Raybar BRAVO 150 User manual

RY-150BR
USER manual

PREFACE
Thank you for Choosing Raybar BRAVO 150/RY-150BR motorcycle. We wish you a happy and reliable riding.
We are committed to customer satisfaction. We strive to provide great user experience by product innovation and excellent after
sales support.
This user manual is guide for you to understand function of various parts, riding operation, maintenance schedule and basic
maintenance of your new Raybar motorcycle. Please go through this manual to understand your motorcycle before using it.
Please contact your dealer for detailed information about the product and for after sale services.

CONTENTS
Motorcycle identification............................................................................................................................................................... 01
View and part names
Front top view...................................................................................................................................................................... 02
Right side view......................................................................................................................................................................03
Left side view........................................................................................................................................................................04
Parts function..................................................................................................................................................................................05
Inspection before riding.................................................................................................................................................................. 11
Starting engine & riding operation...................................................................................................................................................12
Maintenance schedule....................................................................................................................................................................13
General inspection & repair............................................................................................................................................................. 14
Technical specification.................................................................................................................................................................... 16
Electrical circuit diagram................................................................................................................................................................. 18

Note - Frame number and engine number is usually required for vehicle registration and insurance purpose.
MOTORCYCLE IDENTIFICATION
(1)
Engine serial number is engraved on
crankcase assembly.
Vehicle identification number (VIN) is
stamped on steering head tube.
Frame number is engraved on the
steering head tube.
Engine Number VIN Number Frame Number

FRONT TOP VIEW
(2)
1. Rear view Mirror
2. Left handle bar switches
3. Fuel tank
4. Speedometer
5. Ignition switch
6. Right handle bar switches
1
1
5
6
2
4
3

RIGHT SIDE VIEW
(3)
1. Rear carrier
2. Tail lamp
3. Rear fender
4. Big foot rest
5. Muffler
6. Rear tyre
7. Front carrier
8. Head lamp
9. Front suspension
10. Front tyre
11. Front disc brake
12. Pedal brake
1
2
3
7
8
9
10
11
12
6
4
5

LEFT SIDE VIEW
(4)
1. Hand protector
2. Indicator
3. Engine
4. Front wheel
5. Pedal gear change
6. Main stand
7. Seat
8. Rear suspension
9. Chain case
10. Side stand
11. Rear wheel
1
7
8
9
10
11
2
3
4
5
6

PARTS FUNCTION
Meters and indicators
1. Tachometer- Displays RPM (revolutions per minute) of wheel.
2. Odometer – Records accumulated riding distance.
3. Speedometer – Displays riding speed of motorcycle.
4. “ ”High beam indicator–Indicator turns ON when head lamp is in high beam.
5. Gear Indicator – Displays current gear in which vehicle is operating.
6. Neutral gear indicator – Turns ON when transmission is in neutral gear position.
7. Fuel Gauge – It indicates level of fuel contained in fuel tank.
8. Turn signal indicator left & right – Flashes when left or right turn signal switch is operated.
9. Trip meter reset knob – Resets trip meter to zero.
10. Trip meter – Displays traveled distance between two points.
11. Ignition switch –
(a) OFF position – All electrical circuits are cut off. The engine cannot be started. The key can be removed in this position.
(b) ON position – The ignition circuit is completed. Engine can now be started. The key cannot be removed in this position.
(c) LOCK position – To lock the steering, turn the handlebar all the way to the left. Push down the key and rotate to “LOCK”
position, let the key come up and now remove the key.
(5)
1
46 118 8
275
3
9
10

Left handlebar control switches
1. Headlamp dimmer switch – This switch is used to change headlamp position from low
beam to high beam or vice versa .
2. Turn signal switch – Operate the switch when turning right or left by pushing the switch
towards right or left.
(a) Turn right position – The right turning lamp and right turn signal indicator on
instrument panel flashes.
(b) Turn left position–The left turning lamp & left turn signal indicator on instrument
panel flashes.
3. Horn switch – Press the switch to operate the horn.
4. Choke- This switch is used to stop air supply to carburetor, when rich mixture is to
required start the motorcycle during cold start.
5. Pass switch - It ignite high beam of headlamp for the time it is pressed.
(6)
1
2
4
5
3

Right handlebar control switches
1. Engine Stop switch –This switch is used to turn ignition circuit ON/OFF.
(a) Position: To turn ON ignition circuit. Engine can be started in this position.
(b) Position To turn OFF ignition circuit. Engine cannot be started in this position.
2. Electric starter switch – When this switch is pressed, starter motor cranks the engine. This
switch should not be pressed over 5 seconds continuously.
3. Headlamp switch –
(a) Position “ “ – The headlamp , front parking light and tail lamp are turned ON.
(b) Position “ “ – All lamps are turned OFF.
(c) Position “ ” – Front parking lamp and tail lamp are turned ON.
Fuel tank& Fuel tank cap
The capacity of the fuel tank is 14.5L, including reserve fuel.
(a) Opening fuel tank cap - To open the fuel tank cap insert the key and rotate it 90° in
clockwise direction, now fuel tank cap can be taken out.
(b) Closing fuel tank cap - To close fuel tank cap, align the latch on the tank cap with the
groove on the oil filling neck, push the cover down and take out the key.
(c) Fuel filling – Make sure that tank is not over filled. The gasoline is inflammable, so
engine should be stopped before fuel filling. Fuel filling should not be done near fire
and don't smoke while fuel filling.
(7)
1
2
3

