User manual TR 280i 2012 (English)
Contents
1. A a RT User manual OSSA Model without standardisation kit We at OSSA Motor would like to thank you for purchasing one of our products It is very important that you read this User s Guide to ensure the correct functioning and maintenance of your new TR 280i As the owner of an OSSA motorcycle you are the member of an exclusive group You have just acquired a unique model the first model to be produced since the relaunching of OSSA The TR 280i is the visiting card for our new OSSA Factory It marks the comeback after a 25 year interval of the legendary brand with the clover logo which in the 1960s and 1970s earned itself a solid international reputation outside the frontiers of the motorcycling world This is a Introduction really special article that will form part of the history of the brand of trial racing and of motorcycling as a sport The TR 280i is a motorcycle that has been conceived for competition and then adapted to traffic regulations for use on public roads It has been specifically designed for trial competitions which means that its features are ideal for such conditions It is extremely light in weight both its gears and transmission systems and the distribu tion of its component parts have been arranged with careful attention and make it a revolutionary machine that is technically extremely advanced OSSA motorcycles have been designed assembled and tested by experts and each of its pa2. Pressure and condition To ensure that the motorcycle works correctly its very important to check the tyre pressure and that the wheels are in good working condition before each use Using tyres that are in a good condition will mean that the motorcycle is capable of performing to the best of its ability It also ensures that trial riding is safer and more efficient Front tyre 2 bx21 Rear tyre 4 00x18 Front tyre pressure 0 45 bar normal 0 42 bar competition Tyre in bad working condition Rear tyre pressure 0 35 bar normal 0 30 bar competition A NEVER forget to periodically check the tyre pressure to ensure that the tyres have a good grip User manual 45 Checking the crankcase oil Filling and draining the crankcase Crankcase oil is used for lubricating the change pedal and the clutch Check the oil level with the indicator located on the lower part of the clutch cover which is on the right side of the engine The oil level should be lower than the indicated maximum level MAX C Optimum oil level MIN The oil level should be checked when the motorcy cle is in an upright position and on a flat surface The motorcycle should be cold If it is not cold wait some minutes until it goes cold To add oil remove the cap A located on the top of the clutch cover D Use a funnel to add the oil NEVER filling above the Maximum level Replace the cap If you fill above the Maximum le
3. Procedure for obtaining repairs under warranty If your motorcycle needs a repair to be carried out under warranty it should be taken to your official OSSA dealer where the repair will be made YOU ARE RESPONSIBLE FOR THE TRANSPORT COSTS TO AND FROM THE DEALER Ossa recommends that you go to the dealer where your purchase was made However you can go to any Ossa dealer for repairs to be carried out under guarantee This guarantee provides you as a consumer with specific legal rights You may also have additional consumer rights that vary depending upon which country you are in If one of the afore mentioned terms is invalid due to regional or federal laws all other terms stipulated in this warranty continue to be valid 68 User manual We recommend that you stay in contact with your OSSA dealer so that you can receive help advice and information about your new motorcycle as well as information about the new products launched by OSSA Factory SL We aim to provide full customer satisfaction If the service you have received is not adequate we would ask you to send us a written account stating specific instances with as much detail as possible about the incident concerning our dealer This will enable us to improve the OSSA MOTOR customer service and services in general Thank you and we hope you enjoy your new motorcycle Final information User manual 69 O User manual User manual 71 a W WW 0Ssa moto A ww
4. Warranty conditions Final considerations Contents 39 40 42 43 44 45 46 47 48 52 94 58 59 66 67 User manual 7 Technical specifications ENGINE Cubic capacity Type Cooling system Diameter x stroke Power supply Ignition Clutch TRANSMISSION Gear box Transmission Engine lubrication 272 2 cc Mono cylindrical two inverted speeds with admission via slats directly to the sump Liquid 70x60 mm EFI Kokusan Battery less System CDI Kokusan digital magnetic steering Hydraulic clutch knob 6 speeds Primary by gears secondary by chain Mix 0 996 Oil 10096 synthetic Changing lubrication and clutch 350 cc of oil type Gear Extreme 75 W CHASSIS Type Tube form in CR MO steel with pipe and lower part made from forged aluminium Front suspension Fork with aluminium bars 40 mm diameter Marzocchi adjustable in extension and compression Rear suspension Front brake Rear brake Front wheel Rear wheel Engine protector Kick start pedal Transmission and brake pedal 8 User manual Variable progressive system with TTX OHlins mono shock absorber adjustable in extension and compression 185 mm diameter disc with 4 piston brake caliper 150 mm diameter disc with 2 piston brake caliper 28 spokes with 2 75x21 wheel 28 spokes with 4 00 x 18 tubeless wheel Constructed in AA7075 T6 Forged aluminium Forged aluminium with retractable toe cap OSSA Technical specifications WEIGHTS AND MEASUREMENTS Dist
5. As can be seen in the illustration on the right these are located at the bottom of the air filter housing between the steering bar and the front headlight and in the fuel system apparatus Carry out a regular and thorough maintenance of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly Electrical connections A i p Y 4 User manual 35 Simplified diagram of the lights OSSA iR em Se SF 3304 an ig 36 User manual Simplified diagram of the injection installations User manual 37 Air filter Air filter Cleaning and maintenance The air filter should be controlled periodically Detach the upper section of the motorcycle to reach the filter box Remove the sensor on the filter base and the clasp Then remove the filter according to the illustration To clean use water and detergent leave to dry and then lubricate with a special liquid for filters Reassemble using the steps outlined previously but in reverse Make sure that the parts are put in their correct positions Carry out a regular and thorough maintenance of your motorcycle Always use original spare parts and top quality products to ensure that it works correctly 38 User manual E Fr v ru uh The radiator contains the engine refrigerant To fill up with or add refrigerant to the radiator loca
