Rs 300 R - Rs 500 R 2021

RS 300 R - RS 500 R 2021

Manual - Operation - Maintenance PRESENTATION IMPORTANT NOTICES Welcome to the SWM motorcycling Family! Your new SWM motorcycle is designed and manu- 1) RS models are STREET LEGAL motorcycles; they factured to be the best in its field. are guaranteed exempt from functional defects The instructions in this book have been prepared and covered with legal guarantee, as far as the to provide a simple and understandable guide for STANDARD CONFIGURATION IS MAINTAINED and the your motorcycle’s operation and care. suggested maintenance table, shown in Appendix Follow the instructions carefully to obtain maxi- A, is observed. mum performance and your personal motorcycling pleasure. Your owner’s manual contains instruc- 2) All the motorcycles and any of their parts tions for owner care and maintenance. used in competitions of any type are excluded The main repair or maintenance work requires the from the warranty. attention of a skilled mechanic and the use of special tools and equipment. Your SWM Dealer has the facilities, experience and original parts necessary to properly render this valuable service. This “Owner’s Manual” is part and parcel of the motorcycle, hence, it shall remain with the motorcycle even when sold to another user. This motorcycle uses components designed thanks to systems and state-of-the-art technologies which are thereafter tested in competitions. In racing motorcycles, every detail is verified after each race in order to always guarantee better performance. To ensure trouble-free operation of the vehicle, it is necessary to follow the maintenance and inspection table found under Appendix A.

EN - 2 Note*: Giveshelpfulinformation. not followed. injury orvehicledamageifinstructionsare CAUTION*: Indicatesthepossibilityofpersonal followed. personal injuryordeathifinstructionsarenot WARNING*: Indicatesthepossibilityofsevere to statementsprecededbythefollowingwords: Read thismanualcarefullyandpayspecialattention motorcycle isrented. Note*: thewarrantyisNULLANDVOIDif nance planischargedtotheClient. necessary inordertocomplywiththemainte The costforchangingpartsandthelabour inspections atauthorisedSWMdealers. user’s manualbycarryingoutmaintenance maintenance programme indicated in the of Functionality”,theclientmustfollow In ordertomaintainthevehicle’s“Guarantee IMPORTANT Important Notice - other appropriateprotectiveclothing. motorcycle helmet,boots,gloves,gogglesand propriate protectiveclothing. Alwaysweara your motorcycleunlessyouarewearingap WARNING*: Neverattempttostartoroperate can leadtoaseriousaccident. damaged. Ridingwithadamagedmotorcycle brake, clutchandallothersystemsareun cycle carefully.Makesurethatthethrottle, WARNING*: Afteracrash,inspectthemotor ORIGINAL parts. When parts replacement is required, use only SWM Parts Replacement - - - Engine • To • Park • WARNING: PRECAUTIONS FORCHILDREN Even slightorinvoluntarybumpscancause scalds. reach theseparts,inordertoavoidserious cle wherepeopleorchildrencannoteasily during riding. Always park your motorcy- on asphaltstronglyheatedbythesun. never parkitonsoftorunevenground,nor of seriousharmtopeopleorchildren. the vehicletotipover,withsubsequentrisk bumped intoordamaged.

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EN SUMMARY Page Note • References to the “left” or “right” of the motor- PRESENTATION...... 2 cycle are considered from the point of view of a IMPORTANT NOTICES ...... 2 person facing forward. IDENTIFICATION DATA ...... 5 CONTROLS LOCATION ...... 6 • Z: number of teeth TECHNICAL DATA ...... 7 • A: Austria TABLE FOR LUBRICATION, SUPPLIES ...... 8 AUS: Australia CONTROLS...... 9 B: Belgium RIDING ...... 17 BR: Brazil ELECTRICAL COMPONENTS LOCATION...... 55 CDN: Canada EQUIPMENT...... 63 CH: Switzerland APPENDIX...... 64 D: Germany PRE-DELIVERY INSPECTION...... 65 E: Spain ALPHABETICAL INDEX ...... 66 F: France SCHEDULED MAINTENANCE...... APPENDIX A FIN: Finland GB: Great Britain I: Italy J: Japan USA: United States of America

• Unless otherwise specified, all the data and the instructions are referred to any and all Countries.

EN - 4 IDENTIFICATION DATA VEHICLE IDENTIFICATION NUMBER (V.I.N.) The engine identification number is stamped at the top of the crankcase, while vehicle serial number The full 17-digit serial, or Vehicle Identification Num- 1 or Vehicle Identification Number is stamped on the ber, is stamped on the steering tube (R.H. side). EN steering head tube. Always quote the number stamped on the (l) = Model designation frame when ordering spare parts or requesting (▲) = Model Year (2017) further details about your vehicle and note it on this (♦) = Progressive no. booklet. CHASSIS NUMBER 2

RS 300 R

*ZN0B101AAHV000000*

(l) (▲) (♦) 1. Chassis serial number 2. Engine serial number

RS 500 R

*ZN0B103AAHV000000*

(l) (▲) (♦)

EN - 5 CONTROLS LOCATION 14 2 5 1. Front brake control lever 2. Throttle twistgrip 8 3. Rear brake control pedal 4. Manual decompressor 5. Fuel tank filler cap 13 1 7 6. R.H. switch (engine electric starting) 7. Rear shock absorber spring preload adjuster 8. Rear shock absorber compression adjuster (low and high damping speeds) 9. Rear shock absorber rebound adjuster 10. L.H. switch 6 11. Clutch control lever 12. Gear shift control pedal 10 13. Air bleeding screw on front fork leg 4 14. Fork leg rebound adjuster 15. Compression damper adjustment 16 (front fork leg bottom side) 11 16. Choke (L.H. side) KEYS Two keys are supplied with the motorcycle (one of them is a spare key) to be used: 9 12 a) on the ignition switch; 15 b) on the steering lock.

3 EN - 6 Type ENGINE Spark plugtype Type IGNITION Type TIMING SYSTEM Type FUEL SYSTEM Displacement (300) Stroke (300) Stroke (500) Bore (500) Spark pluggap Starting Compression ratio Type LUBRICATION Exhaust Displacement (500) Bore (300) Cooling liquidwithelectricfan Intake Valve clearance(withenginecold) ...... with adjustableadvance(digitalcontrol) . . . . double overheadcamshaft;4valve TECHNICAL DATA . . . (with automaticdecompressor) Electronic, inductivedischarge, Dry sumpwithtwooilpump rotor andcartridgefilter Electronic injectionfeed single cylinder,4stroke 0.004 ÷0,006in. 0.007 ÷0,009in. NGK CR8EB 30.56 cu.in 18,16 cu.in. 0.027 in. electric .3.81 in. 2.67 in. 3,27 in. 2.17 in. 12,9:1 Type TRANSMISSION (300) Drive piniongear-Clutchringgear PRIMARY DRIVE (500) RS 500R Type CLUTCH (300) Transmission ratio RS 300R Transmission ratio RS 500R (500) 2nd gear 6 thgear 5 thgear 4th gear RS 300R Transmission sprocket-Rearwheelsprocket SECONDARY DRIVE 3rd gear 1st gear Transmission ratio ...... oil bathmultiplediscclutch, constant meshgeartype hydraulic control 0,920 (z23/25) 2,000 (z28/14) 1,086 (z25/23) 0,814 (z22/27) 1,333 (z24/18) 1,611 (z29/18) Z 24-88 .Z 13-Z50 Z 23-63 Z 13-46 3,666 3,846 3,538 2,739 Front RIMS Type REAR BRAKE Wheel stroke Legs axisstroke Type FRONT SUSPENSION Type FRAME Type FRONT BRAKE Type REAR SUSPENSION Rear ...... rebound stroke);stanchionstubesØ1.89in. fixed discØ10.23inwithhydrauliccontrol single beam,doublecradleinsteeltubes; . hydraulic controlandfloatingcaliper ”Upside-down” telescopichydraulic . progressive withhydraulicsingle (adjustable incompressionand front forkwithadvancedaxle floating disc,ø9.45in.with rear frameinlightalloy. in lightalloy:2,15x18” and floatingcaliper; in lightalloy:1,6x21” shock absorber 11.81in.; 11.65 in. EN -7

EN TIRES TABLE FOR LUBRICATION, SUPPLIES Front...... 90/90x21” Engine, gearbox and primary drive lubricating oil Rear...... 140/80x18” MOTUL 5100 TECHNOSYNTHESE 10W50 Cold tire pressure on road 2 Engine coolant (front )...... 1 Kg/cm MOTUL MOTOCOOL EXPERT (rear)...... 1,2 Kg/cm2 Cold tire pressure off road Brake system fluid (front )...... 1,5 Kg/cm2 MOTUL DOT 3&4 (rear)...... 2,0 Kg/cm2 Clutch fluid DIMENSION, WEIGHT, CAPACITY SAE 10 MINERAL OIL FOR HYDRAULIC CIRCUITS Wheelbase ...... 58.38 in. Overall length ...... 89.25 in. Overall width...... 32.30 in. Grease lubrication Overall height ...... 50.59 in. MOTUL GREASE 100 Saddle height ...... 37.91 in. Minimum ground clearance ...... 11.81 in. Final drive chain lubrication Dry weight MOTUL CHAIN LUBE (RS 300 R)...... lb. 235.9 (RS 500 R)...... lb. 244.7 Fuel tank capacity (1.58 Imp. Qt./ 1.9 U.S. Qt. Front fork oil reserve included) . . . . 1.58 Imp. Gall./ 1.9 U.S. Gall MOTUL FORK OIL LIGHT 5W Coolant capacity...... 2.0÷2.4 Imp. Pints; 2.3÷2.7 U.S. Pints Oil for rear shock absorber MOTUL FORK OIL LIGHT 5W Transmission oil Oil and oil filter replacement Imp. Quarts 1.5, Electric contact protection U.S. Quarts 1.8 Oil replacement...... Imp. Quarts 1.3, MOTUL EZ LUBE U.S. Quarts 1.6

EN - 8 CONTROLS FUEL SIDE STAND Recommended fuel: premium grade UNLEADED fuel A side stand (1) is supplied with every motorcycle. FUEL TAP (R.O.N. 98). On vehicles which are fitted with a fuel injection en- WARNING*: The stand is designed to support EN gine, the fuel pump is built into the fuel tank and Note*: If the engine "knocks", change fuel brand or the WEIGHT of the MOTORCYCLE ONLY. Do not there is no tap (ON-OFF-RES) mounted on the fuel use a higher octane rating fuel. sit astride the motorcycle using the stand for supply system. support as this could cause structural failure WARNING*: Do not continue operation if the to the stand resulting in serious injury. The reserve warning is indicated on the digital in- engine pings or knocks.The engine will be strument panel by the relevant warning light (See damaged and could seize. WARNING*: The motorcycle MUST be set on the paragraph “Digital instrument, warning lights”). side stand ONLY AFTER the rider has got off WARNING*: Fuel is extremely flammable and the vehicle. Stand AUTOMATICALLY folds back can be explosive under certain conditions. to rest position once the vehicle is vertical, no Always stop the engine and do not smoke or longer resting on the ground. allow flames or sparks in the area where the motorcycle is refuelled or fuel is stored. Periodically check the side stand (see “Scheduled Maintenance Chart”); make sure that the springs WARNING*: Do not overfill the tank. Refer to are not damaged and the side stand freely moves. the lower mark on filler. After refuelling, If the side stand is noisy, lubricate the fastening make sure the tank cap (1) is closed securely. pivot (A).

