Polini Minicross XP 4 User manual

--a
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USE AND MAINTENANCE MANUAL MINICROSS AND MlNlMOTARD

FOREWORD
INSTRUCTIONS MAY BE REPEATED A NUMBER OF TIMES
IN THE COURSE OF THlS MANUAL.
THlS
HAS BEEN DONE PLIRPOSEFUUY TO EMPHASISE THE
IMPORTANCE
OF CERTAIN OPERATIONS ANDTHE NEED
TO BEAR SAFETY CONSTANTLY IN MIND.
ALL ENGINEMAINTENANCE MUST
BE REFERRED TO A
SPECIALIST DEALER.
IMPORTANT
Read this manualcarefully throughout before ridingyour
new motorcycle.
This manual contains importantinformationthat will help
you ovoid causing unnecessary damage to the machine and
serious or even fatal injuryto yourself to other persons and
things.
To ensure care-freeand satisfying oFfroad ridingyou must
get to know your new motorcycle thoroughlyand set it up
correctly beforeyou start riding.
IMPORTANT LEGAL NOTICE
THlS MOTORCYCLE HAS BEEN DESIGNEDAND
MANUFACTURED EXCLUSIVELY
FOR COMPETITION USE
AND
IS SOLD "AS SEEN" WlTH NO WARRANTY.
MIS MOTORCYCLE DOES NOT COMPLY WlTH CERTAIN
ROAD SAFETY REGUIATIONSAND
IT IS THEREFORE
ILLEGAL TO RIDE
IT ON PUBLIC ROADS, HIGHWAYSAND
MOTORWAYS.
APPLICABLE LEGISLATIONPERMITS
THE USE OF THIS
MOTORCYCLE ONLY IN ORGANISED COMPETITIONS OR
CLOSED TRACK SPOR-I'ING EVENTS ORGANISED IN
COMPIJANCEWlTH LOCAL BY-LAWS.
ALWAYS ENSURE THAT
IT IS LEGAL TO OPERATE THE
MOTORCYCLE
BEFORE RIDING IT.
IT IS STRICTLY FORBIDDEN TO CARRY PASSENGERS.
This minicross motorcycle has been designed and
manufacturedfor use byone rider only.
NOTE
Childrenmust always be supervised by an adult when riding
this motorcycle.
READ THlS MANUAL CAREFULLY.
A CAUTION!
This text identifies a risk of serious or even fatal
personal injury if the associated instructions are
not followed. The associated insh.uctions must
be followed carefully to avoid damage to the
motorcycle.
WARNING!
This text identifies a risk of personal injuryor
damage to the motorcycle. The associated
instructionsmust
be followed carefully to avoid
serious or fatal accidents.
This manual is an integral part of the motorcycleandmust
accompany it
if it is sold or transferred to a new owner or
keeper.
WELCOME NOTICE
Congratulations onyour choice of a Polini minicross
motorcycle. By purchasinga Polini motorcycleyou have
become one of
a large Family of satisfied Polini motorcycle
owners and riders.
NOTE!
This Polini minicross is a high performance
competition motorcycle and incorporates the
latest motocross race technology. It must only
be
used in competitive racing by expert riders.
This new Polini minicrossmodel has been designedto
prformas competitively as possible.
Motocross
is nevertheless a physical sport and winning
requires more than iust a good motorcycle.
To achieve
good resultsyou must be in good physical
condition and be a skilful motorcycle rider.
The best results are achieved
by riders who exercise
reguladyto keep in peak physical form andwho practise
their motorcycling
skills frequently.
The purposeof this manual
is to help you get the greatest
satisfactionpssible from you new Polini minicross
motorcycle, both from the performanceof the machine itself
and from success incompetitions.
PERSONAL PROTECTIVE EQUIPMENT
1 - Most deaths in motorcyclingare caused by head iniuries.
ALWAYS wear a helmet. Whenever possible, also wear a
visor or goggles, as well as protectiveboots, gloves and
clothes.
2- the exhaust system becomes extremely hot duringuse
and may remain
so for quite some time afterwards.
Do not touch any partsof the exhaust system. Always
wear clothes that completely cover your legs.
3- Do not wear looseor flowing clothing. This can become
entangled inthe control levers, kick-start lever, footrests,
chain or wheels.
4- Respect the environment.
A DANGEROUS MODIFICATIONS
MODIFICATIONSTO OR THE REMOVAL OF
ORIGINAL PARTS FROM THlS MINICROSS
MOTORCYCLE MAY CAUSE IT TO BECOME UNSAFE
OR ILLEGAL
ALWAYS COMPLY WlTH ALL LOCAL AND
NATIONAL LAWS, REGULATIONS AND SAFETY
STANDARDS.
THIS MOTORCYCLE HAS BEEN PROJECTED FOR A
DRIVER UNDER A WEIGHT OF
85 Kgs.

