Maico 250-B User manual

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PREFACE
Thank you for choos in g th e motorcycle. May you enjoy riding a ll time.
The manual contains
th e necessary instruc ti ons and guidance with respect to th e operation and maintenan ce of th e motorcycle, and BE S URE TO
READ IT CAREFU LLY BEFORE YOU RIDE THE MOTORCYCLE. Proper operation and maintenance can guarantee a safe riding to minimize lroubl es
of th e motorcycle and keep it in a sound condition, w hi ch can extend th e eng in e se rvice life.
All rig ht s reserved. No pa rt of this publication may be reproduced witho ut our prior written permission.
IMPORTANT NOTICES
• Operator and Passenger
This motorcy cl e is designed to car ry th e operator a nd one passenger. The maximum load weig ht of th e motorcycle must not exceed 150kg.
• On·road
This motorcy cl e is designed fo r on-road use.
Pay special attention to stateme nt s pr ece ded by th e fo ll owing words:
.&WARNING: Indicates a strong possibility of severe personal ill jury or death if illstructions are lIotfollowed.
.t.t, CAUTION: Indicates a possibility of equipmellt damage if illstructiolls are Iwtfollowed.
NOTE: Gives helpful information.
E nv
ironm e ntal Prot ection (EP) : Indicates special precautions that must be taken to meet environment protection laws and regulations.
Improper use of a motorcycle may cause environment pollution.
If th e operator fa il s to fo ll ow safe op er at in g and maintenance practices. the Co. w ill not take any responsibility to any injury or damage occured.
This manual sho
ul d be considered as a pe rm ane nt part of the motorcycle a nd should remain with th e motorcycle when resold.
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MOTORCYCLE SAFE RIDING
Safe Ri din g Rul es ................................................... 1
Protective Clo th s .................................................... 1
R efi ttin g ... ................ .......................... ....... I
L oa din g .. ............... . .. ... .... .. ... ..... I
Accesso rie s ....... .. . .. ... .. ... ..... . 1
GENERAL INFORMATION
Pan s Loca ti on ................................
ViN Reco rd ............
Fuel and Eng in e Oil (EP) .
CONTROLLING PARTS
. .. 2
....... 3
........ 3
Meter and lndi ca tors . . .. .... ... .. ... . .... .. . .. ....... 3
Ig niti on Sw it cha nd St ee rin g Loc k ............ ......... 4
Ri g ht Ha ndl eb ar Co n tro ls . .................................... 4
Len Ha ndl eb ar Co ntr ols .. ................... . .. 4
Choke Le ve r ... .. ... .. ... . ... .. . . ... ... .. ... ......... 4
Refu e ling and C ap ....... . .. . .... ... . .... . .. 5
Fuel Cock .......... .. .. ............. .................... .. .. 5
G
ea rs hift Pedal ........... ................... .... . .. ... .... ........ 5
Re ar Brake Pedal.......... ...................... ............... 6
Re
ar Sh oc k Ab so r be r ............................... . .... ......... 6
Stand. . .. ..... .. .......... . ... .......... .... ... .. . .... ......... 6
OPERATION GUIDE
Pr e- rid e in spec ti on
St
art in g Lh eEng in e ...
B reak in g- in ........
Ridin g ......................
