SWM SIDECAR URBAN 525 Manual
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SWM SIDECAR URBAN 525 Manual

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The instructions in this manual have been prepared to provide a simple and understandable guide for your motorcycle's operation and care. Follow the
instructions carefully to enjoy maximum performance. It contains instructions to carry out the required maintenance operations. More specific or major repair
or maintenance operations require the attention of a skilled mechanic and the use of special tools and equipment. Your Dealer has the original spare parts,
the experience and all equipment necessary to provide a valuable service. To ensure proper operation of the motorcycle, it is necessary to follow the mainte-
nance and inspection table available.
Finally, please remember that the "Use and Maintenance Manual" is an integral part of the motorcycle, hence, it shall remain with the motorcycle
even when sold to another user.
IMPORTANT
In order to maintain the vehicle's "Operation Guarantee", the Customer must follow the maintenance programmer indicated in the use and mainte-
nance manual by having scheduled maintenance carried out at authorized workshops.
IMPORTANT NOTICE
Read this manual carefully and pay special attention to statements preceded by the following words:
WARNING
Indicates the possibility of severe personal injury or death if instructions are not followed.
CAUTION
Indicates the possibility of personal injury or vehicle damage if instructions are not followed.
Gives helpful information.
Note*:
PRESENTATION
URBAN 525

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Summary of Contents for SWM SIDECAR URBAN 525

  • Page 1 URBAN 525 PRESENTATION The instructions in this manual have been prepared to provide a simple and understandable guide for your motorcycle’s operation and care. Follow the instructions carefully to enjoy maximum performance. It contains instructions to carry out the required maintenance operations. More specific or major repair or maintenance operations require the attention of a skilled mechanic and the use of special tools and equipment.

  • Page 2: Table Of Contents

    URBAN 525 INDEX ADJUSTING THE REAR-VIEW MIRRORS ..............24 PRESENTATION ........................1 REVERSE CABLE HANDLE ....................24 I、SAFETY GUIDELINES ......................1 SEAT BELT ..........................25 II、TECHNICAL DATA ......................6 STARTING THE ENGINE ....................25 III、VIEWS OF MOTORCYCLES ..................9 STOPPING THE MOTORCYCLE AND THE ENGINE ..........26 INSTRUMENTS ........................
  • Page 3 URBAN 525 TYRES............................. 43 RETURN TO SERVICE ....................... 54 CHAIN ADJUSTMENT ....................... 44 SPECIAL TORQUE VALUES..................... 55 CHAIN/FRONT SPROCKET/REAR SPROCKET WEAR CHECK ......45 VI、ENGINE MANAGEMENT SYSTEM ............... 57 DISASSEMBLING AND INSTALLATION OF FRONT WHEEL ......... 45 VII、ELECTRICAL SYSTEM DIAGRAM ................. 62 DISASSEMBLING AND INSTALLATION OF REAR WHEEL ........

  • Page 4: Presentation

    URBAN 525 I、 SAFETY GUIDELINES • Before turning, Loosen the throttle and use the front and brakes to slow SAFE RIDING PRINCIPLES down. It is recommended that the speed of turning be controlled than 10km/h and max 20Km/h, At the same time, use the rear brake to grad- •...
  • Page 5 URBAN 525 BEING SEEN ACCESSORIES & MODIFICATIONS Many motorcycle accidents are caused by car drivers who do not see mo- We strongly advise that you do not add any accessories that were not spe- torcycle riders on the road. To reduce the chance of an accident, follow these cifically designed or approved for your motorcycle by or make modifications guidelines: to your motorcycle from its original design.
  • Page 6 URBAN 525 LOADING & CARRYING PASSENGERS motorcycle can cause an accident or crash resulting in severe injury or even death to the motorcycle operator, passenger or bystanders. The characteristics of the side car are caused by the load asymmetry, CAUTION he empty load of the side car part is about 150Kg, which has a greater im- The design of the motorcycle requires even distribution of all loads.
  • Page 7 URBAN 525 WEAR PROTECTIVE GEAR DO NOT RIDE WHILE UNDER THE INFLUENCE Wearing appropriate protective wear can prevent or reduce injuries from Before getting on your bike, make sure: • You have not consumed alcohol or taken drugs. accidents. • You are in good physical and mental condition. Helmet –...
  • Page 8 URBAN 525 GASOLINE AND EXHAUST FUMES PRECAUTIONS FOR CHILDREN • Gasoline is highly flammable and exhaust fumes are poisonous: WARNING • Turn off engine before refueling. • Park the vehicle where it cannot be easily bumped or damaged. • Do not overfill fuel tank!! Fill fuel level to 1/2 inch below the neck of the Even slight or involuntary bumps can cause the vehicle to tip over, with sub- fuel tank fill opening.