1 A

EN - 9 COLD START DIGITAL INSTRUMENT, WARNING LIGHTS - To select instrument functions and reset functions, use the SCROLL button (A) For a cold start, the models with a fuel injection en- The motorcycle is fitted with a digital instrument - The functions, which can be selected in order are gine are fitted with a black knob (1) located on the on which 5 warning lights are also displayed: high as follows: left of the throttle body. beam lights, low beam lights (with display lighting), Pull the knob outwards to open the starter and turning indicators, neutral gear and fuel reserve. 1- SPEED / ODO push inwards to close. 2- SPEED / H 1- BLUE warning light “HIGH BEAM” 3- SPEED / CLOCK 2- GREEN warning light ”LOW BEAM” 4- SPEED / TRIP 1 3- GREEN warning light “TURNING INDICATORS” 5- SPEED / STP 1 4- GREEN warning light “NEUTRAL GEAR” 6- SPEED / AVS 1 5- ORANGE warning light “FUEL RESERVE” 7- SPEED / SPEED MAX 8- SPEED / TRIP 2 Note*: 9- SPEED / TRP 2 / CLOCK - After starting the engine, the instrument will 10- SPEED / RPM (engine r.p.m. numerical value) show the SW version for checking for the first 2 ...... seconds; afterwards the instrument will show the Note*: last configured function. The RPM function seen on the vertical bar indicator - When the engine is turned off, the instrument is ALWAYS active. does not show any functions. *IMPORTANT: Functions of the GREEN warning light (4)“NEUTRAL” 1 in case of FUEL INJECTION SYSTEM malfunction (con- 2 3 tact your local SWM Dealer) a) With the GEARBOX NOT in NEUTRAL position: the warning light FLASHES INTERMITTENTLY. b) With the GEARBOX in NEUTRAL position: the warning light is initially constantly ON then it 4 FLASHES TWICE IN RAPID SUCCESSION then returns to being constantly ON. This cycle repeats 1 itself. 5 A After eliminating the malfunction,the warning light (4) returns to its normal operation. EN - 10 1- SPEED (kmh or mph) / ODO / RPM 2- SPEED / H / RPM (figure 2) 3- SPEED / CLOCK / RPM (figure 3) (figure 1) - SPEED: vehicle speed - maximum value: 299 kmh - SPEED: speed - maximum value: 299 kmh or 299 - SPEED: speed - maximum value: 299 kmh or 299 or 299 mph; mph; mph; EN - ODO: odometer - maximum value: 99999 km; - H: shows the running hours of the engine (data - CLOCK: Clock - reading from 0:00 to 23:59:59 (the - RPM: engine r.p.m. shown on the vertical bar in- are saved in permanent memory every 10 min- data will be lost after detaching battery); dicator. utes). To replace kilometres with miles or miles with kilo- - Maximum value: 9999:59; To set clock, press the SCROLL button (A) for 3 sec- metres proceed as follows: - RPM: engine r.p.m. shown on the vertical bar in- onds or more to increase the hour; release button 1) set to figure 1, place the ignition key in the OFF dicator. and after 3 seconds the minutes can be increased; position and push the knob SCROLL (A); 2) place the ignition key in the ON position while - RPM: engine r.p.m. shown on the vertical bar in- pressing the SCROLL wheel for 3 seconds (A) dicator. To confirm the conversion, the “SET” and the Miles and mph or km and kmh segment will activate for 3 seconds; afterwards the standard function in Fig.1 will reappear. Note*: After the previously described operation, the ODO setting will be converted and all other data reset (the H Counter is unchanged).

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EN - 11 4- SPEED / TRIP 1 / RPM (figure 4) 5- SPEED / STP 1 / RPM (figure 5) 6- SPEED / AVS 1 / RPM (figure 6) - SPEED: speed - maximum value: 299 kmh or 299 - SPEED: speed - maximum value: 299 kmh or 299 - SPEED: speed - maximum value: 299 kmh or 299 mph; mph; mph; - TRIP 1: distance - maximum value: 999.9 km (the - STP 1: miles/kilometres covered time - AVS 1: shows the average speed for vehicle cov- data will be lost after detaching battery). - Reading from 0:00 to 23:59:59 (the data will be erage, distance data (TRIP 1) and covered time lost after detaching battery). (STP1) (the data will be lost after detaching bat- Resetting the STP 1 also resets the TRIP 1 and AVS To activate the function STP 1, push the knob SCROLL tery). 1 data. (A) for more than 3 seconds. The function TRIP 1 is ON together with the - pressing SCROLL (A) for more than three seconds, Note*: function STP 1 (*). the counter starts; Resetting the STP 1 also resets the TRIP 1 and AVS - pressing SCROLL (A) once only, the counter stops; 1 data. - RPM: engine r.p.m. shown on the vertical bar in- - pressing SCROLL (A) once only, the counter resets; dicator...... and so on - RPM: engine r.p.m. shown on the vertical bar indicator. (*): see figure 5 Note*: STP 1 data + TRIP 1 data = AVS 1 (*). - RPM: engine r.p.m. shown on the vertical bar indicator. (*): see figure 6

4 5 6

EN - 12 7- SPEED / V MAX / RPM (figure 7) 8- SPEED / TRIP 2 / RPM (figure 8) 10- SPEED /RPM (engine r.p.m. numerical val- - SPEED: speed - maximum value: 299 kmh or 299 ue) (figure 10) - SPEED: speed - maximum value: 299 kmh or 299 mph; mph; - TRIP 2: distance - maximum value: 999.9 km/ - SPEED: speed - maximum value: 299 kmh or 299 EN - V MAX: Shows the maximum speed reached by miles (the data will be lost after detaching bat- mph; the vehicle, in kmh or mph. tery); - RPM: engine r.p.m.; both vertical bar indicator To set TRIP 2 to zero, push the knob SCROLL (A) for and numerical value are on. Maximum value: 299 kmh or 299 mph. To set to zero more than 3 seconds; V MAX, push the knob SCROLL (A) for more than 3 - RPM: engine r.p.m. shown on the vertical bar in- seconds; dicator. - RPM: engine r.p.m. shown on the vertical bar in- 9- TRP 2 / CLOCK / RPM (figure 9) dicator. - TRIP 2: distance - maximum value: 999.9 km/miles (the data will be lost after detaching battery); To set TRIP 2 to zero, push the knob SCROLL (A) for 9 more than 3 seconds; - CLOCK: Clock- reading from 0:00 to 23:59:59 (the data will be lost after detaching battery); To reset the clock, push the knob SCROLL (A) for more than 3 seconds in order to increase the hours; release the knob then, after 3 seconds, it is possible to increase the minutes; A - RPM: engine r.p.m. shown on the vertical bar indicator.

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EN - 13 THROTTLE CONTROL IGNITION SWITCH The throttle twistgrip (1) is located on the right- The ignition switch has two positions. hand side of the handlebar. The position of the - From the OFF position, i.e. where you can remove throttle control can be adjusted by loosening the the key, turn the key (1) clockwise to ON; ignition, two retaining screws. parking lights and utilities are hence activated and the engine can be started. CAUTION*: Do not forget to tighten the screws (A) after the adjustment.

FRONT BRAKE CONTROL The brake control lever (2) is located on the right- hand side of the handlebar. The position of the throttle control can be adjusted by loosening the two retaining screws. CAUTION*: Do not forget to tighten the screws (B) after the adjustment. 1

1 A 2

EN - 14 STEERING LOCK R.H. HANDLEBAR SWITCH L.H. HANDLEBAR SWITCH The motorcycle is equipped with a steering lock (1) The right-hand switch features the following con- The left-hand switch features the following controls: on the R.H. side of the steering head tube. trols: 1) High beam flasher (self-cancelling) EN To lock it, procede as follows: 1) Engine start button turn the handlebar leftwards, place the key in lock 2) Engine KILL SWITCH. 2) High beam and turn counterclockwise. Push the key inwards (if Low beam necessary, turn to and from). Turn the key clockwise and remove it from the lock. 3) Left-hand turning indicators (self-cancel- To unlock the steering lock, reverse the above pro- ling) cedure. Right-hand turning indicators (self-cancelling) To deactivate the turning indicators, press the control lever after it is returned to the centre. 4) Warning horn 1

4 3 1 1 EN - 15 CLUTCH CONTROL REAR BRAKE CONTROL GEAR SHIFT CONTROL The hydraulic clutch control lever (1) is located on The rear brake control (1) is placed on the right- The lever (1) is placed on the left-hand side of the the left-hand side of the handlebar and is protected hand side of the motorcycle. A stop switch, during engine. The operator must release the lever after against dirt. the braking action, causes the stop light on the tail each gear change to allow it to return to its central The clutch control position on the handlebar can be light to come on. position. Neutral position (N) is between the first and second gears. adjusted by loosening the lower retaining screw (A). First gear is engaged by pushing the lever downwards; the other gears are engaged in a sequence CAUTION*: Do not forget to tighten the screw by pushing the lever upwards. after the adjustment. The position of the gear shift lever on the shaft can be varied as follows: loosen the screw, pull the lever out, and place the lever in a new position on the shaft. Tighten the screw once operation is completed. CAUTION*: Do not shift gears without disengaging the clutch and closing the throttle. The engine could be damaged by overspeed. WARNING*: Do not downshift when travelling at a speed that would force the engine to over- 1 rev in the next lower gear, or cause the rear wheel to lose grip.