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For your own safety and for the best of your
motorcycle, always insist on original Polini Motorispore
parts for all repairs. To be ableto recognise your motorcycle
-
and to keep track of its identity in case of theft, make a note
here of its specificationsand frame number:
MODEL: -.------------------ * ----------. -----------*----------.-----.-.-----------------
- ENGINE CAPACIW ------------------------------------.--------.----------------
TYRES: Front. Rear.
-------...---.-------------------------------------.----.------.------------------
FRAME NUMBER:
.---------.-*..------------.-----------------------------------*-
-
IDENTITY CODE: 144.000.
4 x M6x16 ROUNDED HEAD SCREW (IS07380)
1 x M8x18 SCREW (IS07380) (For the stand)
1 x RIGHT FOOTREST
1 x LEFT FOOTREST
1 x FRONT WHEEL HUB
4 x M8 SELF-LOCKINGNUT (UNI7473)
4 x M8x30ALLEN SCREW (cross-slotsunken hex screws)
(UNI6593)
2 x HANDLEBAR ClAMP
1 x HANDLEBAR WlTH FOAM ROLL
1 x FRONT WHEEL WlTH DISK
1 x FRONT MUDGUARD
1 x GEAR PEDAL
1 x FOOTREST SUPPORT
1x NUMBER PLATE
I x STAND
1 x STAND SPRING
LOCATION OF VEHICLE IDENTITY CODE
The motorcycle's identitycode is stamped on the front of the
frame or on the right hand side of the steering head.
1. PREPARINGYOUR MOTORCYCLE FOR USE
When you first open the crateyou will see that hemotorcycle 3- Fit the rear shock-absorber, using the
MI 0x80 hex head
is not ready for use, but has been partly dis-assembledfor bolt, two M10.5 spacers, two washers and the
MI0 nut.
-
reasonsof packingandtransport. Carefully unpackall the Fit one of the washers
at the bolt headandthe other at
parts from the crate and proceed as instructedbelowto
.. . . . . - the nut. The nut, bolt, spacers and washers are pre-fitted
check and assemble your motorcyclefor use.
The following instructionsgive the most practical order for
assembling the various portsof your motorcycle.
1 - Remove hemotorcycle from the crate (photo 1 ).
2- Remove allthe parts neededto reassemblethe motorcycle
from the crateand check them thoroughly (photo 2).
4 x WASHER (UNI6593)
1 x PLASTIC TIE
2 x FOOTREST SPRING
6 x M8x20ALLEN SCREW (cross-slotsunken hex screws)
(UNI593 1 )
2 x M8x40ALLEN SCREW (cross-slotsunken hex screws)
(UNI593
1 )

13- Fit the engine stop button and fix it to the handlebar
with its mounting clamp (photo
12).

