Ossa TR 280i 2011 User manual

User manual

User manual 3
Introduction
On behalf of OSSA Motor we would like to thank you for having
purchased one of our products.
As the owner of an OSSA motorcycle, you form part of an exclusive
group: you have just acquired a unique model, the first of OSSA’s
re-launch. The TR 280i is the OSSA factory’s new presentation
catalogue. It represents a return, after twenty-five years, of the
legendary clover brand. In the 60s and 70s, this brand received
extensive international recognition that went far beyond the world
of motorcycling.
The new OSSA motorcycle belongs to the first series, a production
batch of only 1,250 motorcycles. These bikes will be distributed
both nationally and internationally. It is, therefore, a genuinely
special product that is destined to go down in the history of the
brand and in the history of trial riding and motorcycling.
The TR 280i is designed for competition riding but is also adapted
to traffic regulations for use on public roads. This motorcycle is
designed for motorcycle trials, comprising the best features for this
purpose: it is extremely light-weight and the gears and transmis-
sion are very precise. All of this in addition to the distribution of its
components makes the motorcycle a technically advanced and
cutting edge product.
OSSA motorcycles have been designed, assembled and tested by
experts and all parts have been manufactured under the supervi-
sion of OSSA engineers. This ensures that top-of-the-range motor-
cycles are guaranteed.
At OSSA Motor we know that each motorcycle model is unique with
its own specific features. For this reason, we spend a lot of time on
the research and design phase for each part and for each model.
It is important that you read this manual thoroughly in order to keep
your new TR 280i in full working condition.
* Model without standardisation kit

4 User Manual
Important
Read this manual thoroughly and keep it in a safe place. This
manual provides technical information necessary for keeping your
new TR 280i motorcycle in full working condition. It provides
information on common aspects for the motorcycle’s upkeep and
fine tuning. In the event of questions or queries on aspects not
mentioned in this manual, you should consult the OSSA official
distributor or a specialist engineer.
Follow each stage of the instructions provided below for obtaining
good results.
These instructions are accompanied by icons to make reading
quicker and easier.
Some of the indications specified in this manual are to prevent
possible harm from being inflicted on people or material. Not
following the instructions may result in serious consequences,
which could put people’s lives at risk.
This manual has been put together with the OSSA TR280i current
layout. However, OSSA Motor reserves the right to make changes to
this layout without prior notification to consumers. In the event of
this taking place, your dealer will provide you with the relevant
information.
ATTENTION – This symbol indicates that special attention
must be paid!
INFORMATION – Informative note, advice.
- This motorcycle has been designed to carry one
person only. Never ride with passengers!
- Do not carry loads.
- Any additional weight could destabilise the motorcy-
cle which may provoke accidents that incur serious
injury or even death.

User manual 5
Safety
Both your safety and the safety of others are very important when
riding a motorcycle.
Some important advice for using your motorcycle correctly is
detailed below.
- Always drive in a responsible way.
- Always use a helmet.
- Never drive over the speed limit.
- do not ride with passengers.
- This motorcycle is designed to be used in both urban and rural
areas. It should be used, however, while respecting other people
and the environment. If, in your geographical area, the use of
motorcycles in rural areas is restricted, you must respect the law.
- Always wear appropriate clothing and protective accessories.
Gloves, boots and thick trousers, among others, are recommenda-
ble. Do not wear baggy clothing that might get caught on a mecha-
nism in the motorcycle.
- Be careful with the exhaust system! The exhaust system gets
extremely hot during and after use of the motorcycle. In the event
of suffering burns, see a doctor as soon as possible.
- Take the time necessary to become familiar with your new motor-
cycle.
- Never drive if you have consumed alcohol or any type of substan-
ce (medication, drugs) that might affect your driving capability.
- Make sure your motorcycle is serviced regularly to avoid break-
downs while driving.
- Do not use your motorcycle for transporting or towing loads. In the
event of needing to carry loads, make sure that they are
light-weight and small in volume so that driving is not affected.
Ensure that there are no loose leads or other elements that might
get caught inside a mechanism. Never apply additional weight to
the handlebars, fork or mudguards. Be especially careful when
transporting any type of load.

