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Related Manuals for Sachs Bikes MadAss 125
Summary of Contents for Sachs Bikes MadAss 125
- Page 1 Your Sachs dealer SACHS uses Sachs Fahrzeug- und Motorentechnik GmbH and recommends Ernst-Sachs-Straße 6 • D-90441 Nürnberg Phone: +49 (0)911 4231 400 • Fax +49 (0)911 4231 332 e-Mail: info@sachs-bikes.de • www.sachs-bikes.de Nr. P00 646 008 00 02 000 2006 04 005...
- Page 2 owners manual ...
- Page 4 PREFACE You have purchased a Sachs MadAss, congratulations and thank you for putting your trust in us. This operating manual includes important Reprinting, reproduction and translation, The MadAss is a sturdy motorcycle in mo- instructions for handling your light motor- even of excerpts, without our express dern design.
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Page 5: Table Of Contents
CONTENTS OVERVIEW AND OPERATION RIDING INSTRUCTIONS Safety symbols ................3 Ride safely................22 Ride economically and be aware of the environment ....23 Chassis number, engine number..........3 Running-in instructions ............24 Side view ................4-5 Side stand................25 Engine ..................6 Starting .................. - Page 6 CONTENTS NOTES ON MAINTENANCE TECHNICAL DATA Checking steering bearing............38 Engine ..................59 Checking the telescopic fork and shock absorber ....38 Power transmission ..............60 Adjusting the shock absorber ..........39 Chassis..................61 Removing the front wheel............40 Lubricants and operating fluids ..........62 Installing the front wheel............
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Page 7: Overview And Operation
OVERVIEW AND OPERATION Safety symbols and notes Chassis number Engine number Observe the following: WARNING Precautionary measures against the risk of accidents, injury and/or death. FIRE HAZARD The bike is supplied with a catalyst. The exhaust system becomes very hot. While riding, idling or parking, make sure that no easily inflammable materials (such as hay, leaves, grass, coverings, luggage,... -
Page 8: Side View
OVERVIEW AND OPERATION Right-hand side view 1 Brake fluid reservoir rear brake 2 Brake fluid reservoir front brake 3 Chassis number and rating plate 4 Fork column lock 5 Footbrake lever, rear brake 6 Footrest 7 Kick starter 8 Battery and fuse 9 Pillion footrest, fold-up... -
Page 9: Side View
OVERVIEW AND OPERATION Left-hand side view 10 Cockpit 11 Handlebar fittings 12 Tank cap 13 Adjustment shock absorber 14 Pillion footrest, fold-up 15 Side stand 16 Footrest 17 Gear shift pedal 18 Air filter housing... -
Page 10: Engine
OVERVIEW AND OPERATION Engine left-hand side view Engine right-hand side view 1 Intake valve adjuster cover 8 Carburetor 2 Exhaust valve adjuster cover 9 Fuel tap 3 Spark plug connector 10 Engine number 4 Electric starter 11 Gear shift pedal 5 Oil drain plug 6 Clutch cover 7 Oil filler cap... -
Page 11: Handlebar Fittings
OVERVIEW AND OPERATION Left-handle handlebar fittings Right-handle handlebar fittings 6 Direction-indicator switch Switch to the left: Left indicator on Switch to the right: Right indicator on Push button for switch off Push-button: horn 1 Fixed grip 8 Emergency off switch engine will not start 2 Clutch lever engine starts... -
Page 12: Cockpit
OVERVIEW AND OPERATION Cockpit Ignition-lock WARNING While riding, do not switch the ignition NOTE Activate the parking light only for a limited period. Take into account the charge of the battery. The key can be removed in positions 1 Speedometer NOTE 2 KM/H -odometer The ignition-lock as well as the tank cap are... -
Page 13: Speedometer Set-Up, Time Adjustment
OVERVIEW AND OPERATION Speedometer time adjustment Speedometer set-up 12 : 00 Button M press untill the clock time (CLK) NOTE appears The display is only visible when the ignition is on. Button S press once, the hour value Mode for: flashes DST = total distance (km) The hour value can be set by... -