........................................ 7
. .. .................................... 7
...................................... 7
. .... ........... . .. 7
Br a kin g and Parkin g . ... .. . ...... .. ... .. .. .. ... . .... .. .. 8
MAINTENANCE
T oo l Kit ................................................................ 9
Ma
int e nan ce Sc he dul e ........................................... 9
CONTENTS
En g in e Oil (Ep) ..................................................... 10
Cl ea r away C ar bon Deposit (EP) ........................... 10
Spark Plug (EP) ...................................................... 10
Air Cl ea ner (EP) ..................................................... 10
Val
ve Cl eara n ce ..................... .. .............................. .. II
Cam Cha in Adju s tm e nt ................................... ...... II
Mum er (EP) .. ............ .. ..... ..................................... II
El ec t ro ni c-O pe rated A era ti on Sys tem(EP) ........... 11
O pe ra ti onof Thro ttl e............................................. I I
Idl e Speed of Carburetor (EP) ............................... 12
Check Leaks al ong Air Supply (EP) .................. .. ... 12
Clutch ..................................................................... 12
Dri ve Cha in ........................................................... 12
Fr o nt Br ake ........................................................... 13
Re ar B ra ke ... . ... . .... .......... ,.. ......... 13
Brake Li ght ..... .. ............................................. ........ 13
H ow to U se Br ake We ar Indi c at or ........................ 14
Fr o ntlR ear Sh ock Ab so r be r and Sus pen sion .......... 14
Tyre ........................................................................ 14
Fr o nt Wh ee l . ..... .... ................. ... .... ...... .... ........ ........ 15
Re ar Wheel ................... .. . .. ..................... ..... 15
Fu se ..................................... .. ....................... .. ........ 15
Battery (EP) ...................... ........................ .... ....... 15
TROUBLESHOOTING , STORAGE AND OPTIONAL PARTS
Tro ubl es h oo tin g ..................................................... 16
C
le a nin ga nd St o ra ge............................................... 16
Rem
ov al from St o ra ge ....... ... .. .. ......... ....... ... 16
Anti-the
Ft Devi ce (Optional) .. ............................... 16
ELECI ' RICDIAGRAM .............................................. 17
SPECIFICATIONS .................................................... 18
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MOTORCYCLESAFE RIDING
SAFE RIDING RULES
~ WARNING Motorcycle riding requires special elTorts on your part
to ensure safety. Know these requirements before you ride.
• Always make a pre-ride in spection bef ore you start th e eng in e. You may
prevent acc id ent or equipment damage.
• Most countr i es require a speci al motorcycle riding lest or license. Make
sure you arc qualified before you ride. NEVER lend your motorcycle to an
in experienced rider.
.M ake yourself conspicuous to help avoid the accidenllhat wasn't your
fault:
• Wear bright or renec li ve clothin g.
• Don't ride in another motorist 's "blind spot".
eDon'1 speedily cross another's way.
• Obey all nalional and local l aws and regulations.
• Obey the speed limits, and NEVER travel faster than conditions warrant.
.Signal before you make a turn or lane change to draw other motoris ts '
attention.
.Use extra caution
at int ersections, parking lot en trances and exits.
• Always remember to rid e with both hands and keep both feet on the rider
footrest while the passenger grasps the handrail with both feel on the rear
f
oot res t.
PROTECTIVECLOTHS
• For the safe lY sake. always wear a helme t, a face shiel d. dust g la sses and
prOlective clothing. Your passenger needs the s
am e prOlection.
• The exhausl system becomes hot during operation. and it remains h ot for
a while after stopping Ihe engine. Take care
nOI to touch the exhaust
system
whi le it is hot. Wear clothing that fu ll y covcrs your Icg s.
. 00 not wear loose clothing th at could catch on the cont ro l lever s, wheel s,
etc.
REF ITT ING
&. WARNING Arbit rar il y re fitting th e motorcycle or removing the
original
parts may make riding unsafe, and is illegal also. The user
must obey all national and local laws and regulations in relation to
vehicle
and trame. If you have a good proposal concerning refitting of
the motorcycle, please write us. The refitment can be done with per -
mission of the Co. Otherwise, the user will take the consequences.
LOADING
L!l. WARNING Addition of accessories and cargo may reduce the
motorcycle's stability, performance and safe operating speed.
.K eep cargo and accessory weight lower and close to the ce nl er of the
motorcycle. Load weight equa ll y on both sides to minimize imbalance. As
we ig ht is located further from th e motorcycle's center of gravity, handling
is proportionally affected.
• Adjust tyre pressure and rear suspension to su it load weight and riding
conditions.
• Make sure thai cargo is fastened on the vehicle.
. 00 not attach it ems to the handlebars. fork or fender. Otherwise, unstable
handling or slow stee
rin g re sponse may occur.
.The maximum load weig
ht of the motorcycle is 150k g. Please do not
overload.
ACCESSORIES
Genuine accessories of th e Motors have been spec ifi ca ll y designed and
tested on the motorcycle. Beacuse the factory cannot te st all orner accessories.
you are personally re-sponsible for selection, in stallation and use of acces
so ri es not produced by the Co. AI-ways follow Safe Riding Rules and these
below:
.Carefu ll y inspect lhe accesso ry to make sure lhat it does nOi obscure ::my
lights, reduce ground clearance or banking angle, or limit suspens ion travel,
steer ing travel or control operation.
