SSR Pit Bike Owner`s Manual
Contents
1. On the covers SR150R at Milestone Ranch MX Park Riverside CA ridden by professional racer Jeff Willoh a member of the SSR Motorsports competition team SSR MOTORSPORTS PIT BIKE OWNER S MANUAL Congratulations on choosing an SSR Motorsports pit bike and welcome to our powersports family Your new SSR Motorsports pit bike is designed engineered and manufactured to be the best in its class We have prepared this manual to acquaint you with the proper procedures for operating caring for and maintaining and if necessary troubleshooting your new pit bike This manual also contains important safety information We recommend you follow these instructions and recommendations to obtain maximum performance from your SSR pit bike and to maximize your enjoyment and biking safety Thoroughly read this manual before riding your SSR pit bike for the first time Be certain that you under stand how to operate the bike and that you are familiar with the locations of each control what it does and how it operates This Owner s Manual contains operations and minor maintenance instructions Major repairs may require the attention of a skilled technician and or special tools and equipment While enjoying your SSR Motorsports pit bike please be sure to ride safely and defensively Always wear an approved helmet proper safety eyewear and protective clothing appropriate for the conditions and ter rain Never ride under the influence of alcohol or drugs2. 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person N gt gt gt gt 11 Technical Information cont Emission Control Systems cont AMONG THOSE ACTS PRESUMED TO CONSTI TUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer 78 Problems That May Affect Motorcycle Emissions lf you are aware of any of the following symptoms have the vehicle inspected and repaired by your local Motorcycle Dealer 1 Hard starting or stalling after starting 2 Rough idle 3 Misfiring or backfiring during acceleration 4 Backfiring or popping through the muffler on deceleration 5 Poor performance driveability and poor fuel economy Oxygenated Fuels and Your SSR Pit Bike Some conventional gasoline
3. remove the grime After washing rinse your motorcycle thoroughly with plenty of clean water to remove any residue Thoroughly dry your motorcycle with a chamois real or synthetic or a soft towel Lubricate the drive chain to prevent rusting Start the engine and let it idle for several minutes The engine heat will help dry moist areas AS a precaution ride at a low speed and apply the brakes several times This will help dry the brakes and restore normal braking performance Transporting Your Pit Bike If you use a truck or a motorcycle trailer to transport your motorcycle we recommend that you follow these guidelines 1 Use a loading ramp 2 Make certain that the fuel petcock is in the OFF position 3 Secure the motorcycle in an upright position using motorcycle tie down straps Do not use rope which can loosen and allow the motorcycle to fall over To secure your motorcycle brace the front wheel against the front of the truck bed or trailer rail a wheel chock avail at many motorcycle and powersports shops as well as RV and towing equipment parts suppliers works better but must be bolted to the truck bed or trailer floor 4 Attach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps one on each side of the handlebar close to the fork and handlebar risers Check that the tie down straps do not contact any control cables o
4. CONTO a li tind dee 17 Crankcase Emission Control SyStem cccccccccssccseeceeeseeeceeeceeeeceeeseeeeeaeeseeessueesegeesaeeseueeaeegeeeegeegs 17 NoiSe EMISSION CONTO ES SM da Ls 17 Problems That May Affect Motorcycle EMISSIONS coocccconccconccoconccococnononononnnnonocnnnnonnnonanonannnnanonunons 78 Oxygenated Fuels and Your SSR Pit Bike ccoooccccccccoccccccncocnononncnanocnononacnnnnnonanonnnnncnnnonanonannnnons 79 1 2 3 4 5 8 Clutch Lever Carburetor Fuel Petcock Air Filter Drive Chain COMPOMENT LOCATIONS 11 Mi Iha 2 7 6 Rear Sprocket 7 Chain Adjuster Block 8 Chain Guide 9 Chain Slider 10 Chain Roller 11 Foot Peg 0 LEFT SIDE E F 0 ee 7 E i x ri F e Yo aw e 12 Engine and Stator Cover 13 Gearshift Lever 14 Engine Skidplate 15 Front Brake Caliper 16 Front Brake Rotor COMPOMENT LOCATIONS RIGHT SIDE 1 15 14 anl 11 Rear Brake Rotor 6 Throttle 11 Rear Brake Pedal and Lever Rear Brake Caliper 7 Front Brake Lever 12 Foot Peg Muffler 8 Front Brake Master Cylinder 13 Oil Filler Cap and Dipstick Fuel Filler Cap 9 Auxiliary Oil Cooler 14 Kick Starter 10 1 2 3 4 5 Breather Tube and Breather Cap 10 Exhaust Pipe 15 Rear Swing Arm CONTROLS BRAKES Front Brake Lever Rear Brake Pedal nm The front brake lever is located on the right side of The brak
5. and not dropping below 50 degrees F use SAE 20W 50 viscosity SF or SG oil for air cooled motorcycles Be sure to use oil manufactured specifically for use in air cooled motorcycle engines Do not use oils with graphite or molyodenum additives as such additives can have an adverse affect on clutch op eration and clutch life Checking amp Adding Oil 1 2 Dipstick Oil Filler Cap Location Lower 1 and Upper 2 Oil Level Marks Park your motorcycle on a firm level surface Re If the oil is below or near the lower level mark see move the oil cap dipstick and check the oil level photo add oil of the recommended specifications If the oil is at or near the upper level mark see until it reaches the upper level mark Do not overfill photo you do not have to add oil Insert the dipstick and screw it in tightly Check for oil leaks 39 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS 40 Changing Engine Oil CIA y If the engine is cold start it and let it idle for three to five minutes Turn the engine off and wait two to three minutes for the oil to settle Park your motorcycle on a firm level surface cont Oo o1 W 10 11 13 14 Remove the oil filler cap dipstick Place a drain pan under the crankcase Remove the oil drain bolt After most of the oil is drained gently tilt the motorcycle from side to drain the remaining oil Pour the drained oi
6. could cause serious injury or death Always use the size and type of tires recom mended in this owner s manual 55 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS S6 Side Stand 1 Side Stand 2 Side Stand Spring cont 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly to be sure it moves freely 3 If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with a few drops of clean engine oil NOTE Most SSR Motorsports competition model pit bikes are NOT equipped with a side stand Drive Chain The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when the motorcycle is rid den in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing the drivechain turn the engine OFF lower the side stand and make sure that the transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Drive Chain Inspection With the bike s wheels on the ground check slack in the lower drive chain approximately halfway between the sprockets Correct drive chain slack vertical free play at the midpoint of the lower chain should be between 9 16 and 1 inch when moved by hand Next chec
7. needed to fill 21 OPERATION cont Starting and Riding Starting the engine Be sure the transmission is in neutral and that if applicable the two position on off switch is in the ride on position Turn the three position fuel petcock to the ON position If the bike s engine is cold lift the choke lever up to the fully ON position Next shift the transmission into neutral and for added safety pull the clutch in against the handlebar grip to disengage the clutch Petcock RESERVE then hold the throttle slightly open and follow the following directions to operate the kick starter Petcock ON Petcock OFF 28 Choke Lever If the air temperature is between 50 and 90 de grees F swing the kick start lever s foot peg out from its stored position and with your right foot ro tate the lever down and to the rear until you feel re sistance Then with a rapid and continuous motion kick the lever down through its stroke until it stops at the bottom Do not allow the kick starter to return or snap back freely as it can damage the engine transmission case If your bike has the two position choke on the left side allow the engine to run for approximately 15 seconds after it starts then push the choke lever all the way down to the fully OFF position If the bike has the three position choke on the right side of the carburetor push the choke lever down part way to the DETENT position im mediat
8. repair you may be able to fix it on the trail and con tinue riding Or you may be able to make a tem porary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help When a problem is more serious or you don t have the tools supplies experience or time to deal with it you need to choose the safest way to get yourself and your motorcycle back to base For example if you are close enough you or you and another person might be able to push it back Whatever the problem the most important rules are Always put personal safety first If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs made as soon as possible Do not continue riding if you are hurt or your motorcycle is not in safe riding condition Additional recommendations for specific problems follow Being Prepared For The Unexpected cont If Your Engine Quits or Won t Start If the engine wasn t making any unusual noises before it quit running and it feels normal when you operate the kick starter you can probably rule out a major mechanical problem The next area to check is the fuel system See Troubleshooting pages 68 69 If the fuel system appears to be okay check the ignition system this requires a spark plug wrench Check that the spark plug cap isn t loose or disconnected Disconnect the s
