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CONTENTS SPECIFICATION ···································· 3 OPERATION INSTRUCTION ···························· 4 EQUIPMENT USAGE ···································14 SAFETY PRECAUTIONS ································ 4 SEAT LOCK ··········································14 PRIOR TO STARTING VEHICLE ··························· 5 TRUNK··············································15 OPERATION ·········································· 5 DOCUMENT STORAGE AREA ·····························15 CORRECT
2 MAINTENANCE ········································31 SAFE DRIVING ········································50 MAINTENANCE SCHEDULE ·······························32 PREPARATION BEFORE DRIVING ·····················50 MAINTENANCE PRECAUTIONS ····························34 DRIVING METHOD ··································50 BRAKES ·············································34 DRIVING POSITION ···································51 BRAKE HOSE, PIPE LEAKAGE, DAMAGE, ASSEMBLY STATE ·······36 TAKING
SPECIFICATION ITEM DATA ITEM DATA LENGTH×WIDTH×HEIGHT(mm) 2,110×745×1,356 IGNITION SYSTEM TRANSISTOR WHEEL BASE(mm) 1,481 BATTERY CAPACITY 12V10AH(MF TYPE) GROUND CLEARANCE(mm) 121 FUEL CAPACITY(ℓ) 11.5 SEAT HEIGHT(mm) 760 RESERVE FUEL CAPACITY(ℓ) 2.2 DRY WEIGHT(kgf) 168 PASSENGER 2 ENGINE TYPE WATER- COOLED 4 STROKE 4VALVE PISTON DISPLACEMENT(cc) 249 BORE AND STROKE(mm) 72.
OPERATION INSTRUCTION This manual describes matters pertaining to correct operation, safe operation and simple maintenance of the vehicle you purchased. To ensure more comfortable and safer operation, make sure to read this manual carefully prior to operation. ●The photographs and drawings shown in this manual may differ from those of actual vehicles due to changes in vehicle specifications and modifications made. ●This vehicle is designed for 2 riders including the operator.
PRIOR TO STARTING VEHICLE ●Read user's manual carefully. ●Conduct maintenance checks prior to operation. ●Always maintain vehicle in clean status and carry out specified maintenance checks. ●Make sure to stop engine and stay away from fire when fueling. ●Exhaust gas contains harmful substance such as carbon monoxide. Start engine in well-ventilated places. OPERATION ●Operators should naturally fix bodies to keep smooth driving. ●Please check whether or not you are unnaturally strained and strung up.
CORRECT ATTIRE ●Always make sure to wear helmet for safety. Wear gloves and safety goggles. ●Do not wear uniforms which might hinder operation. It is dangerous if the uniform is caught by brake lever or by the rotating part of drive chain. ●Many automobile/motorcycle accidents happen because the automobile driver does not “see” the motorcyclist. Make yourself conspicuous to help avoid the accident that wasn’t your fault : - Wear bright or reflective clothing. - Don’t ride in another motorist’s “blind spot”.
CARGO MODIFICATION ●When carrying cargo, you must keep in mind that operating the motorcycle, especially when turning, will be different. ●Make sure not to overload the motorcycle with goods as this can make the motorcycle unstable during operation. ●Modification of vehicle structure of function deteriorates manipulatability or causes exhaust noise to become louder shortening the vehicle life. These modifications are not only prohibited by law but also are the acts harmful to other people.
PARTS LOCATION REAR VIEW MIRROR BATTERY FR.
PARTS LOCATION PILLION SEAT RR. BRAKE LEVER MAIN SEAT FUEL TANK LID REAR COMBI. LIGHT HEADLIGHT FR. FENDER FR. CUSHION AIR CLEANER FR.
METER READING AND USAGE METER WINKER INDICATOR WINKER INDICATOR SPEEDOMETER INDICATOR LAMPS Indicates driving speed. Maintain legal speed limits to ensure safe operation. When the winker switch is operated, the winker indicator flashes in union with the flashing of the turn signals. Indicates total distance in kilometers travelled by the vehicle. It indicates the temperature of cooling water.