• 00 not insta ll olher cooling equipment for the engine.
.
Do 110t add electrical equipmen lt hat w ill exceed the mOlo rcycle's electri-
cal system capaci ty .
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GENERALINFORMATION
PARTS LOCATION (Fig.I.2l
Fi g. I (Left-view)
CD Meter ® Fr. wi nker @ Headlig ht @) Gearshift pedal
@Side stand ® Rr. shock absorber
Fig.2 (Right-view)
CD Rearview mirror ® Fuel tank @Taillight ®Exhaust muffler
® Pillion footrest @ Driverfootre st CD Rr. brake pedal
® Fr. shock absorber
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VIN RECORD (Fig. 3-5)
Fi g.3 YIN Fig.4 Eng in e co de Fi g. 5 N am eplate
YIN : I I
II I I I I
Eng in ccodc: I I I I I I I
Pl ea se fill the VIN and engine code of your m otorcy cle in the blank below.
Th ey will help order s par e parts and find out the vehi cle wh en st ole n.
NO T ES
CD Th e YIN is slamped on the ri ght of the st ee ring stem (Fig. 3) .
(%) Th e engine code is stam pe d on the bottom-le ft of the cra nkcase (Fig. 4).
<ID Th e ve hi cle namepl ate is fixed on the le ft of the st ee ring stem (Fig. 5).
FUEL AND ENGINE OIL (EP)
Fuel Selection
Fuel is a key f ac tor in d ec iding the exhaust emissions from the eng in e. so
se l ec ti onor fu el mu st follow th erul es bel ow. Sel ec ted fu el mu st be unl e ad ed
gasoline with oc tane No. RQ-93 or hi gher. Us in g improper fuel co uld redu ce
perfo rm an ce. shorten th eeng in e's se rvi ce li fe.
Engine Oil Selection (Fig. 6)
Thcqua lil y of theengine o il plays a vital role in deciding th e engine pertonnance
and service.
Engine o
il must be sel ec ted in a cco rdan ce with rules bel ow and other o il s,
such as ordinary eng in e oil. ge ar oil and vegeta bl e o il , are fo rbidden to be used.
Th e vehicle has b ee n filled with engine o il SAE15W /4 0·SE bef ore be ing
de li vered. Th e lubri ca nt is o nl y suitable al a
te mp era tur e ran ge within - IO 'C ........ +40'C. lf
o lh er motor oilis 10 be used in stead, the a ll er·
nali
"e must be technically equivalent in eve ry
r
es p ec t. Vi scos ity vari es with r egio ns and
te
mp era tur es, so the lubric ant has to be se-
lected according to our reco mm endation.
If th ere is no gasoline eng in e o il SAEI5W/40- ·30
SE. th eengineoil No. HQB-IO(or HQB-6 in
regions where the temperature is l ower than -
IO 'C ) ca n be used inst ea d.
•
•
D 1 02D3OCI!ID'C
Fi g. 6
CONTROLLING PARTS
METER AND
INDICATORS (Fig. 7)
CD Speedometer
CD Odom eter
Q) Ri ghi turn signal indi ca tor ".,.."
® Le ft turn signal indi ca tor " .. "
® Hi-beam indi ca tor "
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IGN ITIO N SW I TCH AND STEERING LOCK (Fig. 8)
Ignition Switch
The ~ w i t c h is equipped wi th 2 keys in cluding
a spare one.
", ~, " OFF: Engine and li ghts cannOI be
operated an d the key can be removed.
"" 0 "O N: Eng in e a nd lights can be operated.
neutral li ght is lit a nd th e key ca nn ot be
re moved.
Parking
Fig.8 St ee rin g l ock
(n se n the key into the lock core, and pres\) it w hil e turning cou nl erc l oc k w i ~
[0 ••p ,. position. th en remove the key. In th is casco the taillig ht and par ki ng
li g ht wi ll gl ow. a nd eng in e and ot her li g ht s ca nn ot be operated.To c .. nc cl th e
co nd iti on. tum th e key clockwi se to o th er position.