14- Fitthe clutch lever and adiust the travel of the lever as
you prefer usingthe regulator(photo 13)
(See section
4.8).
15-Fit the footrest support first on the engine with the four
M8x20Allen screws and then on the chassis with 2
M8x20screws and 2 self-locking nuts (photo 14).
16-Fit the footrests like shown in photo 15, with M8x40
screws and self-locking nuts.
17-Fit the stand using the M8x18 screw to fasten it and the
spring provided (photo
1 6).
A DANGER! We suggest you to remove the stand during
competitions as it could bedangerous and bruising.
18- Fit the gear lever l~hoto171.
19- Fill the fuel tank (See section 4.13).
20- Check the engine oil level (See section 4.3).
INTRODUCTION
Always ensure that the motorcyclehas been efficiently
serviced and check itover before ridingit.
Take your motorcycleto an authorised POIJNI MOTOR1
dealer for all maiorservicingand repair.
Because ofthe manufacturer's policy OF continuous
development, and becauseof constant innovationsin
technology, your motorcyclemay differ in some details from
that described in the illustrations andtext inthis manual.
Original POLlNl MOTOR1spare partsare always made from
the same materials and in the same way as the parts
originally fitted to your minicross motorcycle.
Always insist on original POIJNIMOTOR1 spore parts.
Their use ensures a longer lifeand improved efficiency for
your motorcycle.
2. STARTING THE ENGINE FOR THE FIRST TIME
Always check over your motorcyclethoroughly before
startingthe engine. To start the engine for the first time,
as instructedbelow.
1 - Turn the fuel tap locatedunder the fuel tank to #ON"
position (photo 18).

3. RUNNING IN
1 - Run your new motorcycleinas instructed Howto ensure
that the engine andtransmission
bed incorrectly and to
ensure continuous reliabilityin Future.
A CAUTION! The first time ywrideyour new motorcycle,
ridefor about two hours at low engine
speeds to ensure that
it runs incorrectly. Also respect the following precautions.
2- Oncethe engine starts, leave it idle until it warms up to
normaltemperature.
If you switch the engine off for a
short time, wait for it to cool down completely beforeyou
re-startit.
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3- Duringthe runningin period, always rideat constant
2- Before startingthe engine put the gear in neutral position speeds. AVOID RAPID ACCELERATION.
(photo 19, gear N).
4- Even when riding at lowengine speeds, avoid extended
A WARNING! IF the gear position is not neutral the bike
could movewhen started.
3- If the engine is cold, liftthe choke lever on the carburettor
(photo 20).
A WARNING! Lower the starter lever againas won as the
engine starts to warm up.
4- Leove the throttle closed. Pivot the kick-start lever out
wards and push energetically downwards with your foot
to start the engine.
5- Return the kick-start lever to its rest position.
Leave the engine idle for a few minutesto warm it up.
A WARNING! Check that the engine stop buttonstops the
engine effectively beforeyw
begin ridingthe motorcycle.
difficult sections
of roador Lckthat could cause the
engine to becomevery hot.
5- Once you have run inyour motorcycle following all these
instructions, take it to a PoliniMotoridealer for its post-
running-inservice. Apart from a change of spark plug
and engine oil, this service also includesthe disassembly
of the cylinder to check on the conditionof the spark plug,
cylinder head and the piston and barrel.
ACAUTION! After the running in it is important to check
the tightening of the head's nuts. Often they can be loosen
after the ~nning-inperiod.
4. SERVICING: INTERVALS AND OPERATIONS
The servicing described below is intended to keep your
motorcycle in pakcondition. Itconsists of tasks that should
be done regularly, or on all occasions beforeyou start riding.
All the tasks and adiushnentsdescribed below can
be done
easily bv followina the instructions aiven in this manual. Refer
to ydur 'WUNI M~RI dealer forkheduledservices and
repairs, and insist hatonly originalspare parts be used to
replace worn or brokencornponenk. Refer to the servicing
tables in sections
5.1 and 5.2 below for heh-equencywith
which the various service operations must
be performed.
4.1 REMOVING THE SEAT
Liftthe seat lock tab and turn the seat lock 180 degrees anti-
clockwise. Lift the seat gentlyand slide it out rearwards
(photo
21 ). To refitthe seat, engage the Front seat catch with
the catch on the fuel tank and push the seat on to the kame
members. Once the seat
is firmly in position, turn the seat
lock
180 degrees clockwiseto lock the seat in place.