6. Rear wheel badly adjusted Align rear wheel Contact an officially registered mechanic Front fork with insufficient oil Add oil to the fork until it reaches a sufficient level Front fork spring weak or broken Replace front fork spring Brake disc wear Replace brake disc Brake pads badly positioned or Change position of break pads or replace them crystallised VAN In the event of breakdown always take the motorcycle to a specialist mechanic A 52 User manual Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The motorcycle makes abnormal Cylinder damaged Replace the damaged cylinder noises Supports screws or nuts are not properly Check and adjust using suitable torque wrench fastened Tyres wear swing arm or its needle Change worn parts for new parts bearings wear Wheel rim not centred Centre wheel rim Wheel not centred Check the tension of the spokes and readjust Lack of engine oil Check and add engine oil The handlebar vibrates Steer axle with excessive tolerance Tighten the handlebar support and the steer axle nut using suitable torque wrenches Handlebar support loose steer axle nut Tighten the handlebar support and the steer axle nut loose using suitable torque wrenches AN In the event of breakdown always take the motorcycle to a specialist mechanic AN User manual 53 Troubleshooting YN PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The motorcycle tends to lea
7. of this motorcycle uses a mixture of unleaded petrol and 2T oil 10076 synthetic in a 0 9 proportion The fuel tank forms a structural part of the chassis and is located on the front inside part To fill up with petrol open the fuel tank lid situated on the upper part by unscrewing in an anti clockwise direction It s recommended that a hose or funnel is used to fill up to avoid spilling the petrol This is especially important if the motorcycle is hot DO NOT fill up with petrol when the motorcycle is turned on 28 User manual OSSA Upper Section To access different parts of the motorcycle or the motorcycle s electrical system the upper section should be removed This section is made up of 2 parts that are screwed onto the chassis and fitted together The first part of this section is located on the front above the fuel tank Next is the second part of this section which corresponds to the seat area and rear mudguards hc Tx UL BL fe im i M irl uh 29 int PF I B A 6 M xS ae E ee oum no 1 i T a a rna I r E D Pe Ma dez hs A 1 EX PIE T i man I ET M qu ATE e aria e UE yus EISE ar uro 1 NIE ET M UN Se eee M La sinat en A uu ui eo CLERC A E E ATA UA 1 for S rs E T vea Te JUN E ril x m rog 1 EU HE unt in E ri ha z DN 4 aT fat 3i A 1 peT qt 3 1 a P oU w EPI
8. so that it lasts longer s E E es ES D I umo ee sx 2 A We SY Af TEE E A n gon D Fi Es TC e 1 hr Y n ou i M utn T MEM PA LL al CR mE SC y AE M 1 M de Tu eX MM IL ET SN o te Ei NA EN no E a t i jet 2M ji i a Au Ae Nang o iun J UE 1 q ADU uT Er XAR o ES amr JL pg E 1 5 ig L oy Tr s LIS ADS Dre s m f SC ra eg i la oe A E A IT m sad eae T A res PR j DURS eo IM on Y Ut tate J se is zu o nee 2 x vs er Tu L I t F 1 i AD AS 1 1 40 User manual OSSA Observe the distance between the electrode and the arch This distance should be 0 7 mm 0 7 mm NOTE The sparkplug should not be handled if the motorcycle is hot OSSA Chain tension adjustments The transmission chain transmits the engine s movement to the rear wheel To ensure that is works correctly it should be checked The axle has easily adjustable eccentrics for tensing the chain and centring the wheel The chain tension should permit 2 cm of oscillation in the chain tension adjuster The chain hook should be positioned in an opposite direction to the gear as can be seen in the photo User manual 41 Lubr
9. 0 rpm Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the Selection by pressing button 2 PICS TAN m SH Fte Malala v MODE E 12 Our 2 Setting the indicator functions to zero after each use of the vehicle After each use of the vehicle it s possible to set the following functions to zero simultaneously Maximum speed Distance Chronometer Maximum temperature Maximum turn rate Confirm that you want to set these functions to zero by simulta neously pressing buttons 1 and 2 Multi function Setting the whole multi function box to zero Press the RESET button by using a suitable object The indicator will boot again excluding data that corresponds to total accumulated distance and time RESET POSITIVE BATTERY CR2030 Internal battery The multi function box works with a 3V internal battery type CR2032 When the battery tension falls beneath 2 45V the screen displays the LO indicator To change the battery open the lid on the bottom of the indicator by unscrewing it as is indicated in the image using a coin Ensure that the positive side of the battery is facing upwards User manual 21 Multi funcition Screen Options The multi function box displays all information on three different screens While on it is possible to see screens 1 or 2 Screen 3 is displayed for three seconds and
10. C or F press button 1 Confirm the selection by pressing button 2 Danger temperature selector Note This stage should only be implemented for those vehicles that have an optional temperatu re sensor When the motorcycle temperature exceeds the set value right hand warning light comes on Default value 110 C 230 F Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pressing button 2 20 User manual m DESEES N m x MODE 22 Warning temperature selector Note This stage should only be implemented for those vehicles that have an optional temperatu re sensor When the motorcycle temperature exceeds the set value the left hand warning light comes on Default value 90 C 190 F Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pressing button 2 Gear change turn rate selector When the set rate is near to being reached the left hand warning light will flash indicating the need to change gear Default value 6000 rpm Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection pressing button 2 Dangerous turn rate selector When the set rate is near to being reached the right hand warning light will flash indica ting that the engine is turning at an excessive rate Default value 10 00