OTE When th e vehicle is nO I kept in use, always .... cl the switch to"OFF '
and re m ove the key.
Ste erin g Lock
To lock th e steering head. turn left th e steering
bar as far as it wi ll go. [urn clockwise th e igni ti on
key until l
oc king th e steering bar. at last remove
th e key. To unlock th e steering head. turn th e
key
co unterclockwise.
RIGHT HANDLEBARCONTROLS
(Fig. 9)
S tarter Button
<D Starter button
<D Li ghting sw.
:l) Emergency sw.
® Thr o tt le grip
Fi
g. 9
Lighting Switch
The 3-position switch fun ct ions as fo ll ows:
:Thc hea
dl ig hl. t ai lli ght and meter lights arc brig ht.
FE :The parking lig ht. tuil ig ht and meter li g ht s are bri ght.
• : (OFF) The headlight. tai lli ght. parking li g ht a nd meter li g ht s are of f.
Emergency Switch
In an emergency, deprc\sing the sw it ch to~ ' J' '' w ill sta ll th e eng in e at once.
In n
om l a! riding cases. always set the switch at "0 ".
Throtlle G rip
111 e grip is used l oco nl rolengine po we r. Turning inlh e grip w ill in c re ase fu el
supply, while turning o
ut it w ill decrease fuel supply.
L EFf HANDLEBAR CONTROLS( Fig. 10 )
Headl ig ht Dimmer Switch
Push the switch to '" .. to se lect high
beam.
Push the sw it ch to M .. to se lect l ower
beam.
Tu rn Signal Switch
Move the switch to ~ ~ " to signal a left
tum. to .. ~ .. to signal a ri g ht tum.
Horn Button
Press th e button .. b- .. to so und th e
hom.
Pass in g Signal Switch .. (F ig. II )
When pass in g. press and release th e
sw
it ch, th e hea dl iglll wi ll wink to wa rn th e
ve hicles.
CHOKE L EVER (Fig. II )
The choke l eve r is l oc aled on the l eft
handlebar co ntrols. Pu sh the lever to open
Fi g. 10 CD Dimmer sw.
<D Turn signal sw.
<» Hom button
Passing signal sw.
Fi g. 11 Choke lever
Depress the
bu tt on "'1)" to start up the engine.
-1 th e throttle.
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REFUELINGANDFUELFILLER
CAP (Fig. 12)
• Open the lock lid, and in ser1 the ignilion key;
• Tum the key clockwise by 90°
• RC'TIove the cap.
To re in stall the cap, just depress it onto the tank
inle
t. The fuel tank capacity is 14 L including
th e reserves supply of 2 L.
Lt WARNlNG
Lock lid Fuel filler cap
Fig.
12
• The fucl cod.. is located m the left-bollom of the tank. With the fuel cock
in "OFF" position. fue l cannot now from th e tank to the carburetor. Turn
the cock to OFF whenever the motorcycle
is not kept in use.
• With th e fuel cock in "'ON" posillon, fuel will Dow from the main fuel
sypply to th e carburetor. With lhe cock in "RES" position, fuel will now
rrom the reserve fuel supply to the carburetor. Use the reserve ruel only
when
th e main supply is gone. Refill the tank at the earliest opportun it y.
Lh CAUTION After refueling, make sure that the fuel cock is in ,. ON"
position. If it is in" RES" position, you may run out of fuel with no reserve.
• Do not overfill the tank (there should be no fuel in the filler neck). Co rr ect use of the fuel cock can avoid the s tat e above-mentioned.
After refueling, make sure the I'uelliller cap is closed securely. GEARSHIFT PEDAL (Fig. 14 & 15)
• Gaso line is extremely flamm able and is explosive unde r certa in The motorcycle is equipped with a 5-speed mesh transmission. The gear
conditions. Refuel in a well-ventilated area with the engine stopped. indicator shows th e gear position at present.
Do not
smoke or allow flames or spar ks in the area where the fuel Fig. 15 shows a gear pattern.
tank is refueled.
• Before refueling, make sure to filter fuel first. Spilled fuel vapor
may ignite. If any fuel is spilled, make sure the ar ea is dry before
starting the engine.
