Italjet Dragster 2022 User manual

Introduction
Thank you
for choosing our product. We have compiled this manual to give you a comprehensive overview of the quality of this motorcycle. Please read it carefully before riding it for the first
time. It contains information about the usage of the motorcycle, key points and precautions. It also specifies the features, details and equipment of the motorcycle to ensure that you can
operate it properly. We believe that you can get to know your new motorcycle quickly and get a completely satisfying ride if you follow our advice.
The purpose of the instructions in this manual is to provide clear and concise guidance for your use of the motorcycle. Moreover, this manual describes the general maintenance
procedures and regular inspection to be carried out at the officially designated dealer or repair shop. This manual also contains instructions for easy repair. Any operations not explicitly
described in this manual require special tools and/or specific expertise: Please take your motorcycle to the officially designated dealer or repair shop for these operations.
Personal safety
Failure to fully comply with these instructions can result in a serious risk of personal injury
Environmental protection
The symbol indicates proper use of the motorcycle to prevent damage to the environment.
Good condition
Incomplete compliance with or complete failure to comply with these regulations will lead to risks of serious damage to the motorcycle and, in some cases, loss of the
right to warranty.
The symbols shown above are very important. They are used to highlight the parts of the manual that should be read with special attention. Different symbols have been used in this
manual to make the headings in the manual concise and convenient for quick search. Please read this manual carefully before starting the engine, especially the "Safe driving" section.
The safety of yourself and others depends not only on your quick reaction and agility, but also on your understanding of the motorcycle, the maintenance of the motorcycle itself and
your mastery of safe driving rules. For your safety, please get to know your vehicle well enough to be able to drive safely and manipulate it freely under any driving condition.
Important As an integral part of the motorcycle, this manual should be handed over to the new owner when the motorcycle is resold.
The 1st edition, February 2022
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Contents
Overview............................................................................................................................................. 5
Warning/Attention/Remark.........................................................................................................6
User Notice..................................................................................................................................6
Important Notes...........................................................................................................................7
Location of Batch Number..........................................................................................................8
Instructions for the Use of Fuel Oil and Engine Oil...................................................................8
Brake Fluid..................................................................................................................................9
Running-in...................................................................................................................................9
Operation suggestions for the running-in period................................................................9
Engine speed change...........................................................................................................9
Running-in of new tyres......................................................................................................9
Avoid driving at a constant low speed............................................................................... 10
Let the oil warm up before driving.................................................................................... 10
Carry out the initial important maintenance...................................................................... 10
Maintenance and Service.................................................................................................................. 11
Maintenance and Regular Inspection........................................................................................12
Oil Level Check........................................................................................................................ 16
Replacement of Engine Oil and Oil Filter................................................................................ 16
Check Coolant Level.................................................................................................................18
Clean the Air Filter Element..................................................................................................... 19
Clean the Transmission Air Filter............................................................................................. 20
Spark Plug Check......................................................................................................................21
Check Tyres and Relative Tyre Pressure...................................................................................21
Check the Wear of Brake Pads..................................................................................................23
Check the Front and Rear Brake Fluid Level........................................................................... 25
Replace the Brake Fluid............................................................................................................26
Check the CVT Belt.................................................................................................................. 26
Regularly Check and Lubricate the Central kickstand or Side Kickstand (Optional)............. 27
Pretension Force Adjustment of Shock Absorber Springs........................................................27
Check the Front Steering System Periodically......................................................................... 28
Check and Charge the Battery.................................................................................................. 28
Check/Replace Fuses................................................................................................................ 30
Steering Column........................................................................................................................33
Front Shock Absorber............................................................................................................... 33
Rear Suspension........................................................................................................................ 33
Exhaust Pipe Bolts and Muffler Bolts...................................................................................... 33
Body Bolts and Nuts................................................................................................................. 33
Motorcycle Maintenance...................................................................................................................34
Motorcycle Parts....................................................................................................................... 35
Controls and Instruments.......................................................................................................... 38
Instruments................................................................................................................................39
Indicator lamps and alarm lamps...................................................................................... 39
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Digital Instruments............................................................................................................41
Adjust and Display Settings......................................................................................................42
Control.......................................................................................................................................43
Ignition switch...................................................................................................................43
“Lock”the steering lock.................................................................................................... 44
Left Handle Switch Assembly.................................................................................................. 45
Right Handle Switch Assembly................................................................................................ 46
Emergency flameout switch..............................................................................................46
Engine start button............................................................................................................ 46
Accelerator control....................................................................................................................46
Front brake control....................................................................................................................47
Rear brake control.....................................................................................................................47
Exhaust system..................................................................................................................48
Accessory parts and USB socket.............................................................................................. 48
Use the USB socket...........................................................................................................48
Storage compartment under the seat cushion................................................................... 49
Side kickstand (optional).................................................................................................. 50
