User manual 2012
User manual
Introduction This model takes advantage of the innovative features of the , such as the two-stroke injection engine and the chassis. A style of bike that is not found in the market; it’s a combination of a Trials and an Enduro bike. It has a bigger seat and offers fun, safety and comfort, together with amazing handling sensations and inexpensive maintenance.
Important Read this manual thoroughly and keep it in a safe place. This manual provides technical information necessary for keeping your new Explorer motorcycle in full working condition. It provides information on common aspects for the motorcycle’s upkeep and fine tuning. In the event of questions or queries on aspects not mentioned in this manual, you should consult the OSSA official distributor or a specialist engineer. Follow each stage of the instructions provided below for obtaining good results.
Safety Both your safety and the safety of others are very important when riding a motorcycle. Some important advice for using your motorcycle correctly is detailed below. - Never drive if you have consumed alcohol or any type of substance (medication, drugs) that might affect your driving capability. - Make sure your motorcycle is serviced regularly to avoid breakdowns while driving. - Always drive in a responsible way. - Always use a helmet. - Never drive over the speed limit.
User manual
Contents Introduction Important warning Saferty Contents Technical specifications Recommendations 3 4 5 7 8-9 10 Section 1 - Components Location Multi-function box Control pad Front suspension Settings Air bleed Seat Anti-theft immobilizer Start lever Fuel tank 11 12-14 15-22 23 Section 2 – Maintenance and basic operations Maintenance grid Adjustments to the motorcycle controls Electric connections Simplified lighting wiring diagram Simplified injection wiring diagram Air filter Radiator Spark pl
Technical specifications ENGINE Cylinder size Type Cooling Bore x Stroke Injection Ignition Clutch Start 272,2 cc 2 stroke inverted monocylinder with reed box admission Liquid cooled 76x60 mm EFI Kokusan Indirect injection Digital flywheel CDI Kokusan Hydraulic Battery-assisted kickstart TRANSMISSION Gearbox Transmission Lubrication Gearbox and clutch lubrication 6 speeds Primary transmission by gears, final transmission by chain.
Technical specifications WEIGHTS AND MEASUREMENTS Wheelbase Seat height Ground clearance Fuel tank capacity Dry weight 1.328 mm 840 mm 340 mm 7,6 litres (2,6 + 5 l.) 78 Kg OSSA Factory reserves the right to make modifications without prior notification. Kokusan, Marzocchi, OHlins are registered trademarks and their use is licensed.
Recommendations It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order. - 12 hours of running-in is recommended to ensure that the engine works correctly and for a long-lasting time period. - It is important to run the engine for some minutes until it reaches the correct temperature to work correctly. - The engine lubrication is a mixture of petrol-oil with a 0.9% oil proportion. Always use synthetic oil.
Section 1 - Components User manual 11
Location of elements 1 Front mudguard 2 OSSA multi-function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide 7 Front tyre 8 Front fork bottles 9 Front fork stanchions 10 Shift pedal 11 Chain 12 Chain slider 13 Rear sprocket protector 14 Rear tyre 2 1 9 3 5 4 8 6 10 7 12 User manual 11 12 13 14
Location of elements 15 Rear break caliper and anti-theft immobilizer 16 Exhaust 17 Kick-start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear brake lever 22 Crankcase protector 23 Front brake caliper 24 Front brake disc 25 Air filter 26 Rear footrests (depending on version) 27 Passenger handle 27 18 16 17 25 26 18 23 15 20 21 22 24 19 User manual 13
Location of elements 27 Front brake lever 28 Throttle grip 29 Throttle control 30 Front brake pump 31 Front fork servicing cap 32 OSSA multi-function box 33 Clutch pump 34 Lights control pad 35 Clutch lever 36 Headlights 37 Ignition key 34 28 35 29 33 32 27 30 31 36 37 14 User manual
Multi-function box The OSSA Explorer multi-function box and the indicator lights next to it provide very useful information at all times. The multi-function box is a power box system with an LCD screen controlled by a console with indicator lights, located in the centre of the handlebars.