9. specified rang using the following instructions Adjustment 1 Slide the rubber dust cover off of and away from the locknut 2 Loosen the locknut 1 on the throttle cable mechanism 3 Turn the adjuster 2 to reduce or increase throttle free play 4 Tighten the lock nut Return the dust cover to its normal position 5 After making the necessary adjustments check the throttle grip to ensure it rotates smoothly from fully closed to open at any steering handlebar position If you cannot adjust throttle free play within the specified range contact your dealer di SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Engine Idle Speed The engine must be at normal operating tempera ture in order to make accurate idle speed adjust ments Ten minutes of stop and go riding should be sufficient Do not attempt to compensate for faults in other systems by adjusting idle speed See your dealer for regularly scheduled adjustments and oer 1 Warm up the engine shift into neutral and rest the bike securely on its side stand 2 Connect a tachometer following the tachometer manufacturer s instructions 3 Adjust the idle speed using the throttle stop screw arrow Idle speed should be 1400 rpm plus minus 100 rpm Note SSR pit bikes are equipped with a variety of different carburetors depending on the models The photos are representative of what is on your bike Air Filter Inspect the air f
10. spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid all products that contain harsh detergents chemical solvents or abrasives these cleansers could damage the metal paint and plastic finishes on your bike If your pit bike is still warm from recent usage give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your motorcycle High pressure washers like those at coin operated car washes can dam age certain parts of your motorcycle If you must use a high pressure washer avoid spraying the wheel hubs muffler outlet the under seat area and the engine off or off run switch Always cover or plug the end of the muffler and cover the air filter if it is exposed NOTICE High pressure water or air can damage certain parts of your pit bike 63 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS 64 cont Washing Your Motorcycle with a Mild Detergent Rinse your motorcycle thoroughly with cool water to remove loose dirt Do not wash it in direct sunlight Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motor cycles or automobiles We strongly recommend you use a car and motorcycle specific product Wash your motorcycle with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to
11. 57 Drive Chain Lubrication Removal Cleaning and Re installing and Replacement occoccocccoo 60 cleaning YOU PIB o rr ceseute gametes 63 TRARSPOMING YOUR PIB sus Tac teaetenascedoaraieat ced iueesnctantaana ars 65 Sind OU PEDO e lao ii 66 TROUBLESHOOTING Engine Does Not Start ls Hard to Start cooccccoccccccccccconncconnnconnnnononnnnnnnononnnnanonannnnnnnnnnnnnnnnenanenos 68 Engine Starts Runs Erratically or Misses Spark Plug Fouled oooccccccccocococococonnconcncnnnononononnnnnos 68 Engine Detonates Pings or Knocks OverhealtS oocccoccccccccoccncccconcnncnonononnnncnnnonnnnnnnnonnnncnnnnnnnnnnnns 69 Engine Vibrates EXcessiveNy Leaks Olla ed 69 Transmission Shifts Hard or Jumps Out of Gear Clutch SlipS cooccocccoccconcnccconnconnconnconncononononons 70 Clutch Drags or Does Not Release Chatters ocooocconccocccocccccoonncncncncnconononnnnnnnnnnnnnnnonononcononononcnnnns 70 Brakes D NOt SOM Or Hold PIO DENY iaa 70 YOWAND THEIENVIRONMIEN Dirt dae 71 6 BEING PREPARED FOR THE UNEXPECTED General GUIG OMIM CS asns ae E E a a E a 72 i YoUr ENGINE QUIS OF WOM T Stai eia o 73 You Geta Flat Tera ida estada 73 NOTES ri ist E E E 74 Ma Pat ral Sureste tii 74 TECHNICAL INFORMATION venicle Identicaton NUDE Sa did 15 righ Altitude Carburetor AUS TM dias ii 76 Emi SIONES ON TORO SMS te ates 76 Waranty Completa deis 76 Sources OP EMISSION Sisi E 77 Exhaust Emission
12. Drive Chain cont cont NOTICE Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your dealer replace a worn sprocket F po E Damaged Teeth REPLACE Normal Teeth GOOD 62 More About the Drive Chain The master link is the most critical element of drive chain security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining clip whenever the drive chain is disas sembled and reassembled You may find it easier to install a new chain by con necting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets Cleaning Your Pit Bike Frequent cleaning and polishing will keep your new pit bike looking like new for a long time Frequent cleaning also identifies you as an owner who values your bike and keeps it well maintained A pit bike that is kept clean is easier to clean up af ter usage and a clean bike is also easier to inspect and more pleasant to service While you re cleaning the bike be sure to look for damage worn parts and gasoline or oil leaks General Recommendations To clean your motorcycle you may use water only a product made specifically for washing cars and motorcycles a mild neutral detergent such as a dish washing liquid and water a mild
13. Thank you for selecting an SSR Motorsports pit bike We wish you fun miles and years of enjoyable riding PLEASE NOTE SSR Motorsports offers over 30 distinct models of pit bikes from entry level to full race Photographs in this manual are of representative examples and show various levels of equipment Photographs of a specific component may differ from the component on your bike but will function the same way In instances where certain components on various models operate differently we show the different types of components CONTENTS O e E yo poo aha tata san ese ate ean ect dae eacnaaueanteeen mua aaaamesoecsey onnnate enssten tee aaees 3 TABLE OF SONTENES nada si 4 COMPONENT LOCA NON Sn leo co 8 CONTROLS BRAKES Front Brake Lever Rear Brake COG cco fact dd hae eet en 10 CONTROLS CLUTCH AND TRANSMISSION Cltitch Lever GearshilLever cistasa ati ld a 11 CONTROLS MISCELLANEOUS AND HANDLEBAR KEK AO a O eae eae 13 Mantal EChoke and Fuel IP ClCOGK va inn ito 13 APA hen at ec Sign oem east ead ec nm ecco se tes av lees asct eee ie 14 ENOine ON OP SWIICHES e a UD acne 15 ICS SUA Gl PACPPEA O0 50 n 5 5o 5 nn E O twas male ieaidioenade Reg nen auaae 16 OPERATION Serore TRIGING TRIGING Salte lt ed ee tae Ed 17 Fede IAS DO CUO IN anida ata 19 THES Whee MA SPORE ie 19 as 22 BA e o O nase T 23 AD St 24 Nout ANG DONS unica o cisiteca 25 Spaik Plug and IGMIMION Wicca dai aida 25 MOO e a A N 26 E PP O E A E a niente 21 E
14. askets Excessive Vibration Engine mounting bolts loose Broken frame See your dealer Drive chain and or sprocket badly worn or links tight from insufficient lubrication Wheel s and or tire s damaged See your dealer Bike is not properly aligned See your dealer 69 TROUBLESHOOTING cont Transmission Shifts Hard or Jumps Out of Gear 1 Clutch controls not adjusted correctly 2 Shifter forks inside transmission are worn See your dealer 3 Worn shifter dogs in transmission See your dealer Clutch Slips 1 Clutch controls not adjusted correctly 2 Worn friction discs See your dealer 3 Insufficient clutch spring tension See your dealer Clutch Drags or Does Not Release 1 Clutch controls not adjusted correctly 2 Insufficient clutch spring tension See your dealer 3 Clutch disc s warped See your dealer Clutch Chatters 1 Clutch discs worn or warped 70 Brakes Do Not Hold Normally Front or rear master cylinder s low on fluid Check for visible leaks Add fluid if no leaks found Brake line contains air bubbles Bleed brakes or see your dealer for service Front or rear master cylinder piston worn See your dealer Brake pads contaminated with grease or oil Replace pads and clean rotors before using Brake pads badly worn Replace or see your dealer for service Brake rotor badly worn or warped Replace or see your deal
15. bound 48 This adjustment is made using a knob on the top of each fork leg turning toward for slower rebound towards the for faster rebound Double or two way adjustable front forks are ad justed for rebound at the top of the fork and com pression at the bottom To increase compression turn the screw inward clockwise to decrease compression turn the adjusting screws outward counter clockwise Rear Suspension Adjustments The suspension on entry level pit bikes uses a coilover shock absorber with adjustable preload This shock absorber will have a notched collar that allows the rider to adjust the rear suspension from soft to firm Adjustable Preload Shock Absorber The simplest truly adjustable rear suspension uses a one way or single adjustable coilover shock and allows the rider to reset the rebound from faster or slower This is usually done at the bottom swing arm end of the shock with a either a hand turned knob or wheel Faster rebound allows the shock to extend or open more quickly after being compressed closed slower retards the shock s extension after being compressed One Way Adjustable Shock Absorber Two way or double adjustable coilover shocks have separate adjustments for both compression and rebound Rebound is usually reset in the same manner as a one way single adjustable shock Compression is generally reset at the top of a two way s