FUEL COCK (Fig. 13)
·· OI ·P
Fig. 13
"R ES "
Fig. 14
Gea r s hift is .<?)-(s)
forbidden to (r-'
gea rs hift up or 0 0
Cl ow n when the 1
throttle is s ti[] not , /
decreased and the t::\ 1':\
clutch is ill. 0 _ \V
Internaitiona 5-speed
Fig. 15
I
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REAR BRAKE PEDAL (Fig.16)
The rear brake will function and th e rear stop
li g ht will gl ow when treading th e pedal.
Fig. [6 Rr. brake pedal
REAR SHOCK ABSORBER (Fig. 17)
The shock absorber has 5 adjustment positions for different loads or riding
conditions. Position I is for
li ght loads and s mo oth road co ndition s. Positions
II to V increa se sp ring preload for a st iffer rear sus pen s ion , and ca ll be
u se d when the motorcycl e is heavily l oa ded or ridden in rugged roads. Use
a pin spanner to turn the adjuster to proper position.
NOTE Be s ur e to adjust shock absorbers both le ft and right 10 the s ame
position.
Fig. 17
D m
IV V
6
SIDE STAND (Fig. 18)
When parking the vehicle, turn the s id e sland clockwise al ong the frame to
position. Before driving the vehicle,
se Lthe stand to the initial po sition.
CAUTION Be sure to set the stand to position before driving the
motorcycle. Otherwise, it may fall over.
Fig. 18
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OPERA TION GUIDE
PRE-RIDE INSPECTION • Move Ih e gearshifl pedal info NEUTRAL 1o lighl up Ihe indicalor .. ~ .,
In spect your motor cy cle every time before you ride it. The items li sted here (green ),
wi ll only take a few minute s to in spect. and in the long run th ey can save
time. expense, and po ss ibly your life .
1. Engine o il l evel- add eng in e oil if required. Check for l ea k s.
2. Fuel level- refucl when necessary. Ch eck f or leak s.
3. Front and rear brakes - ch ec k operation. and adjust free play if necessary.
4. Tyres - check co nd it ion and pressure.
5. Battery electrolyte - check that the electrolyte is suitabl e.
6. Thronle - check for smooth opening and full closing in all steeling position s.
Adjust or replace it if necessar y.
7. Light s and horn - check lhat h ead li ght. ta il /slop li ght. winkers. parking
light, indicalOrs and horn function properly.
8. Drive chain - ch
eck co ndition and slack. Adjust and lubricate if necessary.
9. Fasteners - ch
eck that all nuts, scr ews and bolts are mounted securel y.
10. Steering system - ch eck for it s smoot hness and reliability.
STARTING THE ENGINE
CAUTION Do not start the engine in a narrow area to pr eve nt accident s.
Attempting to start the engine with the transmission in gear may r es ult in
damage to equipment.
Before starting,
confinn the following:
.Mak e sure the fu el in the lank is enough. Set fuel cock to " ON " position.
\.. • In sert the ignition switch and turn it to "0 " position.
• Sel the choke lever to th e fully closed position if the engine is cold.
• With the throllle s li ghtly open (l ess than liS of il s entire opening), oper
ale the sl'H1er so as to start the eng in e. Th en push ch oke l eve r to half-open
position.
• Warm up the en gine entirely at an idle speed of 1 30 0r /min until il wo rks
normally, and then push the choke lever to
it s fully open position.
NOTE
Do not use the electric starter fOI' more than 5 seconds at a time.
Release the
starter button for approximately 10 seconds before press
ing
it again.
BREAKING-lN
Help assure your motorcy cle 's future reliability and perfonnance by paying
eX ira allenlion 10 how you ride the first IOOOkm. During this period avoid
full lhrottle riding. be sure to drive at a speed no more than 80% of each gear
and 10 co ntinually chang in g speed. After the break-in period , be s ure to
co nduct maintenan ce so as to make co mpensation for initial wear . The ser-
vice
lif e will be exte nd ed obviously through such maintenance.
RIDING
• Start the engine and warm up it.
• While the engine idling, pull in the clutch l ever and push down the gear
shift pedal to shift into low (Ist) gear.
• Slowly rel ease the clutch lever and at the s ame time gradua ll y increase
engine speed by ope ning the throttle.
1 • When the motor
cycle atlains a steady speed, close the throttle, pull in the
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