6 5 4 3 A 2 N 1 1 1

EN - 16 ------firstinspection andproceed tocheckthe following: Any timeyou rideyour motorcycle, make ageneral PRE-RIDE CHECKS riding thismotorcycle. operation, read paragraphs on“CONTROLS” before Note*: not allowedtocarryapassenger. used by the pilot only and for this reason it is WARNING*: Themotorbikeisapprovedtobe RIDING

check iftherearstop lightisfunctioning. operate theturningindicatorsandcheck thatthe switch onthelowbeam,highbeam andcheck turn theignitionswitchtoONposition:check check thethrottletwistgripandadjustit,ifneces check thechaintension; check thetyrepressure; check thesteeringbyturninghandlebarboth check thebrakeandclutchfluidslevel; check fuellevelandengineoillevel; warning lightcomeson; that therelevantwarninglightscome on; light comeson; in neutral,makesurethattheneutral warning lighting ofinstrumentdisplayand,withgearbox ways, fullyhome; sary; If you are notfamiliar withthemotorcycle ------THE PERFORMANCEOFMOTORCYCLE: WITH THESERULESMAY COMPROMISETHELIFEAND herebelow. PleasenotethatFAILURE TO COMPLY 1500 Km.,SCRUPULOUSLY follow therulesmentioned from thestart.However, whenrunningfor thefirst the assembly,guarantee thehighercomfort right quality ofthematerialsusedandaccuracy of The exclusivity ofthedesign,coupled tothehigh INSTRUCTIONS FORRUNNING-IN

NEVER drive downhill with GEARBOX IN NEUTRAL, do notrideforalongtimewithoutstopping; do notmaintainthesamespeedforalongtime; apply both brakes several times to settle the pads ride atlowspeeduntiltheengineiswarmedup; avoid quickstartsandneverrevuptheengine warm uptheenginebyrunningatlowrevsbefore brake pads. necessary, thus preventing the fast wear of the but shiftintogeartobrakewiththeengineif and thediscs; when inlowgear; using themotorcycle; Insufficient amount of coolant: topup. - Insufficientamountof - - The engineoverheats - The sparkpluggetseasilydirt: - - The enginestarts,butitiserratic - The enginehasstartingtroubles - faultystartbutton:replacetheswitch - faultystartermotor:repairorreplace; - thesparkplugdoesnotspark:adjustelec - dirtysparkplug:clean - thestartingproceduresarenotcorrectlyfollowed: notstart The enginedoes find thenecessary remedies. The following listisusedfor troubleshooting andto TROUBLESHOOTING

Faulty electricfan:replacethermalswitch the airflowonradiatorsisblocked: clean unfit sparkplug:replace faulty sparkplugelectrodegap:adjust; dirty orwornoutsparkplug:cleanreplace dirty orwornoutsparkplug:cleanreplace trodes gap ing theengine” follow the instructions given on paragraph “Start- EN -17

EN The engine lacks power Faulty brakes STARTING THE ENGINE - dirty air filter: clean - worn-out pads: replace - the spark plug electrode gap is too large: adjust; With cold engine, i.e., after the motorcycle has not - incorrect valve clearance: adjust; been used for a while or in low ambient tempera- - insufficient compression: check for the cause tures, operate in the following manner: 1) Place ignition key (1) to ON position (the buzz that The engine knocks you hear when you turn the key to ON is caused - excessive carbon deposit on the piston crown, or by the fuel pump which puts the feeding system in the combustion chamber: clean under pressure); - faulty spark plug or wrong heat rating: replace 2) pull the starter knob (2); 3) pull the clutch lever (3); The alternator fails to charge, or its charge is insuf- 4) shift the gear pedal (4) into neutral position; ficient 5) Check that the button (5) is in the out position - the cables on the voltage regulator are badly con- and press it, followed by the start button (6). nected, or in short-circuit: correctly connect, or re- Put the knob (2) in its initial position as soon as place the engine is idling - faulty alternator coil: replace When starting with an already warmed up en- - de-magnetised alternator rotor: replace gine DO NOT USE the starter. When a cold engine - faulty voltage regulator: replace has just been started, do not increase revs, to ensure an adequate oil warm-up and circulation. The battery overheats - faulty voltage regulator: replace Note*: A safety switch is fitted on the clutch lever support that allows starting ONLY when the clutch Difficulty in shifting gears lever is pulled. - engine oil with too high viscosity rating: replace with the recommended oil The clutch slips - insufficient spring load: replace - worn-out clutch plates: replace

EN - 18 Although the engine has an automatic decompressor, it may in some cases be necessary (throttle 1

body flooding or starting difficulties due to inad- EN equate battery charge) to use the manual decompressor located on the left-hand side of the handlebar. In these cases, pull the lever (7) whilst simultaneously pressing the starter button (6), re- N lease the lever (7) keeping the button (6) pressed and then release the button. 4 IMPORTANT NOTE IN CASE OF COLD STARTS AT LOW TEMPERATURES It is recommended to briefly warm-up the engine at 5 idle until, after having disengaged the starter, there is a normal response from the engine when opening the throttle. In this way the oil can reach all the surfaces needing lubrication and the coolant will reach the necessary temperature for correct engine function. 2 Avoid overheating the engine. 6 IMPORTANT*: Never accelerate the engine after a cold start. 3 WARNING*: Exhaust contains poisonous carbon monoxide gas. Never run the engine in a closed garage or in a confined area.

EN - 19 STOPPING THE MOTORCYCLE AND THE ENGINE - Close the throttle (1) completely so that the engine 5 will help slow down the motorcycle. 1 - Apply both front (2) and rear (3) brakes while downshifting (for fast deceleration, press firmly on both brake pedal and lever). - When stopped, pull the clutch lever (4) and shift 2 gear lever (5) into the neutral position - Turn the ignition key (6) to the OFF position (position for removing key).

STOPPING THE MOTOR IN AN EMERGENCY - Press the red button (7) to stop the motor; after use, bring it back to the “out” position. 6 WARNING*: Independent use of the front or rear brake may be advantageous under certain conditions. Be careful when using the 3 front brake, especially on slippery surfaces. Improper use of the brakes can lead to a serious crash. WARNING*: In the event of stuck throttle or 4 other malfunction which causes the engine to run uncontrollably, IMMEDIATELY depress the engine kill switch (7). Control the motorcycle by normal use of the brakes and steering while pressing the engine kill switch. 7

EN - 20 CHECKING THE OIL LEVEL ENGINE OIL REPLACEMENT AND BAG FILTERS-FILTER CARTRIDGE CLEANING OR REPLACEMENT Keeping the motorbike level and in a vertical position, check the oil level through the inspection (1) window on WARNING*: Be careful not to touch hot engine EN the right crankcase. Make sure the level is in between oil. the MIN and MAX notches. To top up, remove the filler cap (2). Drain the oil with WARM ENGINE; proceed as follows: • remove oil filler cap (1); Note*: Have this operation made with warm engine. • remove the engine guard (A) 1 • place an oil drain pan under the engine block • remove the oil drain cap (2) • drain the used oil completely then clean the mag- WARNING*: Be careful not to touch hot engine oil. neto on the cap; • replace the filters as described below. 2 MAX

1 MIN A

EN - 21 CLEANING THE METAL FILTERS • Refit everything operating in reverse order from REPLACING THE FILTER CARTRIDGE removal taking care to correctly position the O- After draining the oil as described above, operate as After draining the oil as described above, operate as rings (11) and (12). follows: follows: • Once you have replaced the filters, refit the drain • Undo the two screws (13) and remove the guard • Unscrew the cap (3) and remove the filter (4). cap (2) and the engine guard (A) and pour in the (14). • Clean the filter (4) using petrol. required amount of oil. • Undo the three screws (15) and remove the cap • Check the condition of the O-ring (5) and replace (16). it if worn. • Replace the filter (17). • Refit everything operating in reverse order from removal taking care to correctly position the alu- • Check the condition of the O-ring (18) and replace minium washer (6). it if worn. • Undo the two screws (7) and remove the cap (8). • Clean the filters (9) and (10) using petrol. • Check the condition of the O-rings (11) and (12) and replace them if worn. 2

7 14 3 9 13 A 5 11 16 8 10 4 8 15 15a 6 12 3 7

EN - 22 • Refit everything operating in reverse order from CAUTION*: Avoid removing radiator cap (3) CAUTION*: Because the cooling fan (4) can be removal taking care to correctly position the O- when engine is hot, as coolant may spout out activated even when the start switch is in OFF ring (18) and the spring (19). and cause scalding. position, always keep at a safe distance from the fan blades. EN WARNING*: the longer screw (15a) is to be fitted exactly in the position indicated in the figure. Note*: Difficulties may arise in eliminating coolant from painted surfaces. If this occurs, wash off with water. 15a 16 18 1 17 3

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COOLANT LEVEL CHECK Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximate- 4 ly 10 mm above cells and besides, it shall not exceed the middle of the expansion tank (2) located in front of the rear shock absorber. The radiator cap (3) features two locking positions, 2 the first being for the previous pressure discharge of the cooling system. EN - 23 COOLANT REPLACEMENT - Pour the necessary quantity of coolant in the radiator then warm up the engine in order to elimi- WARNING*: Coolant shall be replaced with cold nate any possible air bubbles. engine and coolant. - Allow the coolant to cool down then remove cap (2) and check the level as explained under “Cool- Standard procedure ant level check”. - Place a vessel on the R.H. side of the cylinder, - Periodically check the connecting hoses (see under the coolant drain screw (1). FIRST remove “Scheduled Maintenance Chart”): this will avoid the screw (1) then SLOWLY open the R.H. radiator coolant leakage and consequent engine seizure: cap (2); slope the motorcycle on the right side to If hoses (A) show cracks, swelling or hardening drain the coolant easily in the vessel. Reassemble due to sheaths desiccation, their replacement the screw (1). shall be advisable. - Check the correct tightening of the clamps (B).

2 B B B 1 A A

EN - 24 THROTTLE CABLE ADJUSTMENT Note*: If replacing the throttle control cables (2) and (5), operate as follows: To check the correct adjustment of the throttle op- - Undo the screw (6) and remove the cap (7). erate as follows: - Replace the cables (2) and (5); when refitting, EN - move the upper rubber cap (1); respect the dimension A (10mm) shown in the - by moving cable (2) back and forth check for 2 photo. Then refit the protection cap (7) using the mm. clearance; screw (6) and adjust the cables on the handlebar - should this not be the case, release the check nut as described above. (3) and appropriately turn the adjustment screw To replace throttle control cables, first remove tha (4) (unscrewing reduces the clearance, tightening fuel tank. increases it); - Lock the check nut (3). WARNING*: Operation with damaged throttle cable could result in an unsafe riding condition. WARNING*: Exhaust gas contains poisonous carbon monoxide gas. Never run the engine in a closed area or in a confined area. A 4 2 3 6 1 5 A

EN - 25 ADJUSTING THE IDLE ADJUSTING THE MANUAL DECOMPRESSOR CABLE TENSION Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as In order to adjust the lever (1) decompressor free follows: play (approximately 3 mm- 0.12 in.), the lever holder - turn the idle speed adjustment screw (1) on the is provided with the adjuster (2); the adjustment throttle body, located on the right-hand side of can be also effected with the tightener (3) on the the vehicle, until the idle speed of 1650 RPM is R.H. side of the engine (use this tightener if it is not reached (turn clockwise to increase the speed possible to obtain the correct free play with the ad- and anticlockwise to reduce the speed). juster on the handlebar).