Page 14: Speedometer Battery Change
OVERVIEW AND OPERATION Speedometer battery change Replace the batteries (6) by using new Remove the screws (3 + 4) and take off NOTE batteries, type AG 13. the cover (5). If the ignition is turn off the clock is supplied Set-in the batteries with the plus termi- by the battery power. -
Page 15: Safety Test
SAFETY TEST Checklist Before each ride, carry out a safety – Lights Important notes for the operation with a catalyst. check using the checklist. – Clutch operation The catalyst. is designed for a optimal Take the safety check seriously. Carry out –... -
Page 16: Clutch
SAFETY TEST Clutch Adjustment: - Remove the rubber cap (1). - Release the lock nut (2). - Turn setting screw (3) as appropriate. - Tighten up the lock nut (2). - Check the play. NOTE Clutch lever play If this adjustment is not sufficient, adjust by turning the setting screw at the other CAUTION end of the clutch cable in the direction of... -
Page 17: Fuel, Fuel Tank
SAFETY TEST Fuel, fuel tank Opening: - Tilt up the cover (2) in the direction of the arrow. - Insert the ignition key (3), turn the cover (2) to the left and open the tank cap (1). Closing: - Close the tank cap (1) by turing the cover (2) to the right and pull out the ignition key. -
Page 18: Fuel Tap
SAFETY TEST Fuel tap Fuel tap (4) CAUTION Fuel tap positions: When you stop the engine, always set = OPEN the fuel tap to position CLOSE. Oth- fuel tank will empty down to a erwise, fuel could enter the engine and reserve quantity of approx. -
Page 19: Engine Oil
SAFETY TEST Engine oil Recommended grade: - 20° -10° 0° 10° 20° 30°40° C CAUTION Per API: SG or higher or also with additional Do not use additives. Since the oil release status: ACEA A3/96 (CCMC G5). SAE 10W/30 also serves to lubricate the clutch, do not use car engine oils supple- Recommended viscosity: mented with friction modifiers (such... -
Page 20: Checking The Oil Level
SAFETY TEST Checking the oil level - Stop the engine and remove the oil filler cap (1) on the lower right of the crank- case. - Clean the oil filler cap at the MIN-MAX aera with a clean rag. CAUTION For checking the oil level only insert the oil filler cap and don't screw in! Otherwise there will be a wrong mea-... -
Page 21: Brakes
SAFETY TEST Brakes Front brake-fluid tank Rear brake-fluid tank WARNING Sudden changes in play or a spongy feel of the brake lever can be caused by UPPER LOWER faults in the hydraulic system. Do not ride on when in doubt about the oper- UPPER ability of the brake system. -
Page 22: Brakes
SAFETY TEST Front brake Rear 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. -
Page 23: Drive Chain
SAFETY TEST Drive chain Check the chain tension CAUTION - Shift the gear to neutral. The chain setting affects the wear on the drive chain and sprocket as well as the - Prop the motorbike up on the side stand. spring excursion of the rear wheel. -
Page 24: Tyre Profile, Tyre Pressure And Size
SAFETY TEST Tyre profile Tyre pressure Tyre size Checking the tyre pressure The standard motorbike is provided with the following tyre sizes: WARNING Front 90/90-16 48J Rear 120/80-16 60J Adjust the tyre pressure according to the total weight load. Never exceed the rated total weight or the bearing capacity WARNING of the tyres. -
Page 25: Load / Lights
SAFETY TEST Load / lights Correctly loaded Checking the lights WARNING - Make sure that the left-right weight For the sake of your safety, use only WARNING distribution is balanced. original Sachs accessories or products Before any ride, check the operation of - Check that fastenings are correct and released by Sachs. -
Page 26: Riding Instructions Ride Safely
RIDING INSTRUCTIONS Ride safely Your reactions can be adversely affected On smooth, slippery roads take into account CAUTION not only by alcohol, but also by drugs and that your riding stability and braking power Riding safety is largely also determined medicines. -
Page 27: Ride Economically And Be Aware Of The Environment