16. chanic and has a good selection of the proper tools and equipment he or she should never attempt to perform these service operations In all other instances service operations should only be performed by your dealer or by a qualified powersports technician 36 Fuel Recommendations For optimum perfor mance run unleaded pump gasoline with an R M 2 US standard octane rating of at least 90 To meet clean air standards much of the gasoline used in the United States and Canada is oxygenated meaning it s blended with alcohol or ether com pounds to help reduce exhaust emissions Do not use a gasoline with higher percentages of any of the following oxygenates than listed as follows ETHANOL ethyl or grain alcohol up to 10 percent by volume MTBE Methyl Tertiary Butyl Ether up to 15 percent by volume Because of its extreme toxicity its use has declined significantly in the US and Canada METHANOL methyl or wood alcohol up to 5 per cent by volume Do not use gasoline oxygenated with methanol if does not also contain co solvents and corrosion inhibitors to protect the fuel system Use of a lower than recommended gasoline can Cause pinging which is also called spark knock or pre ignition an occasionally loud rapping or rattling noise which can if severe or persistent can lead to extensive engine damage Light pinging experienced under a heavy load such as climb ing a steep hill is not a cause for concer
17. ctory Limited Warranty for the Motorcycle Emission Control Systems is necessary in order to keep the warranty in effect The Vehicle Emission Control Information Label is attached to the inside of the left fuel tank shroud Sources of Emissions The combustion process produces carbon monox ide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when sub jected to sunlight Carbon monoxide does not react in the same way but it is toxic SSR Motorsports utilizes very exacting carburetor jetting and other systems to make your pit bike emissions legal and to reduce carbon monoxide and hydrocarbon emis sions Exhaust Emission Control System The exhaust emission control system is composed of precise carburetor jetting and fuel mixture and no adjustment should be made except idle speed adjustment with the throttle stop screw The exhaust emission control system is separate from the crankcase emission control system Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase vapors into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor Noise emission control system TAMPERING WITH THE NOISE CONTROL SYS TEM IS PROHIBITED Federal law strictly prohibits and Canadian provincial laws may prohibit the following acts or the causing thereof
18. d rear tire and tubes Naturally bring along an extra approved can or two of gasoline What you take along on the ride depends on the kind of terrain how long you expect to ride how far you might go from your starting point and how experienced you and or your companions are at making repairs If you do decide to take some tools Spare parts and other supplies on the ride plan ahead of time on how you will carry them safely and know how to use them Do not exceed the bike s maximum weight capacity and pack your load carefully so it doesn t negatively affect riding safely Pre Ride Inspection Check the following items before every ride Tires Use a quality tire pressure gauge to check the air pressure when the tires are cold before riding and add or remove air as necessary to meet the manufacturer s recommended cold tire air pres sure Also inspect both tires for any sign of exces sive wear or damage If a tire is damaged or excessively worn replace it with a new tire of the correct size and type Wheels and spokes Inspect the wheel rims for damage Do not use if the rim is cracked or bent With the bike on a stand rotate each wheel if a wheel appears to wobble it is either out of round or not true If the wheel wobble is noticeable see your dealer Also make sure the spokes are tight 19 OPERATION cont Pre Ride Inspection cont Engine Oil Drain Plug Leaks Inspect the engine transmission ca
19. down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instruc tions on how to dispose of non recyclable wastes 71 Being Prepared For The Unexpected With all the challenges you can encounter off road there s always a chance that something may go wrong This section gives practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in Preparing for a Ride pages17 18 General Guidelines If something goes wrong during a ride the first thing to do is stop as soon as you safely can Do not continue riding if you have a flat tire or you hear an unusual noise or your motorcycle just doesn t feel right If you continue riding you could Cause more damage and endanger your own safety After a stop take time to assess the situation Carefully inspect your motorcycle to identify the problem then consider your options before you decide what to do If a problem is relatively minor and you have the tools supplies and skills to make a permanent 72
20. drive chain Clean the drive chain with a non flammable high flash point solvent such as kerosene and allow it to dry Inspect the drive chain for possible wear or damage Replace the drive chain if it has dam aged rollers loose fitting links or otherwise appears unserviceable 4 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed 5 Lubricate the drive chain 6 Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the retaining clip faces the direction of forward wheel rotation Replacing the Drive Chain If the drive chain slack exceeds specifications when the rear axle is moved to the farthest limit of adjust ment the drive chain must be replaced Excessive slack indicates the chain is worn beyond its service limit To check the chain s service limit remove the drive chain Then measure the distance between a span of 100 pins from pin center to pin center If the distance exceeds the service limit the drive chain is worn out and should be replaced Measure a span of 100 pins New Chain 25 inches 638mm Service Limit 25 4 inches 648mm gt gt gt 61 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Replacing the
21. e of the left boot beneath the shifter peg and lift firmly upward until it stops then release the gear shift lever and re engage the clutch while gradually opening the throttle Repeat this for each upshift To downshift from 4th to 3rd 3rd to 2nd or 2nd to 1st place the toe of the left boot on top of the shifter peg disengage the clutch by pulling the clutch lever against the grip press the gearshift lever firmly downward release the gearshift lever and re engage the clutch Do not fully close the throttle between downshifts this will help eliminate engine drag and smooth the transition to lower gears Re peat this procedure for each downshift Remember lifting the gearshift lever upward always engages a higher gear and pushing the gearshift lever down engages a lower gear Neutral is Y stroke up from 12 1st or down from 2nd Bikes with a four up gear shift pattern are operat ed the same as one down three up models except for the 1st gear location being above neutral in the shift pattern WARNING Always fully disengage the clutch be fore shifting gears Shifting gears without the clutch fully disengaged can cause severe clutch and or transmission damage When shifting to lower gears with the bike in motion do not downshift with the engine running at high speeds doing so can cause severe damage to the transmission and or engine and can cause the rear wheel to lock up lose trac tion and lead to loss of con
22. e pedal which is located on the right side the handlebar and operates the front brake only It a few inches forward and slightly inboard of the is operated by the fingers of the right hand by pull right foot peg operates the rear brake only by ing the lever to the rear pressing downward with the right foot Apply the front and rear brakes smoothly to prevent locking up a wheel 10 CONTROLS CLUTCH AND TRANSMISSION Clutch Lever Gearshift Lever The clutch lever is located on the left end of the handlebar and is operated by the fingers of the rider s left hand The clutch is disengaged by pull ing the lever in against the handlebar grip After shifting gears the clutch is re engaged by slowly releasing the lever and allowing it to return to the outward position The gearshift lever is located on the left side of the bike ahead and inboard of the left foot peg and is operated with the toe of the left foot The gear shift pattern on nearly all SSR models is one down three up and neutral is between 1st and 2nd gears a select few models feature a four up gear shift pattern with neutral below 1st gear e CONTROLS CLUTCH AND TRANSMISSION cont To start any one down three up bike from a full stop pull the clutch lever in against the grip and push the gearshift lever firmly all the way down To upshift from 1st to 2nd 2nd to 3rd or 3rd to 4th pull the clutch lever back against the grip place the to