EN - 26 SPARK PLUG CHECK High heat rating: Before refitting the plug, thoroughly clean the In this case, the insulator tip is dry and covered with electrodes and the insulator using a metal Spark plug (2) gap shall be 0.028 in. dark deposits. brush. Smear some graphite grease on spark A wider gap may cause difficulties in starting the plug thread, do it fully home finger tight then EN engine and overload the coil. Low heat rating: tighten it to 7.37÷8.85 ft-lb. torque. Loosen the A gap that is too narrow may cause difficulties In this case, the spark plug has overheated and in- spark plug then tighten it again to 7.37÷8.85 when accelerating, when idling or poor performance at low speed. sulator tip is vitrified (glazed), white or grey in col- ft-lb. Clean the scale away from the base of the spark our. Spark plugs which have cracked insulators or plug before removing it from the cylinder, after re- corroded electrodes should be replaced. moving the cap (1). WARNING*: If the spark plug is replaced, use It is very useful to examine the state of the spark one with the same rating. plug just after it has been removed from the engine since the scale deposits on the plug and the colour CAUTION*: A spark plug with too hot a heat of the insulator provide useful indications. range may lead to preignition and possible engine damage. A spark plug with too cold a Correct heat rating: heat range may foul as the result of too much The tip of the insulator should be dry and the colour carbon buildup. should be light brown or grey.

1 2

0,7 ÷ 0,8 mm

EN - 27 VOLTAGE REGULATOR AIR FILTER CHECK AIR FILTER AND CLEANING The voltage regulator (1) is fitted to the right side of Turn the rear pin (1) anticlockwise and remove Wash the filter with a specific detergent then dry the chassis, on the front. the saddle disengaging it from the front retaining it fully. screw. Plunge the filter in special oil for filters then wring it to drain superfluous oil. Take out the battery (2) and place it sideways on the vehicle. CAUTION*: Do not use gasoline or a low flash- Remove screw (3) and the filter (4). Separate filter point solvent to clean the element. A fire or (5) from frame (6). explosion could result. CAUTION*: Clean the element in a well venti- 1 lated area, and do not allow sparks or flames anywhere near the working area.

2 4 6 1 3

EN - 28 ASSEMBLY STEERING WHEEL BALL PLAY ADJUSTMENT To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. To ensure maximum safety, the steering wheel While re-inserting the filter into its housing, make should always be regulated so that the handle- EN surs that piece (A) is turned upwards and edge (B) is bars steering the motorcycle rotate freely without on the left lower side of the filter case. Reassemble play. To check steering wheel adjustment, place kick the parts previously removed (battery: connect the stand or other support under the engine so that the positive cable first). front wheel is raised from ground. Place slight pressure on the tips of the handlebars CAUTION*: If the element assembly is not in- to rotate steering wheel; the handlebars should also stalled correctly, dirt and dust may enter and rotate without effort. the engine resulting in rapid wear of the pis- Stand in front of the motorcycle and grasp the low- ton rings and cylinder. er end of the fork rods sliders moving them in the direction of their axis. Se si avverte gioco occorrerà *: upper side A * eseguire la regolazione operando come segue: **: left-hand side - loosen steering sleeve nut (1). - Loosen screws that fix steering head to fork rods (2). ** Turn the steering ring nut (3) clockwise of the steering sleeve proper tool, to adjust play prop- C B erly. - Tighten steering sleeve nut (1) to a torque setting of 57,9÷65,1 Lb/ft; (78,4÷88,3 Nm). - Tighten screws on the steering head (2) to a torque of 22,5÷26,5 Nm (16.6÷19.5 Lb/ft). 1 CAUTION*: Do not ride a motorcycle with damaged steering stem bearings. An unsafe handling condition can result. 2 3

EN - 29 LOCK ADJUSTMENT - the operation done, tighten the screw (1). Once - operate the pump rod (5) to increase or decrease this adjustment is completed, adjust the free play the free play; The lock can be changed, using the adjusting units of the pedal as follows. - tighten nut (4) at the end of the operation. on the sides of the steering tube, as follows: loosen the ring nut (1) and turn the adjusting screw (2) until WARNING*: When the free play requirement is you have the desired angle, then tighten the ring not met, the brake pads will be subjected to nut again (1). Change by the same amount on both 2 an early wear that may lead to TOTAL BRAKE sides. INEFFECTIVENESS.

1 2 5

1 A 4

REAR BRAKE PEDAL POSITION ADJUSTMENT B A The position of the rear brake pedal with respect 3 to the footrest may be adjusted according to the individual needs. REAR BRAKE PEDAL FREE PLAY ADJUSTMENT For adjusting, proceed as follows. - loosen the screw (1); The rear brake pedal (3) should have a free play (B) B - turn the cam (2) in order to raise or lower the (0.2 in.) before the brakes begin to bite. brake pedal (3) within the range available (A); Should this not happen, operate as follows: 3 - loosen nut (4); EN - 30 ADJUSTMENT OF THE CONTROL LEVER AND FRONT WARNING*: If the brake lever feels mushy CAUTION*: Brake fluid may cause irritation. BRAKE FLUID LEVEL CHECK when pulled, there may be air in the brake Avoid contact with skin or eyes. In case of con- lines or the brake may be defective. Since it is tact, flush thoroughly with water and call a On the RS models the adjuster (2), located on the con- dangerous to operate the motorcycle under doctor if your eyes were exposed. EN trol lever, allows adjusting of the free play (a). Free play such conditions, have the brake system im- (a) must be at least 0.1 in. mediately checked by the SWM Dealer. A: to increase clearance The level of the fluid in master cylinder reservoir B: to decrease clearance must never be below the minimum value (1), which CAUTION*: Do not spill brake fluid onto any can be checked from the window on the rear side of painted surface or light lens. the master cylinder body. A decrease of the fluid level will let air into the sys- CAUTION*: Do not mix two brands of fluid. tem, hence an extension of the lever stroke. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand.

2 a + A 1 2

B -

EN - 31 REAR BRAKE FLUID LEVEL CHECK CAUTION*: Do not spill brake fluid onto any ADJUSTMENT OF THE HYDRAULIC CLUTCH CONTROL painted surface or light lens. LEVER The pump fluid level must never be below the minimum value indicated on the pump tank (1). CAUTION*: Do not mix two brands of fluid. Free play (A) must be at least 0.1 in. A decrease of the fluid level will let air into the sys- Completely change the brake fluid in the brake The lever position can be adjusted to suit the rider tem, hence an extension of the lever stroke. system if you wish to switch to another fluid hand size. brand. To decrease the lever distance from the handgrip, WARNING*: If the brake pedal feels mushy rotate the adjuster (B) CLOCKWISE. when pulled, there may be air in the brake CAUTION*: Brake fluid may cause irritation. To increase the lever distance from the handgrip, lines or the brake may be defective. Since it is Avoid contact with skin or eyes. In case of con- rotate the adjuster (B) COUNTER CLOCKWISE. dangerous to operate the motorcycle under tact, flush thoroughly with water and call a such conditions, have the brake system im- doctor if your eyes were exposed. mediately checked by the SWM Dealer. A

EN - 32 HYDRAULIC CLUTCH FLUID LEVEL CHECK Periodically check the connecting hose (see “Periodi- cal maintenance card”): if the hose (C) show is bent To check the fluid level, proceed as follows: or cracked, its replacement is advised. - remove screws (1), cover (2) and rubber (3) pump EN diaphragm on the handlebar clutch control; - by keeping the master cylinder (4) in horizontal position, check the fluid level is NOT BELOW 4 mm (0.16 in.) from the upper surface (D) of the pump body; - if necessary, add fluid until the correct level is reached see TABLE FOR LUBRICATION-SUPPLIES for the fluid type.

CAUTION*: NEVER use brake fluid. 1 Reassembly the removed parts using the reverse 2 procedure.

3 C 1 D 4mm (0,16 in.) 4 2

EN - 33 HYDRAULIC CLUTCH BLEEDING Proceed as follows: - remove screws (1), cap (2) and rubber pump diaphragm; - remove the bleeding nipple (3); - mount a syringe in the bleeding nipple hole, then refill with fresh fluid. CAUTION *: NEVER use brake fluid. - refill until fluid is discharged from the lower hole (B) on the pump body WITHOUT BUBBLES. A B The fluid level MUST NEVER BE below 4 mm from the top (A) of the clutch pump body (see picture). Reassemble the removed parts. 4mm (0,16 in.)