  • Page 9: Technical Data

    URBAN 525 II、 TECHNICAL DATA Item Data Length 2300mm Width 1680mm Height 1180mm Wheelbase 1520mm Wheelbase sidecar 1130mm Min. ground clearance 180 mm Complete vehicle weight Non-loaded weight: 348kg, Curb weight:374kg, Frame type Cradle type Front suspension device spring & hydraulic composite damping Rear suspension device spring &...
  • Page 10 URBAN 525 Mode Double-cylinder; Water –cooling 4-stroke engine Cylinder bore × Stroke 68.0mm×68.0mm Cylinder displacement 493.658ml Compression ratio 11.5:1 Max. power 39.6kW/8500rpm Max. torque 50.5N·m/7000rpm Valve clearance (cold) IN: 0.10-0.15；EX: 0.20-0.25 Valve driving gear Chain drive Air filter Oilpaper filter Cooling method Water-cooling Lubrication method...
  • Page 11 URBAN 525 Clutch Wet clutch, coil clutch, paper friction wafer Clutch operating system Manual mechanical Variable speed gear 5-speed constant mesh +1- reverse Primary reduction ratio 2.029 Transmission gear ratio R2.500;Ⅰ;3.286；Ⅱ 2.050；Ⅲ 1.600 ；Ⅳ1.300；V 1.150 Final reduction ratio 3.538 Gear shifting mode Left foot operated to and back type；...

  • Page 12: Views Of Motorcycles

    URBAN 525 III、 VIEWS OF MOTORCYCLES Ignition & Steer switch Right rear view mirror Instrument panel Switches on right Left rear view mirror handlebar Throttle twist grip Left handlebar Front brake lever Clutch lever Switches on left handlebar...
  • Page 13 URBAN 525 Fuel tank lock Sidecar seat Passenger handle Fuel tank Sidecar brake calliper Sidecar taillight Front brake calliper...
  • Page 14 URBAN 525 Rider seat Throttle body Passenger seat Passenger handle Headlight Taillight Front left turning in- dicators Transmission chain Coolant radiator. Cooling fan Gear shift pedal...