11. ance between axles 1 328 mm Seat height 655 mm Distance to the ground 340 mm Fuel tank capacity 2 6 litres Mass in service 64 kg OSSA Factory reserves the right to make modifications without prior notification Kokusan Marzocchi OHlins are registered trademarks and their use is licensed User manual 9 Recommendations OSSA It is extremely important to follow the recommendations below in order to keep your motorcycle in full working order 12 hours of running in is recommended to ensure that the engine works correctly and for a long lasting time period lt is important to run the engine for some minutes until it reaches the correct temperature to work correctly The engine lubrication is a mixture of petrol oil with a 0 9 oil proportion Always use synthetic oil When the motorcycle is new the oil must be changed for the first time after 5 hours of use and for the second time after x hours of use 10 User manual Section 1 Components User manual 11 Location of elements 1 Front mudguard 2 OSSA multi function box 3 Fan and radiator 4 Cylinder 5 Sparkplug 6 Chain guide 7 Front tyre 8 Front fork stanchion 9 Front suspension bar 10 Gear lever 11 Chain 12 Chain slider 13 Rear crown protector 14 Rear tyre 12 User manual Model without standardisation kit 15 Rear break caliper and anti theft immobilizer 16 Exhaust 17 Kick start pedal 18 Fuel tank 19 Rear brake disc 20 Swing arm 21 Rear b
12. arranty ends Complaints will not be accepted after three years from the product delivery which is understood to have been made on the date that appears on the CERTIFICATE OF DELIVERY AND INSPECTION or on the invoice if a later date is shown Activating the warranty We request that you make an appointment with the OSSA sales representative that sold you the motorcycle or with any authorised OSSA sales representative providing this warranty manual The OSSA dealer is under obligation to repair or change at the discretion of OSSA any part that is faulty due to either the material used or manufacture process Warranty for spare parts and or accessories This warranty covers the repair or exchange at the discretion of OSSA of any original part due to faulty material or fabrication The materials and or labour will be free of charge Other damages are not included in the warranty nor are repairs included that appear due to the replace ment of the original part In any case you must certify that the attached table has been duly filled out 64 User manual OSSA Warranty Exceptions to the warranty The OSSA warranty does not cover the following items a b C d e f g h k Damages that arise from not carrying out periodical revisions as stipulated by OSSA Damages due to repairs or revisions carried out using methods that have not been specified by OSSA Damages due to using the vehicle in races rallies or o
13. chometer displays up to 12 000 rpm The tachometer signal can be captured from the sparkplug wire Warning of gear change due to rpm The rpm appear on the right side on the second line The digital tachometer displays up to 12 000 rpm The tachometer signal is received from the sparkplug wire SPD Speedometer The speedometer information appears on the centre of the screen It displays up to 399 9 km hour or miles hour MS Maximum speed meter It displays the maximum speed reached during the last operation after having set the counter at zero DST Distance covered It appears on the right side on the second line of the screen The TRIP function records the mileage accumulated by the vehicle since the last RESET Multi function 000 Mileage counter It records the distance or total accumulated mileage for the vehicle The data is stored in the memory even when the device is switched off ART Running time controller It calculates the total running time It begins counting as soon as the engine is switched on RT Total running time controller It calculates the vehicle s running time from the last RESET It begins to count from when the vehicle starts to move The data is stored in the memory even when the device is switched off 12 24 hour clock It displays the current time in 12 or 24 hour clock It indicates the temperature of the environment and engine The display screen on the upper left shows the environmental tempe
14. e selection by pushing button 2 Note If you don t know the wheel circumferen ce consult the Measuring the wheel circumference section 18 User manual Time adjuster Set the time by pressing button 1 repeatedly To move to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR Note This step must only be followed for those vehicles that change the PPR pulse type to a specific turn rate If you dont know this value press button 2 to move on to the next screen Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR The indicator receives an electric pulse each time the engine turns PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pressing button 1 repeatedly To move on to the next digit press button 3 Confirm the selection by pushing button 2 Adjustment of the revolution pulse PPR Note This stage must only be implemented if in the previous stage the value O was entered Default value 1 0 If you don t know this value press button 2 to move on to the next screen lo move on to the next digit press button 3 Confirm the selection by pressing button 2 Multi function User manual 19 Multi function Temperature selector To select the unit of temperature either
15. e turns is excessive Multi function box 0SSA multifunction display LED warning of excessive motor rotation Temperature warning LED Left button Right button Function Select Button User manual 15 Multi function box Technical features Current speed Tachometer Tachometer bar Maximum speed Distance covered Running time Mileage Uptime Accumulated uptime Clock AJ 00 00 00 Technical features 4 399 9 Km h o M h O 19999 rpm O 12000 rpm 4 399 9 Km h o M h 0 0 19999 Km M O 9999 hours 59 minutes 0 0 999999 O 999 hours 59 minutes O 9999 hours 59 minutes 12 59 59 23 59 59 0 1 Km h o M h 10 rpm Variable 0 1 Km h o M h 0 1 Km h o M h 1 second 1 minute 1 minute Each use 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Input voltage 9 400 V CA CC Speed sensor magnetic non contact sensor Tachometer input electrical pulse sensor Wheel circumference adjuster 1 mm 3 999 mm increases of 1 mm Running temperature storage from O C to 60 C from 32 F to 140 F from 20 C to 80 C from 4 F to 176 F Battery Life 3V CR2032 1 year approx 16 User manual OSSA Functions RPM Bar Bar graph tachometer The tachometer bar graph displays up to 12 000 rpm RPM Digital tachometer The RPM appear on the right side on the second line The digital ta
