loud rapping or rattling noise) which can, if severe or persistent, can lead to extensive engine damage. Light pinging experienced under a heavy load, such as climb- i...

  • Page 38: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) safety precautions (cont.) oil recommendation api classification sf or sg viscosity (weight) sae 10w-40* suggested oil 4-stroke oil (usa & canada) or equivalent** *for continued use with ambient air temperatures above 90-95-degrees f, and not ...

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    Checking & adding oil park your motorcycle on a firm, level surface. Re- move the oil cap/dipstick and check the oil level. If the oil is at or near the upper level mark (see photo) you do not have to add oil. If the oil is below or near the lower level mark (see photo) add oil of the recommended sp...

  • Page 40: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) changing engine oil 1. If the engine is cold, start it and let it idle for three- to five-minutes. Turn the engine off and wait two- to three-minutes for the oil to settle. 2. Park your motorcycle on a firm, level surface. 3. Remove the oil fi...

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    More about engine oil throttle control free play whenever you buy oil for your bike, check the label on the container to make sure it matches recom- mended specifications. Engine oil has a major influence on both the perfor- mance and the service life of the engine. Non-detergent, vegetable or casto...

  • Page 42: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) engine idle speed the engine must be at normal operating tempera- ture in order to make accurate idle speed adjust- ments. Ten-minutes of stop-and-go riding should be sufficient. Do not attempt to compensate for faults in other systems by adju...

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    Air filter inspect the air filter regularly. When it becomes dirty or contaminated discard it and replace with an equivalent new part. If the air filter is a reusable washable type, wash the dirt out with a mild deter- gent, rinse thoroughly and dry with a clean towel. Soak the filter element in foa...

  • Page 44: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) spark plug spark plug recommendation the recommended standard spark plug is satisfac- tory for most riding conditions. However, if you plan to ride for extended periods at high speeds or near maximum power (high engine rpm) in hot climates, or...

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    Removing or replacing the spark plug 1. Before removing the spark plug clean any dirt from around the spark plug base. 2. Carefully disconnect the spark plug wire cap. Do not pull on the wire as this may damage the conductor within the wire causing high resistance and reduced firing voltage. 3. Remo...

  • Page 46: Service Maintenance,

    Service maintenance, lubrication and adjustments (cont.) suspension front suspension inspection loose, worn, or damaged suspension components may adversely affect the handing and stability of your motorcycle. If any suspension components ap- pear worn or damaged, see your dealer for further inspecti...

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    Rear suspension inspection 1. Place the bike on a maintenance stand. Either strap securely in place or have a helper hold the bike while you push hard against the side of the rear wheel and feel for any free play which indicates worn swing arm bushings (1). Do not ride with worn swing arm bushings. ...

  • Page 48: Service Maintenance,

    Rear suspension inspection (cont.) front suspension adjustments service maintenance, lubrication and adjustments (cont.) shock absorber bushings some ssr pit bikes are equipped with adjustable front and/or rear suspensions. The simplest adjustable front suspensions are forks that are adjustable for ...

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    Rear suspension adjustments the suspension on “entry level” pit bikes uses a coilover shock absorber with adjustable preload. This shock absorber will have a notched collar that allows the rider to adjust the rear suspension from soft to firm. The simplest truly adjustable rear suspension uses a one...

  • Page 50: Service Maintenance,

    Brakes front brake lever free play service maintenance, lubrication and adjustments (cont.) (1) front brake lever free play brake caliper free play adjusting nut 1. Check free play by pulling in slowly on the front brake lever (1) until the brake starts to engage. Free play should be between approxi...

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    Rear brake pedal free play brake wear inspection other inspections & lubrication rear brake pedal free play 1. Rest the bike securely on its side stand. 2. Check free play by slowly depressing the brake pedal (1) until the brake starts to engage. Free play should be between 3/8- to 13/16-inch (10-20...