Multi-function box Technical features Symbol Technical features Current speed SDP0 4 - 399,9 Km/h o M/h ,1 Km/h o M/h+ /- 0,1% Tachometer RPM 0 - 19999 rpm 10 rpm+ /- 0,1% Tachometer bar - 0 - 12000 rpm Variable+ /- 0,1% Maximum speed MS 4 - 399,9 Km/h o M/h 0,1 Km/h o M/h+ /- 0,1% Distance covered DST 0,0 - 19999 Km / M 0,1 Km/h o M/h+ /- 0,1% TT 0 - 9999 hours 59 minutes 1 second +/- 0,1% Mileage ODO 0,0 - 999999 1 Km +/- 0,1% Uptime RT 0 - 999 hours 59 minutes 1 min
Multi-function box Functions RPM: Bar Bar graph tachometer. The tachometer bar graph displays up to 12,000 rpm. RPM: Digital tachometer The RPM appear on the right side, on the second line. The digital tachometer displays up to 12,000 rpm. The tachometer signal can be captured from the sparkplug wire. Warning of gear change due to rpm. The rpm appear on the right side, on the second line. The digital tachometer displays up to 12,000 rpm. The tachometer signal is received from the sparkplug wire.
Multi-function box Adjustment of the multi-function box settings After confirming each value, the multi-function box will move straight on to the next screen adjustment until the process is complete. If no button is pressed, the multi-function box will return to the initial screen after 15 seconds. Activation of the adjustment mode To activate the adjustment mode for the multi-function box settings, push buttons 1,2 and 3 simultaneously for 3 seconds and then release them.
Multi-function box Time adjuster Set the time by pressing button 1 repeatedly. To move to the next digit, press button 3. Confirm the selection by pushing button 2. 1 Adjustment of the revolution pulse (PPR) Note: This step must only be followed for those vehicles that change the PPR pulse type to a specific turn rate. If you don’t know this value, press button 2 to move on to the next screen. Enter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3.
Multi-function box Temperature selector To select the unit of temperature,either ºC or ºF, press button 1. Confirm the selection by pressing button 2. 1 Danger temperature selector Note: This stage should only be implemented for those vehicles that have an optional temperature sensor. When the motorcycle temperature exceeds the set value, right-hand warning light comes on. Default value: 110ºC (230ºF). Enter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3.
Multi-function box Dangerous turn rate selector When the set rate is near to being reached, the right-hand warning light will flash, indicating that the engine is turning at an excessive rate. Default value: 10,000 rpm. Enter the value by pressing button 1 repeatedly. To move on to the next digit, press button 3. Confirm the selection by pressing button 2. Setting the whole multi-function box to zero Press the RESET button by using a suitable object.
Multi-function box Screen Options The multi-function box displays all information on three different screens. While on, it is possible to see screens 1 or 2. Screen 3 is displayed for three seconds and then returns to screen 1. To move from one screen to another repeatedly press button 2 (“Mode”). To edit the distance covered (DST) hold down button 3. Screen 1: Screen 1 displays the following information: - Speed, distance covered, time, environmental temperature, tachometer (bar).
Control Pad Control Pad The control pad is located on the left handlebar, within reach of the thumb. This control pad can be used to control the lights, indicators, horn and engine stop. 6 1 2 3 4 3 2 1 5 4 See the image with information about the control pad. See the image with information about the control pad.
Suspension The front suspension is made up of a fork that fixes the wheel and the front brake system in place. This fork is formed by the suspension bars that contain the shock absorber spring and the suspension mechanism. They are connected to the upper part where the direction pipe is located, a point of connection between the fork and the chassis. A regulating screw and an air bleed are located on the upper part of each suspension bar (see photo).
Seat In order to access some parts of the engine or the wiring, you must previously remove the seat. 1: First, you must open the rear seat lock with the ignition key. 2: Then you must pull the back of the seat upwards and then backwards, as in figure 2. 3: To put the seat back on the bike, repeat the process in inverse order. 2 1 (Fig. 2) (Fig.
Anti-theft immobilizer The Explorer has an immobilization system for protection against theft. This system consists of a lock situated in the area of the brake discs on the rear wheel. It is a mechanism that is operated with a key and blocks the rear wheel. 26 User manual IMPORTANT: this key has a code which is needed for making duplicate copies of the key. This code should be written down in the indicated space on the registration page and series number of this manual.
Kick start pedal Before starting the motorcycle, you must ensure that the key switch at the right hand side of the headlight is activated. Also, it must be in neutral gear. DO NOT try to start in a gear . The kick-start pedal is part of the mechanism that is used to kick start the motorcycle mechanically. To kick start the motorcycle, the kick-start pedal must be separated from the bike and moved outwards. Once separated, place your foot on top and press strongly to turn it counterclockweise.
Fuel tank The engine of this motorcycle works with a mixture of unleaded petrol and 2S oil, 100% synthetic in a 0.9 proportion. The Explorer has two fuel tanks, one forms a structural part of the chassis and is located on the front inside part. The other one is made of polyamide plastic and is located in the classic position on the frame. To fill up with petrol, open the upper fuel tank lid, situated on the upper part, by unscrewing in an anti-clockwise direction.