Introduction 3
Important warning 4
Safety 5
Contents 7
Technical specifications 8-9
Recommendations 10
Section 1 - Components 11
Location 12-14
Multi-function box 15-22
Control pad 23
Front suspension
Readjustment 24
Air bleed 24
Rear suspension
Readjustment 25
Air bleed 25
Anti-theft immobilizer 26
Start lever 27
Fuel tank 28
Upper engine cover 29
Section 2 – Maintenance and basic operations 31
Maintenance grid 32-33
Adjustments to the motorcycle controls 34
Electric connections 35
Air filter 36
Radiator 37
Spark plug 38
Chain
Tension adjustments 39
Lubrication of moving parts 40-42
Tyres
Pressure and condition 43
Control of crankcase oil
Filling up and draining 44
Brakes 45
Torque wrenches 46
Storage 47
Troubleshooting 48-52
Registration, series number and key 54-58
Warranty conditions 59-66
Final considerations 67
User manual 7
Contents

8 User manual
Technical specifications
ENGINE
Cubic capacity 272.2 cc
Type Mono-cylindrical two inverted speeds with admission via slats directly to the sump
Cooling system Liquid
Diameter x stroke 70x60 mm
Power supply EFI Kokusan Battery-less System
Ignition CDI Kokusan digital magnetic steering
Clutch Hydraulic clutch knob
TRANSMISSION
Gear box 6 speeds
Transmission Primary by gears, secondary by chain
Engine lubrication Mix 0.9% Oil 100% synthetic
Changing lubrication and clutch 350 cc. of oil – type Gear Extreme 75 W (+170 CC in the version with ignition refrigerant with oil)
CHASSIS
Type Tube form in CR-MO steel, with pipe and lower part made from forged aluminium
Front suspension Fork with aluminium bars, 40 mm diameter Marzocchi adjustable in extension and compression
Rear suspension Variable progressive system with TTX OHlins mono shock absorber adjustable in extension and compression
Front brake 185 mm diameter disc with 4-piston brake caliper
Rear brake 150 mm diameter disc with 2-piston brake caliper
Front wheel 28 spokes with 2.75x21 wheel
Rear wheel 28 spokes with 4.00 x 18 tubeless wheel
Engine protector Constructed in AA7075 T6
Kick-start pedal Forged aluminium
Transmission and brake pedal Forged aluminium with retractable toe cap

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Technical specifications
WEIGHTS AND MEASUREMENTS
Distance between axles 1.328 mm
Seat height 655 mm
Distance to the ground 340 mm
Fuel tank capacity 2,6 litres
Mass in service 64 kg
OSSA Factory reserves the right to make modifications without prior notification. Kokusan, Marzocchi, OHlins are registered trademarks and their use is licensed.

It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order.
- 12 hours of running-in is recommended to ensure that the engine works correctly and for a long-lasting time period.
- It is important to run the engine for some minutes until it reaches the correct temperature to work correctly.
- The engine lubrication is a mixture of petrol-oil with a 0.9% oil proportion. Always use synthetic oil.
- When the motorcycle is new the oil must be changed for the first time after 5 hours of use and for the second time after x hours of use.
10 User manual
Recommendations

User manual 11
Section 1 - Components

12 User manual
Location of elements
1
7
8
9
10
12 13
14
2
3
4
5
6
11
1 Front mudguard
2 OSSA multi-function box
3 Fan and radiator
4 Cylinder
5 Sparkplug
6 Chain guide
7 Front tyre
8 Front fork stanchion
9 Front suspension bar
10 Gear lever
11 Chain
12 Chain slider
13 Rear crown protector
14 Rear tyre
*Model without standardisation kit

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Location of elements
20
19
15
16
22
21 23
24
17
18
*Model without standardisation kit
15 Rear break caliper and anti-theft immobilizer
16 Exhaust
17 Kick-start pedal
18 Fuel tank
19 Rear brake disc
20 Swing arm
21 Rear break lever
22 Crankcase protector
23 Front break caliper
24 Front brake disc

