Vertigo CAMO WORKS User manual

SERVICE MANUAL

1
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
CONTENTS
1 GENERAL INFORMATION...........................................................................................................................................................................................................5
1.1 Safety guidelines ...............................................................................................................................................................................................................6
1.1.1 Safety icons ............................................................................................................................................................................................ 6
1.1.2 General safety guidelines recommendations ........................................................................................................................................ 7
1.1.3 General recommendations .................................................................................................................................................................... 8
1.2 Technical details of each model ........................................................................................................................................................................................9
1.3 Special tools.....................................................................................................................................................................................................................11
1.4 Repair time ......................................................................................................................................................................................................................12
1.4.1 Frame.................................................................................................................................................................................................... 12
1.4.2 Engine................................................................................................................................................................................................... 12
1.5 Torque .............................................................................................................................................................................................................................13
2 MAINTENANCE ........................................................................................................................................................................................................................22
2.1 Maintenance chart ..........................................................................................................................................................................................................23
3 FRAME SECTION ......................................................................................................................................................................................................................25
3.1 Suspension system ..........................................................................................................................................................................................................25
3.1.1 Specific safety guidelines ..................................................................................................................................................................... 25
3.1.2 Exploded view ...................................................................................................................................................................................... 26
3.1.3 Suspension system maintenance......................................................................................................................................................... 30
3.1.4 Suspension adjustments ...................................................................................................................................................................... 49
3.1.5 Adjustments and settings..................................................................................................................................................................... 52
3.2 Brakes ..............................................................................................................................................................................................................................54
3.2.1 Specific safety guidelines ..................................................................................................................................................................... 54
3.2.2 Exploded view ...................................................................................................................................................................................... 55
3.2.3 Adjustments and settings..................................................................................................................................................................... 57

2
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
3.3 Wheels and tyres.............................................................................................................................................................................................................61
3.3.1 Specific safety guidelines ..................................................................................................................................................................... 61
3.3.2 Exploded view ...................................................................................................................................................................................... 62
3.3.3 Specifications and settings................................................................................................................................................................... 65
3.4 Frame...............................................................................................................................................................................................................................66
3.4.1 Specific safety guidelines ..................................................................................................................................................................... 66
3.4.2 Exploded view ...................................................................................................................................................................................... 67
3.4.3 Adjustments and settings..................................................................................................................................................................... 69
3.5 Homologation kit.............................................................................................................................................................................................................70
3.5.1 Specific safety guidelines ..................................................................................................................................................................... 70
3.5.2 Items list ............................................................................................................................................................................................... 71
3.5.3 Approved versions................................................................................................................................................................................ 72
3.6 Frame section assembly and disassembly.......................................................................................................................................................................73
3.6.1 Front fork disassembly ......................................................................................................................................................................... 73
3.6.2 Frame disassembly............................................................................................................................................................................... 76
3.6.3Swingarm disassembly ......................................................................................................................................................................... 86
3.6.4 Front fork assembly.............................................................................................................................................................................. 88
3.6.5 Frame assembly.................................................................................................................................................................................... 91
3.6.6 Swingarm assembly............................................................................................................................................................................ 101
4 ENGINE SECTION ...................................................................................................................................................................................................................105
4.1 Engine system................................................................................................................................................................................................................105
4.1.1 Specific safety guidelines ................................................................................................................................................................... 105
4.1.2 Exploded view .................................................................................................................................................................................... 106
4.1.3 Adjustments and settings................................................................................................................................................................... 109
4.2 Clutch and gearbox........................................................................................................................................................................................................112