SWITCH OPERATION MAIN SWITCH 1. ON.... Starts engine. Key can not be pulled out. 2. OFF....Stops engine. Key can be placed in or taken out of the main switch. 3. LOCK....Locks handle bars. Key can be placed in or taken out of the main switch. 4. OPEN....When seat lock is released, key returns to its original position(OFF). Key can be placed in or taken out of the main switch. MAIN SWITCH CAUTION KEY ●Do not manipulate main switch key during operation.
START BUTTON HEADLIGHT START BUTTON Put main switch key in “ON” position and turn on headlight switch. High beam or low beam can be operated by the use of dimmer switch. DIMMER SWITCH HEADLIGHT SWITCH The engine is started pressing this button when pressed in a state where the main switch key is placed to an ON position and the brake lever is pulled. CAUTION ●The engine will not start if the brake lever is not pulled.
WINKER SWITCH HORN BUTTON PASSING SWITCH PASSING SWITCH WINKER SWITCH If this switch is turned on when the main switch is in an ON position, the winker will operate. (R)....used when making a right turn. (L)....used when making a left turn. HORN BUTTON The horn is sounded if the horn button is pressed when the main switch is in an ON position. Push the button 2~3 times when you need to call driver’s attention.
EQUIPMENT USAGE STEERING STEM LOCK SEAT LOCK CAUTION KEY STEERING STEM LOCK STEERING STEM LOCK To lock the steering, turn the handlebars all the way to the left, turn the key to LOCK while pushing in. Remove the key. ●The seat automatically locks when the seat is pushed in its downward position, ●Lightly pull upward on the seat to make sure the seat has been properly locked. To unlock the steering, turn the key to the OFF position.
TRUNK DOCUMENT STORAGE AREA TRUNK ●There is a trunk under the seat. ●The seat is opened to gain access to the trunk by using the main switch key on the seat lock. ●The lamp inside the trunk will be turned on if the seat is opened. TRUNK MAXIMUM LOAD:10kg CAUTION ●The temperature inside the trunk rises due to heat from the engine. Do not place foodstuffs and other articles that can be damaged easily by heat. Also do not place flamm-able materials in the trunk.
CORRECT DRIVING OPERATION STARTING THE ENGINE ●Make sure to check the oil, gasoline, etc., before starting the engine. ●Please ensure that the main stand is in a down position when starting the engine. CAUTION ●Make sure that the rear wheel is locked when starting the engine to prevent an unexpected quick start of the vehicle. ●Locking is not possible if the rear wheel brake is not adjusted correctly. ●Drive with care for both safety reasons and longer vehicle life.
Lock the rear wheel. ●Press the starter button without rotating the starter grip (opening the throttle). ●If the engine is hot and does not start after pressing the starter button for 3~4 seconds, rotate the throttle grip to 1/8~1/4 of a rotation and try again. This will allow easy starting 1/8 1/4 Turn the main switch to an ON position. CAUTION ●Immediately release the starter button as soon as the vehicle has started.
IF ENGINE CANNOT BE STARTED ●It is possible that starting will be more difficult if the vehicle has not been used for a long period of time or if the fuel hole is plugged up(starting problems even when there is sufficient fuel in the fuel tank may be an indication of a plugged fuel hole). When this happens, do not rotate the throttle grip and try the starter button a few times. CAUTION ●Do not keep the statter button pressed for more than 5 seconds at a time.
AFTER STARTING ENGINE Fold the main stand. ●Push the vehicle forward to fold the main stand and make sure that the brake lever does not become released during this operation. Get on the vehicle. ●Mounting should be done from the left side, and you should sit squarely on the seat. Leave either one foot or both feet planted on the ground Release the squeezing tension on the rear brake lever and slowly begin to rotate the throttle grip to allow for a slow and easy start.
PROPER DRIVING METHODS ●Before entering traffic, use the correct turn signal to foreward other drivers of your intentions. Speed is controlled by the operation of the throttle grip. Work the front and rear brakes together. ●If the throttle grip is rotated........ The speed of the vehicle increases. Please rotate the throttle grip slowly. When climbing a hill, the throttle grip need to be rotated further to give the vehicle more power.