  • Page 15: Instruments

    URBAN 525 INSTRUMENTS ① Left turn indicator light. ② Right turn indicator light ③ High-beam light. ④ Gear position display light. N ⑤ Position indicator ⑥ Engine failure warning light. ⑦ Engine Oil-Pressure ⑧ Excessive coolant temperature indicator ⑨ Maintenance indicator ⑩...
  • Page 16 URBAN 525 DIRECTION INDICATOR LIGHTS ENGINE OIL PRESSURE WARNING LIGHT The light flashes when activating the left or right hand turning indicator us- The Engine Failure Light comes on (amber light) when you turn on the igni- ing the control lever on the left-hand switch. tion switch.
  • Page 17 URBAN 525 BATTERY CHARGE INDICATOR MILEAGE DISPLAY When the battery voltage is insufficient, the indicator light flashes. ODO displays the total mileage, and TRIP displays the small mileage. When the vehicle speed is less than 5km/h, in ODO state, long press SET to TIRE PRESSURE WARNING LIGHT enter the setting interface;...
  • Page 18 URBAN 525 SET BUTTON DESCRIPTION Button: In ODO mode, short press time: less than 1s; long press time: more than 2s. Input through the two buttons on the instrument: MODE (front button) and SET (rear button); or input the ENT and SET switch buttons on the left hand. In the setting interface: short press the MODE key to move the cursor or modify parameters, short press the SET key to confirm, long press the MODE or SET key to return to the previous menu.
  • Page 19 URBAN 525 SUBTOTAL MILEAGE RESET tings of the ones digit of the minute are completed, it will automatically re- Short press the SET key to enter the subtotal mileage reset, short press the turn to the secondary menu. If the setting is not completed due to timeout MODE key to switch to select OK or return, short press the SET key to con- or power outage and the clock setting is exited, the set digit will take effect；...
  • Page 20 URBAN 525 TIRE PRESSURE SETTINGS maintenance indicator light is reset. It lights up every 3000 kilometers after Short press the SET button to enter the tire pressure setting. Under the tire mileage. pressure setting, short press the MODE button to select; when the cursor Only when the maintenance alarm indicator light is on, in the main selects the front wheel, short press the SET button to learn the front tire interface and in the ODO display state, press and hold the MODE and SET...
  • Page 21 URBAN 525 VEHICLE INFORMATION Fault information, displays the current fault information, short press Short press SET to enter the vehicle status information, which displays MODE to switch options (previous page or return), short press SET to con- parameters such as average fuel consumption, driving time, remaining firm;...

  • Page 22: Controls

    URBAN 525 IV、 CONTROLS Ignition Switch The ignition switch has three positions: Motorcycle start position (key not removable); Key removal position; Steering lock position (key removable). -Key removal position " " Turning the key to position , the engine and the lights go off and you can remove the key from the ignition block.

  • Page 23: Rh Handlebar Switch

    URBAN 525 Hazard Light RH HANDLEBAR SWITCH The Hazard Light and the Left/right turn signal light comes on when you The right-hand switch features the following controls: push on the warning light switch. Engine start button Pressing the button (1) with the key in position and the switch (2) in position, the engine starts.

  • Page 24: Lh Handlebar Switch

    URBAN 525 Horn button LH HANDLEBAR SWITCH When the main switch is in the "on" position, if you press the horn The left-hand switch features the following controls: Overtaking lamp switch button, it will emit a loud sound. According to Ultra Lights, headlights flashing, to indicate the vehicle in Instrument function setting button front to overtake.

  • Page 25: Fuelling

    URBAN 525 FUELLING Recommended fuel: premium grade UNLEADED fuel (R.O.N 92). WARNING Fuel is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke or allow flames or sparks in the area where the motorcycle is refueled or fuel is stored. Proceed as follows: -Turn off the engine.

  • Page 26: Front Brake Control

    URBAN 525 FRONT BRAKE CONTROL REAR BRAKE CONTROL The brake control lever (1) is located on the right-hand side of the handlebar. The rear brake control pedal (1) is placed on the right-hand side of the A stop switch, during the braking action, causes the stop light on the tail motorcycle.

  • Page 27: Adjusting The Rear-View Mirrors

    URBAN 525 GEAR SHIFT CONTROL ADJUSTING THE REAR-VIEW MIRRORS The lever (1) is placed on the left-hand side of the engine. Sit on the motorcycle as described in the relative paragraph. The rider must release the lever after each gear change to allow it to return Adjust both mirrors (1) so that you can clearly see the road behind you when to its central position.

  • Page 28: Seat Belt

    URBAN 525 SEAT BELT STARTING THE ENGINE Deuce safety belt is equipped on the passenger seat. After getting on the motorcycle as described in the relative paragraph, op- To wear the seat belt properly, do the following: erate as follows to start the engine: Hold the latch plate as you pull the belt across your lap and chest.

  • Page 29: Stopping The Motorcycle And The Engine

    URBAN 525 -Shift gear pedal (3) to neutral, STOPPING THE MOTORCYCLE AND THE ENGINE -Fully close the throttle twist grip (1) to decelerate the motorcycle. -Apply both front (2) and rear (3) brakes while downshifting (for sharp de- celeration, operate in a decided manner on the brake lever and pedal). -Check that the button (4) is in position and then press the start button (5).
  • Page 30 URBAN 525 ENGINE EMERGENCY STOP -Flick the red switch (7) to stop the engine and then flick it back to position. WARNING It can be useful to use the front brake independently or to use the combined braking depending on the situation. Be careful when using the front brake, -Turn the ignition key (6) to the position (position for removing key).

