DB Motor ZZ- Super Sport- Pirat User manual

OWNERS MANUAL
ZZ-SUPER SPORT-PIRAT
1
GENERAL INFORMATION
We urge you to read this user manual
completely and carefully before the child
uses the minicross for the first time.
The manual contains tips and information
that will allow you and your child to make
the most of the minibikes
DANGER
Failure to observe the information marked by the symbol may cause serious injury
CAUTION
Failure to observe the information marked by the symbol may damage the vehicle
and reduce its safety considerably.
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OWNERS MANUAL
ZZ-SUPER SPORT-PIRAT
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Dear customer, dear friend
You are now the proud owner of a modern vehicle that will offer loads of fun for you and your child, if
you take the necessary care and attention. This booklet contains the information necessary for using and
servicing your new minicross bikes, which has been built according to the latest technical developments.
However, it is possible that certain additional improvements have been made to the bike since the booklet
was published.
Please read and understand this book before operating your new machine, and keep for future reference.
If you don’t understand any part of this booklet please contact your supplying dealer direct before
continuing.
Perhaps you are a biker enthusiast with sound technical knowledge and therefore, with the aid of this
booklet, will be able to carry out much of the necessary maintenance yourself. If not, we recommend that
you have a trusted mechanic do so, for your own and your child's safety.
It is strictly necessary to observe the provisions for breaking in, and the overhaul and maintenance
schedule. This will contribute significantly to extending the life-span of your minicross.
As a parent, you must do everything possible to ensure your child's safety, which mainly depends on the
safety of the environment in which the minibike is driven and the condition of the minibike itself.
Obviously, as for all vehicles, this minicross also involves a certain percentage of risk. This is why we
recommend that you adopt every possible precaution, and take into account the "Safety warnings for
parents".
Motocross is a fantastic sport, and our aim is for you and your child to have as much fun as possible.
However, one must take into account possible problems with the environment and with other people. A
certain sense of responsibility is enough to reduce these problems even before they occur. In order for this
type of sport to have a future, please observe the law, ensure that you and your child respect the
environment and the rights of others.
It is in this spirit that we say to you and your child: Have a great time!
THE MANUFACTURER RESERVES THE RIGHT TO MAKE ENGINEERING AND DESIGN
CHANGES AT ANY TIME.

OWNERS MANUAL
ZZ-SUPER SPORT-PIRAT
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IMPORTANT SAFETY WARNINGS FOR PARENTS
DB MOTOR minicross bikes have been designed to be driven by a single person and for offroad use only.
These bikes are not authorized for use on public roads.
-The child must have the necessary equipment before driving the bikes. This equipment consists of a
helmet, goggles, chest, arm and leg pads, gloves and boots. It is best to set a good example for your
child, and thus the adult should also use the necessary protective gear when using the bike.
-Adjust the brake levers so that the child can grasp them easily while wearing gloves.
-Before starting the minicross, explain the functions of all controls to your child, and make sure that he
or she has fully understood. The best idea is to read this entire user manual together, point by point.
Draw the child's attention to specific safety recommendations, and make sure he or she is warned
about potential hazards.
-Illustrate driving techniques and how to behave in a fall; you must also explain how the bike reacts
when the driver's weight shifts, etc.
-Before each use, always check that all parts are working properly (see maintenance table) and teach
the child to carry out this type of check.
-When riding together, adapt your driving speed to that of the child. We do not recommended that
adults or children over the recommended age or size ride the bike at all, this often leads to damaged or
broken suspensions that we would not cover by the warranty.
-The child must understand the need to follow the instructions and advice of a responsible adult.
-The child must be physically able to drive the minibike. He or she must at least be able to ride a
bicycle. In this regard, it is certainly an advantage to practice sports that require quick reaction times.
The child must be strong enough to lift the bike if it falls.
-Never demand too much from your child. He or she must have time to become familiar with the
minicross and improve his or her driving ability. Only when the child's physical condition, technique
and motivation are sufficiently developed should one begin to consider taking part in organized races.
-Explain to the child that the speed must be adapted to environmental conditions and one's own ability,
to avoid the risk of falling and serious injury. Children often minimize dangers, and at times ignore
them entirely. Speed must especially be kept down when riding on unfamiliar terrain.
-Never let the child drive without adult supervision.
-The bike is not designed for use by two people. You may therefore not carry passengers.
-When setting off for a ride together with your child, always state the destination and approximate
duration of the ride. This way, if trouble occurs, it will be possible to get help more quickly and
easily.