STOPPING The brakes should never be suddenly applied and the handle bars should never be suddenly turned. ●Sudden braking or turning can cause the vehicle to slide and tip over. ●It is especially dangerous to perform sudden braking on wet roads or in rainy weather as the tires can lose traction and slip easily. Special care in driving should be taken during rainy weather. ●More braking distance is needed when driving on wet roads or in the rain.
After the vehicle has come to a complete stop. Dismount on the left side and lower the main stand on a flat surface. ●Return the winker switch to the center position and turn the main switch to OFF. This will turn the engine off. ●Be sure to park in an area that is free of traffic. Also, the vehicle can tip over if the main stand is not placed on a stable and flat surface.
SELF INSPECTIONS BEFORE OPERATION Self inspect the vehicle and have regular maintenance inspections for increased safety and the prevention of accidents. Regular maintenance inspections should be performed even if the vehicle has not been used for a long period of time. Self inspections before operation should be performed on a daily basis prior to operating the vehicle.
INSPECTION OF CONCENED AREA ●Check areas which caused for concern when last operating the vehicle. ●If happened, contact authorized maintenance shops for necessary inspection and repairs. BRAKE INSPECTION Lightly squeeze the brake levers until tension is felt to check for an appropriate amount of free play. No free play in the brake levers or overly loose brake levers are indication of a problem in the brake system.
FUEL CHECK Check gasoline to see if there is a sufficient amount of gasoline to reach your destination. ●Place the main switch to “ON” position. ●If the fuel meter needle indicates E mark (red portion), fill fuel tank with gasoline as soon as possible. ●Open the key cover on fuel tank cap, and turn the key clockwise to remove the cap. ●Fill the tank with gasoline until it reaches the bottom of the level plate. ●Press the cap firmly, and pull out the main key.
TIRE INSPECTION Check for an appropriate level of air pressure by examining how the tire sits on the ground. If you notice any abnormalities in the shape of the tire with regard to the area contacting the ground, use a tire gauge to check tire pressure and adjust the tire pressure to the appropriate level. Check tire tread and sides for cracks and damage. Check tire tread and sides for nails, rocks, etc. That might have become wedged in the tire.
ENGINE OIL LEVEL CHECK CAUTION ●If air pressure is inadequate or if there are cracks, damage or abnormal wear on tires, it may cause trembling steering wheel and flat tire. ●Insufficient air pressure may cause the heavy steering wheel making handling difficult, fuel over consumption and the excessive wear of tire outer area and excessive air pressure may cause easier wheel handling and lower fuel consumption. But it may also cause the excessive wear of tire center area.
LIGHTS AND WINKER INSPECTION CAUTION ●The lighting head light emits very hot heat. If you touch with naked hand, it may be burned. ●When replacing head light lamp, stop lame and winker lamp, use only a bulb of rated capacity. Using a lamp exceeding the rated capacity can cause over-discharge of battery and wire burning. It can lead a fire. ●If the head light is turned off due to aging while driving at night, it will cause an accident by obstructing driver’s view. Check the condition daily.
(4) Disassemble a headlight socket by pulling it out. (5) Disassemble the rubber cover. (6) Loosen the steel wire, and disassemble the head light bulb. HEADLIGHT BULB: 12V 55W RUBBER COVER BULB ●Adjust headlight lumination angle by turning an adjusting bolt on a headlight. (Use type screwdriver.) (1) Adjust the upper/lower by turning the screw on outside. (2) Adjust the right/left by turning the screw on inside.
CHECKING COOLING WATER Front Winker Bulb (1) Loosen tapping screw to disassemble a winker lens. (2) Press a bulb with a light force and rotate it to counterclockwise to disassemble it. (3) Replace it with new bulb. Apply reverse order of disassembly for assembly. FRONT WINKER BULB: 12V 10W (3) Replace it with new bulb. Apply reverse order of disassembly for assembly. REAR WINKER BULB: 12V 10W (1) Park the vehicle on a flat surface by use of main stand.