23. ecommend that you do not try to ride with a flat tire The motorcycle will be hard to handle and if the tire comes off the rim it may lock up the wheel and can cause you to crash If You Crash Personal safety is your first priority after an accident If you or anyone else has been injured take time to assess the severity of the injuries and whether it is safe to continue riding If you cannot ride safely send someone for help Do not ride if you will risk further injury If you decide you are capable of riding safely care fully inspect your motorcycle for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes and wheels If there is minor damage or you are unsure about possible damage but decide to try riding the motorcycle back to your base ride slowly and cau tiously Sometimes crash damage is hidden or not imme diately apparent When you get home thoroughly ad your motorcycle and correct any problems you find Also be sure to have your dealer check the frame and suspension after any serious crash lf a Part Fails The drive chain master link brake lever or pedal control cables and other components can be damaged as you ride in dense brush or over rocky terrain Making a trailside repair depends on how serious the damages is and what tools and supplies you have with you If the drive chain comes off because the mas
24. ely after the engine starts and after about 15 seconds push the choke lever the rest of the way down to the fully OFF position If the bike s idle is unstable open the throttle slightly until the idle evens out If the air temperature is below 50 degrees F follow the same steps outlined above and warm up the engine by slightly opening and closing the throttle until it responds smoothly with the choke fully OFF If the air temperature is over 90 F or the bike is fully warmed up do not use the choke If the engine will not start after several tries it may be flooded with excess fuel To clear the engine on bikes with the two position off ride switch turn the switch to the off position push the choke lever all the way down fully OFF hold the throttle fully open and turn the engine over several times with the kick starter Then turn the off run switch to the run position and follow gt gt gt 29 OPERATION Starting and Riding cont cont the instructions for a warm engine or high tempera ture start WARNING Do not start or run the bike in an en closed area or any area without good ventilation The exhaust contains carbon monoxide and other toxic gases which can collect quickly in confined areas and cause illness and even death WARNING Running the engine for an extended period with the choke open may cause damage to piston and cylinder walls which could necessitate rebuilding o
25. er for service Brakes fade because of heat build up Excessively hard use of brakes or brake pads are dragging If brake pads are dragging see your dealer for service Brake pads drag due to insufficient hand lever free play Adjust free play or see your dealer for service You amp The Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environ mentally responsible motorcycle owner Tread Lightly Stay on existing roads and trails avoid surfaces that are easily damaged and ride only in areas approved for off road vehicles Keep the Noise Down Loud motorcycles can be offensive Ride as quietly as possible Don t remove your spark arrester and don t modify the muffler or any other part of your air intake and exhaust systems Such modifications not only in crease noise they also reduce engine performance and may be illegal Choose Sensible Cleaners Use a biodegradable detergent when you wash your motorcycle Avoid aerosol spray cleaners that contain chlorofluoro carbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning sol vents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash
26. h on any vehicle and you don t want to experience a mechanical problem miles from help Using an improperly maintained bike or failing to correct a problem can cause a crash in which the rider could be seriously injured or killed Always perform a pre ride inspection 17 OPERATION Before Riding cont cont A safe and enjoyable ride begins with good plan ning and preparation It s safest and usually the most fun to ride with at least one other person If one of you has a problem the other person can help Always let someone know where you re going and when you expect to return Before riding in an unfamiliar area find out if any permits are needed get maps so you can familiarize yourself with the terrain and talk to other riders who may know the area The U S Forest Service Bureau of Land Management state and regional natural resources and parks departments riding clubs and off road magazines are all good sources of information It s a good idea to take some tools spare parts including a drive chain and master link control levers cables a spark plug wire duct tape and rope and supplies along with your pit bike and rid ing gear See Troubleshooting for tips about what sorts of difficulties you might encounter You should always take lots of water food a first aid kit and this owner s manual Other items you should take 18 include a tool kit tire repair material and tools and spare front an
27. hock Most two way shocks use a pressurized inert gas like nitrogen as the compression adjusting medium and adjustments are made from soft to hard using a knob on the pressurized gas res ervoir that is externally mounted on the top of the shock Two Way Adjustable Shock Absorbers SERVICE MAINTENANCE 1 Check free play by pulling in slowly on the front LU BRICATION AND brake lever 1 until the brake starts to engage Free play should be between approximately 3 8 ADJUSTMENTS cont to 13 16 inch 10 20mm Brakes 2 If necessary adjust to the specified range To do this find the brake adjusting nut on the lower portion of the brake caliper Using a hex head Front Brake Lever Free Play wrench turn the bolt clockwise to increase free play or counter clockwise to reduce free play l 1 Front Brake Lever Free Play Brake Caliper Free Play Adjusting Nut 50 Rear Brake Pedal Free Play Rear Brake Pedal Free Play 1 Rest the bike securely on its side stand 2 Check free play by slowly depressing the brake pedal 1 until the brake starts to engage Free play should be between 3 8 to 13 16 inch 10 20mm If necessary adjust to the specified range To do this find the adjusting nut at the bottom of the rod connecting the rear brake pedal and linkage to the master cylinder Turn the nut clockwise to reduce free play or counter clockwise to increase free play Brake Wear Inspection The front and
28. iability and performance by paying extra attention to how you ride during the first five to 10 hours of operation During this period avoid full throttle starts and rapid acceleration See pages 33 34 for detailed break in guidlines High Altitude Carburetor Adjustment When operating this motorcycle at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000m drivability and performance may be reduced and fuel consumption increased The car buretor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your dealer for high altitude modification NOTICE Sustained operation at altitudes below 5 000 feet 1 500m with high altitude carburetor modifications may cause engine overheating and oo Emission Control Systems Exhaust Emission Requirements Your motorcycle will comply with applicable exhaust emissions standards during its useful life when operated and maintained according to the instructions provided Noise Emission Requirements The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 1 865 miles 3 000km after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provided Warranty Compliance Compliance with the terms of the SSR Motorsports Fa
29. ilter regularly When it becomes dirty or contaminated discard it and replace with an equivalent new part If the air filter is a reusable washable type wash the dirt out with a mild deter gent rinse thoroughly and dry with a clean towel Soak the filter element in foam paper filter oil or clean machine oil 15W 40Q is recommended squeeze out excess oil in an absorbent cloth and re install the filter element 43 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Spark Plug Spark Plug Recommendation The recommended standard spark plug is satisfac tory for most riding conditions However If you plan to ride for extended periods at high speeds or near maximum power high engine rpm in hot climates or plan extended riding in cold cli mates a colder or hotter heat range plug may be recommended NOTICE Using spark plugs with an improper heat range can cause engine damage Use only the recommended type of spark plugs in the recommended heat range 44 4 E 4 ul EI E E a 1 Side electrode 2 Sparkplug gap 3 Center electrode Removing or Replacing the Spark Plug Before removing the spark plug clean any dirt 7 Tighten the spark plug about 1 8 to1 4 turn after from around the spark plug base it seats if the old plug is good or about 1 2 Carefully disconnect the spark plug wire cap turn after it seats if installing new plug Do not pul