OWNERS MANUAL
ZZ-SUPER SPORT-PIRAT
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USER INSTRUCTIONS
Checks before each minibike use
Use the bike only if it is in perfect mechanical condition. For safety purposes, we recommend that you get
into the habit of carrying out the following checks before each use.
CHECKING THE OIL LEVEL
Low oil will lead to premature wear and damage to the gears.
FUEL
Check the level in the tank.
CHAIN
A loose chain can come off, a worn chain may break, and an unlubricated chain will wear out, and wear
the sprocket unevenly.
TIRES
Check the condition of the tires. If you find cuts or swollen areas, replace. Check the pressure. Excessive
wear or incorrect pressure will negatively affect the bike's ability to hold the road.
BRAKES
Make sure they are properly adjusted and in good working order
TROTTLE CABLE
Check the setting, and make sure it moves smoothly
CCAUTIONUTION
-The child must have the necessary equipment before driving the minicross bike.
This equipment consists of a helmet, goggles, chest, arm and leg pads, gloves and boots. It is best to
set a good example for your child, and thus the adult should also use the necessary protective gear
when using the bike. Use only original DBMOTORS accessories
Notes on starting the minicross bike
-Adjust the basic position of the brake lever according to the size of the child, who obviously must
wear gloves.
-Perform the first tests in a yard or field, so that the child will not get hurt in a fall. There obviously
must be enough room to perform a few maneuvers. Take every possible precaution to prevent the
child from hitting anyone.
-To teach the child to brake, the first trials should be done while pushing the motorcycle. Only after the
child has learned to gauge both brakes should you start the engine.
-The next step is gauging the throttle. To teach the child to adjust the throttle, start the engine but hold
the motorcycle while the child carefully accelerates. Only after completing these exercises should you
take your first road excursions. The child must travel towards a second person who will assist in
stopping. You must explain to the child how to stop on his or her own.
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ZZ-SUPER SPORT-PIRAT
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-To improve technique, the child should try to ride while standing and as slowly as possible. You may
set up some obstacles to avoid, etc.. The child must look 3/10 meters ahead of the bike, according to
speed, to avoid any obstacles in time. Even in a curve, the rider's gaze must anticipate the turn well in
advance.
-Observe the breaking in recommendations.
CAUTION
-DB motor models have been designed for use by a single person. It is therefore not allowed to carry
passengers.
-These models do not meet legal requirements and safety standards. It is against the law to drive them
on public roads.
-You must be aware that excessive noise can disturb other people.
Breaking in
-Although the parts are precision-machined; it is still essential to break in the engine. For the first 5
running hours, do not push the machine to the limit.
-You must break the bike in at moderate speed, but changing speed often.
-For the first 5 running hours, never drive at maximum speed.
Starting with the engine cold
1Open the fuel tap
2Engage the choke
3Raise the side stand entirely
4Apply both brakes
5Do not open the throttle and swiftly push the kick-starter all the way down.
CAUTION
-To avoid injury, always wear boots before starting the engine.
-Always apply both brakes when starting the engine, and release them gently once the engine is
running. When the throttle is opened, the engine speed increases and the centrifugal clutch begins to
engage. The vehicle may therefore begin to move when the brakes are released.
-The vehicle is equipped with a centrifugal clutch, and thus begins to move as soon as you accelerate.
-Do not start the engine or leave it running in an enclosed area. Exhaust fumes are harmful, and may
lead to unconsciousness and even death. Always provide suitable ventilation.
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ZZ-SUPER SPORT-PIRAT
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Starting with the engine warm
1Open the fuel tap
2Raise the side stand entirely
3Apply both brakes
4Do not open the throttle and swiftly push the kick-starter all the way down.
What to do when the engine is flooded
1Close the fuel tap
2Remove the spark plug; dry if necessary
3Raise the side stand entirely
4Open the throttle all the way.
5Swiftly push the kick-starter all the way down.
6When the engine starts, close the throttle and open the fuel tap.
Restarting
Gently release the brakes while opening the throttle.
CAUTION
Before setting off, always make sure the side stand has been fully raised. If the side stand touches the
ground, you could lose control vehicle.
Driving
The engine, and thus the speed, is controlled by opening the throttle.
CAUTION
-The child must always adapt the speed to his or her own skill level and the type of terrain.
-Never let the child drive without adult supervision
-When the engine speed is so low that the centrifugal clutch slips, there is no engine braking. In these
conditions, speed may be reduced only by the brakes.
-Replace the helmet visor or goggle shield as soon as it becomes necessary. A scratched visor or shield
may lead to dazzling by headlights or the sun.
-After a fall, inspect the motorcycle completely before reuse.
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DANGER
-High speed with a cold engine negatively affects the life-span of the bike. The best solution is to let it
warm up for a few minutes at average speed. Do not accelerate fully until it is warmed up.
-If unusual noises occur while riding, stop immediately, shut off the engine, and contact qualified
mechanic.
Braking
Close the throttle and brake simultaneously with both brakes. On sand, wet or slippery terrain, you should
emphasize the rear brake. Always brake gently. Locked wheels reduce stability and may cause you to fall.
CAUTION
Avoid dragging and overheating the brakes as this reduces their effect.
Stopping
Reduce speed and, just before you have come to a complete stop, place your left foot down as a support.
Push the stop button until the engine has stopped completely. Close the fuel tap.
CAUTION
-Do not leave the bike with the engine running.
-The engine produces a great deal of heat while running. The engine, exhaust and brakes may therefore
be very hot. Be careful to avoid touching these parts, and park the bike so that no one can get burned.
DANGER
-
-
-When shutting off the engine, close the fuel tap, otherwise the carburetor could overflow and let fuel
into the engine.
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OWNERS MANUAL
ZZ-SUPER SPORT-PIRAT
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SERIAL NUMBERS
FRAME NUMBER
The frame number is engraved on the steering
head.
ENGINE NUMBER
The number shown in the photo is the engine
identification number

