Rewaco FX4 Troubleshooting guide

Operating Instructions and Service Manual
for the models FX4 / FX5 / FX6 / RF1

2General
Vehicle Data
Vehicle Ident. No. W09 1 LR38
Vehicle Type
Engine No.
Manufacturer's Order No.
Date of delivery
Stamp of delivering rewaco partner dealership
This vehicle with the regi-
stration number belongs
to:
Name
Street
City
Telephone
Date of 1st registration
rewaco Partner dealership
Vehicle owner

General 3
Foreword
You have decided in favour of a rewaco Trike - thank you
for your confidence.
So that you do not experience any difficulties when handling
your rewaco trike we recommend that you read these
operating instructions as soon as possible.
The expert handling, as well as regular care and mainte-
nance contribute towards the value retention and are also a
pre-
requisite for guarantee claims.
Your rewaco Spezialfahrzeuge GmbH
Informative notes
The texts marked with this sign and with grey
underlay, point to additional information or possible
danger of accidents and injuries.
These operating instructions contain important information
for the use, care and maintenance of the vehicle. It must
therefore be read carefully by the driver prior to driving the
vehicle for the first time.
!

4General
List of Contents
Before starting your first trip 5
Instruments and Operating Elements 6
Service brake 7
Parking brake 7
Ignition light switch 7
Switch device 7
Pilot lights 8
Instruments 8
Driving 10
Running-in rules 10
Running-in rule for the brake 10
Before starting out on a trip 10
Starting the engine 11
Cold start 11
Parking the vehicle 11
Starting with manual gearshift 11
Servobrake 12
Braking in bends and on slippery road surfaces 12
Pedal adjustment 12
Luggage boot 12
Driving safely 14
Operating Instructions 15
Accessories 15
Emergency reflective triangle and first-aid kit 15
Maintenance and Care 16
Checking engine and gear oil level 16
Checking coolant level 17
Checking the brake fluid 17
Checking the battery 17
Wear of brake pads 18
Tyre pressure and wear 18
Cleaning plastic and aluminium parts 18
Cleaning and caring for the bodywork 18
Inspection intervals 18
Malfunctions 19
Vehicle electrical system 19
Lack of engine output 20
Lack of braking power 20
Technical data 20
Tyre pressure 20
Lubricants 21
Coolant 21
Brake and clutch fluid 21
Fuels 22
Load 22
Dimensions and load 23
Service Scope 27
Service Certificates 28

Before starting your first trip 5
Before starting your first trip
Before starting the first trip the driver must undergo
special instructions for the trike. The supplying dealer
or an experienced driver must conduct the instruction.
The following points should be taken into consideration
when instructing the driver:
• Instruction of vehicle driver about wearing eye
protection, a helmet and protective clothing
• Instruction about the operating elements of the vehicle
• Instruction run for the new driver as passenger
• Behaviour in bends
• Vehicle width
• Braking behaviour
• Behaviour in dangerous situations
• Practical instruction of driver on the vehicle
!

6Instruments and operating elements
Instruments and Operating Elements (The individual items can vary slightly depending on model)
1 Speedometer
2 Revolution counter
3 High beam control lamp (see pg. 8)
4 Generator (see pg. 8)
5Oil pressure pilot light (see pg. 8)
6 Pilot light brake fluid level (see pg.)
7 Steering fork lock
8 Blinker control lamp (see pg. 8)
9Pedal adjustment (see pg. 12)
10 Brake pedal
11 Switch device (see pg. 7)
12 Voltage indicator (see pg. 9)
13 Coolant temperature indicator
and Oil temperature indicator (see pg. 8)
14 Ignition lock (see pg. 7)
12
11
1 2
13
14
15
16
3
4
5
6
7
8
9
10
17
18
15 Fuel gauge (see pg. 9)
16 Warning blinker
17 Clutch pedal
18 Handbrake lever