Central kickstand...............................................................................................................51
Check before use.......................................................................................................................52
Instructions on the Use of Motorcycles.................................................................................... 54
Running-in instructions.....................................................................................................54
Identification of operational problems..............................................................................54
Oxygen Sensor.......................................................................................................................... 55
Catalytic Converter................................................................................................................... 56
Canister Purge Solenoid............................................................................................................57
On-board Diagnostics................................................................................................................58
Electronic Control Unit (ECU)................................................................................................. 59
Brake System.............................................................................................................................60
Rear Brake Disc................................................................................................................ 61
Front Brake Disc............................................................................................................... 63
Cooling System......................................................................................................................... 75
Replacement of Cooling Liquid........................................................................................76
Suspension.................................................................................................................................79
Rear suspension inspection...............................................................................................88
Muffler hanger bracket......................................................................................................89
Central Kickstand..............................................................................................................91
Electronic System......................................................................................................................93
Electrical Diagram.......................................................................................................... 102
Summary Table of Torque (unit N*m)....................................................................................103
Engine Maintenance........................................................................................................................105
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目录
Automatic transmission............................................................. 106
Transmission cover.................................................................106
Air duct................................................................................... 106
Air duct filter.......................................................................... 107
Removing the driven pulley shaft bearing..............................107
Refitting the driven pulley shaft bearing................................108
Removing the driven pulley ...................................................108
Inspecting the clutch drum................................................... 109
Inspecting the clutch.............................................................110
Removing the clutch............................................................. 110
Removing the driven half-pulley bearing.............................. 111
Inspecting the driven fixed half-pulley..................................112
Inspecting the driven sliding half-pulley............................... 112
Refitting the driven half-pulley bearing................................ 112
Refitting the driven pulley.....................................................113
Inspecting the clutch spring.................................................. 114
Refitting the clutch................................................................114
Refitting the driven pulley.....................................................115
Drive-belt.............................................................................. 115
Removing the driving pulley..................................................116
Inspecting the rollers case.....................................................118
Refitting the driving pulley....................................................119
Refitting the transmission cover........................................... 120
Removing the hub cover....................................................... 121
Removing the wheel axle...................................................... 122
Removing the hub bearings ...................................................123
Removing the wheel axle bearings.........................................123
Removing the driven pulley shaft bearing..............................123
Inspecting the hub shaft........................................................124
Inspecting the hub cover.......................................................124
Refitting the driven pulley shaft bearing...............................124
Refitting the wheel axle bearing........................................... 125
Refitting the hub cover bearings...........................................125
Refitting the hub bearings.....................................................126
Refitting the ub cover............................................................127
Flywheel cover............................................................................127
Removing the hub cover....................................................... 127
Removing the stator..............................................................128
Refitting the stator................................................................129
Refitting the flywheel cover.................................................. 129
Removing the starter motor................................................. 130
Removing the flywheel magneto.......................................... 131
Intermediate gear................................................................. 132
Refitting the free wheel........................................................ 133
Refitting the flywheel magneto ............................................134
Refitting the starter motor....................................................134
Cylinder assy. and timing system............................................... 134
Removing the rocker-arms cover..........................................134
Removing the timing system drive........................................135
Removing the cam shaft........................................................136
Removing the cylinder head..................................................137
Removing the valves............................................................. 137
Removing the cylinder - piston assy......................................139
Inspecting the small end....................................................... 140
Inspecting the wrist pin.........................................................141
Inspecting the piston.............................................................141
Inspecting the cylinder..........................................................142
Inspecting the piston rings.................................................... 143
Removing the piston............................................................. 143
Choosing the gasket.............................................................. 143
Refitting the piston rings.......................................................145
Refitting the cylinder.............................................................145
Inspecting the cylinder head ................................................ 146
Inspecting the timing system components........................... 146
Inspecting the valve sealings.................................................146
Inspecting the valve housings............................................... 147
Inspecting the valves.............................................................148
Inspecting the springs and half-cones...................................151
Refitting the valves................................................................151
Inspecting the cam shaft....................................................... 151
Refitting the head and timing system components............. 152
Crankcase - crankshaft............................................................... 155
Splitting the crankcase halves............................................... 155
Removing the crankshaft...................................................... 156
Removing the crankshaft bearings........................................156
Refitting the crankshaft bearings.......................................... 156
Inspecting the crankshaft alignment.....................................157
Inspecting the crankcase halves............................................158
Inspecting the crankshaft plain bearings.............................. 158
Refitting the crankshaft.........................................................159
Refitting the crankcase halves.............................................. 159
Oil pressure check................................................................. 160
Crankshaft oil seals................................................................161
Oil pump................................................................................ 161

ITALJET
Chapter 1
Overview
5

Warning/Attention/Remark
Please read this manual and grasp its essentials. In this manual, words such as "Warning", "Attention" and "Remark" are used to emphasize the degree of care. Please understand the
meaning of each word carefully.