Fuel tank In order to access some parts of the engine or the wiring, you must previously lift the upper fuel tank. 1: First you must remove the seat. (see page 25, Seat) 2: Unscrew only the four upper screws of the side tank pannels. 3: Disconnect the air hose located in the front of the upper fuel tank. (see fig.2) 4: Disconnect the conector that connects both fuel tanks. 5: Unscrew the upper tank central screw (which is located where indicated with number 5).
Fuel tank 6 When performing the operation No. 4 (Disconnect the connector that connects the two fuel tanks), You must mind the existence of residual fuel in the quick connector. 30 User manual In operation No. 2 (Unscrew only the four upper screws of the side tank pannels) never release the screws that attach the pannels to the radiator, as it could pierce it or eventually damage the threads.
Section 2 – Maintenance and basic operations User manual 31
Maintenance grid – Engine Item Check / Inspect Adjust Replace / Change Clean Grease / lubricate Air filter Each use _ When damaged Each useE ach wash Transmission oil 30 Hours _ 60 horas _ _ Refrigerant Each use _ Each year _ _ Sparkplug Each use 30 Hours 60 Hours 15 Hours _ Reed block 30 Hours When necessary When damaged _ _ Cylinder 60 Hours _ Each year _ _ Clutch Each use _ When damaged _ _ _ _ When damaged _ _ Exhaust Each use _ When damaged _ _
Maintenance grid - Cycle Item Check / Inspect Adjust Replace / Change Rear shock absorber Each year _ Every 2 years __ Front suspension Each year When necessary Every 2 years _ _ _ _ 60 Hours _ _ Front suspension lubricant Clean Grease / lubricate Brakes Each useW When necessary hen damaged __ Swing arm and linkage arms Each useW _E hen damaged Each use ach wash Secondary transmission Each use When necessary When damaged Each use Each wash Steering bearings Each use
Adjustments to the motorcycle controls The clutch lever is located on the left handlebar grip and is used to activate the clutch mechanism to change gear. The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake. min. 3 mm min. 3 mm Front brake lever Clutch lever It’s important that the levers and rear brake pedal have a 2-3 mm give.
Electrical connections Check the condition of the motorcycle’s electrical connections in order to ensure they are maintained in good working order. As seen in the image on the right, these are located at the left side of the cylinder, between the steering bar and the front headlight, and in the fuel system apparatus. Carry out a regular and thorough maintenance of your motorcycle. Always use original spare parts and top quality products to ensure that it works correctly.
Simplified diagram of the lights wiring 36 User manual
Simplified diagram if the injection installations User manual 37
Air filter Air filter. Cleaning and maintenance The air filter should be controlled periodically. Lift the upper fuel tank, as you can see in the image on page 29, in order to access the filter box. Remove the sensor on the filter base and the clamp. Then remove the filter, according to the illustration. To clean, use water and detergent, leave to dry and then lubricate with a special liquid for filters. Reassemble using the steps outlined previously but in reverse.
Radiator The radiator contains the engine coolant. To fill up with or add To fill the radiator, special coolant should be used coolant to the radiator, locate the tank lid. To locate this lid, -30ºC. lift the upper fuel tank (see pag. 29, Fuel tank). Once the tank is lifted the radiator lid is visible. Unscrew the lid and pour in To ensure that the motorcycle works correctly, periodic controls the coolant. must be carried out to check the coolant levels.
Sparkplug To access the sparkplug detach the right side cover (see fig. 1). Once the cover has been removed, the motorcycle’s electrical system can be accessed. Carefully but firmly, pull away the hood that provides current, leaving the upper part of the sparkplug exposed. Using a special sparkplug tool, unscrew it and take it out from the right side of the motorcycle (see fig. 2). The sparkplug should be checked regularly and a spare sparkplug should be carried at all times in case it comes off.
Cadena - Reglajes de tensión The transmission chain transmits the engine’s movement to the rear wheel. To ensure that is works correctly, it should be checked. The axle has easily adjustable eccentrics for tensing the chain and centring the wheel. The chain hook should be positioned in an opposite direction to the gear, as can be seen in the photo. The chain tension should permit 2 cm of oscillation in the chain tension adjuster.
Lubrication of moving parts Cleaning the motorcycle and lubricating the mobile parts will help protect the motorcycle and guarantee that it works better. If using a high pressure hose to clean the motorcycle, bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle. Lubricate using specific products:: 1.Transmission chain 2.Clutch and brake lever joints 3.Gear lever joints 4.Rear brake pedal joints and bearings 5.Footrest brackets and springs 6.