Fuel cock
The fuel cock is 3 way fuel flow regulator. It has 3 options OFF, ON and RES.
(A) OFF – When the vehicle is not to be used, rotate the knob until it comes to OFF position. This will stop the fuel flow to the
carburetor.
(B) ON – To start the fuel flow to carburetor, rotate the knob and bring it to ON position.
(C) RES – When the main fuel capacity runs out in ON position you can use reserve fuel capacity. To use reserve fuel capacity,
rotate the knob and bring it to RES position. Please add fuel as soon as possible when you start using reserve fuel.
OFF ON RES
(8)

Fuel filter
A fuel filter is a filter in the fuel line that screens out dirt and rust particles from the fuel.
From fuel tank, fuel goes to carburetor after passing through fuel filter.
Throttle
It controls the fuel air mixture flow from carburetor to engine. To increase the speed of
the vehicle, rotate throttle in backward direction and to decrease the speed of the vehicle,
rotate throttle in forward direction.
Pedal gear change
Pedal gear change is used to change gear position. To change gear position, press pedal gear
change up or down by foot, as per gear change pattern. Please use clutch while changing
gear.
Tyre
Proper tyre pressure will provide maximum stability, mileage, riding comfort and tyre life.
Check tyre pressure frequently and adjust if necessary. Select the right replacement tyres in
accordance with the tyre sizes given in table below -
Tyre Size Front 3.00-18
Tyre Size Rear 3.25-18
(9)

Starting lever or Kick
This is used to start the engine manually. To start the engine by kick, you need to place your
foot on the lever and push it downwards quickly.
Pedal brake
This is used to apply braking force on rear wheels. When you want to stop the vehicle or
reduce speed, you need to press the pedal brake in downward direction.
Clutch lever
Clutch lever can be operated when you want to shift gears. Operation of clutch stops power
transfer from engine to transmission. To operate clutch, you need to pull clutch lever towards
yourself.
Front brake lever
This is used to apply braking force on front wheels. When you want to stop the vehicle or
reduce speed, you need to pull front brake lever towards yourself. Always apply front and
rear brake together
(10)

In order to ensure your safety, make a general inspection before riding according to the table given below –
Inspection before riding
No. Item Inspection Remark
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
For the vehicles with different riding miles
and performance, please adopt different
maintenance.
1. Elementary maintenance:
1000km~2000km riding, please
lubricate & check tyre pressure.
2. Secondary maintenance:
3000km~6000km riding, please check
wear and tear of parts and tighten
fasteners.
3. Advanced maintenance:
6000km~10000km riding, please
disassemble, inspect and do
troubleshooting.
4. Inspect and maintain your motorcycle
at professional maintenance station or
service center.
Fuel system Check fuel capacity and fuel leakage
Carburetor Check carburettor for fuel leakage and idle speed for stability and proper
acceleration.
Lubrication oil Check luboil for quality and whether level is lower than the low scale mark.
Electrical system Check electrical system for proper functioning.
Battery Check battery for any leakage or spillage and acidic corrosion.
Clutch/Front brake lever Check whether free stroke is appropriate and clutch can be separated and
meshed normally.
Gearshift/Rear brake
pedal
Check gearshift for flexibility and stability and whether free stroke of brake
pedal is appropriate.
Throttle lever Check throttle lever for flexibility and stroke of 2~6 mm.
Steering mechanism Check steering mechanism for flexibility and stability
Check chain for abrasion and lubrication
Chain
Tyre/Wheel Check tyres for pressure and abrasion
Check Headlamp/Tail lamp/turning lamps for proper functioning.
Headlamp/Tail lamp/
Turning lamps
Brake Check brake disc/ brake pad/brake shoe for abrasion and proper functioning.
Main/Side stand Check whether main stand and side stand are bended or deformed and whether
they can return well.
Fasteners Check fasteners for looseness and possibility of falling.
(11)

Starting Engine - Follow below mentioned steps to start the vehicle :
1. Unlock steering, and turn ignition key to “ON”position. Shift gear to“N”neutral
position or pull clutch lever.
2. Grip front brake lever or press rear brake pedal.
3. Press kick downwards powerfully with foot or press electric starter switch with right
thumb.
4. Rotate throttle backwards to add proper volume of fuel to start motorcycle. Once
motorcycle has started, return kick lever. Preheat 3~5 minutes at idle
speed(1500±100)r/min.
Riding Operation - After starting and preheating, return main and side stand. Now hold clutch
lever and pull it towards yourself. Then press pedal gear change with left foot and shift to the
first gear.
(A) Release the brake lever.
(B) Rotate throttle slowly to accelerate and release clutch lever slowly, this will give
acceleration to motorcycle.
(C) Once clutch lever is released completely and motorcycle reaches to a certain speed,
shift the gear from lower to upper by using clutch.
Starting engine & riding operation
accelerate
slow down
accelerate
slow down
(12)

