Sachs Bikes MadAss 125 Owner's manual

Your Sachs dealer

SACHS

uses

and recommends

Sachs Fahrzeug- und Motorentechnik GmbH

Ernst-Sachs-Straße 6 • D-90441 Nürnberg

Phone: +49 (0)911 4231 400 • Fax +49 (0)911 4231 332

e-Mail:

inf[email protected] • www.sachs-bikes.de

Nr

. P00 646 008 00 02 000 2006 04 005

125

owners manual



125

PREFACE

Reprinting, reproduction and translation,

even of excerpts, without our express

consent is not permitted. All rights stipula-

ted in the copyright law remain expressly

reserved.

Technical changes to the standard motor-

cycles

can cause the EC type approval to

become invalid. Therefore before imple-

menting a change, ask a specialized dealer

whether this is allowed.

We cannot be held liable for any conse-

quential damage caused by accessories

not approved by the factory.

The scope of delivery and version of the mo-

torbike is solely determined by the purchase

agreement concluded with the dealer.

This operating manual includes important

instructions for handling your light motor-

cycle

. Read it carefully, because professi-

onal handling combined with regular care

and maintenance helps to maintain the

motorbike’s value and is one of the require-

ments for warranty claims.

We wish you at all times a safe journey.

Your

SACHS Fahrzeug- und Motorentechnik GmbH

You have purchased a Sachs MadAss,

congratulations and thank you for

putting your trust in us.

The MadAss is a sturdy motorcycle in mo-

der

n design.

Its sound construction, the meticulous

selection of materials, the advanced ma-

nufacturing techniques and conscientious

work of dedicated employees provides the

motorcycle with all the characteristics that

are typical of Sachs, such as economical

operation, quality, reliability and its lasting

value.

Sachs GmbH is continuously involved in

the further development of all types and

models. We therefore ask you for your kind

understanding that we reserve the right to

change the scope of delivery with respect

to appearance, equipment and technology.

No claims can thus be derived from the

data and descriptions contained in this

instruction manual.

1

CONTENTS

RIDING INSTRUCTIONS

Ride safely ............................................................................... 22

Ride economically and be aware of the environment .............. 23

Running-in instr

uctions ............................................................ 24

Side stand ................................................................................ 25

Star

ting .................................................................................... 26

Star

ting with kick starter .......................................................... 27

Star

ting with electric starter ..................................................... 28

Riding, Shifting gears .............................................................. 29

Br

aking ............................................................................... 30-31

Stopping the engine ................................................................. 32

Steer

ing lock ............................................................................ 32

SERVICE INSTRUCTIONS

Servicing the motorbike / cleaning agents .......................... 33-34

Operation in winter and anti-corrosion protection .................... 35

Repair

ing paint damage / servicing the tyres .......................... 35

La

y-up / commission ................................................................ 36

T

echnical changes, accessories and spare parts .................... 37

OVERVIEW AND OPERATION

Safety symbols .......................................................................... 3

Chassis number, engine number ............................................... 3

Side view ................................................................................ 4-5

Engine ....................................................................................... 6

Handlebar ﬁttings ....................................................................... 7

Coc

kpit ....................................................................................... 8

Ignition loc

k ................................................................................ 8

Speedometer set-up

, time adjustment ....................................... 9

Speedometer batter

y change .................................................. 10

SAFETY TEST

Checklist .................................................................................. 11

Clutch ...................................................................................... 12

Fuel, fuel tank .......................................................................... 13

Fuel tap .................................................................................... 14

Engine oil ................................................................................. 15

Chec

king the oil level ............................................................... 16

Br

akes ................................................................................ 17-18

Dr

ive chain ............................................................................... 19

T

yre proﬁle, tyre pressure and size .......................................... 20

Load / lights ............................................................................. 21

2

CONTENTS

NOTES ON MAINTENANCE

Checking steering bearing ....................................................... 38

Checking the telescopic fork and shock absorber ................... 38

Adjusting the shoc

k absorber .................................................. 39

Remo

ving the front wheel ........................................................40

Installing the front wheel .......................................................... 41

Remo

ving the rear wheel ......................................................... 42

Installing the rear wheel ........................................................... 43

Chec

king, adjusting the drive chain ....................................44-45

F

ront wheel brake .................................................................... 46

Rear wheel br

ake ...............................................................46-47

Adjusting the clutch le

ver ......................................................... 48

Cleaning the air ﬁlter

................................................................ 49

Cleaning the fuel ﬁlter

.............................................................. 50

Adjusting the pla

y of the twist grip throttle control ................... 50

Spar

k plug ............................................................................... 51

Batter

y ................................................................................52-53

Cheching the fuse .................................................................... 54

Changing the b

ulbs ............................................................55-57

Adjusting the headlamps ......................................................... 58

TECHNICAL DATA

Engine ..................................................................................... 59

Power transmission ................................................................. 60

Chassis .................................................................................... 61

Lubr

icants and operating ﬂuids ............................................... 62

Electr

ical Equipment ................................................................ 63

Dimensions and w

eights .......................................................... 64

WARRANTY AND SERVICE DATA

Warranty conditions ................................................................. 65

List of wear parts ................................................................ 66-67

Inspection plan ................................................................... 68-70

Maintenance conﬁr

mation .................................................. 71-75

Motorbik

e data / Rating plate ................................................... 77

3

2

1

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,

etc.) can come into contact with it.