Instruments and operating elements 7
Service brake
The vehicle is equipped with a dual circuit integral brake
system. The action is designed so that one circuit acts on
the rear axle and one circuit on the front axle.
If a malfunction should occur, the braking power will be
reduced. In this case you should park the vehicle in a safe
place and immediately visit a rewaco partner dealership.
Normal operation of the vehicle is no longer possible.
Parking brake
The parking brake has a mechanical action on the rear
wheels. When parking the vehicle on an inclining road,
the vehicle should also be put into first gear.
The detailed information for maintenance and what to do
in the case of malfunction of the service brake also apply
here.
!
Ignition light switch
Switch device
Switch positions:
P = Parking light
0= Zero position
1= Ignition on
2= Side light
3= Dipped beam
Switch positions:
= Start engine
= High beam
= Dipped beam
= Blinker left
= Blinker right
= Blinker off (press)
= Horn
P
01
2
3
OFF
OFF
inactive

8Instruments and operating elements
= Blinker pilot light
= Pilot light brake fluid level
= Oil pressure pilot light
= Generator
= High beam pilot light
!
Action to be taken when the following pilot lights illuminate:
= Brake fluid level too low - visit a dealer
= Motor oil pressure too low / malfunction of vehicle's electric system -
Park vehicle in a safe place and visit rewaco partner dealership.
!
Pilot lights
Cold range (to 90°C)
The coolant temperature indicator
only works when the ignition is
switched on. If the pointer is still
in the left range of the scale,
the engine has not yet reached
operating temperature - avoid
high engine speed, full throttle
and high engine load.
Coolant temperature indicator
Normal range (90° - 100°C)
The engine has reached operating temperature when the
pointer settles in the middle range between 90°C and
100°C. In the case of high motor load or high outside
temperatures the operating temperature may rise further
for a short time. This is still a safe range.
If the pointer remains above 110°C over a longer period
however, you should check the coolant level (see page 17).
If the pointer again rises above 110°C after a
short drive, park the vehicle safely to avoid damaging
the engine and contact a rewaco partner dealership.
Cold range (to 60°C)
The oil temperature indicator
only works when the ignition is
switched on. If the pointer is still
in the left range of the scale,
the engine has not yet reached
operating temperature - avoid
high engine speed, full throttle
and high engine load.
Oil temperature indicator

Instruments and operating elements 9
!
!
Normal range (60° - 130°C)
The engine has reached operating temperature when the
pointer settles in the middle range between 60°C and
130°C. In the case of high motor load or high outside
temperatures the operating temperature may rise further
for a short time. This is still a safe range.
If the pointer remains above 130°C over a longer period
however, you should check the oil level (see page 16).
If the pointer again rises above 130°C after a
short drive, park the vehicle safely to avoid damaging
the engine and contact a rewaco partner dealership.
Operating voltage is
12.5 - 14.2 volt
It the operating voltage
does not reach 12.5 volt or
exceeds 14.2 volt, please
contact a rewaco partner
dealership.
The fuel gauge works only when
the ignition is switched on.
When the pointer moves towards
the zero position you should visit
a petrol station and refuel.
Please see page 22 for type
of fuel.
Fuel gauge
Voltage indicator

10 Driving
Driving
Running-in rules
The first 1,000 km (max. 2/3 of the nominal revs.)
During the first operating hours and until all moveable parts
have reached perfect interaction, the engine is subject to
higher inner friction. The degree of running-in achieved
mainly depends on the driving style of the first 1,000 km.
Running-in rule for the brake
The brake of a new vehicle also needs a running-in time
on the first 100 to 200 km.
Running-in the brake pads leads to longer stopping
distances, resp. braking paths of the vehicle.
!
!
Before starting out on a trip
The operational safety of the vehicle is a prerequisite for dri-
ving safety. That is why the vehicle must be checked prior to
driving.
• Function of lights and blinker system
• Cleanliness of headlights and lamps
• Setting of rear vision mirrors
• Fuel level
• Efficiency of brake system
• State of the tyres
Additionally at regular intervals and before longer trips:
• Tyre inflation pressure (at least every two weeks)
• Oil level of engine (at least every 1,000 km)
• Brake fluid level
Wear a helmet and eye protector on every trip,
even short ones. The wearing of a helmet by driver and pas-
senger is prescribed by law.