16. f substance medication drugs that might affect your driving capability Make sure your motorcycle is serviced regularly to avoid break downs while driving Do not clean the motorcycle with pressurized water equipment since this may damage the parts Do not use your motorcycle for transporting or towing loads In the event of needing to carry loads make sure that they are light weight and small in volume so that driving is not affected Ensure that there are no loose leads or other elements that might get caught inside a mechanism Never apply additional weight to the handlebars fork or mudguards Be especially careful when transporting any type of load User manual 5 6 User manual OSSA Introduction Important warning Safety Contents Technical specifications Recommendations Section 1 Components Location Multi function box Control pad Front suspension Readjustment Air bleed Rear suspension Readjustment Air bleed Anti theft immobilizer Start lever Fuel tank Upper engine cover Section 2 Maintenance and basic operations Maintenance grid Adjustments to the motorcycle controls Electric connections Air filter Radiator opark plug CONOR W 11 12 14 15 22 23 Chain Tension adjustments Lubrication of moving parts Tyres Pressure and condition Control of crankcase oil Filling up and draining Brakes Torque wrenches Storage Troubleshooting Registration series number and key
17. ication of moving parts Cleaning the motorcycle and lubricating the mobile parts will help protect the motorcycle and guarantee that it works better If using a high pressure hose to clean the motorcycle bear in mind that the water pressure might rip off the stickers or cause damage to the motorcycle To prevent this hold the hose at a distance of 30 40 cm from the motorcycle and take extra care on delicate parts Lubricate using specific products 1 Transmission chain 2 Clutch and brake lever joints 3 Gear lever joints 4 Rear brake pedal joints and bearings 5 Footrest brackets and springs 6 Engine kick start pedal joints 7 Gas handle right grip 2 Use specific lubricants for each part of the motorcycle Take care NOT to accidentally lubricate the brake caliper or brake pads If this happens clean off the lubricant and carry out controlled braking until the brakes work correctly again Clutch and brake lever joints 42 User manual OSSA Lubrication of moving parts all ehe eese aie wa 1016296 The chain must be lubricated using special oil for chain Check it each time the motorcycle is used and apply a drives lubrication when necessary Gear change lever joints Chain drive Rear brake pedal joints and bearings User manual 43 Lubrication of moving parts Chain drive and tension adjuster springs Gas handle right grip Engine kick start pedal joints 44 User manual OSSA Tyres
18. ilters and their components transmission chains air filters engine sprockets back crown gears disk brake and break pads clutch disks light bulbs except for those that are sealed fuses belts tyres and inner tubes wires and other rubber and or tire parts specified by OSSA Fluids Lubricants such as oil grease etc and fluids for functioning for example refrigerant liquid for the radiator break and gear fluids transmission fluids suspension oil etc m n 0 Cleaning inspection adjustments and other elements of periodical maintenance Additional costs on top of warranty service including notifications accommodation maintenance and other costs due to breakdowns in isolated places Compensation for wasted time commercial losses or hire costs of a substitute product during the adjustment period Any part replaced under warranty will become the legitimate property of OSSA The parts replaced during the period of warranty will be guaranteed for the time remaining for the substituted part OSSA reserves the right to introduce modifications and improvements it deems appropriate for all its models OSSA does not guarantee repairs for noise vibration oil filtrations and other elements that don t affect the product quality functioning and performance 66 User manual e YN Warranty Maintenance and service It is your responsibility to ensure that the services are carried out on your motorcycle within
19. iota MT ciu a EE er Rem h r ion 2 Model without standardisation kit Amer We HD DS SECHNON sad User manual 29 30 User manual Section 2 Maintenance and basic operations User manual 31 Maintenance grid Engine tt ME Check Inspect Adjust Replace Change Clean Grease lubricate Change kick start pedal Each wash 32 User manual YN Maintenance grid Cycle Item Check Inspect Adjust Replace Change Clean Grease lubricate wren damage each use Fue rus ange When damegea _ When oomega tachuse Whendamegea sd User manual 33 Adjustments to the motorcycle controls OSSA The clutch lever is located on the left handlebar grip and is used to activate the clutch mechanism to change gear The front brake lever is located on the right handlebar grip and is used to activate the brake caliper of the front brake 4 Y i min 5 mm 3 Front brake lever Clutch lever N It s important that the levers and rear brake pedal have a 2 3 mm give It s important that the levers can be easily activated by the rider while he she is riding the bike using the index and middle fingers 34 User manual Check the condition of the motorcycle s electrical connections in order to ensure they are maintained in good working order
20. l 25 Anti theftimmobilizer QE The TR280i has an immobilisation system for protection against IMPORTANT this key has a code which is needed for theft making duplicate copies of the key This code should be written down in the indicated space on the registration This system consists of a lock situated in the area of the brake discs page and series number of this manual on the rear wheel It is a mechanism that is operated with a key and blocks the rear wheel 26 User manual The kick start pedal is part of the mechanism that is used to kick start the motorcycle mechanically Before kick starting the motorcycle check that it is at brake point neutral DO NOT try to kick start the motorcycle when it is in gear To kick start the motorcycle the kick start pedal must be separated from the bike and moved outwards Once separated place your foot on top and push strongly in a downwards direction with a kicking motion Kick start pedal If the motorcycle has been inactive for a long period of time its recommended that the kick start pedal is activa ted gently 3 or 4 times without actually kick starting the motorcycle This will enable the engine to move which will help when kick starting it If the motorcycle has been inactive for a very long period of time change the oil and petrol because they might have become degraded This could affect the motorcycle s performance User manual 27 Fuel tank The engine