3
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
4.2.1 Specific safety guidelines ................................................................................................................................................................... 112
4.2.2 Exploded view .................................................................................................................................................................................... 113
4.2.3 Adjustments and settings................................................................................................................................................................... 116
4.3 Combustion system.......................................................................................................................................................................................................120
4.3.1 Specific safety guidelines ................................................................................................................................................................... 120
4.3.2 Exploded view .................................................................................................................................................................................... 121
4.3.3 Adjustments and settings................................................................................................................................................................... 125
4.4 Cooling system ..............................................................................................................................................................................................................126
4.4.1 Specific safety guidelines ................................................................................................................................................................... 126
4.4.2 Exploded view .................................................................................................................................................................................... 127
4.4.3 Adjustments and settings................................................................................................................................................................... 128
4.5 Engine assembly and disassembly.................................................................................................................................................................................129
4.5.1 Engine disassembly ............................................................................................................................................................................ 129
4.5.2 Engine assembly................................................................................................................................................................................. 139
5 ELECTRICAL SECTION.............................................................................................................................................................................................................150
5.1 Specific safety guidelines...............................................................................................................................................................................................150
5.2 Exploded view ...............................................................................................................................................................................................................151
5.3 Adjustments and settings..............................................................................................................................................................................................152
5.4 Electrical diagram ..........................................................................................................................................................................................................155
5.5 ECU Tunning ..................................................................................................................................................................................................................156
5.5.1 Description ......................................................................................................................................................................................... 156
5.5.2 Software installation .......................................................................................................................................................................... 156
5.5.3 Software Winjall ................................................................................................................................................................................. 157
5.5.4 Tuneware............................................................................................................................................................................................ 161
5.5.5 Control panel...................................................................................................................................................................................... 166

4
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
5.5.6 Maps selection ................................................................................................................................................................................... 170
5.6 POLÍTICA DE PRIVACIDAD Y DERECHOS ........................................................................................................................................................................171
6 Contact details.......................................................................................................................................................................................................................172
Notes .........................................................................................................................................................................................................................................173

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SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
1GENERAL INFORMATION
The VERTIGO COMBAT: powerful, lightweight and versatile. Expertly designed for pleasure and performance. Starting from a blank canvas it has
been possible to create the perfect bike. The basic principles were clear, lightweight, powerful and versatile, after that it was important to include
reliability, size and its absolute Trial pedigree. To ensure reliability, all the components (gearbox, starter, water pump, chassis, etc.) have been
thoroughly tested in the toughest conditions for over two years.
As for the size, this was a critical point, because the smaller it could be the easier it would be to control, change direction and ride in a dynamic
way in order to have the ability to conquer more difficult sections. The use of specially designed fan, radiator, water pump and compact engine
has really helped to reduce the overall dimensions of the Combat.
The engine performance of Combat Vertigo is truly spectacular, 31 hp at 9200 rpm combined with the impressive torque and power delivery
provided throughout, allowing confidence to be high to tackle even the most demanding terrain.
The 6-speed gearbox includes 4 Trial related ratios with the top 2 gears designed specifically for the road or trails (top speed limited to 110 km/
h). Each gear is perfectly suited to cover all situations. All gears have 4 different and unique injection maps to provide an endless array of power
options.
The revolutionary chassis combines two types of materials to create a lightness and stiffness like never before. The overall weight of just under
68 kg can be reduced further to 65 kg using the Powerparts option.
By having the fuel tank in a low central position fuel load plays no part in changing the feel or operation of the bike, and furthermore it is hidden
from damage.
The large capacity airbox, located at the highest part of the bike ensures a cool and clean air intake to provide consistent performance.
The suspension is designed to be used both for pleasure and performance, and offers an incredible level of traction. The large diameter clutch
diaphragm delivers a smooth and progressive action, giving the rider good control and instant action when the need arises.

6
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
1.1 Safety guidelines
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of
servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice or check the manufacturer maintenance service.
1.1.1 Safety icons
These are the safety icons of this manual:
SÍMBOL
DESIGNATION
MEANING
DANGER!
This symbol denotes warnings of a safety risk or of serious and fatal injuries,
even resulting in death.
WARNING!
This symbol denotes warnings of a safety risk or of serious injuries.
CAUTION
This symbol denotes warnings of a property damage risk and a possible
safety risk of injuries.
NOTE
This symbol denotes important information.