MAINTENANCE ●The Required Maintenance Schedule specifies how often you should have your motorcycle served, and what things need attention. It is essential that your motorcycle be served as scheduled to retain its high level of safety, dependability, and emission control performance. ●These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose.
MAINTENANCE SCHEDULE Perform the Self Inspections Before Operation at each scheduled maintenance period.
ODOMETER READING(NOTE 1) FREQUENCY ITEM ×1,000Km 1 4 8 12 16 MONTH 1 6 12 18 24 ★ BRAKE SHOE / PAD WEAR I I I I I ★ BRAKE SYSTEM I I I I I I I I I I I I I I I I I BRAKE STOP SWITCH ★ HEADLIGHT ADJUSTMENT ★ SUSPENSION ★ BOLTS, NUTS, FASTENERS I I I I I WHEELS / TIRES I I I I I STEERING I I I I I DRIVE VALTE I I I I ★★ WEIGHT ROLLER I I I I ★★ SLIDE PIECE I I I I MOVABLE DRIVE FACE GREASE L L L L ★ I REMARK ★ If you do not
MAINTENANCE PRECAUTIONS The following is an explanation of correct inspection methods, cleaning and parts replacing. Please always refer to this section when wanting to inspect or repair your vehicle. WARNING ●If your motorcycle is overturned or involved in a collision, inspect control levers, cables, brake hoses, calipers, accessories, and other vital parts for damage. Do not ride the motorcycle if damage impairs safe operation.
●Check that the fluid level is above the LOWER level mark with the motorcycle in an upright position. ●Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark. 1. Remove the wind screen. 2. Clean dust and other foreign materials around reserve tank to prevent foreign materials from falling inside tank. 3. Remove the screws and take oil cup cap, diaphragm plate, diaphragm off. 4.
BRAKE HOSE, PIPE LEAKAGE, DAMAGE, ASSEMBLY STATE Visually check for fluid leaks or damage and, using a spanner, check joints and clamps for clearance. Also, check hose and pipe protective parts to see if they contact other parts when turning the handle bars or due to vibration when driving. BRAKE PAD WEAR Brake pad wear depends upon the severity of usage, the type of riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.
CHANGING ENGINE OIL When the engine oil is contaminated, the life of engine will be remarkably shortened. Keep the proper oil level, kind and replacing period. ●Place the vehicle on a flat surface, and idle (warm up) the engine 2~3 minutes. ●Stop the engine, separate the oil level gauge, place a vessel under the engine, and remove the oil drain bolt to drain the oil. ●Remove the adjusting hole cap, and clean the oil filter screen. ●Check the condition of O-ring of oil filter screen.
TRANSMISSION OIL INSPECTION ●Start the engine and let it idle for a few minutes. ●Stop the engine and put the motorcycle on its mainstand on level ground. ●Check to see if transmission oil leaks out of the transmission case. ●Fill the recommended oil when you need. CAUTION ●Pay special attention not to leak out. ●When draining the oil, make sure that all of the oil is removed. ●The engine can be harmed if there is too much or not enough oil. ●Do not use low-quality oil.
WHEEL REMOVAL ① Raise the front wheel off the ground by placing a support block under the engine. ② Loosen the oval screw and remove the speedometer cable. ④ Loosen the axle nut. ⑤ Withdraw the front wheel axle and remove the front wheel. DEPRESSED PART FRONT WHEEL AXLE FIXING BOLTS SPEEDOMETER CABLE FRONT CALIPER AXLE NUT ③ Remove the front caliper assembly from the front fork by removing the fixing bolts. OVAL SCREW ⑥ Install in the reverse order of removal.
① Set vehicle on main stand in upright position on the ground. REAR BRAKE HOSE SETTING BOLT ●If a torque wrench was not used for installation, see your authorized dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. ② Remove the muffler. ③ Remove the rear caliper assembly from the rear swing arm by removing the 2 fixing bolts. ④ Remove the special bolt of RR. cushion securing the RR.swing arm and pull it up.