Lubrication of moving parts The chain drive should always be well lubricated. Check it each time the motorcycle is used and apply lubrication when necessary.
Lubrication of moving parts Footrest bracket and springs Chain drive and tension adjuster springs Engine kick-start pedal joints Gas handle (right grip) 44 User manual
Tyres Pressure and condition To ensure that the motorcycle works correctly, it’s very important to check the tyre pressure and that the wheels are in good working condition before each use. Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability. It also ensures that trial riding is safer and more efficient. Front tyre: 2.75x21” Tyre in good working condition Rear tyre: 4.
Checking the crankcase oil Filling and draining the crankcase Crankcase oil is used for lubricating the change pedal and the clutch. Check the oil level with the indicator located on the lower part of the clutch cover, which is on the right side of the engine. The oil level should be lower than the indicated maximum level. MAX. IMPORTANT: Clean the plug and change the sealing washer each time the oil is changed. The crankcase has a 375cc oil capacity. 2T 100% synthetic oil should always be used.
Brakes The brakes permit precise and controlled riding. It is necessary to check them in order to ensure that they work correctly. Wear on the front and rear brake pads must be periodically controlled so that the brakes work effectively. The oil level can be checked using the indicator on the front handle and on the rear pump tank. The oil level should be situated between the min and max values. MAX. MIN. To remove surplus air from the break circuit, the calipers are equipped with air bleeds. See image.
Torque wrenches These grids show the pressure that should be used to tighten parts.
Storage Storage Starting the motorcycle again If the motorcycle is to be stored for a long period of time, the following procedure should be followed to ensure that it is stored correctly. - Clean the motorcycle as much as possible because dirt can cause the deterioration of components. -Turn on the engine for a few minutes to warm up the transmission fluid and then drain. (see section on draining fluid). -Fill up with new transmission fluid. -Empty the fuel tank (petrol degrades over time).
Troubleshooting PROBLEM POSSIBLE CAUSE The engine won’t start POSSIBLE SOLUTION - Long period of engine inactivity - Change the old petrol for new petrol - Sparkplug dirty or wet - Dry / clean or change the sparkplug - General fuse damaged - Change general fuse - Bad electrical connection - Check electrical connections and position correctly - Take the motorcycle to a specialist mechanic The engine starts and then stops - Lack or deterioration of petrol - Fill the fuel tank with new petrol - T
Troubleshooting PROBLEM POSSIBLE CAUSE The motorcycle is unstable The shock absorption is too hard POSSIBLE SOLUTION - Wire makes it difficult for the handlebar to turn - Steer axle screw is very tight - Steering bearings are damaged or with wear - Steer axle bent - Move wire or loosen it a bit - Excessive oil on front fork - Oil too viscous on front fork - Front fork bent - Remove surplus oil until it reaches the correct level. - Drain fork oil and fill up with viscous oil. - Change the front fork.
Troubleshooting PROBLEM POSSIBLE CAUSE The shock absorption is too soft - Too little oil in front fork - Front fork oil not sufficiently viscous - Front fork bent - Rear shock absorber badly adjusted The motorcycle makes abnormal noises - Chain badly adjusted - Chain wear - Rear crow teeth wear - Insufficient chain lubrication - Rear wheel badly adjusted - Front fork with insufficient oil - Front fork spring weak or broken - Brake disc wear - Brake pads badly positioned or crystallised POSSIBLE SOLUTI
Troubleshooting PROBLEM POSSIBLE CAUSE The motorcycle makes abnormal noises The handlebar vibrates POSSIBLE SOLUTION - Cylinder damaged - Replace the damaged cylinder - Supports, screws or nuts are not properly fastened - Check and adjust using suitable torque wrench - Tyres wear, swing arm or its needle bearings wear - Change worn parts for new parts - Wheel rim not centred - Centre wheel rim - Wheel not centred - Check the tension of the spokes and readjust - Lack of engine oil - Check and
Troubleshooting PROBLEM POSSIBLE CAUSE La moto tiende a inclinarse a un lado Los frenos no actúan correctamente POSSIBLE SOLUTION -Chasis torcido. -Cambiar el chasis. Ir a un taller especializado. -Dirección mal ajustada. -Ajustar dirección. Ir a un taller especializado. -Eje de dirección torcido. -Cambiar eje dirección. Ir a un taller especializado. -Horquilla delantyera torcida. -Cambiar horquilla delantera. -Ruedas mal alineadas. -Alinear las ruedas. -Disco desgastado. -Cambiar disco.