CAUTION

Important instructions and precautionary

rules to be followed in order to prevent

the motorbike from being damaged. Non-

observation can lead to the guarantee

becoming void.

NOTE

Special instructions for better handling

during operation and inspection and when

carrying out adjustment procedures and

service activities.

Safety symbols and notes

NOTE

The description for right- and left-hand side

is viewed from the driver.

The chassis number (1) is located on the

right-hand side in front of the frame.

Key

With the motorbike you get two indeﬁnite

ignition keys. Keep the spare key at a

safety place.

With the key you control ignition, all

functional circuits and steerage lock.

The engine number (2) is located on the

left-hand side.

OVERVIEW AND OPERATION

Chassis number

Engine number

4

2

5

1

7

4

3

6

8

9

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

OVERVIEW AND OPERATION

5

11

10

12

13

15

16

14

17

18

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

Left-hand side view

OVERVIEW AND OPERATION

6

5

4

7

3

2

1

6

11

10

8

9

1 Intake valve adjuster cover

2 Exhaust valve adjuster cover

3 Spark plug connector

4 Electric starter

5 Oil drain plug

6 Clutch cover

7 Oil ﬁller cap

Engine right-hand side view

8 Carburetor

9 Fuel tap

10 Engine number

11 Gear shift pedal

Engine left-hand side view

OVERVIEW AND OPERATION

7

8

9

10

12

11

1

2

6

3

5

4

7

A

B

8 Emergency off switch

engine will not start

engine starts

9 Handbrake lever

10 Throttle

11 light switch

off

position light

driving light

12

Starter button

Right-handle handlebar ﬁttings

Left-handle handlebar ﬁttings

1 Fixed grip

2 Clutch lever

3 Head light switch

High beam

Low beam

4 Head light signal

5 Choke lever (

)

Operating positions:

A Cold start

B Warm start

6 Direction-indicator switch

Switch to the left:

Left indicator on

Switch to the right:

Right indicator on

Push button for switch off

7

Push-button: horn

OVERVIEW AND OPERATION

8

1

2

1

4

5

6

3

7

Ignition-lock

NOTE

The ignition-lock as well as the tank cap are

operated with the same key.

Key positions

1

Operating position: ignition and all

circuits activated.

2

Ignition off.

WARNING

While riding, do not switch the ignition

off

!

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

.

Cockpit

1 Speedometer

2 KM/H -odometer

3 DST - total distance (km)

TRIP- trip meter

Instrument lights

4

left direction indicator

green

5

right direction indicator

green

6

high beam b

lue

7

Change-over gear Neutral green

OVERVIEW AND OPERATION

9

S M

0

KMH

0

DST

S M

0

KMH

12 : 00

CLK

S M

0

KMH

11 : 55

CLK

S M

Speedometer set-up

NOTE

The display is only visible when the ignition

is on.

M Mode for:

DST = total distance (km)

TRIP = trip odometer

CLK = clock time

S Set for clock time and to clear trip

odometer

Button M press once changing from DST

to

TRIP or to CLK

Button S press in TRIP Mode to clear the

tr

ip odometer to zero

Button M press untill the clock time (CLK)

appears

Button S press once, the hour value

ﬂashes

The hour value can be set by

pressing button M

Button S press once the minute value

ﬂashes

The min

ute value can be set by

pressing button M

Button S press once, the time is set and

(

: ) ﬂashes.

Speedometer time adjustment

OVERVIEW AND OPERATION

10

3

4

5

6

7

1

2

3

4

Speedometer battery change

NOTE

If the ignition is turn off the clock is supplied

by the battery power. Always replace both

batteries.

After disconnecting and reconnecting the

battery the clock time needs to be reset.

- Remove the screws (1) and take off the

speedometer (2).

- Remove the screws (3 + 4) and take off

the co

ver (5).

- Replace the batteries (6) by using new

batter

ies, type AG 13.

- Set-in the batteries with the plus termi-

nal (+) sho

wing upwards.

- Insert the O-rings (7) and close the

co

ver properly.

DISPOSAL

T

ake a dead battery to a collection point.

Never dispose of one with household

refuse.

OVERVIEW AND OPERATION

11

Before each ride, carry out a safety

check using the checklist.

Take the safety check seriously. Carry out

maintenance activities before you start

your ride (

MAINTENANCE) or ask a

specialized Sachs dealer to do so. This will

provide you with the certainty that your mo-

torcycle corresponds to trafﬁc regulations.

A technically faultless motorcycle is a basic

requirement for the safety of both yourself

and other road users.

Before starting your ride, check the fol-

lowing:

– Steering (smooth and free of play)

– Clutch lever play

– Fuel quantity

– Engine oil (level)

– Front brake

– Rear brake

– Tyres (proﬁle and pressure)

– Telescopic fork

– Load / lights

– Total weight

– Lights

– Clutch operation

–

Brake ﬂuid (level)

– Brakes (operation)

In case of problems or difﬁculties, contact a

Sachs dealer, who will do everything pos-

sib

le to assist you.