CHANGING COOLING WATER (1) Separate the front cover and front under cover. (2) Remove the radiator cap. (3) Loosen the drain bolt of water pump, and drain the cooling water. (4) Tilt the vehicle right hand to drain the remaining water. (5) Drain the cooling water in reservoir. (6) Install the drain bolt. SPARK PLUG CAUTION ●While the engine is hot, don’t open the radiator cap, because the hot water burst to cause injury. Stop the engine and wait until cool down.
●Clean plug with plug cleaner. ●Check electrode for wear and corrosion. If the ends become round, replace it with a new one. ●Check the plug gap using a feeler gauge. ●Plug gap: 0.7mm ●Tighten with hands until the plug washer touches cylinder head. ●Standard plug: DPR7EA-9 ●If new plug is installed, turn 1/2 and tighten using a plug wrench. ●If plug is reused, turn 1/3~1/4 and tighten.
BATTERY INSPECTION When removing the pillion seat and open the battery box cover, you can find the battery. If the battery terminal is polluted or in-rust, separate battery and clean it. ●Battery terminal in rust with white powder should be cleaned with warm water. ●In case of serious rust of battery terminal, disassemble the battery cord and grind it with wire brush or sandpaper. PILLION SEAT BATTERY COVER CAUTION CAUTION ●Turn the ignition switch OFF before disconnecting the terminal from the battery.
FUSE REPLACEMENT Turn off the main switch to see if the fuse is severed. If the fuse is severed, exchange the fuse into a fuse with same capacity. ●Fuse is installed in fuse box around the battery. ●To change a fuse, first take off fuse cover. Then, remove the disconnected fuse, and insert the reserved fuse with same capacity.
COUPLER CONNECTION AIR CLEANER ELEMENT INSPECTION CAUTION ① Loosen the 6 washer screws and 1 flange bolt, and remove the tube clip and air cleaner case cover. ② Inspect the air cleaner element. ③ If the air cleaner element is excessively dirt or damaged, replace it with a new one. EXPORT USE ONLY /WHITE DOMESTIC USE ONLY /BLACK AIR CLEANER ELEMENT Connect the white colored coupler only. NOTE ●If the black coupler is connected by mistake the fuses are cutoff.
SIDE STAND INSPECTION ●Erect main stand and place vehicle in upright position on level ground. ●Check the spring for damage or loss of tension and the side stand assembly for freedom of movement. ●Check the side stand ignition cut-off system; ① Put the side stand up. ② Start the engine. ③ Lower the side stand. The engine should stop as you put the side stand down. ●If the side stand system does not operate as described, inspect it in the closest authorized repair center.
CLEANING ●Make sure to stop the engine prior to car washing. ●Be careful not to allow water to enter the muffler during the washing.Water inside the muffler may cause an improper engine starting or rust occurrence. ●Do not let water get inside the braking system during the washing, as water inside the brake system may weaken the braking power. Upon completion of washing, select a safe place where there is no traffic obstruction, and start the vehicle.
CAUTION ●Petrol is extremely flammable and isexplosive under certain conditions. Perform this operation in a wellventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where petrol is drained or stored and where the fuel tank is refueled. 48 ●Remove the battery. Store in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month. ●Wash and dry the motorcycle. Wax all painted surfaces.
FRAME AND ENGINE NUMBER ●The frame number is stamped on the front central part of the frame. ●The engine number is stamped on the lower part of the left crankcase. ●The frame and engine numbers will be used as the basis of recovering the vehicle when is stolen. ●Record the frame and engine numbers along with the vehicle license plate numbers and keep them separately from the vehicle.
SAFE DRIVING PREPARATION BEFORE DRIVING ● Performing daily inspection ● Putting on the protective gears (Helmet, glove, goggles, etc.
DRIVING METHOD DRIVING POSITION The appropriate driving position is most important thing to driving safely. ① Eyes : Look at the front direction widely. ② Shoulders : Relieve the tension. ③ Arms : Relieve the tension and bend arms to inside and let them act as the spring. ④ Hands : Grip the handle the position away from the inside end of the handle with distance of one finger to facilitate the operation of the switch and lever.