30. ip operated by rotating the hand grip on the right side forward away from the rider The throttle is spring of the handlebar To increase engine speed the loaded and will unless improperly adjusted return grip is rotated rearward toward the rider to the closed engine idle position when released 14 Engine ON OFF Switches Engine OFF Kill Switch SSR pit bikes are equipped with one of two types of on off or engine off switches The first is a simple momentary style engine stop ignition kill switch a button that is pressed to stop the engine Two Position ON OFF Switch The second type of switch is a two position ON OFF rocker style switch the engine can be started only in the run position and to shut off the engine the switch is pushed into the off position 15 CONTROLS HANDLEBAR MISCELLANEOUS cont Side Stand lat UE i A Mz A Side Stand Up Side Stand Down The side stand is used to support the bike in an below the left foot peg The side stand is raised or upright slightly leaning position while parked The lowered with the left foot side stand is located on the left side of the bike either directly behind or on select models NOTE Some competition models are not equipped with a side stand 16 OPERATION Before Riding Before each ride be certain that both you and your SSR pit bike are ready to ride Make sure that you are in good physical and mental condition tha
31. k drivechain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking gt gt gt 57 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Drive Chain Inspection cont NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 58 2 1 3 1 Pin 2 Roller 3 Link Inspect the drive chain for damaged rollers dry or rusted links excessive wear kinked or binding links or loose pins If the drive chain has damaged rollers loose pins or kinks that cannot be freed the chain should be replaced Lubricate the drive chain if it appears to be dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed see Replacing the Drive Chain immediately following Boi Chain Slider Check the chain slider for wear If the ridge in the center of the slider is worn have your dealer replace the chain slider Adjusting the Drive chain gt ey 1 Adjusting nut 2 Lock nuts 3 Rear axle nut 1 Loosen the rear axle nut 3 2 Loosen the lock nuts 2 on both sides of the swing arm Turn the adjusting nuts 1 on the right and left chain adjusters an equal number of turns to increase or decrease chain slack Torque the rear axle nut to 35 lb ft If a torque
32. l YOR Engine Oil Strainer Sereen RO ll DriveChain A Brake Fluid Reservoir Levels 1 J Z EE E R Brake Fluid Condition Brake Pads A Adjust Inspect and if necessary clean correct fill or replace L Lubricate R Change or replace T Tighten to proper torque X Perform Inspect and service your SSR Pit Bike more frequently if ridden hard or in dusty hot or other extreme con ditions Regardless of hours of riding always perform all service operations prior to storage or annually Unless the owner is an experienced and skilled mechanic and has a good selection of the proper tools and equipment he or she should never attempt to perform these service operations In all other instances service operations should only be performed by your dealer or by a qualified powersports technician gt gt gt 35 Recommended Service amp Maintenance Schedule cont INTERVALS po Arter It Wheel Spokes Tightness Wheel Bearings Fasteners Suspension Fluids A Adjust Inspect and if necessary clean correct fill or replace L Lubricate R Change or replace T Tighten to proper torque X Perform Inspect and service your SSR Pit Bike more frequently if ridden hard or in dusty hot or other extreme con ditions Regardless of hours of riding always perform all service operations prior to storage or annually Unless the owner is an experienced and skilled me
33. l into a suitable container and dispose of it in an environmentally safe manner Most auto parts stores accept used engine oil for recycling Remove the old sealing washer from the drain bolt and install a new sealing washer Install the oil drain bolt and tighten it to the specified torque 18 Ib ft Pour approximately 0 6 US quart 0 57 liter of the recommended oil into the crankcase Install the oil filler cap dipstick securely 12 Start the engine Let it idle for two to three minutes then turn it off With the motorcycle held upright on a level surface check the oil level If needed add oil until it reaches the upper level mark on the dipstick Do not overfill Check for oil leaks More About Engine Oil Whenever you buy oil for your bike check the label on the container to make sure it matches recom mended specifications Engine oil has a major influence on both the perfor mance and the service life of the engine Non detergent vegetable or castor based racing oils are not recommended Aftermarket oil additives are not needed and can negatively affect the bike s engine Use the recommended oil Throttle Control Free Play Inspection Check free play Free play is the amount the throttle control will move before starting to open the throttle on the carburetor Free play should be between 5 64 and 5 32 inch 2 0mm to 4 0mm movement at the grip Adjust if necessary to bring free play within the
34. l on the wire as this may damage the conductor within the wire causing high resistance and reduced firing voltage Remove the spark plug with a spark plug NOTICE wrench Inspect the spark plug electrodes for wear The Improperly tightened spark plugs can cause dam center electrode 1 should have square edges age to the engine Aloose plug can cause a burned The side electrodes 2 should not be eroded piston over tightening the plug can damage or strip The insulator should not be cracked or chipped the threads in the cylinder head Check the spark plug gap 3 using a wire type feeler gauge If an adjustment is necessary bend the side electrode carefully to open or close the gap which should be 0 024 to 0 028 in 0 60 to 0 70mm Make sure the plug washer is in good condition If you need to install a new spark plug check and if necessary adjust the gap With the plug washer attached thread the spark plug in by hand to prevent cross threading Do not force fit the plug 45 SERVICE MAINTENANCE Front Suspension Inspection LUBRICATION AND 1 Check fork operation Pull the front brake lever in to lock the brake Then push up and down ADJUSTMENTS co nt on the fork legs several times The suspension should function smoothly There should be no Suspension oil leakage 2 Check to be sure that the fork mounting bolts and handlebar riser mounting nuts are tight If any front suspension components appear worn or da
35. ld reduce speed and finish braking before entering a turn Riders should avoid braking or closing the throttle abruptly while turning either action can cause one or both wheels to lose traction and a loss of traction at either wheel will cause a reduced or complete loss of control Riding on wet or loose surfaces reduces the ability to maneuver and stop All control inputs must be smooth under these conditions Hard acceleration braking or turning may cause loss of control Al ways exercise extreme caution when accelerating braking or turning on slippery or loose surfaces When descending long steep grades or any grades with loose or slippery surfaces use engine compression braking by downshifting to the lowest applicable gear and applying the brakes gently and intermittently 31 OPERATION Starting and Riding cont cont Stopping and parking After coming to a com plete stop lower the side stand Shut off the engine Depending on how your specific bike is equipped this is accomplished by either pressing the button on the momentary style engine stop ignition kill switch or if equipped with a two position rocker style switch from the run to the off position If the bike is not going to be run again within a few minutes also turn the fuel petcock to the OFF position 32 Post ride inspection After completing a day of riding clean the bike as thoroughly as conditions allow Remove all dirt
36. lige hs VU SILC AAA PP zen oind tien ind Saetiet glade taateeueaees 28 Stanno the ENGIN ssetewsnteedersecn laren setuid seus ot tag A 28 ii A A re tena ey 30 O e ee eee eee 30 DIOP PING Ge A A sie caden os 32 PostRide INS DECI ON psi e 32 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Why Proper Maintenance 1S IMPONE 33 BrEAKING IM the ENJING arosine E a a a aa aa a a d baclol 33 A T T eee ee era ee 34 Recommended Service and Maintenance Schedule oocccocccoocncccnccocnconcnnncncconnnonnnoncnnnnncnnnnnonoss 35 Fuel Recommendations asa o ad 37 Engine Oil Checking and Adding Changing Recommendati0ONS ooccoccccoccccccncconnconnncncnnncncnncnnnnnos 38 oigo pe Had AAA E A S 41 MONG ESPE a e edi a 42 AIr PIE AA T E 43 Spark Plug Specifications Removing and Replacino ooccooccoonconnconnccnococnconnconnnonncncncncncnnncononononos 44 CONTENTS cont Suspension InSPecI Nn Erontana ROMs did 46 suspension Aqjustments Front and Rear wad N i 48 Brakes Frontand REA enea oe eee ee 50 Brakes Wear Inspections and LubricCatiON ococcocconconioononnonconennoncononconnonconcnnennonnonnonnonnonnennencnnnnnns 51 VV ICEIS A a phiaa monies ane onan ancumesiameneiearn ates 52 Wheel Removal Front annann a a aan 53 Tires and Tubes Air Pressure Inspection Replacing coococcconconconiocnnnonnconcononnnononnnonnnnonnnonnnnnnnoos 53 Sde Stand A NO ee 56 Drive Chain Inspection and AQUUStMEN ao sein