  • Page 52: Service Maintenance,

    Wheels service maintenance, lubrication and adjustments (cont.) maintaining correct spoke tension and trueness (roundness) of the wheels is critical to safe motor- cycle operation. During the first hour or two, spokes will loosen rapidly due to the initial “seating” of the parts. Ex- cessively loose...

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    Front wheel removal tires and tubes tire air pressure removal 1. Raise the front wheel off the ground by placing a maintenance stand or support block under the engine. Secure the rear of the motorcycle with tie-down straps. 2. Remove the front axle nut and front axle. 3. Remove the wheel. Do not get...

  • Page 54: Service Maintenance,

    Tire air pressure inspection service maintenance, lubrication and adjustments (cont.) check tire pressure cold recommended tire pressure, cold always check tire air pressure when the tires are cold. Tire pressure measurements will be inaccu- rate, inconsistent and always higher if the air pres- sure...

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    Tube replacement tire replacement measure the tread depth. Replace the tire before tread depth at the center is 1/8- inch (3mm) or less, or any time you begin to notice a reduction in trac- tion. Check the position of the valve stems on both wheels. A tilted valve stem indicates the tube is slip- pi...

  • Page 56: Service Maintenance,

    Side stand service maintenance, lubrication and adjustments (cont.) (1) side stand (2) side stand spring 1. Check the side stand spring (1) for damage and loss of tension. 2. Check the side stand assembly to be sure it moves freely 3. If the side stand is stiff or squeaky, clean the pivot area and i...

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    Drive chain drive chain inspection with the bike’s wheels on the ground, check slack in the lower drive chain approximately halfway between the sprockets. Correct drive chain slack (vertical free play) at the midpoint of the lower chain should be between 9/16- and 1-inch when moved by hand. Next, ch...

  • Page 58: Service Maintenance,

    Drive chain inspection (cont.) service maintenance, lubrication and adjustments (cont.) notice! Excessive chain slack may allow the drive chain to damage the engine cases. Inspect the drive chain for damaged rollers, dry or rusted links, excessive wear, kinked or binding links, or loose pins. If the...

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    Adjusting the drive chain 1. Loosen the rear axle nut (3). 2. Loosen the lock nuts (2) on both sides of the swing arm. 3. Turn the adjusting nuts (1) on the right and left chain adjusters an equal number of turns to increase or decrease chain slack. 4. Torque the rear axle nut to: 35 lb-ft. If a tor...

  • Page 60: Service Maintenance,

    Lubricating the drive chain removing, cleaning and re-installing the drive chain lubricate the drive chain after every three hours of riding, sooner if the chain appears dry. Raise the rear wheel off the ground using a maintenance stand. Slowly turn the rear wheel by hand and satu- rate each drive c...

  • Page 61

    4. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. 5. Lubricate the drive chain. 6. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent ...

  • Page 62: Service Maintenance,

    Notice! Use of a new chain with worn sprockets will cause rapid chain wear inspect the front and rear sprocket teeth for excessive wear or damage. If necessary, have your dealer replace a worn sprocket. The master link is the most critical element of drive chain security. Master links are reusable, ...

  • Page 63

    Frequent cleaning and polishing will keep your new pit bike looking like new for a long time. Frequent cleaning also identifies you as an owner who values your bike and keeps it well-maintained. A pit bike that is kept clean is easier to clean up af- ter usage, and a clean bike is also easier to ins...

  • Page 64: Service Maintenance,

    Washing your motorcycle with a mild detergent service maintenance, lubrication and adjustments (cont.) 1. Rinse your motorcycle thoroughly with cool water to remove loose dirt. Do not wash it in direct sunlight. 2. Fill a bucket with cool water. Mix in a mild, neutral detergent, such as dish washing...

  • Page 65

    Transporting your pit bike if you use a truck or a motorcycle trailer to transport your motorcycle, we recommend that you follow these guidelines: 1. Use a loading ramp. 2. Make certain that the fuel petcock is in the “off” position. 3. Secure the motorcycle in an upright position, using motorcycle ...