21. n to one Bent chassis Change chassis Go to specialist mechanic side Steering badly adjusted Adjust steering Go to specialist mechanic Steer axle bent Change steering axle Go to specialist mechanic Front fork bent Change front fork Wheels badly centred Align wheels The brakes don t work correctly Disc wear Change disc Loss of brake fluid Check brake circuits Change if damaged or broken Brake fluid in bad condition Drain brake fluid and replace with new fluid recommended by a mechanic Pump piston broken Replace the pump piston Brakes badly adjusted Adjust brakes AN In the event of breakdown always take the motorcycle to a specialist mechanic AN 54 User manual OSSA Elementos de homologaci n User manual 55 Standardisation components RII N Your Ossa TR280i is standardised in compliance with UE regulations It adheres to all standardisation requisites EURO 3 The obligatory elements to be registered for driving on public roads and for passing the vehicle s MOT are listed below The elements to be registered among others are identified with a specific mark and registration Each of the registered elements should be part of the vehicle In the event of breakages loss or bad functio ning it is recommended that you go to an official OSSA mechanic to remedy the problem 56 User manual 1 EY W Standardisation components 1 Front headlight 9 Exhaust system 2 Front indicators 10 S
22. of 4 User manual OSSA this taking place your dealer will provide you with the relevant information This motorcycle has been designed to carry one person only Never ride with passengers Do not carry loads Any additional weight could destabilise the motor cycle which may provoke accidents that incur serious injury or even death OSSA Safety Both your safety and the safety of others are very important when riding a motorcycle Some important advice for using your motorcycle correctly is detailed below Always drive in a responsible way Always use a helmet Never drive over the speed limit do not ride with passengers This motorcycle is designed to be used in both urban and rural areas It should be used however while respecting other people and the environment If in your geographical area the use of motor cycles in rural areas is restricted you must respect the law Always wear appropriate clothing and protective accessories Gloves boots and thick trousers among others are recommenda ble Do not wear baggy clothing that might get caught on a mecha nism in the motorcycle Be careful with the exhaust system The exhaust system gets extremely hot during and after use of the motorcycle In the event of suffering burns see a doctor as soon as possible Take the time necessary to become familiar with your new motor cycle Never drive if you have consumed alcohol or any type o
23. ong range lights 4 Pilot lamp for footrest Position lights 2 Cross lights 3 Long range lights 4 Lights for changing direction left right 5 Horn 6 Button to switch off engine User manual 23 Front suspension The front suspension is made up of a fork that fixes the wheel and the front brake system in place This fork is formed by the suspen sion bars that contain the shock absorber spring and the suspension mechanism They are connected to the upper part where the direction pipe is located a point of connection between the fork and the chassis A regulating screw and an air bleed are located on the upper part of each suspension bar see photo To regulate the extension use the screw located on the right suspension bar Fig A To regulate the compression use the screw located on the left suspension bar Fig B Each of the suspension bars also has an air bleed to remove air that accumulates in the inside of the fork stanchion Fig C 24 User manual The rear suspension is formed by a single shock absorber spring The pre charge of this spring can be adjusted by turning the toothed rings that dictate its direction 2 A special key is needed to adjust these toothed rings The compression C extension R and spring pre charge see Fig are adjustable in the rear shock absorber Rear suspension a unii P Adjustable rings for the spring pr e charge User manua
24. peedometer 3 Rear indicators 11 Pinion output 4 Rear pilot 12 Lock 5 License plate support 13 Horn 6 Reflector 14 Kickstand 7 Mirrors 15 Gas stop 8 Manufacturer s plate Each of the registered elements should be part of the vehicle In the event of breakages loss or bad functioning it is recommended that you go to an official OSSA mechanic to remedy the problem User manual 57 Standardisation components Element Standardisation identification 1 Front headlight 11 12 9 97 24 97 24 4367 00 Front position lamp R55 00 14839 Driving beam R113 00 14839 Passing Beam R113 00 14839 2 Front indicators 11001200 94367 11001200 94367 4 Rear pilot e13 50 ROO 5OROO 12448 00 5 License plate support 6 Reflector IA E9 02 01269 7 Mirror 1 9 80 780 80 780 0143 01 8 Manufacturer plaque 9 Exhaust system 10 Speedometer 11 Pinion output zen 12 Lock 13 Horn el3 28R00 28R00 0037 00 14 Kickstand 58 User manual Manufacturer s plate Serial number Standardisation components User manual 59 Standardisation components Engine number DEED UU 60 User manual The key number can be found under the red disk Remove the disk to see the number Key number Warranty User manual 61 Warranty OSSA Terms and conditions of the warranty The warranty is associated to the product indicated in the CERTIFICATE OF DELIVERY AND INSPECTION which shall be filed out by autho
25. r material This will protect the motorcycle from dust and other external factors Avoid storing the motorcycle outside or in direct sunlight Storage Starting the motorcycle again To start up the motorcycle after a period of inactivity the following procedure should be followed Remove the plastic covers that were placed over the motorcycle before storing including the exhaust pipe and those parts that had special protection lighten the sparkplug Fill up the fuel tank with new petrol Carry out general lubrication Check tyre pressure Leave the engine running for some minutes to warm up the engine oil User manual 49 Troubleshooting YN PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The engine won t start Long period of engine inactivity Change the old petrol for new petrol Sparkplug dirty or wet Dry clean or change the sparkplug General fuse damaged Change general fuse Bad electrical connection Check electrical connections and position correctly Take the motorcycle to a specialist mechanic The engine starts and then stops Lack or deterioration of petrol Fill the fuel tank with new petrol Take the motorcycle to a specialist mechanic AN In the event of breakdown always take the motorcycle to a specialist mechanic A 50 User manual Troubleshooting PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The motorcycle is unstable Wire makes it difficult for the handlebar Move wire or loo