RIDING INSTRUCTIONS Ride economically and be aware of the environment Turn the engine off when waiting in Fuel consumption is also affected by Fuel consumption, environmental pollution traffic. conditions that are out of your control, for and wear of engine, brakes and tyres de- Different riding conditions affect fuel con- instance, poor road condition, hills, riding pend on various factors. -
Page 28: Running-In Instructions
RIDING INSTRUCTIONS Running-in Running-in new tyres - During the first 800 km: Running-in instructions for engine Less than 1/2 throttle. and transmission CAUTION CAUTION - Up to 1.600 km: New tyres have a smooth surface. They Less than 3/4 throttle. Excessive revs while running-in the en- must therefore be roughened by care- gine increases the wear of the engine. -
Page 29: Side Stand
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. -
Page 30: Starting
RIDING INSTRUCTIONS Starting Before starting - Turn the ignition key (2) to its operating - Shift the foot-operated gear lever (3) to neutral. position - Put the motorcycle it in a vertical position and fould up the side stand. NOTE - Turn the fuel chock (1) to position WARNING A = ON or... -
Page 31: Starting With Kick Starter
RIDING INSTRUCTIONS Starting with kick starter - As soon as the engine is no longer run- CAUTION CAUTION ning smoothly, turn back the CHOKE (1) Avoid high engine-speed counts after in position "B". The EMERGENCY OFF switch (3) is a a cold start. -
Page 32: Starting With Electric Starter
RIDING INSTRUCTIONS Starting with electric starter - As soon as the engine is no longer run- ning smoothly, turn back the CHOKE (1) in position "B". - When the operating temperature is in- creasing, turn back the CHOKE all the way in the opposite direction to the arrow "B". -
Page 33: Riding, Shifting Gears
RIDING INSTRUCTIONS Riding, shifting gears Starting / shifting up Shifting down CAUTION - Pull in the clutch lever (1). - Close the throttle. Avoid: – Crashing the gears - Push down on the foot-operated gear - Adapt your riding speed. –... -
Page 34: Braking
RIDING INSTRUCTIONS Braking Wet brakes Oil and grease WARNING Washing the motorcycle or riding through WARNING Operate the brakes to grind off the salt water or rain can delay the braking effect deposited on the brake discs. The brake discs and linings must be free due to wet or (in winter) ice-covered brake of oil and grease! discs and linings. -
Page 35: Braking
RIDING INSTRUCTIONS Braking Brake with care. Locked wheels do not have much braking effect and can lead to skid- ding / crashing. In principle, do not brake on a curve, but before the curve. Braking on a curve increases the danger of sliding. -
Page 36: Stopping The Engine
RIDING INSTRUCTIONS Stopping the engine Steering lock Stopping the engine Safeguard the steering against unautho- CAUTION rized use. - Turn the ignition key to the position Lock: Turn the fuel chock (2) to the OFF (1). position (Z). In the ON (A) or RES (R) Turn the handlebar fully to the left. -
Page 37: Service Instructions
SERVICE INSTRUCTIONS Servicing the motorbike / cleaning agents WARNING Always carry out a brake test after NOTE cleaning and before starting a ride! Regular, expert service will help maintain the value of your motorcycle and is a CAUTION condition for guarantee claims for corrosion Do not use steam or high-pressure jet and other such damage. -
Page 38: Servicing The Motorbike / Cleaning Agents
SERVICE INSTRUCTIONS Servicing the motorbike / cleaning agents CAUTION Never use paint-polishing agents on plastic parts. - After a longish ride, thoroughly clean the chassis and the aluminium parts and preserve them with a commercially available anti-corrosion agent. Cleaning - To wash the motorcycle, use a soft sponge and clean water. -
Page 39: Operation In Winter And Anti-Corrosion Protection
SERVICE INSTRUCTIONS Operation in winter and Repairing paint damage Servicing tyres anti-corrosion protection If the motorcycle is not used for a longer period, it is recommended to support the motorcycle so that its weight is not on the NOTE tyres. Protect the environment by using only en- You can prevent the tyres from becoming vironmentally friendly preservation agents,... -