Warning
This word refers to something that has to do with the safety of drivers, and failure to comply with it may result in injury accidents.
Attention
This word denotes those operation instructions or precautions that must be followed to avoid damaging the motorcycle.
Remark
This is a special explanation added to facilitate maintenance or to make important statements more explicit.
User Notice
Accessory installation and precautions for guaranteeing safe driving
You can buy all kinds of accessories to assemble your motorcycle. However, additional, improper accessories are very likely to bring unsafe factors to your driving. ITALJET can
not check the quality and suitability of all the accessories in the market one by one for you, but your ITALJET authorized service shop can help you select high-quality accessories, and
install them properly for you.
Extreme care must be taken for selecting and installing accessories on the motorcycle. We have made the following rules that you must follow.
（1）For all extra weight accessories, or accessories easy to produce wind resistance, their installation position should be as low as possible, and be attached to the body and close
to the center of gravity.
（2）Check the height above ground and proper roll angle of the accessories installed. Improper installation will reduce these two safety factors.
（3）Any installation of the accessories on the steering handle or front suspension part will cause serious imbalance. Consequently, weight increase of the front end will reduce the
steering agility, thus leading to the vibration of the front wheel, resulting in the instability of driving.
（4）Wind deflectors, backrests, saddle bags and suitcases, etc., are accessories easy to produce wind resistance, easily causing driving instability. This is especially evident in case
of crosswind or meeting of large vehicles.
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If the accessories are not properly installed or the accessories with bad design are installed, the driving safety will be endangered . Therefore, the selection and installation of
accessories should be especially careful .
（5）Some accessories can cause the driver to deviate from the normal riding position, which not only limits the driver's range of motion, but also restricts his maneuvering
capability.
（6）Additional electronic components can overload the existing electronic system. Severe overloading may damage wiring or lead to outage during riding, causing danger.
If you want to install accessories, try to install them in a low position close to the body. In case of poor installation or higher center of gravity, driving is not only dangerous,
but also hard to operate. The size of the mounting accessories can directly affect air resistance and maneuverability. Be sure to keep the balance on the left and right sides of
the motorcycle, and firmly install the accessories.
Important Notes
Knowledge of motorcycle running-in
The first 1000km of motorcycle driving plays the most important role in the whole service life of the motorcycle. During this period, the correct running-in can not only ensure the
longest service life, but also give full play to the performance of the new motorcycle. The parts of ITALJET motorcycles are made of high-quality materials and machined with
precision. Correct running-in operation can eliminate the blocking force on the surface of the parts to reduce mechanical loss and prolong service life.
During the running-in period, careful and patient running-in can guarantee the reliability and performance of the motorcycle. It is particularly important not to perform operations
that can cause engine parts to overheat.
For the specific running-in method, please refer to the section of running-in of new motorcycles.
7

Location of Batch Number
VIN (Vehicle ldentification Number) and engine number are used to register the
motorcycle. In the case of ordering parts or requesting special service information, these
batch numbers are also useful for ITALJET authorized service shops.
The engine number ①is printed on the lower part of the left crankcase.
VIN (Vehicle ldentification Number) ②is printed on the body near the front. Please fill
the above two numbers in the box below for reference.
VIN (Vehicle ldentification Number)
Engine number
Instructions for the Use of Fuel Oil and Engine Oil
Fuel oil
Choose GB17930 lead-free oil with octane number 95 or higher. The use of
lead-free gasoline can prolong the service life of spark plugs, exhaust system
components and machinery, and protect the environment and reduce air pollution.
Attention!
Spilled gasoline is harmful to the motorcycle and can damage the paint surface.
During refueling, pay attention not to spill fuel oil. In case of any spill, clean it up
immediately.
Engine lubrication oil
The following describes the range of use of lubrication oil of various grades for different
temperatures.
