Sachs Bikes SAXY 25 User manual

Your Sachs dealer
SACHS
uses
and recommends
Sachs Fahrzeug- und Motorentechnik GmbH
Ernst-Sachs-Straße 6 • D-90441 Nürnberg
Phone: +49 (0)911 4231 400 • Fax +49 (0)911 4231 332
e-Mail: info@sachs-bikes.de • www.sachs-bikes.de
Nr. P00 638 008 00 02 000 2006 05 005

SAXY 25/45
owners manual

PREFACE
Reprinting, reproduction and translation,
even of excerpts, without our express
consent is not permitted. All rights stipula-
ted in the copyright law remain expressly
reserved.
Technical changes to the standard motor-
cycles can cause the EC type approval to
become invalid. Therefore before imple-
menting a change, ask a specialized dealer
whether this is allowed.
We cannot be held liable for any conse-
quential damage caused by accessories
not approved by the factory.
The scope of delivery and version of the mo-
torbike is solely determined by the purchase
agreement concluded with the dealer.
This operating manual includes important
instructions for handling your light motor-
cycle. Read it carefully, because professi-
onal handling combined with regular care
and maintenance helps to maintain the
motorbike’s value and is one of the require-
ments for warranty claims.
We wish you at all times a safe journey.
Your
SACHS Fahrzeug- und Motorentechnik GmbH
You have purchased a Saxy,
congratulations and thank you for
putting your trust in us.
The Saxy is a sturdy motorcycle in modern
design.
Its sound construction, the meticulous
selection of materials, the advanced ma-
nufacturing techniques and conscientious
work of dedicated employees provides the
motorcycle with all the characteristics that
are typical of Sachs, such as economical
operation, quality, reliability and its lasting
value.
Sachs GmbH is continuously involved in
the further development of all types and
models. We therefore ask you for your kind
understanding that we reserve the right to
change the scope of delivery with respect
to appearance, equipment and technology.
No claims can thus be derived from the
data and descriptions contained in this
instruction manual.

1
CONTENTS
RIDING INSTRUCTIONS
Ride safely............................................................................... 19
Ride economically and be aware of the environment......... 20-21
Running-in instructions ............................................................ 22
Side stand................................................................................ 23
Starting .................................................................................... 24
Starting with kick starter .......................................................... 25
Starting with electric starter..................................................... 26
Braking ............................................................................... 27-28
Stopping the engine................................................................. 29
Steering lock............................................................................ 29
SERVICE INSTRUCTIONS
Servicing the motorbike / cleaning agents.......................... 30-31
Operation in winter and anti-corrosion protection.................... 32
Repairing paint damage / servicing the tyres .......................... 33
Lay-up / commission................................................................ 34
Technical changes, accessories and spare parts.................... 35
OVERVIEW AND OPERATION
Safety symbols .......................................................................... 3
Side views .............................................................................. 4-5
Engine ....................................................................................... 6
Handlebar fittings....................................................................... 7
Ignition lock................................................................................ 8
Cockpit....................................................................................... 9
SAFETY TEST
Checklist .................................................................................. 10
Fuel, fuel tank.......................................................................... 11
Fuel tap.................................................................................... 12
Engine oil................................................................................. 13
Checking the oil level............................................................... 14
Brakes ..................................................................................... 15
Drive chain............................................................................... 16
Tyre profile, tyre pressure and size.......................................... 17
Load / lights ............................................................................. 18