Standardisation components User manual 55
Standardisation components Your Ossa Explorer is standardised in compliance with UE regulations. It adheres to all standardisation requirements EURO-3 regulations. The obligatory elements to be registered for driving on public roads and for passing the vehicle’s MOT are listed below. The elements to be registered among others are identified with a specific mark and registration. Each of the registered elements should be part of the vehicle.
Standardisation components 7 1 8 17 10 16 16 3 4 13 9 2 5 15 6 11 1.Front headlight 2.Front indicators 3.Rear indicators 4.Rear pilot 5.License plate support 6.Reector 7.Mirrors 8.Manufacturer’s plate 14 12 9.Exhaust system 10.Speedometer 11.Pinion output 12.Lock 13.Horn 14.Kickstand 15.Throttle limiting bolt 16. Handle 17. Passenger footrests (in the bike homologated for 2 people). Each of the registered elements should be part of the vehicle.
Standardisation components Element Homologation identification 1. Front headlight 11/12-e9*97/24*97/24/*4367*00 Front position lamp R55.00.14839 Driving beam R113.00.14839 Passing Beam R113.00.14839 2. Front indicators 11001200e94367 3. Rear indicators 11001200e94367 4. Rear pilot e13*50 R00*50R00*12448*00 5. License plate support 6. Reflector IA.E9.02.01269 7. Mirror L-e9*80/780*80/780*0143*01 8. Manufacturer plaque 9. Exhaust system 10. Speedometer 11. Pinion output z=11 12.
Standardisation components Manufacturer’s plate Serial number User manual 59
Standardisation components El número de llave se encuentra marcado debajo del tapón rojo, se debe retirar para ver el número.
Warranty User manual 61
Warranty Terms and conditions of the warranty The warranty is associated to the product indicated in the “CERTIFICATE OF DELIVERY AND INSPECTION”, which shall be filed out by authorised staff in OSSA FACTORY, SL (hereinafter referred to as OSSA). It is valid for those countries indicated on page 33. The warranty is only applicable to motorcycles that have been initially imported via the official OSSA importer for your country, meeting all the regulatory requirements and authorisations of each country.
Warranty The repair is disproportionate when it is uneconomic, or when the reparation is more expensive than the value of the product. If this occurs, the purchaser can choose between a price reduction or contract resolution. Resolution is not permitted when the non-compliance is insignificant. Regulations for repairs, product replacement, price reduction or contract resolution: 1. It will be free for the purchaser. 2. It will be carried out in a reasonable time period. 3.
Warranty PERIOD OF WARRANTY OSSA is answerable for faults that appear over a two-year period from the product delivery, but if the non-compliance shows up after the sixth month, the purchaser must demonstrate that the fault was present at origin and existed when the product was delivered. Complaints made for the non-compliance of that which is set out in the warranty must be done within a six month period from when the warranty ends.
Warranty EXCEPTIONS TO THE WARRANTY The OSSA warranty does not cover the following items: a) Damages that arise from not carrying out periodical revisions as stipulated by OSSA. b) Damages due to repairs or revisions carried out using methods that have not been specified by OSSA. c) Damages due to using the vehicle in races, rallies or other similar competition sports.
Warranty Parts Spark plugs, fuel and oil filters and their components, transmission chains, air filters, engine sprockets, back crown gears, disk brake and break pads, clutch disks, light bulbs (except for those that are sealed), fuses, belts, tyres and inner tubes, wires and other rubber and/or tire parts specified by OSSA. Fluids Lubricants (such as oil, grease, etc.
Warranty MAINTENANCE AND SERVICE It is your responsibility to ensure that the services are carried out on your motorcycle within the specified time periods and that the services are correctly registered. This means that your motorcycle will receive all the benefits of the OSSA warranty. It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was purchased, where both you and your motorcycle are known.
Warranty Procedure for obtaining repairs under warranty If your motorcycle needs a repair to be carried out under warranty, it should be taken to your official OSSA dealer where the repair will be made (YOU ARE RESPONSIBLE FOR THE TRANSPORT COSTS TO AND FROM THE DEALER). Ossa recommends that you go to the dealer where your purchase was made. However, you can go to any Ossa dealer for repairs to be carried out under guarantee. This guarantee provides you as a consumer with specific legal rights.
Final information We recommend that you stay in contact with your OSSA dealer so that you can receive help, advice and information about your new motorcycle, as well as information about the new products launched by OSSA Factory, SL. We aim to provide full customer satisfaction. If the service you have received is not adequate, we would ask you to send us a written account, stating specific instances with as much detail as possible about the incident concerning our dealer.
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