24
13
R
Driving 11
!
!
Starting the engine
Before starting the engine, put the gearbox into idle. While
starting, press down the clutch and press the starter button
for the starting motor. As soon as the engine starts, release
the starter button. Do not let the engine run warm while
standing, drive off immediately.
Be careful when starting the engine in closed rooms -
danger of poisoning
Cold start
Start engine without operating the accelerator grip. The
engine is managed by a Motor Management feature.
Parking the vehicle
When parking the vehicle on a sloping road, you must apply
the parking brake and put the vehicle into first gear.
Starting with manual gearshift
24
13
R
5
Attention! When the catalyser is hot, do not park the
vehicle on an inflammable surface - fire danger!
Gear shift scheme:
FX4 / FX5 / FX6
Gear shift scheme: RF1
With models
FX4 / FX5 and
FX6 please lift the
locking catch to
shift into reverse
gear.
Your vehicle is equipped with a mechani-
cal gearshift with 4 or 5 forward gears
and one reverse gear.
You must press down on the clutch
before engaging the gears.
Adjust engine output so that the front tyre
does not rise in the air when driving off,
as the vehicle cannot be steered in this
state.

12 Driving
!
!
Servobrake
This vehicle is equipped with a servobrake, it increases
the pressure you generate with the brake pedal.
The servobrake only works when the engine is running.
Please note that the brake effect is reduced when the
engine is turned off and you need to push the brake pedal
harder than usual!
Braking in bends and on slippery
road surfaces
Sharp braking or blocking of the wheels must be avoided in
bends, as controlled driving or steering becomes impossible
otherwise. The driving style must be adjusted to road and
weather conditions.
Pedal adjustment
For vehicles with pedal adjustment you have the option of
adjusting the brake and clutch pedals to your body height
in two or three steps.
Please have the pedal adjustment carried out by a
rewaco specialist workshop, as certain settings for
fastening need to be observed.
(The tightness torque of the screw connection is 28 Nm)
!
Luggage boot
All items of luggage or other items must be secured safely
in the luggage compartment or on the storage surfaces
provided. Pay attention that the maximum permissible load
(see pg. 23) of the vehicle is not exceeded.
Items which have not been secured and fall around
in the luggage compartment can influence driving safety
or driving quality of the vehicle.
The first and reverse gear may only be engaged when the
vehicle is standing.

Driving 13
1Service box
2 Glove box
3 Boot
The boot latch/unlatch
mechanism is located
in the service box
1Pull spring
slightly towards
you to close
1 2
3
Luggage boot: FX4 / FX5 / FX6
The models FX4, FX5 and FX6 can be
optionally equipped with a Topcase. This Topcase
offers the option of storing your luggage and
protecting it against theft.
Luggage boot: RF1
The model RF1 is series equipped with an integrated boot
and glove compartment (only RF1 GT).
1
2
3
Service box
1Tank cap
2Dipstick
3Boot latch
In the open state the Topcase lid is held by an upright
spring. To close the Topcase lid, please pull the centre
of the spring lightly towards you, as shown in the figure,
and the lid will close.
1
open close

14 Driving
Glove box and Saftybag
The glove box, located in driving direction on the right hand
side, next to the passenger seat, is ideal for small items of
luggage such as wallet, mobile phone, key ring etc.
Items which need to be protected from moisture should be
stored in the rewaco Saftybag first. (optionally available)
Driving safely
Always adjust the driving speed to the road surface and
weather conditions. Aquaplaning can occur on wet roads.
This may lead to a loss of steering and braking capability
of the vehicle. When driving on long, severe inclines the
vehicle brake must be assisted by the engine braking action.
A correspondingly low gear must be selected,
which assists the braking effect.
The rewaco Saftybag protects against moisture (optionally available)
On model RF1 LT you find the dipstick under
the hood with the passenger seat/s.
1
RF1 LT engine
compartment
1Dipstick