Page 40: Lay-Up / Commission
SERVICE INSTRUCTIONS Lay-up / commission Lay-up Commission NOTE - Clean the motorcycle. - Remove the preservation agents from the Before laying up the motorcycle, have a outside. - Remove the battery. Sachs dealer change the engine oil. Observe the maintenance instructions. - Clean the motorcycle. -
Page 41: Technical Changes, Accessories And Spare Parts
SERVICE INSTRUCTIONS Technical changes, accessories and spare parts For approved Sachs accessories and WARNING CAUTION or iginal Sachs spare par ts, see a Technical changes to the motorcycle can We recommend using only approved specialised Sachs dealer. lead to cancellation of the EC operating Sachs accessories and original Sachs He will also ensure that they are license. -
Page 42: Notes On Maintenance
NOTES ON MAINTENANCE Checking the steering bearings Checking the telescopic fork Checking the shock absorber - Pull the hand brake to block the front Check the fastenings (2) of the spring NOTE wheel brake. strut for tight fit. The telescopic fork should not jam up when - Now pump the fork girders several times turned and it should swing back lightly to - Check the spring strut for oil leaks. -
Page 43: Adjusting The Shock Absorber
NOTES ON MAINTENANCE Adjusting the shock absorber Adjusting the spring preload CAUTION The spring strut is manufactured with NOTE a gas filling. The spring preload can be infinitely ad- justed. Do not open the valve cap (3) and do not make any changes. -
Page 44: Removing The Front Wheel
NOTES ON MAINTENANCE Removing the front wheel - Support the motorcycle so that the front CAUTION wheel can move freely and the motor- Take care not to damage the brake discs cycle is standing securely. and linings while removing them. - Loosen the shaft-clamping screws (1). -
Page 45: Installing The Front Wheel
NOTES ON MAINTENANCE Installing the front wheel - Grease the full floating axle (3) and push CAUTION it in with the spacer bushing (5) as far as it will go. Take care not to damage the brake discs and linings (4) while installing - Attach the axle nut (2) and screw tight. -
Page 46: Removing The Rear Wheel
NOTES ON MAINTENANCE Removing the rear wheel - Prop up the motorbike so that the rear CAUTION NOTE wheel can turn freely and that the Do not damage brake disc and linings motorbike is secure. When taking off the rear wheel, make sure during removal! that the bush (3) to the left of the wheel - Hold the full floating axle (4) and release... -
Page 47: Installing The Rear Wheel
NOTES ON MAINTENANCE Installing the rear wheel - Insert right chain adjuster (2) and CAUTION NOTE reassemble with axle nut (1). Do not damage brake disc and linings Insert brake support into the guide (9) of - Adjust the drive chain (5). during installation! Have a Sachs dealer rear suspension. -
Page 48: Checking, Adjusting The Drive Chain
NOTES ON MAINTENANCE Checking the drive chain Checking the chain for wear - With correct chain tension, it should not be possible to lift the chain higher than CAUTION the teeth of the sprocket. The chain, sprocket and pinion must be - If the chain can be pulled higher, have changed as one unit. -
Page 50: Front Wheel Brake
NOTES ON MAINTENANCE Front wheel brake Rear wheel brake � � � � � � � � Checking the brake linings - Visually inspect the brake calliper (1). - If the lining thickness is below the mini- mum, have the brake lining (2) replaced - Check the thickness of the brake lining. - Page 51 NOTES ON MAINTENANCE Rear wheel brake Adjusting the footbrake pedal position NOTE WARNING The footbrake pedal position can be adjus- Check the play on the footbrake pedal ted with the setscrew (1). and ensure that the brake is functioning properly. A soft and spongy feel when WARNING operating the foot brake indicates that The adjustment measurement A must...