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ZZ-SUPER SPORT-PIRAT
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OPERATING INSTRUCTIONS
ACCELERATOR
The throttle is located on the right-hand side of the
handlebars, and serves to increase or decrease the
engine speed (and thus driving speed).
Speed increases when it is turned in the direction of arrow
A, and decreases in the opposite direction (as in arrow B).
FRONT BRAKE LEVER (B)
Used to apply the front brake via a cable (drum brake)
or hydraulic control (disc brake)
REAR BRAKE LEVER (A)
Used to apply the rear brake via a cable (drum brake)
or hydraulic control (disc brake)
KILL SWITCH (C)
Stops the engine when pressed.

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ZZ-SUPER SPORT-PIRAT
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TANK CAP
To open the cap, turn it counter-clockwise (A).
To close it, turn clockwise (B).
Fuel
We strongly recommend the use of unleaded (95) petrol mixed with a 2% fully synthetic 2 stroke oil.
Lower quality oils (e.g. semi-synthetic) require between 2 & 4% mix as recommended on the container.
During the run in period you must use a 3% mix of fully synthetic. Thoroughly mix the oil/petrol in a
can before filling the tank on the bike.
DANGER
Petrol is highly flammable and harmful: be extremely cautious when handling it. We recommend the
greatest possible caution. Do not fill the tank near an open flame or lit cigarette. Always remember to
shut off the engine before filling the tank. Be careful not to spill fuel on the exhaust box or engine while
warm.
If swallowed or in contact with the eyes, contact a physician immediately.
CAUTION
A lack of oil prematurely wears the engine.
An excess of oil increases the exhaust fume and leads to build-up on the thermal unit.

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ZZ-SUPER SPORT-PIRAT
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Fuel increases in volume as temperature
increases: never fill the tank to the top.
FUEL TAP
Located under the left side of the tank.
The figure shows the fuel tap open. To close
it, place the valve horizontally to the”off”
position.
CAUTION
Once the engine has stopped, you must close the fuel tap to avoid flooding the engine.
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ZZ-SUPER SPORT-PIRAT
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CHOKE (FOR DELL’ORTO
CARBURETOR 14/12)
The choke lever is on the right side
of the carburetor (A).
By pressing the lever downward
and holding (B), the air/fuel
mixture becomes richer (with fuel).
This is needed when starting a cold
engine.
When the throttle control is turned
all the way, the lever automatically
returns to its starting position (A)
and the choke is deactivated.
CHOKE (FOR DELL’ORTO
CARBURETOR 15/21/24)
The choke knob is on the left side
of the carburetor.
To apply the choke, raise the knob
(A) and turn it until it remains
raised.
In these conditions the air/fuel
mixture becomes richer (with fuel).
This is needed when starting a cold
engine.
To deactivate the choke, perform
the above in reverse.

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ZZ-SUPER SPORT-PIRAT
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KICK STARTER
The kick starter (A) is on the right side of the
engine: the top (B) folds out.
Starting takes place rapidly moving the kick
starter all the way down and forward in the
direction of the arrow (C)
CAUTION
Never use high-pressure means to clean the bike: water could penetrate the bearings, carburetor, electrical
system, etc.
Before beginning each maintenance operation, let the motorcycle cool to avoid being burned.
Oil, filters, grease, fuel, cleansers, etc. must be disposed off properly. Observe current legislation.
Do not dump used oil into the environment: one liter of used oil contaminates 1,000,000 liters of water.
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ZZ-SUPER SPORT-PIRAT
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CHECK THE CHAIN TENSION
Check the chain tension approximately
in the middle between the two
sprockets.
In this area the chain must move up and
down within a range of 10 mm. (as in
the figure).
D
DANGER
If the chain is too tight, the secondary transmission parts (such as the chain, sprockets, etc.) are subject to
additional stress that may lead to premature wear and/or breakage of the chain.
If the chain is too loose, it may slip out of its housing and jam the rear wheel or damage the engine.
In either case, the driver may lose control of the bike.