3 2

EN - 34 torcycle ridingheight(rear end). settings; Work onthespringpreload toliftthemo harder absorber: Shock compression andrebound Front fork: harder compression setting. MUDDY GROUND end). preload to lower themotorcycle riding height (rear cially harder rebound settings.Work onthespring harder absorber: Shock compression, andespe Front fork: harder compression setting. SANDY GROUND softercompression absorber: Shock setting. Front fork: softercompression setting. HARD GROUND time. increase ordecrease theadjustingclicks,oneata ard setting before making any change. Afterwards, for setup. Always start from stand- the suspensions more ground, specific following are a few guidelines tions of the vehicles. If you intend to use them on extensive demanding tests in various usage condi- Standard settingderives suspensions from several SUSPENSIONS - - sation. holding therelevant drivinglicenceorauthori in “CLOSED CIRCUITS” by authorisedsubjects public roads: usedonly consequentlyitmaybe and it is henceunsuitable for circulating on ANCE WITHTYPE-APPROVAL REQUIREMENTS configuration causeTHEVEHICLENONCOMPLI - ranty tostandard andthatallmodifications tions ofany are type excluded from thewar - motorcycles usedincompeti andtheirparts WARNING*: ALWAYS remember that all the - - EN -35

EN ADJUSTING THE FRONT FORK - bring fork to stroke end; a - check that the level is at distance “A” below the a) REBOUND (TOP ADJUSTER) C upper limit of damper rod. Standard setting: - 10 clicks. To reset standard calibration, turn adjuster (C) OIL QUANTITY IN EACH FORK LEG clockwise to reach the fully closed position; then, turn it back by the mentioned clicks. In order to D - 39.23 in3. (643 cm3) obtain a smooth braking action, turn the adjuster - A: 5.51 in. (140 mm) counter clockwise. Vice versa to obtain a harder with fork leg fully compressed and without spring. braking action. Note*: b Standard spring elastic constant: b) COMPRESSION (UPPER REGISTER) Standard calibration : A - K= 8.8N/mm - 10 clicks. Note*: To reset to the standadr calibration turn register (A) Always replace both the spring and the spacers to clockwise until the position of fully closed is reached keep the preload value unchanged. then, turn back by the mentioned clicks. To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. - AIR VENT (to carry out monthly). Set the motorcycle on a central stand, release the FORK OIL LEVEL fork fully extended and loosen the air vent valve (D). A Once this operation is over, tighten the valve. For regular fork operation, both legs must be provided with the necessary oil quantity. Remove the Note*: Never force the adjusting screws beyond the fork legs from the fork to check the oil level. Work maximum open and closed positions. as follows: - remove the damper rod caps; - remove springs from the legs letting the oil drain into the legs; EN - 36 ADJUSTING THE SHOCK ABSORBER WARNING*: The shock absorber adjustment ADJUSTING THE SHOCK ABSORBER SPRING PRELOAD affects both the stability and the handling of The rear shock absorber must be adjusted accord- the motorcycle. After changing the standard Proceed as follows: ing to the rider weight and track conditions. suspension setting, ride with care. We advise 1. First turn counterclockwise fastening rear pin EN Proceed as follows: measuring the reference distance “A” before (1) then remove saddle, screws (2) and R.H. side 1. With the motorcycle on the ground in vertical po- making any change. panel (3). sition, measure the distance (A). 2. Take the normal riding position on the motorcycle WARNING*: Never disassemble the shock ab- with all your riding apparel. sorber, which contains compressed gas. Con- 3. With somebody’s help, take the new distance (A). tact your SWM Dealer for any major service. 4. The difference between these two measure- ments constitutes the “SAG” of the motorcycle’s rear end. 1 The recommended SAG is 0.98/1.18 (25-30 mm). 5. To get the right SAG according to your weight, B adjust the shock absorber spring preload as described at side. B: rear mudguard top height C: rear wheel axle height A 2

C 3

EN - 37 2. Clean ringnut (4) and adjusting nut (5) of the ADJUSTING THE SHOCK ABSORBER HYDRAULIC B) REBOUND - Standard setting: spring (6). DAMPING - 10 clicks 3. Either with a hook wrench or an aluminium Adjustment of the compression stroke is independ- (adjuster 9) punch, loosen the lock ring nut. ent from the rebound stroke. 4. Turn the adjuster ring nut as required. To reset the standard setting, turn lower adjuster 5. When the adjusting operation is over (according A) COMPRESSION - Standard setting: (9) clockwise until reaching fully closed position. to your weight and riding style), tighten the lock 1) Low damping speed: Then turn it back by the mentioned clicks. ring nut. (Torque: 36.2 ft/lb). - 14 clicks In order to obtain a smooth braking action, turn the 6. Refit the R.H. side panel and the saddle. (adjuster 7) adjuster counter clockwise. Vice versa to obtain a harder braking action. WARNING*: Be careful not to touch hot exhaust 2) High damping speed: pipe while adjusting the shock absorber. - 1 ½ turn (adjuster 8) Standard spring elastic constant: - 52 N/mm To reset the standard setting, turn upper adjusters (7) and (8) clockwise until reaching fully closed position.Then turn them back to the above-mentioned positions. In order to obtain a smooth braking action, turn the adjusters counter clockwise. Vice versa to obtain a harder braking action. 4

5 - + - + 7 8 9 6

EN - 38 CHAIN ADJUSTMENT (FIG. A) FAST ADJUSTMENT (FIG. B) Chain should be checked, adjusted and lubricated as In the point shown in the figure, fit a bush (a), 1.37 per the Maintenance Chart to ensure security and in. (35 mm) diameter (or alternatively a shim in the EN prevent excessive wear. If the chains becomes bad- same size) and make sure the lower branch (C) of ly worn or is poorly adjusted (i.e., if it is too loose or the chain is slightly taut. too taught), it could escape from sprocket or break. If it is not, proceed as follows: To adjust the rear chain it is necessary to lower - on the right side, with a 1.06 in. (27 mm) Allen the rear part of motorcycle so to line up the drive screwdriver, loosen the locking nut (1) of the sprocket axle, the rear swing arm axle and the rear wheel pin; 1 wheel axle as shown on drawing. Than let turn - with a 0.47 in. (12 mm) screwdriver, loosen the three times the rear wheel. Now the chain should check nuts (2) on both chain stretchers and work not be tight. on the screws (3) to achieve the right tension; - when the adjustment is over, tighten the check 35 mm (1.37 in.) nuts (2) and the wheel pin nut (1). 145 mm (5.7 in.) a When the adjustment is over check the wheel for alignment.

Fig. A a 2

Sprocket axis 3 Swinging arm axis Wheel axis

EN - 39 CHECKING THE WEAR OF CHAIN, PINION AND SPROCKET Check the pinion damages or wear and replace it Note*: In muddy and wet conditions, mud sticks to should the wear degree be as the one shown in fig- the chain and sprockets resulting in an overtight Proceed as follows: ure. chain. The pinion, the chain, and the rear sprocket - fully stretch the chain with the adjusting screws. Remove the wheel and check the wear of the rear wheel wear increases when running on muddy - mark 20 chain links. sproket teeth. The below figure shows the outline ground. - measure the distance “L” between 1st pin center of teeth in normal and excessive wear. Should the and 21st pin center. sprocket be badly worn out, replace it by loosening the six fastening screws to the hub.

STANDARD WEAR LIMIT WARNING*: Misalignment of the wheel will result in abnormal wear and may result in an 12.5 in. 12.71 in. unsafe riding condition.

1 2 3 21 Normal consumption

L Excessive consumption

EN - 40 LUBRICATING THE CHAIN Disassembling and cleaning 3- Ensure that the sprockets are not damaged. When particularly dirty, remove and clean the chain 4- Wash and clean the chain as described hereun- Lubricate the chain following these instructions. before lubrication. Proceed as follows. der. 1- Set a stand or a block under the engine and see 5- If the chain has been cut, reassemble it using the EN CAUTION*: Never use grease to lubricate the that the rear wheel is lifted from the ground. master link. chain. Grease helps to accumulate dust and Remove: screws (1), sprocket guard (2), clip (3), 6- Assemble the master link spring (3) by setting the mud, which act as abrasive and help to rapidly master link (4) with its O-rings and chain (5). closed side facing the chain direction of rotation, wear out the chain, the front and rear sprock- To reassemble, reverse the above procedure, as shown below. ets. making sure to correctly set the clip (3) and master link (4) as well as the relevant O-rings. Note*: The master link is the most critical safety 2- Make sure that the chain is neither worn out nor part in the drive chain. Even if the master links damaged. If the rollers or the links are damaged, are reusable when in good conditions, for safe- replace the chain by following the instructions ty purposes we advise using a new master link given in the Scheduled Maintenance Chart. when reassembling the chain. 7- Accurately adjust the chain as described in the relevant paragraph.

4 2

1 3

EN - 41 Washing the chain with O-rings Chain guide roller, chain guide eye, chain Wash using petroleum, naphtha or paraffin oil. slider Never use fuel, trichloroethylene or solvents, as the Check the wear of the above-mentioned elements O-rings may get damaged. and replace them when necessary. Use instead special sprays for chains with O-rings.

Lubricating the chain with O-rings CAUTION*: Check the chain guide alignment, Lubricate all metallic and rubber (O-ring) elements and remember that a bent element can cause using a brush and engine oil with SAE 80-90 viscos- chain early wear. In this case, chain might un- ity, inside and outside parts. wrap from the sprocket. CAUTION*: The chain lubricant shall NEVER get in contact with the tyres or the rear brake disc.

1 - Chain tensioner roller 3 2 - Chain guide eye 3 - Chain slider

1 2

EN - 42 REMOVING THE FRONT WHEEL Note*: Do not operate the front brake lever when the wheel has been removed; this causes the calliper Set a stand or a block under the engine and see that pistons to move outwards. After removal, lay down the front wheel is lifted from the ground. the wheel with brake disc on top. EN Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. Hold the head of the wheel axle in place, and unscrew the bolt (3) on the opposite side; draw the wheel axle out.

2 1

1 3

EN - 43 REASSEMBLING THE FRONT WHEEL Now, pump for a while, pushing the handlebar Note*: After reassembly, pull the brake control le- downwards until you are sure that the fork legs are ver until the pads are against the brake disc. Fit the L.H. spacer (D) on the wheel hub. perfectly aligned. Lock: the screws (1) on the R.H. leg (7.67 ft-lb), the screw (3) on the L.H. side (37.95 ft-lb), Fit the wheel between the fork legs so as to set the the screws (1) on the L.H. leg (7.67 ft-lb). brake disc into the calliper. Fit the wheel axle (2) from the R.H. side, after greas- ing it and push it fully home against the L.H. fork leg; during this operation, the wheel should be turned. Tighten the screw (3) on the fork L.H. side but DO NOT lock it.

2 1 3 1

EN - 44 REMOVING THE REAR WHEEL Note*: Do not operate the rear brake pedal when TYRES the wheel has been removed; this causes the cal- Unscrew the nut (1) of the wheel axle (3) and extract liper pistons to move outwards. Care should be taken to keep the tyres properly in- it. It is not necessary to loosen the chain tension- After removal, lay down the wheel with brake disc flated. See "Technical data" chart at the beginning EN ers (2); in this way, the chain tension will remain on top. of the manual for correct tyre inflation pressure. unchanged after reassembly. Extract the complete After reassembly, depress the brake pedal until the Replace the tyre if its wear exceeds reference val- rear wheel, keeping the spacers located at the hub pads are against the brake disc. ues on the table below. sides. To reassemble, reverse the above procedure re- MINIMUM HEIGHT membering to insert the brake disc into the calliper. OF THE TREAD FRONT 0.12 in. REAR 0.12 in.