Maintenance schedule
Perform maintenance according to the odometer reading or time interval, whichever comes first.
NOTE : Inspect and clean, adjust, replace or lubricate as necessary,I=Inspect,C=Clean, R=Replace, T=Tighten.
TOOLS - To assist you in the performance of periodic maintenance, a tool kit is supplied.
Km Initial 1000 km Every 4000 km Every 8000 km
Miles 600 2400 4800
Months 5 20 40
I I -
T T -
I I -
I I -
I C R
I I -
R R -
I I -
I I -
C - C
I I -
I I -
I I -
- I I
I T -
Clean every 3,000km Replace every 12,000km
Valve clearance
Clean and lubricate every 1000km
Brake
Tyres
Steering
Spark plug
Fuel hose Replace every four years
Engine oil and oil filter
Carburetor
Clutch
Front fork and rear suspension
Chassis bolts and nuts
Interval
Item
Fuel strainer cup
Drive chain
Battery ( Specific gravity of electrolyte )
Cylinder head nuts & exhaust pipe bolts
Camshaft drive chain
Air cleaner
(13)

Check and replacement of engine oil
Engine oil level check
(1) Stop the engine and park the motorcycle with main stand vertically in flat surface.
(2) Wait for one minute and then check the oil level through the engine oil level sight glass.
Replacement of engine oil
Following procedure needs to be followed to replace oil -
(1) Park the motorcycle vertically with main stand in flat surface.
(2) Remove the oil filler cap.
(3) Drain the oil by removing the drain plug located on the bottom of the engine.
(4) Once used oil is drained completely tighten the drain plug, fill engine with new engine
oil. Tighten the filler cap. Do not over tight the filler cap.
(5) Start engine in idle speed for 2~3 minutes.
(6) Stop the engine and wait for a minute. Inspect the engine oil level through the engine
oil level sight glass. Make sure that oil level is appropriate.
General inspection & repair
(14)
oil dip kit
top line bottom line

Check and replace
1. Disconnect the spark plug cap from the spark plug.
2. Clean any dirt from around the spark plug base. Remove the spark plug by using the plug wrench.
3. Inspect the electrodes for erosion or carbon deposit. If the erosion or deposit is heavy, replace
the plug. If there is small carbon deposit, clean carbon deposit with a plug cleaner or use a wire
brush.
4. Check the spark plug gap using a wire-type feeler gauge. The spark plug gap should be 0.6-0.7mm. If adjustment is required, bend the side
electrode carefully. Make sure the plug washer is in good condition.
5. With the plug washer attached, tighten the sparkplug initially by hand to prevent cross threading and then tighten it by spark plug wrench.
6. Reconnect the spark plug cap.
General inspection & repair
Clean the air cleaner
At least once after every 4000Km, clean and immerse the air cleaner element into engine oil. If you drive your motorcycle in a dusty condition,
more frequent cleaning will be required.
Carburetor idle speed adjustment
Start up the engine and let the engine run until it warms up fully. After engine has warmed up, close the throttle and turn the idle speed adjuster
screw clockwise or anti-clockwise so that the engine may run at 1500r/min. The idle speed increases when the bolt is turned clockwise and the
idle speed decreases when the bolt is turned anti-clockwise. Idle speed of the carburetor should always be optimum. If the idle speed is not
appropriate, make sure to adjust the idle speed bolt once again.
Spark plug
(15)
0.6-0.7 mm

Technical specification
Cooling Air cooled
No. of cylinders 1
Type (CG or CB) CG
Balanced or Non balanced Non balanced
Displacement/Capacity 150 CC
Max. Power 9.0kw/8500r/min
Max. Torque 11.0N.m/7500r/min
Bore x Stroke 62.0×49.9
Compression Ratio 9.4:1
Starting Electric/ Kick start
Top speed 96 KM/H
Mileage (Litres/100 kms) 2.1L/100km
Carburetor PZ27
Clutch Wet multi plate
Gear box 5 speed
Front Telescopic
Rear Spring coil type
Engine Specification
Transmission & Chassis
Suspension
Front Brake Disc
Rear Brake Drum
Brakes
(16)

Technical specification
Wheel Size Front 1.6×18
Wheel Size Rear 2.15×18
Tyre Size Front 3.00-18
Tyre Size Rear 3.25-18
Tyre Type (Tubeless or with Tube) With tube
Battery DC-12V7AH
Head Lamp 12V/35W
Head Lamp Type (Normal/LED) Normal
Tail/Stop Lamp 12V/21W/5W
Tail Lamp Type (Normal/LED) Normal
Turn Signal Lamp 12V/1.3W
Turn Signal Lamp Type (Normal/LED) LED
Ignition system A/C CDI
Speedometer Mechanical with LED
Length (mm) 2040
Width (mm) 780
Height (mm) 1120
Wheelbase (mm) 1182
Ground Clearance (mm) 170
Fuel Tank Capacity (Litres) 14.5
Kerb Weight (kg) 135
Dimension
Electrical/Control System
Wheels & Tyres
(17)