2
CONTENTS
NOTES ON MAINTENANCE
Checking steering bearing....................................................... 36
Checking the telescopic fork and shock absorber ................... 36
Removing the front wheel........................................................ 37
Installing the front wheel.......................................................... 37
Removing the rear wheel......................................................... 38
Installing the rear wheel........................................................... 38
Adjusting the front and rear brake ........................................... 39
Checking, adjusting the drive chain......................................... 40
Cleaning the air filter................................................................ 41
Cleaning the fuel filter.............................................................. 42
Spark plug ............................................................................... 42
Adjusting the play of the twist grip throttle control ................... 43
Battery ................................................................................ 44-45
Changing the bulbs ................................................................. 46
Adjusting the headlight ............................................................ 47
TECHNICAL DATA
Engine ..................................................................................... 48
Power transmission ................................................................. 49
Chassis.................................................................................... 50
Lubricants and operating fluids ............................................... 51
Electrical Equipment................................................................ 52
Dimensions and weights.......................................................... 53
WARRANTY AND SERVICE DATA
Warranty conditions ................................................................. 54
List of wear parts ................................................................ 55-56
Inspection plan ................................................................... 57-59
Maintenance confirmation .................................................. 60-63
Motorbike data / Rating plate................................................... 65

3
Observe the following:
WARNING
Precautionary measures against the risk of
accidents, injury and/or death.
FIRE HAZARD
The bike is supplied with a catalyst.
The exhaust system becomes very hot.
While riding, idling or parking, make sure
that no easily inflammable materials (such
as hay, leaves, grass, coverings, luggage,
etc.) can come into contact with it.
Safety symbols and notes
OVERVIEW AND OPERATION
CAUTION
Important instructions and precautionary
rules to be followed in order to prevent
the motorbike from being damaged. Non-
observation can lead to the guarantee
becoming void.
NOTE
Special instructions for better handling
during operation and inspection and when
carrying out adjustment procedures and
service activities.

4
1
3
4
5
2
1 Chassis number and rating plate
2 Fork column lock
3 Kick starter
4 Footrest
5 Battery and fuse
OVERVIEW AND OPERATION

5
67
8
10
11
12
9
13
14
6 Cockpit
7 Handlebar fittings
8 Tank cap
9 Fuel tap
10 Shock absorber
11 Side stand
12 Footrest
13 Main stand
14 Air filter housing
Left-hand side view
OVERVIEW AND OPERATION

6
1
4
2
3
9
5
6
7
8
10
1 Carburetor
2 Oil drain plug
3 Engine number
4 Footrest left
Engine left-hand side view
5 Spark plug connector
6 Electric starter
7 Footrest right
8 Oil filler cap
9 Kick starter
10 Oil level sight glass
Engine right-hand side view
OVERVIEW AND OPERATION

7
1 2
3
4
7
5
86
Right-handle handlebar fittings
Left-handle handlebar fittings
1 Handbrake lever rear brake
2 Choke lever ( )
3 Emergency off switch
4 Push-button: horn
5 Handbrake lever front brake
6 Throttle
7 Direction-indicator switch
Switch to the left:
Left indicator on
Switch to the right:
Right indicator on
8 Starter button
OVERVIEW AND OPERATION

8
2
3
1
Ignition-lock
NOTE
With the motorbike you get two indefinite
ignition keys. Keep the spare keys at a
safety place.
The ignition-lock is operated with a sepa-
rate key.
The tank cap as well as the steering lock
are operated with the same key.
Key positions
1 Ignition off
2 Operating position: ignition and all
circuits activated
3 Ignition and lights on
WARNING
While riding, do not switch the ignition
off !
OVERVIEW AND OPERATION
NOTE
Activate the parking light only for a limited
period. Take into account the charge of the
battery.
The key can be removed in positions .

9
3
1
2
OVERVIEW AND OPERATION
Cockpit
Speedometer
1 KM/H -odometer
2 DST - total distance (km)
Instrument lights
3
left and right direction indicator
green