The use of high-quality four-stroke engine oil can prolong engine life. Engine lubrication
oil should be selected for crankcase oil in accordance with the national standard GB11121.
According to API Classification Method, the oil should be at SG grade; the viscosity
should be 10W-40. 10W-40 motorcycle oil is recommended for use.
75W-80 gearbox oil should be used as gearbox lubricating oil. Do not use ordinary oil,
plant oil or castor oil.
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In the process of your use of the motorcycle, in order to give full play to the performance of
your motorcycle, and prolong its service life, please be sure to use the original dedicated
gasoline and accessories, and to regularly replace the oil specified by our company (for
crankcase lubricating oil, when the running-in mileage or period of the new motorcycle reaches
500km or half a year, the motorcycle must be driven to the authorized service shop for oil
maintenance and replacement with designated special oil, and crankcase oil should also be
checked and replaced every 1000km; for gearbox lubricating oil, when the running-in mileage
or period of the new motorcycle reaches 2000km or half a year, the lubricating oil must be
replaced (with designated special oil). Original accessories and engine oil are affixed with
digital anti-counterfeiting marks. In purchasing accessories and engine oil, please identify the
marks carefully to avoid counterfeiting.
Brake Fluid
Warning！
·Accidental ingestion of brake fluid or its contact with eyes or skin is harmful. At this time,
immediately go to see a doctor for examination. In case of accidental ingestion, brake fluid
should be spit out. In case of contact with eyes or skin, the eyes or skin should be rinsed with
plenty of water.
·Check the amount of fluid stored in the front brake fluid cylinder. Without brake fluid of
appropriate volume or type, the brakes will not work properly. This may cause an accident.
·Check the brake fluid level before each use. Only DOT3 or DOT4 brake fluid in sealed
containers can be used. Do not use or mix different types of brake fluid. In case of rapid loss of
brake fluid, it should be checked by an ITALJET dealer or a qualified technician.
Attention！
·Spilled brake fluid can damage paint and plastic parts.
· Brake fluid may not be spilled during injection. Any spills should be cleaned
immediately.
Check the brake fluid level of the front and rear disc brake fluid storage tanks. If it is below
the Lower mark, add DOT3 or DOT4 brake fluid and check brake lining shoes for any wear and
brake fluid for any leakage.
Running-in
The preface explains the importance of proper running-in for the longest life
and best performance of your motorcycle. The procedure for proper running-in is
explained below.
Operation suggestions for the running-in period
The run-in period of the motorcycle is stipulated to be within the initial mileage
of 1600km.
The following table shows the opening of the accelerator during running-in of
the new motorcycle.
The initial mileage of 500km
Less than 1/4 accelerator
The mileage of 800km
Less than 3/4 accelerator
Engine speed change
Engine speed should vary rather than remain constant, which concentrates
stress on parts. Changing speed regularly equalizes stress on parts and helps with the
running-in process of parts. During the running-in period, it is necessary to expose
the engine parts to certain stress. However, it is not allowed to overload the engine.
Running-in of new tyres
New tyres, like engines, require the proper running-in to ensure optimum
performance. Within the mileage of 50km before the optimal performance, the
turning angle should be gradually increased for tread running-in. Great acceleration,
sharp turning and slamming on the brakes should be avoided.
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Warning！
·Improper running-in of tyres can cause tyres to skid and run out of control.
·Be extra careful when you have new tyres. For proper running-in of tyres as described in
this chapter, it is required to avoid great acceleration, sharp turning and slamming on the brakes
during the first 50km.
Avoid driving at a constant low speed
Driving a motorcycle at a constant low speed (light load) will overwear and overheat parts
and components and affect their running-in. To let the engine accelerate freely, the acceleration
speed may not exceed the specified maximum. However, don’t speed up the motorcycle to the
maximum for the initial 1000km.
Let the oil warm up before driving
Before loading the engine, let the cold or hot engine idle for about 30 seconds to 1 minute,
so that the lubricating oil has enough time to lubricate the engine parts.
Carry out the initial important maintenance
The initial 1000km maintenance is the most important maintenance a motorcycle should
receive. During the running-in period, all the engine parts will run in and all the other parts will
fit into place. All adjustments must be remade and all fasteners be tightened, and dirty oil should
be replaced.
The initial 1000 km timely maintenance will guarantee the best performance and the
longest life of the engine.
Remark：
The initial 1000km maintenance should be the most important maintenance in this manual.
Special attention should be paid to the attentions and warnings in the maintenance schedule.
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