37. maged see your dealer for further inspection Loose worn or damaged suspension components may adversely affect the handing and stability of your motorcycle If any suspension components ap pear worn or damaged see your dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed a SO Y 46 Rear Suspension Inspection 1 Swing arm bushing 1 Place the bike on a maintenance stand Either strap securely in place or have a helper hold the bike while you push hard against the side of the rear wheel and feel for any free play which indicates worn swing arm bushings 1 Do not ride with worn swing arm bushings 2 Check that the fasteners for the shock absorber attachment points 2 are secure 4 i nS n mt 7 i me L a j a 1 aa 3 2 Shock absorber attachment points 3 Shock absorber bushing Check that the shock absorber bushings 3 are not worn check for oil leaks in the shock absorber If any rear suspension components appear worn or damaged see your dealer for further inspection gt gt gt 47 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Rear Suspension Inspection cont Shock absorber bushings Front Suspension Adjustments Some SSR pit bikes are equipped with adjustable front and or rear suspensions The simplest adjustable front suspensions are forks that are adjustable for re
38. more times 2 Warm up the engine again and ride the bike for about five minutes at an easy pace Vary the rom do not ride at more than 1 3 of maximum throttle or rom Let the engine cool completely and repeat the cycle two more times 3 Ride the bike for five to ten minutes at a mod erate pace varying the rom and not going over Y throttle or rom Let the engine cool completely and repeat this secondary break in two more times 4 Complete the break in by riding aggressively for about 15 minutes Ride hard without revving the engine fully vary the rom and do not cruise at part throttle By the time you completed the break in process you will probably have used at least one and maybe as much as two gallons of gasoline In addition for the first five hours do not use the bike to climb steep slopes do not ride more than two hours at a time without shutting the engine off and allowing it to cool and vary the engine speed regularly gt gt gt 33 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Why Proper Maintenance is Important cont cont Allow the engine to warm up for three to five min utes before each ride this gives all internal com ponents a chance to become fully and thoroughly lubricated For the first five hours try to observe a maximum speed no more than 25 mph and not more than 35 mph during the second five hours Safety Precautions The engine must be off before beginning any ser
39. mud brush rocks and or other objects that you may have picked up along the ride After cleaning carefully inspect the bike for any damage or leaks Repair any damage that might affect the safe operation of the bike before its next use Be sure to lubricate the drive chain if possible before the bike s next use SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Why Proper Maintenance is Important Keeping your pit bike well maintained is essential to your safety as well as being a good way to protect your investment realize its maximum performance avoid breakdowns and have fun To help you keep your new pit bike in top condition this section includes a Service Intervals Schedule simple and easy to follow instructions for specific maintenance work safety precautions information and recommendations for oils plus tips to keep your bike looking its best Breaking in the engine While the engine in your new SSR pit bike does not require a formal break in procedure we recommend you follow the follow ing tips to get the best performance and longevity from your bike Note None of the pit bikes covered in this manual are equipped with soeedometers or odometers so you will need to guesstimate both your speed and miles traveled 1 Start your engine and let it idle for four to five minutes blipping the throttle occasionally Shut off the engine and allow it to cool completely Repeat this heat cycle process four
40. n If ping ing occurs at steady speeds under normal loads change brands of fuel If the pinging persists see your dealer WARNING Gasoline is highly flammable and explosive You can be severely burned or injured when handling fuels Always stop the engine and keep gasoline away from sources of heat sparks and flame Only handle gasoline outdoors Wipe up spills immediately Do not use as a solvent or cleaner 37 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Safety Precautions cont Engine oil Using the proper oil plus regularly checking the oil level adding additional oil if need ed and changing the oil as recommended will all help extend the life of your bike s engine Remem ber the engine in this pit bike is cooled by outside air flowing over the engine and the oil circulating within the engine Even the best oil gradually wears out reducing its lubricity It also picks up dirt and other contaminants from the inside of the engine and becomes more and more contaminated as the miles of use add up Old and or dirty oil can dam age your engine or cause accelerated wear on moving parts running the engine with insufficient oil can cause serious damage to the engine and transmission 38 Oil Recommendation API Classification SF or SG Viscosity weight SAE 10W 40 Suggested Oil 4 stroke oil USA amp Canada or equivalent For continued use with ambient air temperatures above 90 95 degrees F
41. n bad condition has improper gap or is partially fouled 2 Spark plug cable is in bad condition 68 Carburetor is not adjusted correctly Fuel tank vent is plugged or the fuel line to the carburetor is closed off restricting fuel flow Carburetor flooded by excessive pumping of hand throttle Water or dirt in the fuel system and or carburetor Engine Starts But Runs Irregularly or Misses Spark plug is in bad condition or partially fouled Spark plug cable is in bad condition Spark plug gap is too close or too wide Intermittent short circuit due to damaged wire insulation Water or dirt in the fuel system or carburetor Fuel system vent is plugged or the fuel line to the carburetor is partially obstructed Spark Plug Fouls Repeatedly Excessive use of choke Fuel mixture is too rich Incorrect spark plug Pre ignition or Detonation Knocks or Pings Incorrect fuel not high enough octane rating or blend of additives incorrect for bike engine Incorrect spark plug heat range for type of usage Overheats Insufficient oil supply or the oil is not circulating properly Heavy carbon deposits from lugging the engine See your dealer Insufficient air flow over cylinder head from idling too long or obstructed by mud and debris Engine Leaks Oil Loose parts Check for loose bolts and nuts or see your dealer Bad seal s and or g
42. n the tire Check for rocks or other objects embedded in the tire or tread Remove any objects Measure the tread depth Replace the tire before tread depth at the center is 1 8 inch 3mm or less or any time you begin to notice a reduction in trac tion Check the position of the valve stems on both wheels A tilted valve stem indicates the tube is slip ping inside the tire or the tire is slipping on the rim See your dealer Tube Replacement If a tube is punctured or damaged you should re place it as soon as possible A repaired tube may not be as reliable as a new one and it could fail while you are riding For information on making a temporary repair see page 73 Always use a replacement tube that is equivalent to the original We recommend that tubes be replaced by your dealer Replacing a tube requires remov ing and re installing the wheel Any time a tube is replaced carefully inspect the tire Tire Replacement The tires that came on your pit bike were engi neered to provide the optimum combination of handling braking durability and comfort Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and If installed in a new tire could fail We recommend that tires and tubes be replaced by your dealer WARNING Installing improper tires can negatively affect handling and stability This can lead to a loss of control which
43. park plug cap and remove the spark plug Connect the spark plug cap to the spark plug and ground the threaded portion of the spark plug on the cylinder head Operate the kick starter while you watch the spark plug If it sparks the C D I ignition system is probably working If there is no spark install a new spark plug if you have one with you If there is still no spark there is a problem in the ignition system Also see Troubleshooting page 68 69 If you cannot identify or correct the problem you will have to push your motorcycle back to your base or get some help lf You Get a Flat Tire How you handle a flat tire on the trail depends on how serious the tube or tire damage is and what tools and supplies you have with you lf you have a slow leak or a minor puncture there are two ways to try making a temporary repair Use an aerosol tire sealer to seat the puncture and inflate the tube This can be done without removing the tire or wheel Use a tube patch kit to repair the puncture This requires removing the tire and wheel If the leak is more serious or a temporary repair doesn t work the inner tube must be replaced The tire will also need to be replaced if it is damaged Replacing a tube or tire involves removing and re installing the wheel see pages 53 55 73 If you are unable to repair a flat tire on the trail you will need to push the motorcycle back to your base or send for help We strongly r