10
Before each ride, carry out a safety
check using the checklist.
Take the safety check seriously. Carry out
maintenance activities before you start
your ride (
MAINTENANCE) or ask a
specialized Sachs dealer to do so. This will
provide you with the certainty that your mo-
torcycle corresponds to traffic regulations.
A technically faultless motorcycle is a basic
requirement for the safety of both yourself
and other road users.
Before starting your ride, check the fol-
lowing:
– Steering (smooth and free of play)
– Clutch lever play
– Fuel quantity
– Engine oil (level)
– Front brake
– Rear brake
– Tyres (profile and pressure)
– Telescopic fork
– Load / lights
– Total weight
– Lights
– Clutch operation
– Brake fluid (level)
– Brakes (operation)
In case of problems or difficulties, contact a
Sachs dealer, who will do everything pos-
sible to assist you.
WARNING
While the engine is running or the ig-
nition is on, do not touch the ignition
system.
FIRE HAZARD
The exhaust system becomes very hot.
While riding, idling or parking, make sure
that no inflammable materials (e.g. hay,
leaves, grass, coverings or luggage, etc.)
can come into contact with it!
Important notes for the operation with
a catalyst.
The catalyst. is designed for a optimal
performance and lifetime.Note the
following:
- Operate a catalyst. bike only with lead
free fuel.
- Don’t turn off the ignition if the bike still
rolls.
- Don’t drive on at misfiring, decline in
performance and poor engine run.
- In case of problems, contact the next
Sachs dealer.
- Longer starting tests by moving the bike
in cold or warm operating state should be
refrained.
At the mentioned operating states unburned
fuel can reach the catalyst., burn and cause
overheating of the exhaust system.
SAFETY TEST
Checklist

11
1
SAFETY TEST
WARNING
Fuel is highly inflammable and can ex-
plode. Do not smoke or bring a naked
flame near the fuel tank.
Fuel expands under the influence of heat
and the sun.Therefore, never fill the tank
to the brim. Never fill the tank while the
engine is running.
Never bring a glowing cigarette or naked
flame near an open tank, because fuel
vapour could suddenly ignite.
NOTE
The tank cap as well as the steering lock
are operated with the same key.
Tank cap (1)
The fuel-tank cap (1) is designed to allow
for ventilation. Do not make any changes
to the cap.
Opening:
- Insert the key, turn to the right and pull
out the tank cap.
Closing:
- Push in the tank cap turn the key to the
left and remove.
Checking the fuel level
- Open the tank cap (1) on the fuel tank.
- Visually inspect the fuel level.
- Close the tank cap (1) on the fuel tank.
Filling up with fuel
- Use only normal lead-free fuel (min. 91
octane)
Fuel, fuel tank

12
R
ON
OFF
1
SAFETY TEST
Fuel tap
CAUTION
When you stop the engine, always set
the fuel tap to position CLOSE. Oth-
erwise, fuel could enter the engine and
this could make starting difficult or lead
to serious engine damage.
We cannot be held liable under the
guarantee for damage caused by non-
observance of this caution.
Fuel tap (1)
Fuel tap positions:
ON = OPEN
fuel tank will empty down to a
reserve quantity of approx.
0,35 litres
R = RESERVE
fuel tank is drained. There is a
remaining quantity which can
not be used.
OFF = CLOSED
fuel supply closed.

13
SFM 649001.1
-10° 0° 10° 20° 30°40° C- 20°
SAE 10W/30
SAE 10W/40 10W/50
SAE 15W/40 15W50
SAE 20W/50
Engine oil
CAUTION
Do not use additives. Since the oil
also serves to lubricate the clutch,
do not use car engine oils supple-
mented with friction modifiers (such
energy-conserving oils can lead to the
clutch slipping). Use a suitable, light
engine oil for motorcycles, such as
Motorex SAE 15W/40 mineral oil API (SG
or higher).
- If required, replenish the engine oil
(for classification and viscosity, see
the table) via the oil-filler opening
up to the maximum level marking.
Recommended grade:
Per API: SG or higher or also with additional
release status: ACEA A3/96 (CCMC G5).
Recommended viscosity:
Viscosity depends on the outside tem-
perature. For short while, the temperature
may exceed or fall short of the limits of the
SAE grades.
The recommended viscosity grade SAE
15W/40 covers the ambient temperature
range –15 °C to +40 °C and therefore
represents the optimum for our latitudes.
SAFETY TEST