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SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
1.1.2 General safety guidelines recommendations
In addition to the specific safety guidelines of each procedure, these general safety rules must be taken into account.
•Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this
manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.
•Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.
•When two or more persons work together, pay attention to the safety of each other.
•When it is necessary to run the engine indoors, make sure that exhaust gas in forced outdoors.
•When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material
manufacturer's instructions.
•Never use gasoline as a cleaning solvent.
•To avoid getting burned, do not touch the engine, engine oil, radiator, cooling agent and exhaust system until they have cooled.
•After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.
•Before starting work, ensure the motorcycle is stabilized and adequately supported. This will help prevent it from falling and causing injury to the
operator or damage to the motorcycle.
•Some procedures often require lifting of heavy components. To avoid injury, always lift heavy components with a hoist or block and tackle and never
attempt to manually lift items that are too heavy. Injury may result from failure to use the correct lifting equipment.

8
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
1.1.3 General recommendations
In addition to the specific recommendations of each procedure, these general recommendations must be taken into account.
•If parts replacement is necessary, replace the parts with Genuine Parts or their proven equivalence.
•When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and
orientation.
•Be sure to use special tools when instructed.
•Make sure that all parts used in reassembly are clean. Lubricate them when specified.
•Use the specified lubricant, bond, or sealant.
•Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as
specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any leftover material from
the mating surfaces.
•Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After
installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
•Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
•After reassembling, check parts for tightness and proper operation.
•To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires.
•To protect Earth's natural resources, properly dispose of used motorcycle and parts.

9
SERVICE MANUAL
-VERTIGO COMBAT-V07-ENG.DOCX - GENERAL INFORMATION
Vertigo.
Carrer Argenteria 8-10, Pol. Ind. Riera de Caldes. 08184 Palau-Solità i Plegamans (Barcelona - Spain) T + 34 931 70 16 55.
1.2 Technical details of each model
CAMO WORKS
COMBAT ICE HELL
COMBAT TITANIUM R
IMAGE
ENGINE
2 stroke engine
ENGINE SIZE
247cc EFI
300cc EFI
247cc EFI
300cc EFI
250cc EFI
300cc EFI
POWER
25hp / 9200rpm
31hp / 9200rpm
25hp / 9200rpm
31hp / 9200rpm
25hp / 9200rpm
31hp / 9200rpm
TORQUE
4.0 kg.m / 4500rpm
4.9 kg.m /4500 rpm
4.0 kg.m / 4500rpm
4.9 kg.m /4500 rpm
4.0 kg.m / 4500rpm
4.9 kg.m /4500 rpm
COMPRESSION
8,8:1
8,7:1
8,8:1
8,7:1
8,8:1
8,7:1
STROKE
72.5x60mm
79x60mm
72.5x60mm
79x60mm
72.5x60mm
79x60mm
CRANKCASE
Aluminium
Magnesium
GEARBOX
6 speed gearbox, 4 gears trial developed, each one ECU controlled
TRANSMISSION
9z/38
10z/42
CLUTCH
Multi-disc oil wet
EXHAUST MUFFLER
Symmetric and centered silencer
MANIFOLD
Stainless steel
Titanium
RADIATOR
Vertigo special design, adapted to frame shape
CONTROL UNIT
Vertigo design, controlling: gear position, engine temp, pressure, petrol pump, water pump, electric timming
ENGINE SENSORS
Integrated injection driver
Barrel gearbox sensor, can control each engaged gear
Protocol CAN 2.0 B
TPS (Throttle position sensor)
PWM water pump control
POWERBOX ECU
Vertigo design, control all the electrical power, save all the components from shorcircuit
FRAME
25CRMO4 steel + aluminium 6082
15CDV6 steel + aluminiun 6082
Titanium GR5 + aluminium 6082
SWINGARM
Aluminium cast
Magnesium cast