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4.2 REMOVING AND CLEANING THE AIR FILTER - Check that the oil level reaches the bottom edge OF the oil
Dirtyair fihenare one of the most common causes of poor dipstick. Check oil level without screwingthe dipstick onto
engine performance. its thread.
-
Proceed as follow to clean the air filter.
- Remove the seat. (See section 4.1)
4.4 CHANGINGTHE ENGINE OIL
- Remove the coyer from the filter box (photo22).
Do not throw spent oil into the environment. Disposeof it
correctly through authorised collection points.
- Screw the drain screw bock in. Add 850 grams of SAE
20W50 engineoil. Only employ highly detergent engine
oil classifiedfor service API SF or SG.
4.5 ADJUSTlNG ENGINE lDLlNG SPEED
- Warm upthe engine beforeadiustingthe idling speed.
- Leave the engine idlewith the throttle closed.
- Turn the idle speed adiustment screw on the right hand side
of the carburettar inor out to achieve the lowest engine
speed possiblewithout runningbecoming irregular
(photo
26).
CAUTION! Dirty air filters chokethe engine and cause
poor performance. Torn or broken filters can allow dirt to
enter the engine and cause rapid deteriorationof the piston
rings and barrel.
4.3 CHECKING THE ENGINE OIL LEVEL
- Stand the motorcycleupright.
- Removethe oil level screw from the gearbox casing on the
right handside of the engine (photo 24).
4.6 ADJUSTING THE AIR SCREW
The air screw can be adiusted inorder to obtain better
performancewhen the bikeis out of idling speed.
- If the engine has difficulty incurve (richmixture) unscrew
the air screw.
- If the engine has difficulty incurve (poormixture) screw
the air screw (photo
27).

-
A WARNING! The adjustingscrew is near the cylinder.
Pay attention not to scald oneself while adiusting it.
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4.7 ADJUSTING THE THROTTLE CONTROL AND
CABLE
- Make sure that the throttletwist grip operates smoothly.
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- Makesure that the play in the throttle cable measures 3-5
mm.
If lay exceeds this measurement, reduce play by
screwingout
the adiusteron the twist grip control
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(photo28) or on the top of the carburettor.
Generously lubricatethe partaher disassemblingit by
removingthe pin (3).
4.9 ADJUSTING MECHANICAL BRAKES
To adjust the broke lever, follow these instructions:
1 - Remove the protection cover of the brakelever
2- Unlock the locking ring screwed on the brakelever and
screw the adiuster clockwise direction
if you want to
decrease the lever play, or anti-clockwise
if you want to
increase it.
3- Once the operation
is concluded, insert the protection
cover on the cable tensioner again.
NOTE: Use a strokeof 5/10mm (measuredfrom the head
of the lever or of the pedal)on the lever and on the pedal
brake. For the adiusting, act on the brake calliper, unscrew
nut No.
1 andscrew grub screw No. 2 tillyou reset the right
stroke of the handlebarlever; keeping grub screw No.
2 in
its position, block nut No. 1 and check that the wheel does
not remain braked.
4.10 TYRE PRESSURES
Correcttyre pressureensures maximum stabilityand control
and also extends tyre life.
Check tyre pressure frequently and adiust as necessary.
CAUTION! Failureto keep this parts in peak condition Always measure tyre pressurewhen the tyres are cold.
and
to make repairswhenever necessary can leadto serious
--
Keep in mindthat the tyre pressure can change depending
personalaccidents and serious damage to the motorcycle. on the track's conditions and on the rider's weight.
4.8 ADJUSTING THE CLUTCH
- Shouldthe clutch adjustment with the clutch lever (photo 13) FRONT REAR
be insufficient, it is possible to screw the adjuster (I) (photo 1.3 BAR
- 18.9 PSI 1.3 BAR - 18.9 PSI
29) locatedunder the cover of the clutch casing.
4.1 1 ADJUSTING THE TRANSMISSIONCHAIN
The final drive chain is an extremely important component
and deserves specialcare and regular servicing.
5 WARNING! When workingon the chain, take care not
to jam your fingers betweenthe chain and sprocket.
1 - Check the chaintension with the motorcycle standing
upright andwith
no pressureon the suspensions. Measure
chain movement
at the positionshown in photo 30.
- Chain movementmust be 35-39mm as shown inthe
figure.
If necessary, proceed as follows to adjust the
-
chain tension (photo31 ).
A WARNING! Often lubricatethe clutch shah (2) inorder
- Loosen the nut (3) on the rear wheel spindle.
to
mid itto grip while the casing moves.