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Page 52: Adjusting The Clutch Lever
NOTES ON MAINTENANCE Adjusting the clutch lever - Tighten up the lock nut (2). CAUTION NOTE - Remove screws (4) and take off the clutch If you drive with no clutch lever play, the If the clutch play cannot be corrected with cover (5). -
Page 53: Cleaning The Air Filter
NOTES ON MAINTENANCE Cleaning the air filter Remove the air filter Clean the foam with Motorrex air clean- NOTE Loosen the clamp (1) and take off the The motorbike is attached with a oil foam hose. Afterward soak and wring out the foam air filter. -
Page 54: Cleaning The Fuel Filter
NOTES ON MAINTENANCE Cleaning the fuel filter Adjusting the play of the twist grip throttle control CHECK: Adjustment: NOTE - Slacken the lock nut (2) on the handle- - Check the throttle cable for light move- We recommend to have the fuel filter (1) bar. -
Page 55: Spark Plug
NOTES ON MAINTENANCE Spark plug ��� � ��� �� Check and change - Insert new spark plug NGK CR7 HSA and tighten up. CAUTION Torque 20 Nm. Check or change the spark plug only when the engine is cold. - Plug in the connector (1). - Pull the spark plug connector (1). -
Page 56: Battery
NOTES ON MAINTENANCE Battery Charging the battery WARNING FIRST AID After a long lay-up (3-4 months), charge the Always wear safety glasses. If acid comes into contact with an eye, im- battery. The charging current (in amperes) Keep children away from acids and mediately flush the eye for several minutes must not exceed 1/10 of the battery ca-... -
Page 57: Battery
NOTES ON MAINTENANCE Battery Removing and installing the battery - Remove the screws (1) on both sides and take off the cover (2). CAUTION - Disconnect the rubber band (3) on the barttery case. The battery may only be connected or disconnected while the ignition is - Remove the battery. -
Page 59: Changing The Bulbs
NOTES ON 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 removing them. - Page 60 NOTES ON MAINTENANCE Tail / brake light If this is not the case, the tail light must be replaced by a Sachs dealer. The tail / brake light (1) is not fitted with a replaceable light bulb (diode light). If the tail light does not work you should first check, whether a cable connection is interrupted.
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Page 61: Changing The Bulbs
NOTES ON MAINTENANCE Changing the bulbs Rear indicator Front indicator - Push the bulb (3) back and release it by - Release the light case (2). turning to the left. Take the bulb out. Indicator lamps NOTE Installation takes place in reverse order to For changing the bulbs an opening of the disassembly. -
Page 62: Adjusting The Headlamps
NOTES ON MAINTENANCE 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. -
Page 63: Technical Data
TECHNICAL DATA Engine Engine type: 4-Speed model: IP52FMI Construction: One cylinder 4-stroke petrol engine Valve steering: 1 overhead cam with rocker arms Valve: 2 valve Valve clearance, cold: intake + exhaust 0.05 mm - 0.08 mm Pistion displacement: 119.7 cm Bore: ø... -
Page 64: Power Transmission
TECHNICAL DATA Power transmission Clutch: Wet multi-plate type Gear box: 4-gear claw dog-clutch engagement, pedal gear shifting Gear ratios: 1. gear = 34/12 (2,832) 2. gear = 29/17 (1,706) 3. gear = 26/21 (1,238) 4. gear = 23/24 (0,958) Chain pinion: 16 teeth Sprocket: 46 teeth... -
Page 65: Chassis
TECHNICAL DATA Chassis Motorbike version: 4-speed model: Type 646 Frame: Center-type frame made of tubular steel Front suspension: Telescopic fork ø 37 mm , hydraulic shock absorption, travel 100 mm Rear suspension: Mono shock absorber, travel 65 mm Wheels: Light metal (Alu) Front rim size: = 1,85 x 16"... -
Page 66: Lubricants And Operating Fluids
TECHNICAL DATA Lubricants and operating fluids Fuel tank capacity: 5,1 litres, including 0,35 litres reserve Fuel: Unleaded fuel min. 91 octane Telescopic-fork oil: Viscosity SAE 10 W Filling quantity per fork tube: 180 cm Engine oil: SAE 15 W 40 mineral oil API (SG or higher) Filling quantity: 0,8 litres Brake fluid:... -
Page 67: Electrical Equipment