26. rature Using an optional temperature sensor the screen displays the engine temperature If excessive the yellow light comes on Indicator that engine turn rate is excessive Warning of gear change due to rpm If the engine turn rate is excessive a second red warning light will come on This function acts as a warning to change gear when a specific number of rpm is reached The red light flashes when the rpm reaches the established value and stops flashing when the gear is changed User manual 17 Multi function S GC Adjustment of the multi function box settings After confirming each value the multi function box will move straight on to the next screen adjustment until the process is complete If no button is pressed the multi function box will return to the initial screen after 15 seconds Activation of the adjustment mode Select the speed unit To activate the adjustment To select the speed unit mode the Mu 2 between km h and m h press box settings push buttons 1 2 SS 2888588 1 Confirm your selection by and 3 simultaneously for 3 pressing 2 seconds and then release them Select the time format To select the time format change between the 12 and 24 press l Confirm your selection by pressing 2 Select the wheel circumference Enter the wheel circumferen ce by pushing button 1 repea tedly To move to the next digit press button 3 Confirm th
27. reak lever 22 Crankcase protector 23 Front break caliper 24 Front brake disc Location of elements Model without standardisation kit User manual 13 Location of elements 25 Front brake handle 26 Throttle grip 27 Throttle grip mechanism 28 Front brake pump 29 Right fork stanchion regulator 30 OSSA multi function box 31 Left fork stanchion regulator 32 Clutch pump 33 Lights control pad 34 Clutch handle 35 Headlights 14 User manual Model without standardisation kit The OSSA TR280i multi function box and the indicator lights next to it provide very useful information at all times The multi function box is a power box system with an LCD screen controlled by a console with indicator lights located in the centre of the handlebars The information displayed on the multi function box includes the number of revolutions made by the engine speed distance covered total distance covered time average speed maximum speed environmental temperature running time and uptime This device has an internal memory unit that stores data like total Km and total running time even when it is switched off some features may be personalised the device can measure in kilometres or miles The wheel circumference value can also be changed A temperature sensor warns us with a yellow light 1 when the engine temperature is excessive Another sensor provides a warning with a red light 2 when the rate at which the engin
28. rised staff in OSSA FACTORY SL hereinafter referred to as OSSA It is valid for those countries indicated on page 33 The warranty is only applicable to motorcycles that have been initially imported via the official OSSA importer for your country meeting all the regulatory require ments and authorisations of each country This warranty does not limit or adversely affect consumers legal rights and guarantees by virtue of any obligatory national regulations It is independent of the legal warranty provided by the official dealer Name and address of guarantor The guarantor is the commercial organisation OSSA FACTORY SL Crta Antiga d Amer nave 12 Pol Ind Domeny 17150 Domeny Girona opain Consumer s rights as warranty holder With this document OSSA provides the final user with a guarantee that the motorcycle manufactured by OSSA is free from defects and that it has been manufactured in compliance with the strictest quality control regulations Therefore the warranty extends to both the parts and the labour costs in the event of any repair provoked by faulty materials or manufacture detected in a new motorcycle This is applicable for the time period stipulated within the warranty without limitation except for those that are listed in this manual The maintenance and service requirements indicated by OSSA must have been adhered to in compliance with the conditions herewith for the warranty to be valid OSSA 15 held responsible before the p
29. rts has been produced under the supervi sion of OSSA engineers so as to obtain the best possible results and the best possible performance At OSSA Motor we know that each motorcycle model is unique and has its own features which is why we dedicate so much time to the research and design for each item User manual 3 Important Read this manual thoroughly and keep it in a safe place This manual provides technical information necessary for keeping your new TR 280i motorcycle in full working condition It provides information on common aspects for the motorcycle s upkeep and fine tuning In the event of questions or queries on aspects not mentioned in this manual you should consult the OSSA official distributor or a specia list engineer Follow each stage of the instructions provided below for obtaining good results These instructions are accompanied by icons to make reading quicker and easier INFORMATION Informative note advice AN ATTENTION This symbol indicates that special attention must be paid Some of the indications specified in this manual are to prevent possible harm from being inflicted on people or material Not following the instructions may result in serious consequences which could put people s lives at risk This manual has been put together with the OSSA TR280i current layout However OSSA Motor reserves the right to make changes to this layout without prior notification to consumers In the event
30. sen it a bit to turn Steer axle screw is very tight Loosen the steer axle screw Steering bearings are damaged or with Replace steering bearings wear Steer axle bent Change the steer axle Contact an officially registered mechanic The shock absorption is too hard Excessive oil on front fork Remove surplus oil until it reaches the correct level Oil too viscous on front fork Drain fork oil and fill up with viscous oil Front fork bent Change the front fork Contact an officially registered mechanic Tyre pressure too great Check the pressure of the tyres Rear shock absorber badly adjusted Adjust the rear shock absorber AN In the event of breakdown always take the motorcycle to a specialist mechanic A User manual 51 Troubleshooting OSSA PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION The shock absorption is too soft Too little oil in front fork Add oil to the fork until it reaches a sufficient level Front fork oil not sufficiently viscous Drain fork oil and fill up with suitably viscous oil Front fork bent Change the front fork Contact an officially registered mechanic Rear shock absorber badly adjusted Adjust the rear shock absorber The motorcycle makes abnormal Chain badly adjusted Adjust chain 015 5 Chain wear Change chain rear crown and secondary transmission pinion Rear crow teeth wear Change rear crown Insufficient chain lubrication Lubricate chain
