new-chopper-manual-2016-3r3

CHOPPER
PAGSTA LLC
Las Vegas, NV 89128
www.pagstamotors.com
855.572.4782
PAGSTA MOTORCYCLES - 320CC - CRUISER / CHOPPER / BOBBER
Thank you for purchasing a PAGSTA motorcycle.
For your safety, and to maintain your PAGSTA, please
familiarize yourself with this manual before riding.
This motorcycle has a total displacement of 320cm³(cc).
You must hold a corresponding motorcycle driver's license
in order to drive on public roads. The vehicle is designed to
carry a maximum of two people, including the rider. Note
that you cannot carry a passenger for the first 12 months
after obtaining your motorcycle license in most areas.
CONTENTS
Preface
Important Notice
Motorcycle Safety
Safe Riding Rules
Protective Apparel
Modification
Loading
Instruction
Parts location
Parts function
Operation
Pre-ride Inspection
Starting the engine
Riding
Breaking-in
Maintenance
Checking and changing of Engine oil
Spark Plug Selection and Replacement
Changing and assembly of Air Filter
1
2
4
5
5
6
7
10
18
19
20
21
23
25
26
Clutch Adjustment
Drive Chain Check, Adjustment and Lubrication
Front wheel hydraulic left, right disc brake
Wheel Hydraulic left, right disc brake Front
Wheel Disassembly and Replacement Rear
Wheel Disassembly and Replacement
Battery Maintenance
Cooling system
Fuse replacement
Cleaning
Storage guide
Maintenance Schedule
Maintenance Schedule
Maintenance Schedule
Motorcycle Specifications
Motorcycle circuit / wire diagram
27
28
29
30
31
33
35
36
38
39
40
40
41
42
43
44
Preface
This manual introduces to you basic operation and method of maintenance of this motorcycle. Please
read the manual carefully before driving the motorcycle. Proper operation and maintenance of the
motorcycle will ensure less trouble, optimum performance and service life.
Your authorized PAGSTA dealer will be happy to provide you with instruction, guidence and aftersales service.
The data, instructions, specifications, and pictures demonstrated in the manual are based on the
latest design information available at the time of approval for printing. Our company reserves the right
to make changes at any time without notice of changed parameters and other information.
Please visit our website or check with your dealer for the latest information and updates to this manual.
PAGSTA - A NEW BREED OF FUN - ENJOY THE PAGSTA EXPERIENCE
1
IMPORTANT NOTICE
Initial vehicle break in period information.
To allow your engine to wear-in its critical parts, we recommend that you observe the riding rules
provided below for the first 500 miles 800 kilometers . Adherence to these suggestions will help to provide
good future durability and performance.
1. During this period, avoid full-throttle starts and rapid acceleration.
2. Keep RPMs below 6,000 at all times during this period.
3. After the first 500 miles, have your initial service performed at an authorized PAGSTA dealer or service
center in accordance with the requirements of Operation and Maintenance Schedule in this Manual.
Failure to follow the Maintenance Schedule may result in voiding of warranty.
Please keep all your maintenance receipts.
Since accidents can happen to anyone, all motorcyclists, regardless of age and experience, should consider
taking a motorcycle safety course or training course even if it's not required by the state in which they live.
These courses are designed to help keep you from becoming a motorcycle safety statistic.
California Proposition 65 Warning
WARNING: This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold.
2
CAUTION
Motorcycles are different from other vehicles. They operate, steer, handle and brake differently. Unskilled or
improper use could result in loss of control, death or serious injury.
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Take a rider training course.
Read Owner's Manual before riding, adding accessories or servicing.
Wear a helmet, eye protection and protective clothing.
Never tow a trailer.
Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive
speed can cause loss of vehicle control, which could result in death or serious injury.
Do not run the engine at extremely high RPM with clutch disengaged or transmission in neutral. Running an
engine at high RPM can result in engine damage.
Do not exceed the maximum safe RPM specified below under any conditions. Exceeding the maximum safe
engine RPM can result in equipment damage.
When riding on wet roads, brake efficiency and traction are greatly reduced. Failure to use care when braking,
accelerating or turning on wet roads can cause loss of control, which could result in death or serious injury.
Continuous use of brake causes overheating and reduced efficiency, which could result in death or serious injury.
Do not tow a disabled motorcycle. Towing can adversely affect stability and handling, which could result in death
or serious injury.
ALWAYS WEAR A HELMET!
3
MOTORCYCLE SAFETY
1. Make yourself visible. A motorcycle is smaller than a passenger car, with a much smaller outline from behind.
Motorists tend to expect to see larger vehicles, and they are not looking for motorcycles. In self-defense,
motorcycle riders should wear bright colors and reflective material on helmets and clothing. They should use
turn signals, flash their brake lights before slowing down, and avoid riding in a car’s “blind spot.”
Your headlight should be on at all times, day or night, while riding.
2. Do not consume alcohol before you ride. Any amount of alcohol can slow your reflexes and dull your abilities.
It requires more skill and coordination to operate a motorcycle than a car. According to the NHTSA,
approximately half of all single-vehicle motorcycle crashes involve alcohol. Do not risk it!