25 Front brake handle
26 Throttle grip
27 Throttle grip mechanism
28 Front brake pump
29 Right fork stanchion regulator
30 OSSA multi-function box
31 Left fork stanchion regulator
32 Clutch pump
33 Lights control pad
34 Clutch handle
35 Headlights 25
26 27
28
29
30 32
31
33
34
35
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Location of elements
*Model without standardisation kit

User manual 15
Multi-function box
The OSSA TR280i multi-function box and the indicator lights next
to it provide very useful information at all times.
The multi-function box is a power box system with an LCD screen
controlled by a console with indicator lights, located in the centre of
the handlebars.
The information displayed on the multi-function box includes: the
number of revolutions made by the engine, speed, distance
covered, total distance covered, time, average speed, maximum
speed, environmental temperature, running time and uptime.
This device has an internal memory unit that stores data like total
Km and total running time, even when it is switched off.
Some features may be personalised: the device can measure in
kilometres or miles. The wheel circumference value can also be
changed.
A temperature sensor warns us with a yellow light (1) when the
engine temperature is excessive.
Another sensor provides a warning with a red light (2) when the
rate at which the engine turns is excessive.
OSSA multifunction display
Temperature warning LED
Function Select Button
Right buttonLeft button
LED warning of
excessive motor rotation

16 User manual
Multi-function box
Technical features
Functions Technical features Accuracy Symbol Increasess
Current speed 4 - 399,9 Km/h o M/hSDP 0,1 Km/h o M/h +/- 0,1%
0 - 19999 rpm
RPM 10 rpm +/- 0,1%
Tachometer
Distance covered 0,1 Km/h o M/h +/- 0,1% 0,0 - 19999 Km / M
DST
Maximum speed MS 4 - 399,9 Km/h o M/h 0,1 Km/h o M/h +/- 0,1%
TT
Running time 0 - 9999 hours 59 minutes 1 second +/- 0,1%
0 - 12000 rpm
-Variable +/- 0,1%
Tachometer bar
0,0 - 999999
ODO 1 Km +/- 0,1%
Mileage
1 minute
0 - 999 hours 59 minutes
RT +/- 0,1%
Uptime
1 minute
0 - 9999 hours 59 minutes
ART +/- 0,1%
Accumulated uptime
Each use
12:59:59 - 23:59:59
00:00:00 +/- 0,1%
Clock
Each use
1 year's duration approx
LO +/- 0,1%
Battery low
0 - 3999 mm
-- -
Tyre size
Input voltage: 9-400 V CA/CC.
Speed sensor: magnetic non-contact sensor
Tachometer input: electrical pulse sensor
Wheel circumference adjuster: 1 mm -3.999 mm (increases of 1 mm)
Running temperature / storage: from 0ºC to 60ºC (from 32ºF to 140ºF) / from -20ºC to 80ºC (from - 4ºF to 176ºF)
Battery / Life: 3V CR2032 / 1 year approx

User manual 17
Functions
RPM: Bar
Bar graph tachometer. The tachometer bar graph displays up to
12,000 rpm.
RPM: Digital tachometer
The RPM appear on the right side, on the second line. The digital
tachometer displays up to 12,000 rpm. The tachometer signal can
be captured from the sparkplug wire.
Warning of gear change due to rpm.
The rpm appear on the right side, on the second line. The digital
tachometer displays up to 12,000 rpm. The tachometer signal is
received from the sparkplug wire.
SPD: Speedometer
The speedometer information appears on the centre of the screen.
It displays up to 399.9 km/hour or miles/hour.
MS: Maximum speed meter
It displays the maximum speed reached during the last operation
after having set the counter at zero.
DST: Distance covered
It appears on the right side, on the second line of the screen. The
TRIP function records the mileage accumulated by the vehicle
since the last RESET.
ODO: Mileage counter
It records the distance or total accumulated mileage for the vehicle.
The data is stored in the memory, even when the device is switched
off.
ART: Running time controller
It calculates the total running time. It begins counting as soon as
the engine is switched on.
RT: Total running time controller
It calculates the vehicle’s running time from the last RESET. It
begins to count from when the vehicle starts to move. The data is
stored in the memory, even when the device is switched off.
12/24 hour clock
It displays the current time in 12 or 24 hour clock. It indicates the
temperature of the environment and engine. The display screen on
the upper left shows the environmental temperature. Using an
optional temperature sensor, the screen displays the engine
temperature. If excessive, the yellow light comes on.
Indicator that engine turn rate is excessive / Warning of gear change
due to rpm.
If the engine turn rate is excessive a second red warning light will
come on. This function acts as a warning to change gear when a
specific number of rpm is reached. The red light flashes when the
rpm reaches the established value and stops flashing when the
gear is changed.
Multi-function