- Loom the two lock nuts (1 ) and turn the two adjusters (2)
4- If you have to removeor change the chain, remember to
anti-clockwiseto tighten or clockwise to slacken the chain. replace the clip on the split link with the closed end facing
-
Makesure that the edges of the spindle plates are
perpendicularto the swingingarm and measure distance
"A" betweenthe swinging arm and the plates. Makesure
-
hatdistance "A" is the same on both sides.
- Tightenthe rear spindle nut (3) (photo32). See section 6.2
for the tightening torque.
- - Measurethe chain movement again and repeat the
adjustmentprocedure
if necessary.
- Gently turn the two adjusters (2) to bring them into firm
contact with the axle plates. Holdthe adjusters firmlywith a
spanner and tighten the lock nuts (I
).
inthe directionof travel (photo 33).
A CAUTION! Never fit a new chain to worn sprockets or
vice-versa. Incorrectwheel alignment not only causes rapid
chain and sprocket wear but also affects the handlingand
controlof the motorcycle.
WARNING! Loose, worn or badlyaligned chains can
break or come off the sprockets.
If this occurs the chain can
jam the rearwheel and cause accidents with serious
prsonal injuryand damage to the motorcycle.
4.1 2 ADJUSTING 'THE REAR SHOCK
The shock is set up in the factory and has no user
adiustments.
SERVICING
1 - Check the spring for damage or wear.
2- Bounce the rearof the motorcycleup and down and
check that the rear suspension functions smoothly.
3- Check that the shock rod is perfectlystraight and that
there are no oil leaks around it.
4- Push the rearwheel sideways to check for play inthe
swingingarm bushings. Replace the bushings immediately
any play is detected.
4.13 ADJUSTING THE FRONT FORK
The front fork is set up inthe factory and has no user
adiustments.
SERVICING
1 - Check that the fork seals are clean and free from oil, dust
and dirt.
2- Check the legs for oil leaks. Replace damaged fork seals
beforeusing the motorcycle.
3- Apply the front brakeand bounce the Front of the
motorcycleup and down to check that the front fork
is
functioningsmoothly.
4.14 FUEL
2- Whenever you check chain tension, also check the chain Only use petrolwith an octane rating of
96 to 100or more.
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andthe front and rear sprockets for wear or damage. Incase of pre-ignition (knocking)try a different brandof fuel
3- Always lubricate the chain after washing the motorcycle. or a higher octane rating. Fuel tank capacity
is 3 litres.
Dirtychains can be cleanedwith diesel fuel.
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A good quality chain lube spray reduces chain wear and
improvesthe efficiency of the transmission.