2 1

EN - 45 BRAKES The key components of the braking systems are: brake master cylinder with its lever (front) or pedal (rear), brake lines, calliper assembly and disc. 2 LEGEND 1. Front brake control lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 5 4. Front brake calliper 1 4 5. Front brake disc 6. Rear brake pump with oil tank 7. Rear brake line 8. Rear brake calliper 9. Rear brake disc 10. Rear brake control pedal 3 6 7 10 8

EN - 46 BRAKE PADS REMOVAL PADS WEAR - Remove clips (1). Check brake pad wear. - Slide out pin (2). Respect the service limit “A” indicated in the relative EN - Remove pads. figures. If service limit is exceeded, always replace the pads WARNING*: Do not work the brake lever or ped- in pairs. al while removing the pads.

FRONT REAR A= 4 mm A= 6,5 mm (0.15 in.) (0.25 in.)

FRONT REAR 1 1

2 2

EN - 47 PADS CLEANING WARNING*: Do not attempt to ride the motorcycle until the brake lever or pedal are fully ef- Be careful that no brake fluid or any oil gets on fective. "Pump" with the brake lever or pedal brake pads or discs. Clean off with alcohol any fluid until the pads are against the discs. The brake or oil that inadvertently gets on the pads or disc. will not function on the first application of the Replace the pads with new ones if they cannot be lever or pedal. cleaned satisfactorily.

PADS INSTALLATION - Install new brake pads. - Reassemble the two pins (2) and the clips (1).

FRONT REAR 2 1

3 1

EN - 48 Disc thickness has wornpasttheservicelimit. where ithas worn themost.Replace the discifit Measure thethicknessofeachdiscatpoint BRAKE DISCWEAR Front Rear DISC STANDARD (4 mm) (3 mm) 0.15 in. 0.11 in. (3,6 mm) (2,5 mm) SERVICE 0.09 in. 0.14 in. LIMIT lacquer thinner. high flash-pointoilfreesolvent,suchasacetoneor Oil orgreaseonthediscmustbecleanedoffwitha Poor brakingcanalsobecausedbyoilonthedisc. DISC CLEANING EN -49

EN FLUID CHANGE To replace the fluid, proceed as follows: The brake fluid should be checked and changed in - Remove the rubber cap on the bleeding valve (1) accordance with the Periodic Maintenance Chart or (1A). or whenever it is contaminated with dirt or water. - Attach a clear plastic hose to the bleeding valve Don't change the fluid in the rain or when a strong on the brake caliper and turn the other end of wind is blowing. the hose into a container. CAUTION*: - Remove fluid reservoir cap (2)or (2A: 21 mm * Use only brake fluid from a sealed contain- wrench) and the rubber. er (DOT 4). Never use old brake fluid. - Loosen bleeding valve on the brake caliper. * Never allow contaminants (dirt, water, etc.) to enter the brake fluid reservoir. * Don't leave the reservoir cap off any length of time to avoid moisture contami- 2 nation of the fluid. * Handle brake fluid with care because it can damage paint. * Don't mix two types of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be inef- fective. It may also cause the rubber brake part to deteriorate.

1A 1

EN - 50 - Pump with brake lever (3) or brake pedal (3A) in order to push brake fluid out of line. - Close the bleeding valve and fill the reservoir with fresh brake fluid. EN - Open the bleeding valve, apply the brake us- A ing the brake lever or pedal, close the bleeding valve with the brake lever or pedal applied and then quickly release the lever or pedal. - Repeat this operation until the brake line is filled 3 and clear fluid starts coming out of the plastic hose: now close the bleeding valve. - Restore the brake fluid level (A) or (B) then reassemble the rubber and the fluid reservoir cap. After changing the fluid, bleed the system as described in the relative paragraph.

3A B

EN - 51 WARNING*: FRONT BRAKING SYSTEM BLEEDING Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up im- The braking system must be bled after the fluid mediately. replacement or when, due to air in the circuit, the * Brake fluid may cause irritation. Avoid con- lever stroke is long and spongy. tact with skin or eyes. In case of contact, flush Proceed as follows: thoroughly and call a doctor if your eyes were exposed. - Remove the rubber cap on the bleeding valve (1). Periodically check the connecting hoses (see - Attach a clear plastic hose to the bleeding valve “Periodical maintenance card”): if the hoses on the brake caliper and turn the other end of (A) and (B) are worned or cracked, their re- the hose into a container (make sure that the placement is advised end of the hose is submerged in brake fluid during the entire bleeding operation).

B 1

EN - 52 - Remove fluid reservoir cap (2), the rubber and WARNING*: If the lever stroke gets stretchy and the brak- fill the reservoir with fresh brake fluid. During the bleed operation the fluid level in- ing action results as poor in the case of falls - Open the bleeding valve and pump with brake side the reservoir must never be lower than during competitions, or after repair work lever (3) several times until the fluid, clear and the minimum level. in shops, repeat the bleeding operation de- EN without bubbles, comes out of the hose: now Tightening torque for bleed valve is 1,2 ÷ 1,6 scribed above. close the bleeding valve.- kgm (12 ÷ 16 Nm; 8.8 ÷ 11.8 ft-lb). - Restore the brake fluid level (A) then reassem- As the bleeding operation does not fully elimi- ble the rubber and the fluid reservoir cap (2). As the braking fluid is a very corrosive sub- nate the air inside the circuit, the small quan- stance, in the case it comes in contact with tity of air remaining inside will be eliminated your eyes wash them abundantly with water. after a short time of use of the brake. In this case however, the action of the lever will be During the bleeding of the braking circuit keep harder and the stroke shorter. the handlebar turned leftwards. This is the way to lift the pump tank and to make easier the bleeding of the braking system.

3 A

EN - 53 REAR BRAKING SYSTEM BLEEDING - Depress the pedal (2) and keep it full down. If the bleeding operation has be done correctly, the - Loosen the bleed union letting out fluid (at first, pedal will have no mushy feel. If not, repeat the op- The braking system must be bled after the fluid only air will come out), then, closing the union eration. replacement or when, due to air in the circuit, the slightly. pedal stroke is long and spongy. - Release the pedal and wait for a few seconds Note*: If following falls or repairs, the brake lever or To bleed the system: before repeating the operation until only fluid pedal stroke is stretchy resulting in reduced brak- - Remove the reservoir cover (A) (21 mm wrench) come out of the tube. ing efficiency, repeat circuit bleeding as described rubber boot and top up with (DOT 4) brake fluid. - Close the bleed union to the prescribed torque above. and check the fluid level (B) inside the reservoir - Attach a clear plastic hose to the bleed valve before reassemblle the cap (1). WARNING*: (1) on the caliper and turn the other end of the During the bleed operation the fluid level inside hose into a container. the reservoir must never be lower than the minimum level. Tightening torque for bleed valve is 1,2 ÷ 1,6 kgm (12 ÷ 16 Nm; 8.8 ÷ 11.8 ft-lb).

A B 2

EN - 54 EXHAUST MUFFLER - Starting motor 12V-450W (6) behind the cylin- The electric system includes the following elements: der; - Battery 12V-14Ah (9) under the saddle; The muffler reduces the noise of the exhaust gases, - Electric start remote control switch (7) on the - Intermittent flasher device (10) located on the but it is an integral part of the exhaust as well. As left side of the rear frame. utility plate underneath the saddle; EN such, its conditions affect the motorcycle perfor- - M.A.Q.S. sensor (pressure, throttle control posi- - Relays located on the utility plate underneath mance. tion, air temperature) (8) on the throttle body. the saddle; When the noise on the exhaust is too high, it means - Relay (11): warning horn, turning indicators, stop that the deadening material set on the holed tube lights, low-beam lights, high-beam lights; inside the muffler is deteriorated.

ELECTRICAL COMPONENTS LOCATION 2 4 The ignition system includes the following elements: 11 - Generator (1), in oil bath, on the inner side of L.H. 3 crankcase cover; - Electronic ignition coil (2) under the fuel tank; - Electronic power unit C.D.I. (3) under the fuel 7 tank; - Voltage regulator (4) under the fuel tank; - Spark plug (5) on the R.H. side of cylinder head; 6 10 5

EN - 55 - Relay (12): injector, Lambda sensor, fuel pump, - Headlamp (19) with two filaments bulb of 12V- coil; 35/35W and parking light bulb of 12V-5W; - Solenoid valve relay (13); - LED tail light (20) with 12V-21W stop warning - Two fuses (14) 15A and one (15) 20A, on the right light and 12V-5W position light; side of the rear mudguard; - Turn signals bulb (21) of 12V-10W; - Coolant temperature sensor (17); - Fuel pump (22) inside the fuel tank. - Lambda probe (18);

13 8

12 17 21 21 20 18

14 9 22

21 21 15 19

EN - 56 Y W/Y W/V W/R W/G W/Bk W/B W V Sb R/Bk R Pk O/G O/Bk O Gr/Bk Gr/B Gr G/R G/Gr G/Bk G Br/W Br/R Br/Bk Br Bk B/Bk B CABLE COLOURCODING

Violet Red/Black Orange/Black Green Brown/White Blue Yellow White/Yellow White/Violet White/Red White/Black White/Blue Sky blue Red Pink Orange/Green Orange Grey/Blue Grey Green/Red Green/Grey Green/Black Brown/Black Brown Black Blue/Black White/Green White Grey/Black Brown/Red 21. 20. 19. 18. 17. 16. 15. 14. 13. 12. 11. 10. 9. 8. 7. 6. 5. 4. 3. 2. 1. KEY TOELECTRICDIAGRAM Y/R Y/Sb Y/O Y/G Y/Br Y/Bk

L.H. rear turnindicator R.H. rear turnindicator plug Spark Starting motor Electric startremote contr Battery Tail light Turn indicators flasher L.H. commutator Horn L.H. front turnindicator fanCooling Front headlamp R.H. front turnindicator Instrument Injector Front stopswitch Rear stopswitch Voltage regulator Alternator Electronic power unit

Yellow/Brown Yellow/Red Yellow/Sky blue Yellow/Orange Yellow/Black Yellow/Green ol switch (*): 40. 39. 38. 37. 36. 35. 34. 33. 32. 31. 30. 29. 28. 27. 26. 25. 24. 23. 22.

it stopstheengineincaseofafall M.A.Q.S. (34+24+32) Power unitinterface Power relay Fuses Fall sensor Fuel pump Pressure sensor(40) temperatureCoolant sensor Air temperature sensor(40) LAMBDA probe Direct current relay Relay for electricfan sensor Speed Clutch microswitch Ignition switch R.H. switch throttleSensor position control (40) H.T. coil sensor Gear shiftposition EN -57