WARNING

While the engine is running or the ig-

nition is on, do not touch the ignition

system.

FIRE HAZARD

The exhaust system becomes very hot.

While riding, idling or parking, make sure

that no inﬂammable materials (e.g. hay,

leaves, grass, coverings or luggage, etc.)

can come into contact with it!

Important notes for the operation with

a catalyst.

The catalyst. is designed for a optimal

perfor mance and lifetime.N ote the

following:

- Operate a catalyst. bike only with lead

free fuel.

-

Don’t turn off the ignition if the bike still

rolls.

- Don’t drive on at misﬁring, decline in

performance and poor engine run.

- In case of problems, contact the next

Sachs dealer.

- Longer starting tests by moving the bike

in cold or warm operating state should be

refrained.

At the mentioned operating states unburned

fuel can reach the catalyst., burn and cause

overheating of the exhaust system.

SAFETY TEST

Checklist

12

1

A

2

3

SAFETY TEST

Clutch

Clutch lever play

CAUTION

If you drive with no clutch lever play, the

clutch will be damaged.

Checks:

- Pull the lever until there is discernable

resistance

.

- Measure the play. Required value:

A = 3-4 mm

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

If this adjustment is not sufﬁcient, adjust

by turning the setting screw at the other

end of the clutch cable in the direction of

the engine

MAINTENANCE.

13

1

3

2

SAFETY TEST

WARNING

Fuel is highly inﬂammable and can ex-

plode. Do not smoke or bring a naked

ﬂame near the fuel tank.

Fuel expands under the inﬂuence of heat

and the sun. Therefore, never ﬁll the tank

to the brim. Never ﬁll the tank while the

engine is running.

Never bring a glowing cigarette or naked

ﬂame near an open tank, because fuel

vapour could suddenly ignite.

Tank cap (1)

NOTE

For opening the tank cap (1) only insert the

ignition key (3) and do not turn. Open by

using the cover (2).

The fuel-tank cap (1) is designed to allow

for ventilation. Do not make any changes

to the cap.

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.

Checking the fuel level

- Open the tank cap (1) on the fuel tank.

- Visually inspect the fuel level.

- Close the tank cap (1) on the fuel tank.

Filling up with fuel

- Use only normal lead-free fuel (min. 91

octane)

Fuel, fuel tank

14

R

A

Z

4

R

A

Z

SAFETY TEST

Fuel tap

CAUTION

When you stop the engine, always set

the fuel tap to position CLOSE. Oth-

erwise, fuel could enter the engine and

this could make starting difﬁcult or lead

to serious engine damage.

We cannot be held liable under the

guarantee for damage caused by non-

observance of this caution.

Fuel tap (4)

Fuel tap positions:

A = OPEN

fuel tank will empty down to a

reserve quantity of approx.

0,35 litres

R = RESERVE

fuel tank is drained. There is a

remaining quantity which can

not be used.

Z = CLOSED

fuel supply closed.

15

-10° 0° 10° 20° 30°40° C- 20°

SAE 10W/30

SAE 10W/40 10W/50

SAE 15W/40 15W50

SAE 20W/50

Engine oil

CAUTION

Do not use additives. Since the oil

also serves to lubricate the clutch,

do not use car engine oils supple-

mented with friction modifiers (such

energy-conserving oils can lead to the

clutch slipping). Use a suitable, light

engine oil for motorcycles, such as

Motorex SAE 15W/40 mineral oil API (SG

or higher).

Recommended grade:

Per API: SG or higher or also with additional

release status: ACEA A3/96 (CCMC G5).

Recommended viscosity:

Viscosity depends on the outside tem-

perature. For short while, the temperature

may exceed or fall short of the limits of the

SAE grades.

The recommended viscosity grade SAE

15W/40 covers the ambient temperature

range –15 °C to +40 °C and therefore

represents the optimum for our latitudes.

SAFETY TEST

- If required, replenish the engine oil

(for classification and viscosity, see

the table) via the oil-filler opening

up to the maximum level marking.

16

MAX.

MIN.

1

SAFETY TEST

Checking the oil level

CAUTION

Checking the oil while the engine is cold

will lead to a wrong measurement and

therefore the wrong oil quantity. In order

to avoid engine damage, never exceed

the maximum oil level nor let it drop

below the minimum level.

- Stop the warmed-up engine, wait for ap-

prox. 5 minutes and hold the motorcycle

upright.

NOTE

Make sure that the motorcycle during oil-

level checks stands level in all respects.

Even the slightest inclination towards the

side will produce measurement errors.

- 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-

surement in order to avoid engine

damage.

- The oil level must be between the mini-

mum and maximum marks.

If required, replenish the engine oil SAE

15W/40 via the oil-ﬁller opening of the oil

ﬁller cap.

- Tighten the oil ﬁller cap by hand.

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Sachs Bikes MadAss 125 Owner's manual

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