  • Page 31: Engine Maintenance

    URBAN 525 severely worn chain may break, insufficient lubrication can cause chain and ENGINE MAINTENANCE sprocket wear, and if the chain is too tight, then the transmission system will When the engine has been run-in for 500 miles, a mandatory first service incur extra burden, which can in turn wear or break the chain.
  • Page 32 URBAN 525 Check that, after starting, the " " “Engine fault” lights are not on. LAUNCH AND SHIFTING GEARS Rear view mirror check: Sit on the motorcycle and keep your body While sitting on the motorcycle with the engine running at idle in vertical to the ground, see if you get a clear view behind you from the rear neutral, raise the side-stand and place both feet firmly on the ground.
  • Page 33 URBAN 525 BRAKE USAGE PARK Use the front and rear brake simultaneously for maximum braking power. Shift the motorcycle to neutral and switch off the motorcycle. Avoid unnecessary sudden braking. Close the throttle. Please use the main stand to keep the motorcycle steady, and park the CAUTION motorcycle on horizontal ground or the motorcycle may fall over.

  • Page 34: Inspection And Adjustment

    URBAN 525 V、 INSPECTION AND ADJUSTMENT The following table shows the interval of regular maintenance in travel distance or number of months. At the end of an interval, be sure to carry out the specified inspection, lubrication and maintenance. If your motorcycle is used with heavy loads, such as high power driving in a dusty environment, the maintenance shall be carried out more frequently.
  • Page 35 URBAN 525 TABLE OF MAINTENANCE INTERVAL 1000 4000 7000 10000 Interval: based on odometer reading or num- mile 5000 2500 4500 6500 ber of months Number of Battery months *Butterfly throttle, throttle cable *Spark plug *Clutch *Air Filter *Fuel filter *Fuel hoses Replace every 4 years *Engine oil and oil filter...
  • Page 36 URBAN 525 Driving chain Clean and lubricate every 1 000 kms *Steering *Cylinder head nut and exhaust pipe bolt Caption: Inspection: I Tightening: T Cleaning: C Replace: R Note*: That the maintenance interval is 3000 km. Do not forget to certify them in the manual provided by your dealer LUBRICATION TABLE Interval Every 6000 km or 6 months...

  • Page 37: Removing The Side Panels

    URBAN 525 REMOVING THE SIDE PANELS SPARK PLUG CHECK For some maintenance operations, one or both the side panels need to be Spark plug gap must be 0.6 ~ 0.8 mm. removed. A greater gap may cause starting difficulties and coil overload, a shorter gap To remove the left- and right-hand side panels, operate as follows: may cause problems with acceleration, idling and low speed performance.
  • Page 38 URBAN 525 spark plug then tighten it again to 10~12 Nm. IT is very useful to examine the status of the spark plug just after it has been Spark plugs with cracked insulators or corroded electrodes should be re- removed from its seat, since the deposits and the cooler of the insulator provide useful information.
  • Page 39 URBAN 525 OIL LEVEL CHECK CAUTION The engine oil level should be checked before each use. In addition, the oil The insufficiency or poor quality of the engine oil will lead to the premature wear-out of the engine. and the oil filter must be changed and replaced at the intervals specified in Substitution of the engine oil the periodic maintenance and lubrication chart Keeping the motorbike level and in a vertical position, check the oil level...

  • Page 40: Valve Clearance

    URBAN 525 Cleaning the oil pan and the primary filter VALVE CLEARANCE Do not adjust valve clearance without consulting your genuine dealer. Remove the oil filter cap with an oil filter (4) wrench. Cleaning the installation valve clearance: Intake: 0.10-0.15mm Exhaust: 0.20-0.25mm surface, Install the new oil filter with an oil filter wrench, and then tighten it If you need to adjust, please follow the steps below:...