44. r electrical wiring Tighten both straps until the front suspension is compressed about half way Use one or two additional tie down straps to keep the rear of the motorcycle from moving Do not transport your bike on its side This can damage the bike and leaking gasoline or oil can create hazardous conditions 65 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Storing Your Pit Bike If you won t be riding your bike for an extended pe riod such as during the winter thoroughly inspect your bike and correct any problems before storing it That way needed repairs won t be forgotten and it will be easier to put your motorcycle back in service come riding season cont We suggest you perform the following procedures to keep your motorcycle in top condition These storage procedures will reduce the deteriora tion that can occur during storage Preparation for Storage 1 Change the engine oil 2 Be absolutely certain that the fuel petcock is in the OFF position 66 3 Drain the carburetor into an approved gasoline container and dispose of it in an approved manner or pour into the fuel tank 4 Fill the fuel tank and make certain that the cap is properly fitted and completely closed If the bike is going to be stored for more than one month drain the carburetor This will help assure the bike performs well when it s time to ride again WARNING Gasoline is highly flammable and explosi
45. r not true If the wobble is noticeable see your dealer for inspection FRONT WHEEL REMOVAL Removal 1 Raise the front wheel off the ground by placing a maintenance stand or support block under the engine Secure the rear of the motorcycle with tie down straps 2 Remove the front axle nut and front axle 3 Remove the wheel Do not get any grease oil or dirt on the brake pad surfaces This can cause poor or erratic brake performance or rapid brake pad wear after reassembly Installation 1 Reverse the removal procedure 2 Torque the axle to 35 Ib ft 3 Check front brake adjustment If a torque wrench was not used to re install the wheel have your dealer inspect the bike as soon as possible to verify proper assembly Improper re assembly may lead to loss of front braking function TIRES and TUBES To safely operate your pit bike the tires must be of the proper type for off road use only and size in good condition with adequate tread no cuts or oth er visible signs of damage and correctly inflated WARNING Using a tire that is excessively worn or improperly inflated can lead to a loss of control which could result in serious injury or death Follow all instructions in this owner s manual regarding tire inflation and maintenance Tire Air Pressure Properly inflated tires provide the best combination of handing tread life and riding comfort Under inflated tires wear unevenly which adversely affec
46. r replacing the engine Shifting gears See the Gearshift Lever in the CONTROLS CLUTCH AND TRANSMISSION section of this manual pages 11 12 30 Braking To slow or stop the bike apply the front and rear brakes smoothly while downshifting to match the engine speed to the bike s forward speed Gradually increase braking pressure as you slow down As the bike slows to a stop put your left foot down then when you are through using the rear brake put your right foot down For maximum braking close the throttle and firmly apply the front lever and rear pedal controls to the threshold of wheel lock up Applying the front and or rear brakes too hard may cause the wheel to lock up and slide reducing or eliminating control of the bike If this happens momentarily release the brake controls steer straight ahead until regaining control and reapply the brakes with less pressure Beginning or novice riders should always apply the brakes as evenly and smoothly as possible Slightly more pressure on the front brake than on the rear gives better control for less experienced riders more rear brake pressure can cause a loss of rear tire traction and result in losing control of the bike Experienced skilled riders can vary the proportions of front to rear brake pressure to compensate for riding conditions and speeds Hand amp Foot Brake Controls All riders except those who are experienced with expert level skills shou
47. rear brakes should be checked for wear after every 15 hours of riding We recommend that this inspection be performed by your dealer Other Inspections 4 Lubrication Check that the front lever and rear pedal assem blies are positioned properly and that all fasteners are tight Check the front brake hydraulic fluid line for kinks or signs of wear or abrasion that could cause sticking or failure Front Make sure the front brake lever spring and fasteners are in good condition Rear Make sure the rear brake pedal arm spring and fasteners are in good condition 51 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Wheels Maintaining correct spoke tension and trueness roundness of the wheels is critical to safe motor cycle operation During the first hour or two spokes will loosen rapidly due to the initial seating of the parts Ex cessively loose spokes may result in instability at moderate and high speeds leading to a possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended services in the Maintenance Schedule However information for wheel removal is provided for emergency situations 1 Inspect the rims and spokes for damage 52 Tighten any loose spokes Rotate the wheel slowly to check for signs of wobble If the wheel appears to wobble the rim is out of round o
48. s are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygen ated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states and or provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 etha nol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing methanol containing up 5 methanol by volume as long as it contains co solvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system 79
49. se and the fuel tank for leaks Look beneath the bike for signs of leaking fluids If the bike has an auxiliary oil i H z 7 cooler check lines and fittings to be sure that there a p Y nik is no leakage If there is any leakage clean and tighten fittings as necessary Auxiliary Oil Cooler 20 a Dipstick Location Engine oil Check oil level using the dipstick on the right side of the engine transmission case and add oil if necessary Be sure to use the correct type and weight oil as specified in this manual Be sure the dipstick is properly and securely refitted into the engine transmission case For more information see Engine Oil Checking and Adding in the SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS section 21 OPERATION cont Pre Ride Inspection cont Filler Neck amp Fuel Cap Fuel Check the fuel level and add more if neces sary filling to the bottom of the filler neck Be sure to use 90 or higher octane unleaded pump gaso line ZZ Fuel Cap Breather Tube amp Cap Make certain that the fuel filler cap is securely fas tened and that the breather tube is properly seated on the cap and in good condition Drive Chain Chain Slider amp Roller Drive Chain Check the chain for condition and Check the chain slider located on the forward por correct tension slack The chain may break if too tion of the left side of the swing arm for exce
50. ssive tight not enough slack excessive chain slack wear and replace if necessary can cause accelerated wear kinked or binding links loose pins and or damaged rollers 23 OPERATION Pre Ride Inspection cont cont Throttle Cable Cables The clutch and throttle are actuated by cables from the handlebar levers Check the cable housings for wear and the fittings for looseness and replace or tighten as necessary 24 Clut h Cable at Handlebar ba r G Clutch Cable at Transmission Case If a cable does not operate freely it may need to be lubricated Nuts and bolts Using appropriate size wrenches be sure that all accessible nuts and bolts are tight And tighten if necessary i h a Spark Plug o Spark Plug Spark plug and ignition wire Make sure that Be certain that the ignition wire terminals fit secure spark plug is not loose in cylinder head tighten if ly onto the spark plug and ignition coil necessary 25 OPERATION cont Pre Ride Inspection cont Throttle Closed Throttle Open Throttle Check the throttle control for free play and adjust if necessary 26 Front Brake Control Rear Brake Control Brakes Test front and rear brake controls for nor Adjust mechanical free play in front and rear levers mal operation If either feels soft check the appro and linkages if necessary priate master cylinder fluid reservoir and add DOT 3 or 4 fluid as