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1 2 1 2
1 2
3
123
Multi-function
Adjustment of the multi-function box settings
After confirming each value, the multi-function box will move straight on to the next screen adjustment until the process is complete. If no
button is pressed, the multi-function box will return to the initial screen after 15 seconds.
Activation of the adjustment mode
To activate the adjustment
mode for the multi-function
box settings, push buttons 1,2
and 3 simultaneously for 3
seconds and then release
them.
Select the wheel circumference
Enter the wheel circumferen-
ce by pushing button 1 repea-
tedly. To move to the next
digit, press button 3. Confirm
the selection by pushing
button 2. Note: If you don’t
know the wheel circumferen-
ce, consult the “Measuring
the wheel circumference”
section.
Select the speed unit
To select the speed unit
between km/h and m/h, press
1. Confirm your selection by
pressing 2.
Select the time format
To select the time format
change between the 12 and
24, press 1. Confirm your
selection by pressing 2.

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1 2
1 2
123
3
Multi-function
Time adjuster
Set the time by pressing
button 1 repeatedly. To move
to the next digit, press button
3. Confirm the selection by
pushing button 2.
Adjustment of the revolution pulse
(PPR)
Note:
This step must only be
followed for those vehicles
that change the PPR pulse
type to a specific turn rate. If
you don't know this value,
press button 2 to move on to
the next screen. Enter the
value by pressing button 1
repeatedly. To move on to the
next digit, press button 3.
Confirm the selection by
pushing button 2.
Adjustment of the revolution pulse
(PPR)
The indicator receives an
electric pulse each time the
engine turns (PPR). Default
value for 2 and 4 stroke
engines:
1 PPR. Enter the value by
pressing button 1 repeatedly.
To move on to the next digit,
press button 3. Confirm the
selection by pushing button 2.
Adjustment of the revolution pulse
(PPR)
Note:
This stage must only be
implemented if in the
previous stage the value 0
was entered.
Default value: 1.0. If you don’t
know this value press button
2 to move on to the next
screen. To move on to the
next digit, press button 3.
Confirm the selection by
pressing button 2.

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123123
123
Multi-function
Temperature selector
To select the unit of temperature,
either ºC or ºF, press button 1.
Confirm the selection by
pressing button 2.
Danger temperature selector
Note:
This stage should only be
implemented for those vehicles
that have an optional temperatu-
re sensor. When the motorcycle
temperature exceeds the set
value, right-hand warning light
comes on.Default value: 110ºC
(230ºF).
Enter the value by pressing
button 1 repeatedly. To move on
to the next digit, press button 3.
Confirm the selection by
pressing button 2.
Warning temperature selector
Note:
This stage should only be
implemented for those vehicles
that have an optional temperatu-
re sensor. When the motorcycle
temperature exceeds the set
value, the left-hand warning light
comes on.
Default value: 90ºC (190ºF).
Enter the value by pressing
button 1 repeatedly. To move on
to the next digit, press button 3.
Confirm the selection by
pressing button 2.
Gear change turn rate selector
When the set rate is near to
being reached, the left-hand
warning light will flash, indicating
the need to change gear.
Default value: 6000 rpm
Enter the value by pressing
button 1 repeatedly. To move on
to the next digit, press button 3.
Confirm the selection by
pressing button 2.