  • Page 41: Air Filter Check And/Or Replacement

    URBAN 525 AIR FILTER CHECK AND/OR REPLACEMENT IDLE SPEED - Remove the right panel as described in the relevant paragraph. CAUTION Do not adjust idle speed without consulting your genuine dealer. - Release the OBD (1). - Unscrew the screws (2) and remove the filter cover (3). The idle speed is controlled by the ECU.

  • Page 42: Clutch Adjustment

    URBAN 525 CLUTCH ADJUSTMENT Normally, the clutch is adjusted by only stretching the cable using the ad- justing unit positioned on the handlebar. As a rule, it is sufficient to operate on the handlebar adjuster to restore the clearance due to the flexible trans- mission stretch.

  • Page 43: Brake System

    URBAN 525 BRAKE SYSTEM The front brake and the rear brake is hydraulic disk type, Inspect the brake system prior to each ride. Properly functioning brake systems are vitally im- portant to your personal safety. Check for fluid leaks, fluid level, brake shoe wear, and rotor and drum condition.
  • Page 44 URBAN 525 The combined braking pedal (3) must have a free play (B) of 3 mm before WARNING the braking action starts. In the absence of the required free play, the brake pads will rapidly wear, Should this not happen, adjust as follows: resulting in the risk of TOTAL BRAKE INEFFICIENCY or rear brake lock.
  • Page 45 URBAN 525 CAUTION Do not spill brake fluid onto any painted surface or light lens. CAUTION Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand. CAUTION Brake fluid may cause pungency.

  • Page 46: Tyres

    URBAN 525 PAD CLEANING TYRES Make sure that there are no traces of brake fluid or oil on the pads or discs Check the condition of the tyres, they should not have any cracks, abrasions, Use alcohol to clean the pads or discs from any traces of fluid or oil. etc;...

  • Page 47: Chain Adjustment

    URBAN 525 CHAIN ADJUSTMENT Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break.

  • Page 48: Chain/Front Sprocket/Rear Sprocket Wear Check

    URBAN 525 CHAIN/FRONT SPROCKET/REAR SPROCKET WEAR CHECK DISASSEMBLING AND INSTALLATION OF FRONT WHEEL - Check the condition of the chain (1); there may not be any damaged rollers, To remove the front wheel loosened pins or missing O-rings. Position the motorcycle in such a way that the front wheel is lifted from the ground.

  • Page 49: Disassembling And Installation Of Rear Wheel

    URBAN 525 DISASSEMBLING AND INSTALLATION OF REAR WHEEL Unscrew the nut (1) of the wheel shaft (3) and extract it. It is not necessary to loosen the chain tensioners (2); in this way, the chain tension will remain unchanged after reassembly. Extract the complete wheel, paying attention to the bush at the hub sides.

  • Page 50: Disassembling And Installation Of Side Car Wheel

    URBAN 525 DISASSEMBLING AND INSTALLATION OF SIDE CAR WHEEL SPOKE Check the wheel for loosened or broken spokes. Position the motorcycle in such a way that the sidecar wheel is lifted from the ground. Screw the loosened spokes to the specified torque with a spoke nut fas- Remove the side wheel rim decorative cover;...

  • Page 51: Shock Absorber Adjustment

    URBAN 525 SHOCK ABSORBER ADJUSTMENT COOLING SYSTEM MAINTENANCE The shock absorber spring and pressure can be adjusted. The adjustment The water pump (1) in the engine forces the coolant to circulate. steps are as follows: The pressure in the cooling system due to temperature rise is regulated by Use a suitable wrench to loosen the ring nut (1) and adjust the adjuster with the valve in the radiator cap (2).
  • Page 52 URBAN 525 COOLANT CHECK When the engine is cooling (the motorcycle is upright), check the fluid level in the radiator (1) on the right side. The coolant level should be within the upper and lower scale lines of the kettle (2), by adding to the scale. The radiator cover (3) is in the locked position, the first Is used to relieve the previous pressure in the cooling system.
  • Page 53 URBAN 525 BATTERY CAUTION When the engine is hot and the water temperature reaches above 40 de- The sealed battery does not require any maintenance. If electrolyte leaks, or grees, do not open the radiator cap to prevent the coolant from spraying other failure of the electrical system is detected, contact the your Dealer.
  • Page 54 URBAN 525 WARNING The battery contains sulphuric acid Avoid contact with skin, eyes or clothing. Antidote: In case of contact with the acid: Flush with water. In case of acid ingestion: Drink large quantities of water or milk. After milk, take magnesia, beaten eggs or vegetable oil.