51. t you are not under the influence of alcohol or drugs and that you are wearing proper safety gear We want to keep you as a customer so for your safety we strongly urge you to wear an approved helmet high quality eye protection and protective clothing that includes at a minimum motorcycle gloves and boots durable long pants and a long sleeved shirt A helmet reduces the possibility of serious head injury or death in a crash An open face helmet offers good protection but a full face helmet offers much more Always be certain that any helmet has a DOT Department of Transportation certification sticker For even better protection get a helmet that is both DOT and Snell Snell Memorial Foundation which has more rigorous standards than the DOT certified A helmet should fit your head comfortably but snuggly and have an adjustable chinstrap that can be tightened securely To maximize your safety when riding you should wear a face shield or preferably high quality goggles designed for off road use Off road motorcycle boots will provide better pro tect your feet ankles and lower legs than boots intended for street riding The same holds true for gloves For the utmost protection also wear riding pants with knee and hip pads a riding shirt or jersey with padded elbows and a chest or shoulder protector Before each ride thoroughly inspect your bike and if you discover any problems correct them Off road riding is very toug
52. ter link clip gets knocked off you may be able to put the chain back on with a new master link However if the chain breaks or does other damage when it comes off you may not be able to make a trailside repair lf any component of the front brake system is dam aged you may be able to ride carefully back to your base using the rear brake for slowing or stopping lf you damage a throttle cable or other critical component your motorcycle may be unsafe to ride Carefully assess the damage and make any repairs that you can If there is any doubt it s best to be conservative and safe Technical Information This section contains dimensions capacities and other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification Numbers The frame PIN Product Identification Number or VIN Vehicle Identification Number and engine serial numbers are required when you register your motorcycle They may also be required when ordering replace ment parts You can record these numbers in the back of the manual The frame number is stamped on the right side of the steering head or on an etched or stamped tag riveted to the steering head 1 VIN on Steering Head The engine number is stamped on the left side of the engine 2 Engine Number 75 Technical Information cont Break in Guidelines Help assure your motorcycle s future rel
53. trol which could cause serious injury or death CONTROLS HANDLEBAR MISCELLANEOUS Kick Starter YE All SSR pit bikes are kick start only with the excep tion of the SR125 AUTO model which is equipped with an electric start and continuously variable au tomatic transmission The kick start lever is located on the right side of the engine case just to the rear of the right foot peg The kick start lever features a peg that rotates 90 degrees from a front to back position when the bike is running or at rest to point ing outward to the right for kick starting the bike Manual Choke and Fuel Petcock All SSR pit bikes utilize carburetors with manual chokes to assist cold starts On most models the choke lever is attached to the left side of the carburetor and has two positions fully ON or fully OFF the choke on several models is attached to the right side of the carburetor and features three positions fully ON DETENT a halfway position and fully OF F Fuel feed to the carburetor from the fuel tank is controlled by use of a manually operated three position petcock or regulator valve that is located on the left side The three positions are ON OFF AND RES reserve 13 CONTROLS HANDLEBAR amp MISCELLANEOUS cont Throttle Throttle Closed Throttle Open The throttle controls the engine speed RPM andis to reduce engine and vehicle speed rotate the gr
54. ts handling Under inflated tires are more likely to fail from overheating Under inflated tires may also cause wheel damage in rocky terrain Over inflated tires will make your motorcycle ride more harshly are more prone to being damaged by surface hazards and wear unevenly gt gt gt 53 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS Tire Air Pressure cont Check Tire Pressure Cold Always check tire air pressure when the tires are cold Tire pressure measurements will be inaccu rate inconsistent and always higher if the air pres sure is checked when the tires are warm or hot a happens even if the motorcycle has only been ridden for a few miles If you let air out of warm or hot tires to match the recommended cold air pressures the tires will be under inflated Make sure the valve stem caps are secure If a cap is damaged or missing install a new cap 25 psi_ 1 8 kgf cm 2 25 psi_ 1 8 kgf cm 2 Recommended Tire Pressure COLD If you decide to adjust tire pressure for a particular riding condition make changes a little at a time Inspection A flat tire is inconvenient at best and may cause an accident Carefully inspect your bike s tires and wheels every time before you ride Look for bumps or bulges in the tire sidewall and tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace the tire if you can see any fabric or cord anywhere o
55. ve You can be burned or seriously injured when handing fuel Stop the engine and keep heat sparks and flame away Do not handle fuel indoors Wipe up any spills immedi ately Wash and dry your motorcycle Lubricate the drive chain Inflate the tires to the recommended air pressure Store your motorcycle in an unheated area free of dampness away from sunlight with a minimum of temperature variation Cover your motorcycle with a porous material Avoid using plastic or similar non breathable or coated materials that restrict air flow and allow heat and moisture to accumulate Removal from Storage Uncover and clean your motorcycle If your motorcycle has been stored for more than four months change the engine oil If your motorcycle has been stored for more than two months drain and replace the fuel Lubricate the drive chain Check tire inflation and add air if needed to return inflation to specifications Perform a pre ride inspection then test ride your motorcycle at low speeds 67 TROUBLESHOOTING Engine Does Not Start 1 Fuel tank is empty 2 Fuel petcock is turned off 3 Fuel petcock is clogged 4 Fouled spark plug 5 Spark plug cable connectors loose or in bad condition and are shorting 6 Engine flooded with fuel from over enrichening excessive use of the choke 7 Throttle held too open when using the choke Engine Starts Hard 1 Spark plug is i
56. vice maintenance or repair operation unless the instructions specifically state that it is to be running Do not run the engine in an enclosed area or any area without adequate ventilation The exhaust contains carbon monoxide and other toxic gases which can collect quickly in confined areas and can cause illness and even death Hot engine parts can cause serious and painful burns let the engine and exhaust cool before touching Read all instructions before beginning any mainte nance or adjustment procedures Be sure you have the necessary tools skills and experience to suc cessfully complete whatever work you start To help prevent the bike from falling over which can cause damage to the bike and injure any per sons hit by it park it on a solid and level surface and use the bike s side stand or a maintenance lift stand designed specifically for motorcycles to provide proper support Always be careful when working around gasoline to reduce the possibility of a fire or explosion Use only a non flammable high flashpoint solvent such as kerosene or a specially prepared cleaning prod uct for washing parts Keep all fuel system related parts away from any sources of heat sparks or flame Never smoke around gasoline or other flam mable materials Recommended Service amp Maintenance Schedule AAA INTERVALS SERVICE OPERATION Every 3 Hours Every 5 Hours Every 10 Hours Every 15 Hours Valve Adjustment X Engine Oi
57. wrench was not used for this installation have your dealer inspect the bike as soon as possible to verify proper assembly Improper re assembly may lead to premature chain and or sprocket wear chain or sprocket failure damage to the bike and loss of control which could result in injury or death Tighten the adjusting nuts lightly Then while holding the adjusting nuts with a wrench tighten the lock nuts Recheck drive chain slack Check rear brake pedal free play and adjust as necessary Free play may be affected when the rear wheel is repositioned to adjust drive chain slack 59 SERVICE MAINTENANCE LUBRICATION AND ADJUSTMENTS cont Lubricating the Drive Chain Lubricate the drive chain after every three hours of riding sooner if the chain appears dry Raise the rear wheel off the ground using a maintenance stand Slowly turn the rear wheel by hand and satu rate each drive chain link joint so that the lubricant penetrates between the link plates pins bushings and rollers Drive chain lubricant for motorcycle use should be available at your dealer and most power sports shops Removing Cleaning and Re installing the Drive Chain When the drive chain becomes extremely dirty it should be removed and cleaned prior to lubricating 60 1 Master Link Retaining Clip Remove the master link retaining clip 1 with pliers Do not bend or twist the clip Remove the master link then remove the
Download Pdf Manuals
Related Search