  • Page 66: Service Maintenance,

    Storing your pit bike service maintenance, lubrication and adjustments (cont.) if you won’t be riding your bike for an extended pe- riod, such as during the winter, thoroughly inspect your bike and correct any problems before storing it. That way, needed repairs won’t be forgotten, and it will be ea...

  • Page 67

    Removal from storage 5. Wash and dry your motorcycle. 6. Lubricate the drive chain. 7. Inflate the tires to the recommended air pressure. 8. Store your motorcycle in an unheated area, free of dampness, away from sunlight, with a minimum of temperature variation. 9. Cover your motorcycle with a porou...

  • Page 68: Troubleshooting

    Troubleshooting engine does not start engine starts hard engine starts but runs irregularly or misses 1. Fuel tank is empty. 2. Fuel petcock is turned off. 3. Fuel petcock is clogged. 4. Fouled spark plug 5. Spark plug cable connectors loose or in bad condition and are shorting. 6. Engine flooded wi...

  • Page 69

    Spark plug fouls repeatedly pre-ignition or detonation (knocks or pings) excessive vibration overheats engine leaks oil 1. Excessive use of choke. 2. Fuel mixture is too rich. 3. Incorrect spark plug. 1. Incorrect fuel (not high enough octane rating or blend of additives incorrect for bike engine) 2...

  • Page 70: Troubleshooting  (Cont.)

    Troubleshooting (cont.) transmission shifts hard or jumps out of gear clutch slips clutch drags or does not release clutch chatters 1. Clutch controls not adjusted correctly. 3. Worn shifter “dogs” in transmission. See your dealer. 2. Shifter forks (inside transmission) are worn. See your dealer. 1....

  • Page 71: You & The Environment

    You & the environment owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environ- mentally-responsib...

  • Page 72: Being Prepared For The

    Being prepared for the unexpected with all the challenges you can encounter off-road, there’s always a chance that something may go wrong. This section gives practical advice to help you deal with a wide range of problems. Take time to read this section before you ride. Also review the tips in ‘prep...

  • Page 73: Being Prepared For The

    Being prepared for the unexpected (cont.) if your engine quits or won’t start if you get a flat tire if the engine wasn’t making any unusual noises before it quit running, and it feels normal when you operate the kick-starter, you can probably rule out a major mechanical problem. The next area to ch...

  • Page 74

    If you crash if a part fails if you are unable to repair a flat tire on the trail, you will need to push the motorcycle back to your base or send for help. We strongly recommend that you do not try to ride with a flat tire.The motorcycle will be hard to handle, and if the tire comes off the rim it m...

  • Page 75: Technical Information

    Technical information this section contains dimensions, capacities, and other technical data, plus information on government requirements and how to break-in your motorcycle. Vehicle identification numbers the frame (pin - product identification number, or vin - vehicle identification number) and en...

  • Page 76

    Technical information (cont.) break-in guidelines emission control systems high altitude carburetor adjustment help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first five- to 10-hours of operation. During this period, avoid full-th...

  • Page 77

    Sources of emissions the combustion process produces carbon monox- ide and hydrocarbons. Control of hydrocarbons is very important because under certain conditions, they react to form photochemical smog when sub- jected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Ss...

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    Technical information (cont) emission control systems (cont.) among those acts presumed to consti- tute tampering are the acts listed below: (1) removal of or puncturing the muffler, baffles, header pipes, or any other component which conducts exhaust gases. (2) removal of or puncturing of any part ...

  • Page 79: Your Ssr Pit Bike

    Oxygenated fuels and your ssr pit bike mtbe (methyl tertiary butyl ether) 15% by volume. You may use gasoline containing up to 15% mtbe by volume. Methanol (methyl or wood alcohol) 5% by volume. You may use gasoline containing methanol containing up 5% methanol by volume as long as it contains co-so...

  • Page 80

    Authorized dealer gokartsusa. 2442 estand way pleasant hill, ca 94523 (800) 603-1437 (925) 691-0330 gokartsusa.Com sales, parts, service.