  • Page 55: Fuses

    URBAN 525 FUSES FORK FUNCTIONALITY CHECK Fuse malfunction could cause problems for the motorcycle. To check proper operation of front fork, operate as follows: To access the fuse box, remove the left-hand side panel. and open the pro- -Get on the motorcycle; tective door (1).

  • Page 56: Steering Bearing Check

    URBAN 525 STEERING BEARING CHECK -Plug the muffler before cleaning, to prevent water from getting inside the muffler. Position the motorcycle in such a way that the front wheel is lifted from the -After washing, dry off the motorcycle. Ride for a distance until the engine ground.

  • Page 57: Return To Service

    URBAN 525 Clean the motorcycle and apply anti-corrosion to parts vulnerable to rust. Drain the fuel if possible, use fuel stabilizer if draining fuel tank is not possible. Remove the ignition key. Cover the motorcycle. RETURN TO SERVICE Remove the cover and clean the motorcycle. Change the oil if the vehicle has not been used for over 4 months.

  • Page 58: Special Torque Values

    URBAN 525 SPECIAL TORQUE VALUES Thread diameter (mm) Torque value (N.m) Item Brake caliper bolt 25～35 25～35 Engine hanging bolt 40～50 60～70 Front fork nut 90～110 Front shock absorber 40～50 Rear shock absorber 40～50 Side car frame to adjust tube 40～50 Joint frame tube 40～50...
  • Page 59 URBAN 525 Standard Torque Values Name and dimensions Torque value (N.m) 6mm bolt & nut 8-15 20-30 8mm bolt & nut 30-40 10mm bolt & nut 40-50 12mm bolt & nut 60-70 14mm bolt & nut 60-70 16mm bolt & nut 60-80 20mm bolt &...

  • Page 60: Engine Management System

    URBAN 525 VI、 ENGINE MANAGEMENT SYSTEM EFI System Composition The Engine Management System (EMS) is comprised of the following components: Electronic control unit (ECU), throttle body, Idle speed control valve, fuel pump, fuel injector, ignition coil, O2 sensor, throttle position sensor, T-MAP sensor, cylinder head temperature sensor, etc. The EMS uses sensors to collect parameters such as air flow, temperature of inlet air, cylinder head temperature, atmospheric pressure and the operational state of engine (rpm, load, acceleration and deceleration).
  • Page 61 URBAN 525...
  • Page 62 URBAN 525 EMS failure diagnosis code list Component/System Fault Type Fault Code Monitor Strategy Description circuit Hi/Open circuit P 0118 Circuit check circuit Lo P 0117 Circuit check Engine coolant temperature sensor Performance P 0116 Circuit check Out of Range P 1116 Circuit check Crankshaft position sensor...
  • Page 63 URBAN 525 circuit Hi P 0108 Circuit check circuit Lo/Open circuit P 0107 Circuit check Manifold Absolute Pressure Sensor Performance P 3106 Circuit check Signal Stuck P 0105 Circuit check circuit Hi/Open circuit P 0113 Circuit check circuit Lo P 0112 Circuit check Intake Air Temperature Sensor Signal Stuck...
  • Page 64 URBAN 525 Performance P 014E Circuit check circuit Hi P 0037 Circuit check O2 sensor Heater 2 cylinder circuit Lo/Open circuit P 0038 Circuit check performance P 00D3 Circuit check performance P 0300 Circuit check Misfire detection performance P 0301 Circuit check performance P 0302...

  • Page 65: Electrical System Diagram

    URBAN 525 VII、 ELECTRICAL SYSTEM DIAGRAM...

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