31. ssing any button it will start up again Measuring the wheel circumference Method 1 Measure the diameter of the front wheel Multiply the diameter obtained by 3 14 If necessary convert the measurement into mm by multiplying the obtained figure by 25 4 The measurement obtained corresponds to the measurement of the wheel circumference Method 2 On a smooth and flat surface put a mark on the side of the tyre and in the area where it is touching the ground Move forward with the vehicle until the wheel has tuned completely once and the mark is on the lowest part again Put a new mark on the ground at this point Measure the distance between the two marks on the ground If necessary convert the measure ment in mm by multiplying the figure obtained by 25 4 The measure ment obtained corresponds to the wheel circumference To obtain a more accurate measurement the rider should remain on the vehicle when the measurement is taken OSSMA Control Pad Control Pad The control pad is located on the left handlebar within reach of the thumb This control pad can be used to control the lights indica tors horn and engine stop solnm O 2 WS SEL SE SS PIT 2 6 08 88 lt 0008 a O See the image with information about the control pad a 5 Pilot lamp for change of direction left right 2 Pilot lamp for cross lights See the image with information about the control pad 3 Pilot lamp for l
32. ssitated the repair When defects occur of the same origin as those initially repaired it will be presumed that it is the same fault 4 If after the product has been repaired the product still has faults while the warranty is in force the purchaser can choose between a replacement a price reduction or refund If the purchaser selected a product replacement they can request a repair always while the cost of this repair is not disproportionate a price reduction or refund D The seller is not obliged to replace fungible or second hand goods 6 The price reduction will be proportional to the difference between the value that the product would have had on delivery if the fault did not exist and the value that the product had at the time of delivery ra In the event of it being impossible for the purchaser to address the seller for the product s non compliance with the purchase agreement they will be allowed to claim directly to the manufacturer in order to obtain a replacement or product repair User manual 63 Warranty OSSA Period of warranty OSSA is answerable for faults that appear over a two year period from the product delivery but if the non compliance shows up after the sixth month the purchaser must demonstrate that the fault was present at origin and existed when the product was delivered Complaints made for the non compliance of that which is set out in the warranty must be done within a six month period from when the w
33. te the tank lid To locate this lid detach the air filter lid see page 36 Air Filter Once the filter lid is detached the radiator lid is visible Unscrew the lid and pour in refrigerant ATTENTION Use gloves Do not open the lid if the engine is hot This could cause burns Avoid contact of the liquid with the eyes mouth or nasal passage Do not ingest In the event of this happening follow the product instructions and consult a doctor The radiator has an electric fan to force air through it as can be seen in the image below Radiator To fill the radiator special refrigerant should be used 309C To ensure that the motorcycle works correctly periodic controls must be carried out to check the refrigerant levels This will ensure that the motorcycle is running at an optimum temperature Always use special refrigerant for light alloy engines User manual 39 Sparkplug To access the sparkplug detach the upper section of the motorcy cle see page 29 Once the upper cover has been removed the motorcycle s electrical system can be accessed Carefully but firmly pull away the hood that provides a current leaving the upper part of the sparkplug exposed Using a special sparkplug key unscrew it The sparkplug should be checked regularly and a spare sparkplug should be carried at all times in case it comes off The sparkplug can accumulate charcoal and dirt with use For this reason it can be removed and cleaned
34. the specified time periods and that the services are correctly registered This means that your motorcycle will receive all the benefits of the OSSA warranty It is recommended that the routine service is carried out by an authorised OSSA dealer where the motorcycle was purchased where both you and your motorcycle are known Under normal circumstances periodical revisions reduce overall maintenance costs If you need to use the warranty service please contact your authorised OSSA dealer immediately and make an appointment so that the necessary work can be carried out It is recommended that periodical motorcycle services are planned in advance Looking after your motorcycle Inspect your motorcycle on a daily basis before driving The Owner s Manual contains a list of things to be checked These inspections will help avoid problems Remember that minor adjustments are made more easily at home rather than on the road As well as improving the motorcycle s appearance thorough cleaning take care when using pressure or steam cleaning equipment as it can damage the paint and lacquer of the product s finish provides the perfect opportunity for inspecting your motorcycle The appearance and value of your motorcycle depends greatly on how it is looked after It is important to clean your motorcycle periodically during the winter because if not salt on the roads can cause uncovered metal surfaces to deteriorate User manual 67 Warranty OSSA