EN 13 SM RS 7 30 2828 10 31 26 29 27 35 23 33 39 1

20 8 15 21 9

34 24 32 4 5 14 12 6 25 36 37 38 40 22 2 3 1718 4116

EN - 58 BATTERY - first remove the BLACK or BLUE negative cable, WARNING*: The battery contains sulphuric then the RED positive cable (when reassembling, acid. Avoid contact with skin, eyes or clothing. The sealed battery does not require any mainte- first connect the RED positive cable, then the nance. When electrolyte leaks, or other failure of BLACK or BLUE negative cable); SOLUTIONS: EN the electrical system is detected, apply to the SWM - remove the battery (1) from its housing. CONTACT WITH THE SKIN: Rinse with plenty of Dealer. water. If the vehicle remains unused for long periods, it is Check, using a voltmeter, that battery voltage is not INGESTION: Drink large amounts of water. Im- recommended to disconnect the battery from the less than 12.5 V. mediately call a doctor. Do not induce vomit- electrical system and store it in a dry place. If it is not so, the battery needs to be charged. ing. - After an intensive use of the battery, it is advis- Using a battery charger with a constant voltage, CONTACT WITH THE EYES: Flush with water for able to carry out a standard slow charging cycle first connect the RED positive cable to the battery no less than 15 minutes and get prompt medi- (12V-6Ah battery: 0,6A for 8 hours). positive terminal then the BLACK or BLUE negative cal attention. - Quick charging is advised only in situations of ex- cable to the battery negative terminal. treme necessity since the life of lead elements is WARNING*: If the battery is left unused, it has drastically reduced by such cycle (12V-6Ah battery: The voltage reaches a constant value only after a to be in any case recharged with slow cycle 6A for 0,5 hours). few hours, therefore it is suggested NOT to meas- (12V-6Ah battery: 0,6A for 8 hours) at least ure it immediately after having charged or dis- every 3 weeks. charged the battery. WARNING*: Batteries produce explosive gas, BATTERY CHARGER Always check the battery charge before reinstalling it on the vehicle. ventilate when charging or using indoors. To gain access to the battery (1): When using a battery charger, always connect - first turn counterclockwise fastening rear pin (2) The battery should be kept clean and the terminals the battery before turning on the charger. This then remove the saddle. coated with grease. procedure prevents sparks at the battery ter- - Release the elastic strap holding the battery; minals which could ignite any battery gases.

EN - 59 HEADLAMP BULBS REPLACEMENT - remove the two filaments bulb connector (1) and the boot (2); 3 To gain access to the healamp bulbs, proceede as - remove the screw (3); 4 follows: - release the bulb holding spring (4) and then the - remove the upper fastening screw of the the bulb (5) itself. headlamp carrier to the instrument panuel support (A); Note*: Headlamp bulb (5) is of the halogen type; be - push forward the headlamp carrier (B) and pull careful when replacing it since the glass part shall it towards the high (C) in order to uncouple not be touched with bare hands. from the two lower supports. 5 - remove the headlamp carrier; To replace the position light bulb (6), disconnect the connector (7) and remove it from the internal cap. After replacement, reverse operations for reassembly. 7 6

2 1 C

EN - 60 TAIL LIGHT REPLACING THE NUMBER PLATE BULB The tail light (1) is a LED light; Replace it when it does - loosen screw (1) and remove the number plate not function. bulb (2) from the mudguard; EN - take bulb holder (3) and bulb (4) out of the support; - pull the bulb (4) to detach it from bulb holder. Once the bulb has been replaced, reverse the above procedure to reassemble.

4 1

EN - 61 HEADLIGHT ADJUSTMENT Beam height can be adjusted as follows: When checking the proper aiming of the headlight - Work adjuster screw (1); beam: inflate tyres at the right pressure, have a tighten to lower the beam, person sit astride the motorcycle and set the mo- loosen to raise the beam. torcycle perpendicular to its longitudinal axis at 33 ft from a wall or screen. Then trace a horizontal line at the height of headlight centre and a vertical one, in line with vehicle longitudinal axis. If possible, execute this operation in a shaded place. When the low beam is on, the upper edge between dark and lit zone should be at 9/10th of headlight centre from ground.

9 X 10X 1 10m

EN - 62 EQUIPMENT Pos. No. Part no. DESCRIPTION 1 EN 1 A000P01249 MULTILANGUAGE QUICK MANUAL (1) 2 FA00P01471 R.H. REAR-VIEW MIRROR (1) 2 F000P01471 L.H. REAR-VIEW MIRROR (1)

RS 300 R - RS 500 R 2017 Manuale rapido Quick Reference Manual Guide rapide Kurzanleitung Guía rápida

Cope_retro QUICK 300-500_codA000P01249_ed00_12-2016.indd 1 16/12/16 12:31

EN - 63 APPENDIX To set the motorcycle back ready for use after stor- CLEANING age: LONG PERIOD OF INACTIVITY - Make sure the spark plug is tight. Before washing the motorcycle, it is necessary to - Fill the fuel tank. duly protect the following parts: When the motorcycle is to be stored for a certain - Run the engine to warm the oil up then drain the a) Rear opening of the muffler; period, it should be prepared for storage as follows: oil. b) Air filter intake; - clean the entire motorcycle thoroughly. - Refill with fresh oil. c) Clutch and brake levers, hand grips, handlebar - Drain all fuel from the tank. - Check all the points listed under the inspection commutators; - Fill the tank with fuel added with a stabiliser and Adjustment Section (Appendix A). d) Fork head, wheel bearings; - Lubricate all the points listed under the "Lubrica- e) Rear suspension links. WARNING*: Never release fuel into the environ- tion" Section (Appendix A). ment or let the engine run indoors. DO NOT INSIST WITH HIGH-PRESSURE AIR OR WATER on the ELECTRICAL PARTS and on the - Lubricate the final drive chain and all the cables. 1 INJECTION FUEL FEEDING SYSTEM, especially on - Spray oil on all unpainted metal surfaces to pre- the electronic control unit (1) and the M.A.Q.S. vent rusting. Avoid getting oil on rubber parts or unit (2). brakes. - Set the motorcycle on a support or stand so that After washing: both wheels are raised off the ground (if this can- - Lubricate the points listed in the "Maintenance not be done, put boards under the wheels to keep Chart" (Appendix A). moisture away from the tyres). - Briefly warm up the engine - Tie a plastic bag over the exhaust pipe to prevent - Test the brakes before riding the motorcycle. moisture from entering. - Put a cover over the motorcycle to keep dust and 2 WARNING*: Never wax or lubricate the brake dirt from collecting on it. discs. Loss of braking efficiency and an acci- dent could result. Clean the disc with a solvent such as acetone.

EN - 64 PRE-DELIVERY INSPECTION Brakes /Clutch Throttle body/Carburettor Spark plugs Electric fans Cooling system Coolant Two-stroke mixoillevel Engine oil Description Brakes /Clutch uid PRE -DELIVERYINSPECTION Drive chain Flexible controlsandtransm. Choke control Throttle control Throttle control Brakes /Clutch only forsomemodels only formotorcycleswith2strokeengine Check operation Check andadjust Check /Replace Check operation Check forleakage Check /Restorelevel Check level Check level Check level prto Pre-delivery Operation Check /Adjust Check /Adjust Check operation Check /Adjustplay Check operation Check linesforleakage Description General test General lubrication Hose clamps Screws andnuts Locks Ignition switch Headlight Horn Lights /Visulasignals Instrument panel Electrical equipment Side standswitch Side stand Tyres prto Pre-delivery Operation Check /Tighten Check /Tighten Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check pressure EN -65

EN ALPHABETICAL INDEX CLEANING...... 64 FRONT SUSPENSION...... 7 Page CLUTCH...... 7 FUEL...... 9 A CLUTCH CONTROL...... 16 FUEL TAP...... 9 ADJUSTING THE FRONT FORK...... 36 COLD START...... 10 ADJUSTING THE IDLE...... 26 CONTROLS...... 9 G ADJUSTING THE SHOCK ABSORBER...... 37 CONTROLS LOCATION...... 6 GEAR SHIFT CONTROL...... 16 ADJUSTING THE SHOCK ABSORBER HYDRAULIC HYDRAULIC CLUTCH FLUID LEVEL CHECK...... 33 DAMPING ...... 38 COOLANT LEVEL CHECK...... 23 H ADJUSTING THE SHOCK ABSORBER SPRING COOLANT REPLACEMENT...... 24 HEADLAMP BULBS REPLACEMENT...... 60 PRELOAD...... 37 HEADLIGHT ADJUSTMENT...... 62 ADJUSTMENT OF THE CONTROL LEVER D HYDRAULIC CLUTCH BLEEDING...... 34 AND FRONT BRAKE FLUID LEVEL CHECK ...... 31 DECOMPRESSIONE MANUALE...... 26 ADJUSTMENT OF THE HYDRAULIC DIGITAL INSTRUMENT, WARNING LIGHTS...... 10 I CLUTCH CONTROL LEVER...... 32 DIMENSION, WEIGHT, CAPACITY...... 8 IDENTIFICATION DATA...... 5 AIR FILTER AND CLEANING...... 28 DISC CLEANING...... 49 IGNITION...... 7 AIR FILTER CHECK...... 28 IGNITION SWITCH...... 14 APPENDIX...... 64 E IMPORTANT NOTICES...... 2 ASSEMBLY...... 29 ELECTRICAL COMPONENTS LOCATION...... 55 INSTRUCTIONS FOR RUNNING-IN...... 17 ENGINE...... 7 B ENGINE OIL REPLACEMENT AND BAG L BATTERY...... 59 FILTERS-FILTER CARTRIDGE CLEANING LUBRICATION...... 7 BATTERY CHARGER...... 59 OR REPLACEMENT...... 21 BRAKE DISC WEAR...... 49 EXHAUST MUFFLER...... 55 K BRAKE PADS REMOVAL...... 47 KEY TO ELECTRIC DIAGRAM ...... 57 BRAKES...... 46 F FAST ADJUSTMENT...... 39 L C FLUID CHANGE...... 50 L.H. HANDLEBAR SWITCH ...... 15 CABLE COLOUR CODING...... 57 FORK OIL LEVEL...... 36 LOCK ADJUSTMENT...... 30 CHAIN ADJUSTMENT...... 39 FRAME...... 7 LONG PERIOD OF INACTIVITY ...... 64 CHECKING THE OIL LEVEL...... 21 FRONT BRAKE...... 7 LUBRICATING THE CHAIN...... 41 CHECKING THE WEAR OF CHAIN, PINION FRONT BRAKE CONTROL...... 14 AND SPROCKET...... 40 FRONT BRAKING SYSTEM BLEEDING...... 52 EN - 66 REASSEMBLING THEFRONTWHEEL REAR BRAKINGSYSTEMBLEEDING REAR BRAKEPEDALPOSITIONADJUSTMENT REAR BRAKECONTROL PRE-DELIVERY INSPECTION PADS CLEANING P R.H. HANDLEBARSWITCH REMOVING THEREARWHEEL REPLACING THENUMBERPLATEBULB REAR BRAKEPEDALFREEPLAYADJUSTMENT CLEANING THEMETALFILTERS PRIMARY DRIVE PRECAUTIONS FORCHILDREN RIMS RIDING REMOVING THEFRONTWHEEL REGOLAZIONE TENSIONECAVO REAR SUSPENSION REAR BRAKEFLUIDLEVELCHECK REAR BRAKE R PRESENTATION PRE-RIDE CHECKS PADS WEAR PADS INSTALLATION OIL QUANTITYIN EACHFORKLEG O ...... 48 48 30 30 65 26 36 44 45 54 47 43 22 32 61 16 15 17 17 8 7 7 7 2 3 TROUBLESHOOTING TIRES THROTTLE CABLEADJUSTMENT VOLTAGE REGULATOR TECHNICAL DATA TAIL LIGHT T SUSPENSIONS STOPPING THEMOTORINANEMERGENCY STOPPING THEMOTORCYCLEANDENGINE REPLACING THEFILTERCARTRIDGE SIDE STAND TIMING SYSTEM THROTTLE CONTROL STEERING WHEELBALLPLAYADJUSTMENT STEERING LOCK VEHICLE IDENTIFICATIONNUMBER(V.I.N.) V TRANSMISSION STARTING THEENGINE TYRES SPARK PLUGCHECK SECONDARY DRIVE S ...... 20 20 28 29 45 25 35 27 22 18 61 14 15 17 8 9 5 7 7 7 7 EN -67