TAKING POSE OF FELLOW PASSENGER ① Hands: Hold the rear grip. ② Feet and knees: Put the feet on pillion step, and adhere the knees closely to body. ① ② 52 WARNING ●If the fellow passenger doesn’t hold the rear grip or put the step on the pillion step, it may lead death or serious injury due to falling from the vehicle as sudden start, stop or turning. ●Do not operate the throttle while setting the main stand.
PRECAUTION WHEN DRIVING ● ● ● ● ● ● ● ● Secure the safe distance. Drive protectively. Do not obstruct the traffic. Do not drive on the pedestrian way or walkway. Drive on the left driveway when passing away. Make sure that you can apply the brake anytime. Always apply the brake when stopping temporarily. Do not drive excessively long distance and take enough break. ● If any abnormality is found, stop driving and contact service center to inspect the vehicle.
STARTING Prior to starting always look around to avoid accident. ① Get on the vehicle after pulling back the stand. ② Start driving slowly after turning on the winker and releasing the brake while ensuring the safety around the vehicle. CAUTION ●Return the side stand to its original position. Keep driving without doing this may cause turnover accident. ●Drive the vehicle only on the driveway. Driving on the walkway can cause accident.
TURNING METHOD PRINCIPLE OF TURN EFFECT OF SPEED CENTRIFUGAL FORCE GRAVITY The basic principle of turn is balancing using the centrifugal force which makes vehicle go outside and the gravity which makes vehicle fall inside. The centrifugal force increases in inverse portion to the radius of a curve and in portion to the square speed. Decelerate prior to entering the curved way to reduce the centrifugal force.
3 POSITIONS OF TURNING The basic principle of turn is balancing using combined force of the centrifugal force and the gravity. All 3 positions require straightening the head and keeping the eyes horizontally. < LEAN-WITH > This is a turning position with motorcycle and driver in a line. This position is the most natural and exact, so driver must learn it thoroughly. 56 < LEAN-IN > This is a turning position with driver leaned inside more than motorcycle.
TURNING METHOD < LEAN-OUT > This is a turning position with motorcycle leaned inside more than driver, which is opposite to the lean-in position. With this position, quick turn is well performed and driver can obtain wide front visual field adequate to drive on the rained or slippy road because it has best road holding. However, special attention is required because there is danger of slipping on the bad holding road.
PRECAUTION WHEN TURNING Do not drive inside of large truck's turn circle. < DEAD ANGLE ZONE > Dead angle zone is the sight range which cannot be identified by driver and increases in proportion to the width of the vehicle. 58 < DISTANCE BETWEEN THE FRONT AND REAR WHEEL TURN > It is distance between path of the front and rear wheel and increases in proportion to the length of the vehicle.
BRAKING METHOD BASIC PRINCIPLE OF BRAKE (FRICTION FORCE) RESTRAINT OF BRAKE EFFECT (INERTIA) ● Vehicle is braked using friction between road surface and tires. ● Braking distance increases 1.5 times on wet road and 3 times on icy road because friction force of road surface is decreased. NEW TIRE NEW TIRE IN A RAINY DAY EXISTING TIRE IN A RAINY DAY Due to the inertia, vehicle does not stop immediately after applying the brake.
BRAKING METHOD IMPACT WHEN COLLISION ● Turn the throttle grip to its original position and decelerate Learn the proper braking method to prevent accident. using the engine brake. ● Erect the vehicle straight. ● Brake using both front and rear brakes. COMPARISION OF BRAKING DISTANCE ·Vehicle speed : 50 km/h When using both front and rear brakes When using only front brake When using only rear brake 60 Impact increases in proportion to the speed and weight.
WIRING DIAGRAM 61
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IMPORTANT NOTICE ●OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger. ●ON-ROAD USE This motorcycle is designed to be used only on the road. ●READ THIS OWNER'S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: OWNER’S MANUAL WARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed.