!
Operating Instructions 15
Emergency reflective triangle and
first-aid kit
As a trike is a multitrack vehicle, it is recommended
where not already regulated by law, to carry an emergency
reflecting triangle and a DIN approved first-aid kit.
(optionally available)
Operating Instructions
Accessories
Before buying accessories and making technical changes
you should always consult your rewaco contract dealer.
You can buy released accessories and original rewaco
parts from your rewaco contract dealers.
In your own interest we recommend that you use only
accessories released by the manufacturer and original
rewaco parts for your trike.
The reliability, safety and suitability especially for rewaco
trikes have been tested for these accessories and parts.
For other products - even when acceptance by an officially
authorized technical testing and inspection association or
an official approval are available - we cannot assess this
despite current market observation and cannot take liability
for this.

!
16 Maintenance and Care
Maintenance and Care
Regular competent care retains the value of the vehicle and
is the prerequisite for maintaining the vehicle guarantee.
The best protection for the trike from damaging environmen-
tal influences, particularly in winter, is a regular wash and
preservation of bodywork colour/chrome and aluminium
parts.
The longer road salt, road and industrial dust, insect residue
and bird excrements, etc. can act on the vehicle parts, the
more lasting the damage.
Please use suitable and specially indicated products for
the care.
Despite constant quality controls, malfunctions of
the vehicle cannot be excluded. In this case, please turn
directly to the manufacturer/importer or to one of our
rewaco partnership dealers, so that immediate rectification
can be carried out to your satisfaction and to avoid any pos-
sible consequential damages.
Damage which indicates inadequate care of the vehicle
does not fall under warranty claims.
Checking engine and gear oil level
FX4/FX5: The dip stick is located on the engine
FX6: The dip stick is located on the lid underneath
the passenger seat
RF1: The dip stick is located in the service compartment
(GT, see pg.13) engine compartment (LT, see pg.14)
The engine oil level must be checked every 1,000 km, the
oil level must be between the min. and max. mark on the
dipstick. If there is a lack of engine oil, top up the missing
amount through the engine oil filler neck (see figures) in the
engine compartment.
It is not necessary to check the gear oil level of the manual
gearbox between the intervals specified in the service plan.
1Engine oil filler neck 2 Dip stick
1
11
2
2
FX4 / FX5 FX6 RF1

!
!
Maintenance and Care 17
Checking coolant level (applies only to RF1)
The coolant equalizing tank is located in the engine
compartment. The cooling level can really only be
checked properly when the engine is switched off.
Read the coolant level from the coolant equalizing tank.
With a cold engine it must be at the level of the container
seam. If the engine is warm it may also lie slightly above
the container seam.
The cooling system is under pressure! Do not open
the lid of the coolant equalizing tank when the engine is
hot - there is danger of scalding.
Checking the brake fluid
The brake fluid reservoir is located underneath the tank dummy.
The state of the brake fluid is also checked within the scope
of an inspection service.
Over time, brake fluid absorbs moisture from the environ-
mental air. A too high moisture content of the fluid can
lead to damage of the brake system. You should therefore
have the brake fluid checked regularly by a rewaco partner
dealership.
Checking the battery
With the models FX4 / FX5 / FX6 the battery is located
underneath the passenger seat and with the RF1 under
the driver's seat.
The batteries are practically maintenance free under normal
operating conditions. If the external temperatures are very
high it is recommended to check the acid level at regular
intervals. It should always lie between the min. and max.
marker. A low acid level should be corrected by a rewaco
partner dealership.
Battery acid is corrosive and must not come in contact
with your eyes, skin or clothing.