4.1 5 FUEL FILTER
The fuel filter is incorporated inthe fuel tap under the tank.
As dirt buildsup in the filter itgradually impedes the Row OF
fuel to the carburettor.
For this reasonthe filter must be cleanedregularly.
SERVICING
1 - Drainthe fuel out of the tank into a clean petrol can.
2- Unscrewthe two fixing screws and remove the fuel tap
from the tank.
3- Wash the filter inwater with neutral soap.
Leove the filter dry, inthe sun if possible.
4- Replace the fuel tap on the tank, making sure that the seal
is Correctly seated.
A WARNING! Petrol is extremely inflammableand petrol
vapour can explode easily. Only drain the tank ina well
ventilatedarea and with the engine switched off. Refrain
from smoking and avoid all naked flames or sparks while
drainingfuel or refuelling.
4.1 6 WASHING THE MOTORCYCLE
Cover the following parts to preventwater from entering
bebrewashing your motorcycle:
- the throtflecontrol
- the brake controls
- the air intake and filter
- the exhaust hole.
Avoiddirecting
jets of water directly onto the following
parts:
- the wheel hubs
- the swinging arm pivot
- the steering heod
- the brakecallipers
- the spark plug hood.
Oncompletion of washing, lubricatethe above partsas
necessary then start the engine and leave it run for a
few
minutes.
A WARNING! Makesure-thatthe brakes are fully efficient
beforeyou start ridingthe motorcycle.
4.1 7 SUPERMOTARDVERSION
For the supermotard version assembly the providedfootrest
covers (photon.
34)) handlebarguards (photon. 35) and
fork guards for the rear wheel axe (photon. 36).
5. PRE-RACE INSPECTION AND PREPARATION
5.1 DAILY CHECKS: TO BE PERFORMED ALWAYS
BEFORE RIDINGTHE MOTORCYCLE
- Engine oil: check for leaks; check oil level.
- Carburettor: check that the throttle cable operates smoothly
and without sticking.
- Fuel filler cap: check for tightness.
- Air filter and filter box: check that filter and box are free
from dust and dirt.
- Brakes: check that the brakes lines are not kinkedor
pinchedand that the callipers are clean.
- Seat: check that the seat is correc+lyfitted and locked in
place.
- Chain: check that the chain is free from caked mud and
that it
is well lubricatedand correctly tensioned.
- Sprockets: check that the sprockets are free from dirt and
stones.
- Handlebars: check that the handlebarclamp bolts are tight.
- Tyres: check the tyre pressures.
- Front fork: check functioningand cleanliness.
- Steering: check the steering heod for play.

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%*= INSPECT/ADJUST
:g>= CLEAN
- m= LUBRICATE
",= REPLACE
A C = CAUTION!
- A W = WARNING!
X = Industy race conditions, clean the air filter after every heat.

STARTING KICK STARTER KICK STARTER
TRANSMISSION
4 SPEED 4 SPEED
FRAME STEEL STEEL
FRONT MECHANICAL BRAKE 0 150 mm. 0 190 mm.
REAR MECHANICAL BRAKE 0 150 mm. 0 150 mm.
FROMTYRE 2,50x12" 90/90- 1 0
REAR TYRE 2,75x10" 90/90- 10
FRONT SUSPENSION HYDRAULIC FORK,
0 33 mm
HYDRAULIC FORK, 0 33 mm
REAR SUSPENSION HYDRAULIC MONOSHOCK HYDRAULIC MONOSHOCK
FUEL TANK CAPACR
3 litres 3 litres
EMPTY WEIGHT 60 Kgs 60 Kgs
SEAT HEIGHT
725 mm. 725 mm.
WHEELBASE 1.061 mm. 1.061 mm.
The toque values listed in the
-
tables above cover the most
important nuts and bolts on the
motorcycle.
Apply the following standard
-
tighteningtoque values to all
nuts and bolts not listedabove.
-
-
I CHAMPKIN ZW I I 0,15 mm. / 0,006 in I
-
I
NGK CMSA
I
CYLINDER HEAD NUTS
CRANKSHAFT NUT, CLUTCH SIDE
CRANKSHAFT NUT, IGNrrlONSIDE
DRIVEN SHAFT NUT
SPARK PLUG
M6
MI 2
M8
10
60
27
18
10
1
6
2,7
1,8
1
7,40
444
19,98
13,32
7,40
LOCTITE 270
LOCTITE 242