APPENDIX A A -1

A SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) S RS 300R - RS 500R

EVERY EVERY EVERY EVERY EVERY AFTER FIRST 3 HOURS - REPLACE IF 4h MX / 8h MX / 16h MX / 32h MX / 40h MX / NECESSARY - 8h EN 16h EN 32h EN 64h EN 80h EN

OR EVERY OR EVERY OR EVERY OR EVERY OR EVERY 500 KM 2000 KM - 4000 KM 8000 KM 10000 KM

VALVES CLEARANCE CLEARANCE S (#)

VALVE SPRING C X VALVE CUP, VALVE HALF CONE C X

ROCKER ARM (INTAKE-EXHAUST) C X

CAMSHAFT C TIMING CHAIN C S TIMING CHAIN SLIDER S

A - 2 STARTER DECOMPRESSORSYSTEM TIMING CHAINTENSIONER VALVETIMINGGEAR VALVE TIMINGDRIVENGEAR CONNECTING RODASSY. PISTON ASSY CYLINDER ASSY. INTAKE MANIFOLD RS 300R-500R AFTER FIRS OR E 3 HOURS 500 KM VERY T

SCHEDULED MAINTENANCECHART(TOBECARRIEDOUTATTHESWMDEALER) 4h MX/ E 8h EN VERY OR E 2000 KM 8h MX/ 16h EN E VERY C VERY OR E 4000 KM 16h MX/ 32h EN E VERY VERY OR E 32h MX/ 8000 KM 64h EN E VERY C C C S VERY 10000 KM OR EVERY 40h MX/ 80h EN E VERY S S C C C NECESSARY - - REPLACE IF X X X X A -3

A SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) RS 300R - RS 500R

EVERY EVERY EVERY EVERY EVERY AFTER FIRST 3 HOURS - REPLACE IF 4h MX / 8h MX / 16h MX / 32h MX / 40h MX / NECESSARY - 8h EN 16h EN 32h EN 64h EN 80h EN

OR EVERY OR EVERY OR EVERY OR EVERY OR EVERY 500 KM 2000 KM 4000 KM 8000 KM 10000 KM

CRANKCASE BEARINGS S ENGINE OIL S S OIL PUMP C OIL FILTER CARTRIDGE / NET OIL FILTER S, P S, P

OIL PUMP / CRANKCASE HOSE C

SET OF MATCHED PRIMARY C

CLUTCH HUB C X CLUTCH DISCS C S X

A - 4 GEAR CONTROLPEDAL CLUTCH DISENGAGEMENTROD CLUTCH DISCSPRESSUREPLATE STARTING PEDAL STARTING GEARS DRIVE SPROCKET CLUTCH DISCSHOUSING MOCLUTCH SPRING RS 300R-500R AFTER FIRS OR E 3 HOURS 500 KM VERY T

SCHEDULED MAINTENANCECHART(TOBECARRIEDOUTATTHESWMDEALER) 4h MX/ E 8h EN VERY C OR E 2000 KM 8h MX/ 16h EN E VERY S C VERY OR E 4000 KM 16h MX/ 32h EN E VERY L VERY OR E 32h MX/ 8000 KM 64h EN E VERY C C C C C VERY 10000 KM OR EVERY 40h MX/ 80h EN E VERY NECESSARY - - REPLACE IF X X X A -5

A SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) RS 300R - RS 500R

EVERY EVERY EVERY EVERY EVERY AFTER FIRST 3 HOURS REPLACE IF 4h MX / 8h MX / 16h MX / 32h MX / 40h MX / NECESSARY 8h EN 16h EN 32h EN 64h EN 80h EN

OR EVERY OR EVERY OR EVERY OR EVERY OR EVERY 500 KM 2000 KM 4000 KM 8000 KM 10000 KM

PARK PLUG P S SPARK PLUG CAP C CARBURETOR P R CARBURETOR THROTTLE VALVE C

AIR FILTER P, L RADIATORS C COOLANT HOSES AND CLAMPS C

RADIATORS HOSE / WATER PUMP C

A - 6 STEERING CHAIN GUIDEROLLER,BEARINGS SADDLE FRAMEFASTENINGBOLTS, ENGINEFASTENINGBOLTS FOOTRESTS, FOOTRESTSPINSANDSPRINGS SIDE STAND COOLANT HEAD, STEERINGCROWNWITHPIN RS 300R-500R AFTER FIRS OR E 3 HOURS 500 KM C VERY T

SCHEDULED MAINTENANCECHART(TOBECARRIEDOUTATTHESWMDEALER) 4h MX/ E 8h EN VERY C C C OR E 2000 KM 8h MX/ 16h EN E VERY C L VERY OR E 4000 KM 16h MX/ 32h EN E VERY C VERY OR E 32h MX/ 8000 KM 64h EN E VERY VERY 10000 KM OR EVERY 40h MX/ 80h EN E VERY NECESSARY REPLACE IF X X A -7

A SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) RS 300R - RS 500R

EVERY EVERY EVERY EVERY EVERY AFTER FIRST 3 HOURS REPLACE IF 4h MX / 8h MX / 16h MX / 32h MX / 40h MX / NECESSARY 8h EN 16h EN 32h EN 64h EN 80h EN

OR EVERY OR EVERY OR EVERY OR EVERY OR EVERY 500 KM 2000 KM 4000 KM 8000 KM 10000 KM

FRONT FORK R HANDLEBAR HOLDERS AND FASTENING SET C C

REAR SWING ARM BUSHING C

REAR CHAIN SLIDER C X REAR SUSPENSION LINKS BUSHINGS C

REAR CHAIN GUIDE / REAR CHIAN GUARD C X

REAR SWING ARM PIVOT NEEDLE BEARINGS L

A - 8 FRONT BRAKESYSTEM FLUID THROTTLE CLUTCH CONTROLASSY FRONT BRAKEDISC REAR SHOCKABSORBER THROTTLE CONTROL ASSY REAR SUSPENSIONLINKSNEEDLEBEARINGSANDGUDGEONPIN AND STARTING DECOMPRESSOR CABLES RS 300R-500R AFTER FIRS OR E 3 HOURS 500 KM VERY T

SCHEDULED MAINTENANCECHART(TOBECARRIEDOUTATTHESWMDEALER) 4h MX/ E 8h EN VERY C (•) C, L C C L OR E 2000 KM 8h MX/ 16h EN E VERY C VERY OR E 4000 KM 16h MX/ 32h EN E VERY L VERY OR E 32h MX/ 8000 KM 64h EN E VERY VERY 10000 KM OR EVERY 40h MX/ 80h EN E R (#) VERY R S NECESSARY REPLACE IF X X A -9

A SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE SWM DEALER) RS 300R - RS 500R

EVERY EVERY EVERY EVERY EVERY AFTER FIRST 3 HOURS REPLACE IF 4h MX / 8h MX / 16h MX / 32h MX / 40h MX / NECESSARY 8h EN 16h EN 32h EN 64h EN 80h EN

OR EVERY OR EVERY OR EVERY OR EVERY OR EVERY 500 KM 2000 KM 4000 KM 8000 KM 10000 KM

REAR BRAKE DISC C X REAR BRAKE SYSTEM FLUID C S

BRAKE PADS C X BRAKE SYSTEM PUMP / CALIPER HOSES C

FUEL HOSES C S X EXHAUST SILENCER PACKING S X

EXHAUST PIPE AND SILNECER C X

WHEEL SPOKES TENSION C C A - 10 WHEEL HuB BEARINGS REAR DRIVENSPROCKET CHAIN REAR DRIVENSPROCKETSCREWSTIGHTENING SERBOL TS AND NUTS RS 300R-500R TIGHTNESS GENERAL CHECK AFTER FIRS OR E 3 HOURS 500 KM C,L C C VERY T

SCHEDULED MAINTENANCECHART(TOBECARRIEDOUTATTHESWMDEALER) 4h MX/ E 8h EN VERY OR E 2000 KM 8h MX/ 16h EN E VERY C S S VERY OR E 4000 KM 16h MX/ 32h EN E VERY C VERY OR E 32h MX/ 8000 KM 64h EN E VERY S VERY 10000 KM OR EVERY 40h MX/ 80h EN E VERY NECESSARY REPLACE IF X X X A -11

A KEY FOR MAINTENANCE SCHEDULE: h: HOURS S: REPLACEMENT C: CHECK P: CLEAN R: OVERHAUL L: IGREASING / LUBRICATION MX: MOTOCROSS EN: ENDURO #: REFER TO MANUAL WORKSHOP NOTE: EVERY REMOVAL REPLACE ALL GASKETS REPLACE SCREWS AND NUTS IF WORN GENERAL CHECK AFTER RACING USE AND MUDDY OR SANDY GROUNDS

A - 12 SWM Motorcycles USA (605) 878-1005, www.swm-usa.com