14
1
2
max
min
CAUTION
Checking the oil while the engine is cold
will lead to a wrong measurement and
therefore the wrong oil quantity. In order
to avoid engine damage, never exceed
the maximum oil level nor let it drop
below the minimum level.
- Stop the warmed-up engine, wait for ap-
prox. 5 minutes and hold the motorcycle
upright.
NOTE
Make sure that the motorcycle during oil-
level checks stands level in all respects.
Even the slightest inclination towards the
side will produce measurement errors.
-With the engine stopped, read off the oil
level from the sight glass (1) on the lower
right of the crankcase.
-The oil level must be between the mini-
mum and maximum marks.
If required, replenish the engine oil SAE
15W/40 via the oil-filler opening of the oil
filler cap (2).
Checking the oil level
SAFETY TEST

15
1
2
Braking
Braking
The front brake and rear brake are operated
independently from each other.
The front brake is operated via the right-
hand brake lever (1) on the handlebars, and
the rear brake is operated via the left-hand
brake lever (2).
When stopping or slowing down, release
the throttle gas and operate both brakes
at the same time.
On tight curves, sandy / dirty streets, wet
asphalt and icy roads, use the front brake
carefully: if the front wheel locks, the bike
will slide sideways.
Brake with care. Locked wheels do not have
much braking effect and can lead to skid-
ding / crashing. In principle, do not brake
on a curve, but before the curve.
Braking on a curve increases the danger
of sliding.
SAFETY TEST
WARNING
If the motorcycle is not used for a while,
a rust film may form on the brakes and
thus increase the braking effect. A thick
rust film can cause the brakes to lock
up.
When setting out on a ride after a long
lay-up period, carefully operate the
brakes several times until they work
normally.
NOTE
Make sure you practice braking for emer-
gency situations, but do so where you will
not pose a risk to yourself or others (e.g. a
deserted parking area).

16
A
30 - 35 mm
SAFETY TEST
Drive chain
CAUTION
The chain setting affects the wear on the
drive chain and sprocket as well as the
spring excursion of the rear wheel.
Regularly clean and lubricate the drive
chain.
Check the chain setting and the drive
chain for damage before each run.
Check the chain tension
- Prop the motorbike up on the side
stand.
- Let the motorbike rear end drop to the
limit imposed by the suspension.
- Push in the drive chain from the top half
way between the sprocket and pinion.
Measure the travel.
Required value: A =30-35 mm
- Adjust the drive chain is necessary.
MAINTENANCE

17
2
1
SAFETY TEST
Checking the tyre pressure
WARNING
Adjust the tyre pressure according to
the total weight load. Never exceed the
rated total weight or the bearing capacity
of the tyres.
Incorrect tyre pressure will have a con-
siderable effect on the riding properties
of the motorbike and the lifespan of the
tyres.
- While the tyres are cold:
- Twist off the valve caps.
- Check/adjust the tyre pressure.
- Twist on the valve caps.
Tyre pressure
Front 2.0 bar
Rear 2,5 bar
Tyre profile
The standard motorbike is provided with the
following tyre sizes:
Front 2.75-17
Rear 2.75-17
WARNING
Use only tyres approved by the manu-
facturer. The use of non-approved tyre
brands, types or sizes leads to the op-
erating permit of the vehicle becoming
null and void. Use only pairs of tyres
produced by the same manufacturer.
Tyre pressure Tyre size
Checking the tyre profiles
WARNING
Observe the minimum profile depth
prescribed by law.
Never ride without valve caps (2). Firmly
tightened valve caps prevent the tyre
from suddenly losing pressure.
- Measure the profile depth at the centre
(1) of the tyre’s tread.
Recommended minimum profile depth:
Front 2.0 mm
Rear 2.5 mm
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1
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