35. then returns to screen 1 To move from one screen to another repeatedly press button 2 Mode To edit the distance covered DST hold down button 3 Screen 1 Screen 1 displays the following information Speed distance covered time environmental temperature tachometer bar Screen 2 Screen 2 displays the following information Speed digital tachometer running time uptime engine temperature tachometer bar Pantalla 3 Screen 3 displays the following information Maximum speed dangerous turn rate accumulated running time mileage counter maximum temperature optional Screen illumination The multi function box works by using a 3V internal battery type CR2032 To change the battery open the lid on the bottom of the indicator by unscrewing it as indicated in the image using a coin Ensure that the positive side of the battery is facing upwards When the multi function box is powered exclusively by the internal battery the screen illumination is partially maintained for 3 seconds when the button is pressed When it is connected to the 12V vehicle installation the illumination will 22 User manual OSSA be brighter and will remain constant for 20 minutes after the vehicle has stopped Sleep Mode If the multi function box receives no information for 20 minutes wheel signal turn signal or pressed button the screen will turn off displaying only the time When the vehicle moves or by pre
36. ther similar competition sports Damages due to the practice of functions that are not indicated in the Owner s Manual using the motorcycle beyond those limits or specifications indicated by OSSA maximum load passenger capacity speed of motor and others Damages due to the use of parts that are not original or not recommended by OSSA or the use of fuel lubricant and compound liquids with specifications that are different to those indicated in the Owner s Manual Damages due to modifications that are not approved by OSSA motorcycle preparations modifications for increased vehicle perfor mance light reduction increases and other changes Damages due to the vehicle s aging natural decolouration of painted or chrome surfaces peeling and other types of deterioration The replacement or repair labour with non original OSSA parts or that are assembled by staff not authorised as part of the Official OSSA Post Sales Service or as OSSA dealers Damages due to incorrect storage or transportation Damages due to uses that disregard traffic regulations and damages due to accidents Spare parts that need to be replaced frequently OSSA does not offer a guarantee for parts or fluids that have deteriorated due to use The parts or elements mentioned below are not covered by the warranty except when it is necessary to replace them during a repair carried out under warranty User manual 65 Warranty OSSA Parts Spark plugs fuel and oil f
37. urchaser in the event of the product s non compliance at the time of product delivery When the product is non conforming the purchaser must decide whether they want the product to be repaired or replaced The purchaser s decision when notified to the seller is binding for both parties with one sole exception if the cost of reparation or replacement is disproportionate to the product s value the most reasonable solution will be taken into account Rectification considered as disproportionate is that which implies costs for the seller which are not reasonable in contrast with the other means of rectification This takes into account the value the product would have if the non compliance did not exist as well as the relevance of the non compliance and if the alternative means of rectification could be carried out without any inconvenience 62 User manual OSSA Warranty The repair is disproportionate when it is uneconomic or when the reparation is more expensive than the value of the product If this occurs the purchaser can choose between a price reduction or contract resolution Resolution is not permitted when the non compliance is insignifi cant Regulations for repairs product replacement price reduction or contract resolution l It will be free for the purchaser It will be carried out in a reasonable time period 3 In the six months following delivery of the repaired product the seller will be answerable for those faults which nece
38. vel oil must be removed To remove oil from the hood place a receptacle under the motorcycle and remove the lid B located on the side of the hood leaning the bike over in both directions to ensure that no oil remains inside the hood 46 User manual IMPORTANT Clean the plug and change the sealing washer each time the oil is changed The crankcase has a 350cc oil capacity 2T 10096 synthetic oil should always be used Clutch cover D verb Cur Dn ORE See eee or e OS 3 T ee XA Ignition cover C The brakes permit precise and controlled trial riding It is necessary to check them in order to ensure that they work correctly gt bb Wear on the front and rear brake pads must be periodically controlled so that the brakes work effectively The oil level can be checked using the indicator on the front handle and on the rear pump tank The oil level should be situated between the min and max values MAX MIN To remove surplus air from the break circuit the calipers are equipped with air bleeds See image User manual 47 Torque wrenches These grids show the pressure that should be used to tighten parts CHASSIS Part Front wheel axle Swing arm fixing to chassis Upper shock absorber fixing Lower shock absorber fixing Linkage arm fixing Handles Handlebar Radiator fixing Front wing bridge section Break pedal Silencer fi
39. w ossafactory es SSA MOTOR Ctra Anriga d Amer Pot nd Domeny Nau 12 17007 Girona SPAIN 00 34 972 107 107 00 34 972 117 899 infocroassamntor es
40. xing Rear wheel axle Rear brake caliper fixing Front brake caliper fixing Exhaust pipe fixing Engine fixing Rear brake pump fixing 48 User manual 40 50 7 10 MOTOR Part Sparkplug Clutch fixing Cylinder clasp fixing Cylinder reed fixing Pressure plate fixing Clutch mass fixing Crankcase half fixing Water pump cover fixing Clutch cover fixing Steering fixing Water separator Ignition cover Engine drain plug Kick start pedal screw Transmission pedal screw Cylinder block screws Cylinder nuts OSSA Storage If the motorcycle is to be stored for a long period of time the following procedure should be followed to ensure that it is stored correctly Clean the motorcycle as much as possible because dirt can cause the deterioration of components Turn on the engine for a few minutes to warm up the transmission fluid and then drain see section on draining fluid Fill up with new transmission fluid Empty the fuel tank petrol degrades over time Lubricate the chain and all wires Apply oil to non painted metal surfaces to prevent rust Avoid putting oil on the brakes and rubber parts Wrap the outside of the exhaust pipe in a plastic bag to prevent rust Position the motorcycle so that the wheels don t touch the ground to prevent possible tyre deformation If this is not possible cardboard can be placed underneath the wheels Place a cover over the motorcycle such as canvas plastic o
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