TECHNICAL DATA Electrical Equipment Generator: 12 V 150 W Battery: 12 V 6 Ah MF Fuse: 15 A Lights: - Headlight: Low beam 12V 55W E1, high beam 12V 55W E1 - Position light: 12 V 5W - Instrument lights: Direction-indicator 12V 3W Change over gear 12 V 3W Cockpit 12 V 3W... -
Page 68: Dimensions And Weights
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: 100 kg Weight in running order: 105,5 kg Max. -
Page 69: Warranty Conditions
WARRANTY Warranty conditions In case of an occurring fault the company then entitled to legal claims. Replaced tomer must present the correctly filled in Sachs Fahrzeug- und Motorentechnik parts pass over into the possession of service book to the seller. GmbH will provide the customer with the Sachs Fahrzeug- und Motorentechnik 6. -
Page 70: List Of Wear Parts
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 after only 2500 km or even earlier. -
Page 71: List Of Wear Parts
WARRANTY List of wear parts Wear parts Wear limits Cleaning and lubrication of drive chain according of use and of every washing. Drive chain, pinion, sprocket wheels, depending on road conditions / ground and care, a wear is possible after 1500 km. chain guidance, chain pulley Do not wash with high pressure cleaner! Control during every maintenance. -
Page 72: Inspection Plan
INSPECTION PLAN Please observe the following: WARNING CAUTION - During and after the warranty period all For safety reasons, do not carry out any inspections should solely be performed In case of non-compliance the warranty repair or adjustment activities to the by a specialised dealer approved by us. - Page 73 INSPECTION PLAN Component Servicing Tasks Before 1st service Every Every Assembly (*Only by an authorised Sachs dealer) each after 4.000 km / 8.000 km / trip 1000 km 4 months 8 months Valves Check and adjust valves if necessary (cold)* Spark plugs Check condition and accordingly clean or replace Replace...
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Page 74: Inspection Plan
INSPECTION PLAN Component Servicing Tasks Before 1st service Every Every Assembly (*Only by an authorised Sachs dealer) each after 4.000 km / 8.000 km / trip 1000 km 4 months 8 months Rear suspension Check, retighten, replace if necessary or lubricate* Every 24.000km / 2 Years Tyres Check gereral condition and profile depth and... -
Page 75: Maintenance Confirmation
MAINTENANCE CONFIRMATION Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date... - Page 76 MAINTENANCE CONFIRMATION Workshop activities carried out Workshop activities carried out Activities carried out date Activities carried out date...
- Page 77 MAINTENANCE CONFIRMATION 1.000 km/1 months 4.000 km/4 months After 8.000 km/8 months After 12.000 km/12 months service dealer stamp: dealer stamp: dealer stamp: dealer stamp: km ........km ........km ........km ........date......... date......... date......... date......... After 16.000 km/16 months After 20.000 km/20 months After 24.000 km/24 months After 28.000 km/28 months...
- Page 78 MAINTENANCE CONFIRMATION After 32.000 km/32 months After 36.000 km/36 months After 40.000 km/40 months After 44.000 km/44 months dealer stamp dealer stamp dealer stamp dealer stamp km ........km ........km ........km ........date......... date......... date......... date......... After 48.000 km/48 months After 52.000 km/52 months After56.000 km/56 months After 60.000 km/60 months...
- Page 79 MAINTENANCE CONFIRMATION New brake fluid New brake fluid New brake fluid New brake fluid Km........Km........Km........Km........Date ........Date ........Date ........Date ........Stamp, signature Stamp, signature Stamp, signature Stamp, signature...
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Page 81: Motorbike Data / Rating Plate
Motorbike data Rating plate (sample): (fill out on purchase) Model designation: ............Sachs Fahrzeug-und Motorentechnik GmbH Vehicle identily No: ............(Chassis No) e1-0279 WSF 646A1061000101 Key No: ......................3.750 min — d B ( A ) EC license: ............EC-license: Owner: ............
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