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ZZ-SUPER SPORT-PIRAT
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ADJUSTING THE CHAIN TENSION
(model ZZ)
Loosen the nuts of the rear wheel axle (A) and
tighten/loosen the 2-chain adjuster (B)
equally.
Before tightening the wheel nuts (30 Nm),
make sure the wheel is aligned with the
swing-arm.

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ZZ-SUPER SPORT-PIRAT
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ADJUSTING THE CHAIN TENSION
(SUPER-SPORT and PIRAT models)
Loosen the nuts of the rear wheel axle (A) and
tighten/loosen the 2-chain adjuster bolts (B)
equally (after first loosening the lock nuts).
Before tightening the wheel nuts (30 Nm), make
sure the wheel is aligned with the swing-arm
and that the bushings (C) are against the chain
adjuster bolts.
DANGER
When lubricating, take care not to get oil on the tires; this could seriously reduce their adherence, and
lead to losing control of the motorcycle. CAUTION
For a long chain life-span, we recommend frequent cleaning with petroleum and lubrication with specific
oils and greases.
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The closed part of the masterling clip mist
follow the direction of rotation.
You must check the condition of the sprocket
and chain-guide; replace when necessary.
ADJUSTING THE FRONT DRUM
BRAKE CABLE
The front brake lever must have free
play of 10-15 mm.
You may adjust the cable using the
adjuster (A) on the brake lever or the
adjuster (B) on the wheel.
In either case you must:
loosen the lock-nut;
adjust the tension of the brake cable;
tighten the lock-nut..
CAUTION
After adjusting the cable, always make sure the wheel turns freely.
CHECKING FOR WEAR ON THE
FRONT BRAKE SHOES
The shoes must be replaced when the
distance between the brake lever and cable
support is less than 50 mm, with the brake
engaged.
CAUTION
If the brake shoes are replaced too late, they may cause metal to rub against metal, thus reducing the
braking effect and ruining the drum.
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CLEANING
CLEAN YOUR MOTORCYCLE REGULARLY TO PROTECT SURFACE FINISHES & INSPECT FOR DAMAGE,
WEAR & OIL, COOLANT OR BRAKE FLUID LEAKAGE. WE RECOMMEND THE USE OF HOT WATER,
SPONGE & SUITABLE AUTO TYPE CLEANING PRODUCTS. THE USE OF AUTO POLISH'S & SURFACE
PROTECTION PRODUCTS WILL ENHANCE & MAINTAIN THE APPEARANCE OF THE BIKE & PREVENT
CORROSION AFTER USE & CLEANINGCAUTION
THE USE OF HIGH PRESSURE WATER (OR AIR) CAN CAUSE DAMAGE,
ACCELERATE WEAR AND CAUSE ENGINE MISFIRES
**DO NOT** SPRAY HIGH PRESSURE WATER (TYPICALLY IN COIN
OPERATED OR HOME PRESSURE WASHERS) ON ANY OF THE
FOLLOWING COMPONENTS
AIR BOX
CARBURETTOR
ENGINE & ENGINE ELECTRIC'S
WHEEL SPINDLES & BEARINGS
ALL BRAKE COMPONENTS
FRONT SUSPENSION SEALS
MUFFLER OUTLET
UNDER SEAT
PANEL DECALS (STICKERS) DANGER
Braking efficiency may be temporarily impaired immediately after washing the
motorcycle. Anticipate longer stopping distance to avoid a possible accident
Avoid applying surface protection products to brake components,brake pads may be
permanently contaminated.
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ZZ-SUPER SPORT-PIRAT
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ADJUSTING THE REAR
DRUM BRAKE CABLE
The rear brake lever must have a free play of
10-15 mm.
You may adjust the cable using the adjuster (A)
on the brake lever or the adjuster (B) on the
drum.
In either case you must:
-loosen the lock-nut;
-adjust the tension of the brake cable;
-tighten the lock-nut
CAUTION
After adjusting the cable, always make sure the wheel turns freely.
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CHECKING FOR WEAR ON THE REAR
BRAKE SHOES
The shoes must be replaced when the distance
between the brake lever and cable support is
less than 50 mm, with the brake engaged.
CHECKING FOR WEAR ON THE
PADS
(models with front and/or rear disk brake)
The pads must be replaced when their thickness
is reduced to less than 3.5 mm.
CAUTION
If the brake shoes are replaced too late, they may cause metal to rub against metal, thus reducing the
braking effect and ruining the drum.
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