18 Maintenance and Care
!
!
Wear of brake pads
The wear of brake pads is largely dependent on the
conditions of use and the driving style. The maintenance
of the braking system must be carried out in an expert work-
shop in accordance with the prescribed inspection
and maintenance intervals.
Tyre pressure and wear
Too high or too low tyre pressure not only impedes driving
safety of the trike but also has an effect on their wear. The
tyre pressure should therefore be checked twice a month
of before and after a longer trip. (see pg. 20)
Cleaning plastic and aluminium parts
If normal washing is insufficient, plastic and imitation
leather may only be treated with special plastic cleaners.
Aluminium parts should be cleaned regularly and
preserved.
Cleaning and caring for the bodywork
Frequent washing will keep up the value of your vehicle.
Treat the bodywork and paint with preserver and polish
from time to time.
There will be no guarantee accepted when applying and
removing stickers, decorative strips and similar materials.
Inspection intervals
The maintenance inspection intervals are described in the annex.
The necessary work and controls may only be carried out by
rewaco partner dealerships. The execution of this work is certified
in this service book.
Warranty claims may only be made directly with the
manufacturer/importer or a rewaco partner dealership.
If defects are to be rectified within the scope of the legal
warranty guidelines by an expert workshop which is not
authorised by the manufacturer or importer, a written
approval from the manufacturer or importer must be
available to carry out the work.

Malfunctions 19
!
Malfunctions
Vehicle electrical system
The control panel is located behind the passenger seat.
Blown fuses must be replaced.
Reserve fuses are located in the free slots on the control
panel. Please proceed as follows when changing a
defective fuse:
• Switch off the ignition and the affected electric load
• Find out which fuse belongs to the failed electric
load (see right side)
• Remove the concerned fuse
• If the fuse has blown (you can recognise this by the
molten metal strip), replace it with a fuse of the same
strength
If the malfunction cannot be rectified by exchanging
a defective fuse, the electrical system must be checked
as quickly as possible by a rewaco partner dealership.
Multiple changes of a defective fuse can lead to further
damage.
Fuse assignment, control panel:
110 A
210 A
3
4
515 A
615 A
715 A
810 A
910 A
10 20 A
25 A 20 A 20 A
25 A 20 A 15 A
radiator
fan
low beam
light
high
beam
control
unit
blinker
fog
light
starter
20 A
two tone
horn
fuel
pump
1 Engine control
2 Warning blinker switch
3 Free
4 Free
5 Generator / reverse light
6 Combined instruments /
Tank dummy
7 Brake light
8 Side light, right /
Rear fog light
9 Side light left
10 Engine control

!
!
!
20 Malfunctions / Technical data
Lack of engine output
If engine output is lost while driving, please park the
vehicle as quickly as possible in a safe place (approach
next available parking opportunity or parking place).
If the ignition of one cylinder fails, the catalyser of your
vehicle will be destroyed. Park the vehicle at a safe place
and visit the next closest rewaco partner dealership for an
inspection.
Lack of braking power
If you discover a loss of braking power or changed
braking behaviour while driving, stop the vehicle at
moderate speed. Have the braking system checked by
an expert workshop.
Technical data
Tyre pressure
Front tyre: Inflation pressure PSI KPA
150/60 ZR 17 1,3 - 1,4 bar 20 140
180/55 ZR 17 1,8 - 2,0 bar 29 200
200/50 ZR 17 1,8 - 2,0 bar 29 200
Rear tyres:
275/40 ZR 17 2,0 - 2,2 bar 32 220
285/35 ZR 18 1,9 - 2,1 bar 30 210
295/50 R 15 1,6 - 1,7 bar 25 170
335/30 ZR 18 1,9 - 2,1 bar 30 210
Please control also regularly the wheel bolts.
(The tightness torque of the screw connection is 110 Nm)