User manual

MAINTENANCE OF THE COOLING SYSTEM
1. Filling up with uid:
Remove the top cowling. Place the minibike so that the front wheel is 30 cm higher
than the rear wheel, see g. 24. Remove the cap from the leveling reservoir and
loosen the bleeding bolt M5 by 6 turns, which is located in the upper left part of the
radiator.Slowly pour the cooling liquid into the leveling reservoir. The cooling uid
volume in the system is 0.5 l. Close the reservoir and the bleeding bolts. Place the
minibike onto the stand and start it up, leave it running for about 1 minute. Then
again place a support under the front wheel and use the bleeding screw to perform
the additional bleeding. Hereby the minibike is prepared for operation.
2. Checking the cooling:
Check the amount of the uid in the leveling reservoir before every ride! After 10
hours of operation, remove the starting cover and check the condition of the cog
belt which drives the cooling uid pump.
Important warning: turn off the engine immediately if the cooling uid level rises in
the leveling reservoir during operation! Check the drive of the cooling pump and the
cooling system for leaks. After this inspection perform an air venting. The increased
level of the cooling uid is a sign of an overheated motor and the piston can get
seized in the cylinder!
3. Draining the uid:
Drain the uid by removing the hose on the bottom part of the engine. Unscrew the
cap of the leveling reservoir during the draining. Drain the uid into a container that
is prepared ahead of time and ensure the ecological liquidation of the uid.
g. 24
30 cm
TIGHTENING TORQUES
21 22
use - MOTOR number g. pc
tightening
torque (Nm)
securing
Cylinder head, water – M6 920.015.01 35, 36 5 10
Cylinder bolt – M6 920.015.01 35, 36 4 9,5
Intake ange – M5 914.003.01 34, 35, 36 4 5
Starter housing – M6 914.008.01 34, 35, 36 3 10,5
Ratchet bolt – M6 916.012.01 38 1 9 thread glue
Rotor nut – M10 920.021.01 34, 35, 36 1 25
Starter levers’ bolts – M5 916.051.01 37 2 5,5 thread glue
Coil bolts – M5 914.026.01, 914.003.01 34, 35, 36 2 5,5
Coil holder bolt – M6 914.510.01 34, 35, 36 1 8
Engine block bolts – M6 914.035.01 34, 35, 36 5 12
Clutch catch driver nut – M8 920.020.01 34, 35, 36 1 22 thread glue
Clutch housing bolts – M6 914.008.01 34, 35, 36 3 10,5
Bearing housing bolts – M6 914.001.01 39 2 10,5
Pump axle nut – M6 920.009.01 34, 35, 36 1 8 self-locking
Membranes bolts – M3 912.010.01 41 4 0,8 thread glue
Float chamber bolts – M4 carburettor - 2 2
Slider cover bolts – M4 carburettor - 2 2
Fuel strainer cover bolt – M5 carburettor - 1 2,5
Pinion – M8 330.029.00 39 1 22 thread glue
used - FRAME number pc
tightening
torque (Nm)
securing
Axle nut for front wheel – M10 920.011.01 45 1 35 self-locking
Brake disc front – M5 918.550.00 46 3 15
Front brake holder – M6 914.035.02, 914.008.01 45 4 12,5 thread glue
Steering axle – M10 920.011.01 45 1 20 self-locking
Handlebar clamp – M6 + M5 914.003.01, 914.008.01 45 2 + 2 9,5
Fork holders – M5 914.006.01 45 4 9
Engine holders, head – M8 920.010.01 48 1 18,5 self-locking
Engine holders, bottom – M8 914.063.11 48 1 22 thread glue
Axle nut for rear wheel – M10 920.011.01 47 1 35 self-locking
Brake disc, rear – M5 918.550.00 47 3 15
Sprocket-wheel – M5 914.001.01 47 3 15
Cover for sprocket-wheel – M5 916.050.01 48 2 10
Bolt – M3 916.179.02 53 2 2,5
Bolts of the fairing, seat
916.005.01, 916.014.01
916.415.01
55 5 6
Clamps for the handlebar levers – M6 brakes - 2 7,5
Brake levers in a clamp – M5 brakes - 2 3,5
Throttle handle clamp – M5 throttle grip - 2 5
Throttle handle cap – M4 throttle grip - 2 2
Reservoir holder – M6 914.080.01 50 1 6
Front fender – M5 918.900.01 55 4 5,5
Rear forks – M8 914.043.01 48 2 22 self-locking
Under-seat frame – M8 920.010.01 48 10 15 self-locking