3. Wear protective gear and clothing. Motorcycle riders must rely on their helmets, clothing, and eye protection
to make the ride more comfortable and reduce the risk of injury. Thick, protective gloves, shoes, and clothing
can protect you from the elements and might be the only thing between you and the pavement in a motorcycle
crash. Never ride without a certified helmet and eye protection. Look for the U.S. Department of Transportation
label.
4. Get the training you need. Read this owner’s manual cover to cover to get familiar with your PAGSTA. Take a
motorcycle rider training course. Proper training can provide the knowledge and skills you need to operate your
motorcycle safely and proficiently.
5. Perform a pre-ride safety check. Before each ride inspect your PAGSTA by checking the air pressure in your
tires, engine oil level, fuel level and the all lights, blinkers and horn functions properly.
6. Become familiar with and follow ALL laws regarding motorcycle riding. Motorcycle traffic laws are
different from automobiles.
7. SPEED KILLS - SLOW DOWN! OBEY ALL MOTORCYCLE TRAFFIC LAWS!
A motorcycle collision is highly likely to cause injury or death and this risk increases with speed.
4
IMPORTANT SAFETY INFORMATION
Your PAGSTA motorcycle can provide many years of service and pleasure if you take responsibility for your own
safety and understand the challenges you can meet while riding. There is much that you can do to protect yourself
when you ride. You'll find many helpful recommendations throughout this manual. The following are a few that
we consider most important.
Always Wear a Helmet
It's a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an
approved motorcycle helmet and make sure your passenger does the same. We also recommend that you wear eye
protection, sturdy boots, gloves, and other protective gear.
MODIFICATIONS
LOADING
WARNING
Modification of your PAGSTA motorcycle or
change of original equipment may render the
motorcycle unsafe or illegal and can result in loss of
warranty.
WARNING
The motorcycle is sensitive to changes in weight
distribution.
Improper loading of cargo can impair the
motorcycle's performance and stability.
Driving with a passenger can be dangerous and
special attention must be taken to ensure that the
passengers movements do not effect the driver.
Tampering with emission or evaporative controls or
devices will immediately void your warranty and may
result in legal action.
5
LOADING
Keep cargo low and close to the center of the motorcycle. Load weight equally on both sides of the
motorcycle to minimize imbalance. As weight is located further from the center of gravity, handling is
proportionally affected. Improper loading of your motorcycle can result in injury or death. Firmly mount
loads on the motorcycle in order to ensure stable handling.
Properly adjust the tire pressure and the spring of the rear shock absorber according to the load weight
and road conditions. Avoid fastening large or heavy loads to handlebars, front forks or dashboard,
otherwise it can adversely affect stability and handling.
NEVER exceed the maximum weight limit of 350lbs.
ACCESSORIES
Accessories produced by our company have undergone special design and testing to ensure safety of
the rider. They are optional for users. Users will take responsibility for their selection, installation and
use of accessories not produced by our company. Please obey safe riding rules and follow the next points:
Carefully check your accessories & keep them out of your line of sight. Reduce the distance
between them and the ground and side dip angle. Also keep them clear of the suspension or steering as
movement can affect handling.
Avoid attaching any electrical equipment to the main wiring harness. This may void your warranty.
6
INSTRUCTIONS
PARTS LOCATION
11
1. Rearview mirror
2. Clutch lever
3. Left handlebar control
(horn button, Headlight
dimmer switch, turn signal
switch)
Please note: Your specific model
4. Left fuel cap (fake)
may have some design differences.
5. Front brake lever
7
6. Throttle grip
7.Right handlebar control
(starter button, headlight
switch, engine cut-off
8.Instrument panel
9.Right fuel cap(true)
10.Ignition switch
11.Fuel tank dashboard
Please note: Your specific model may
have some slight design differences.
¢1Ù
15
¢2Ú
¢3Û
¢4Ü
¢5Ý 6
7
8à¢á9â 10
11
12
13
14
1. Front Headlight 2. Front left turn signal 3. Side reflector 4. Front brake disc 5. Front brake pump
6. Radiator cap 7. Gearshift lever 8. Left footpeg 9. Engine 10. Engine serial number 11. Kick stand
12. Left exhaust 13. Passenger footpeg 14. Rear left turn signal light 15. Taillight,plate light
Note: Motorcycle will not start with kick stand (11) in down position.
8
Please note: Your specific model may
have some slight design differences.
19
18
20
22
21
¢1Ù
¢2Ú
17
16
15
14
13
12
11
10 9
8
7
6
5
4
3
1. Front right turn signal light 2. Front fork 3. Front wheel 4. Front brake disc 5. Front brake pump
6. Vin # Location 7. Rear brake pedal 8. Right foot peg 9. Radiator 10. Radiator 11. Throttle valve assembly
12. Battery 13.Right exhaust 14. Rear brake Disc 15. Rear brake Pump 16. Rear wheel 17. Rear right turn signal
light 18. Back seat rest 19. Seat 20. Fuel tank 21. Dashboard 22. Ignition
9
Please note: Your specific model may
have some slight design differences.
[INSTRUMENTS AND INDICATORS]
1. Odometer is located in instrument cluster
2. Multi-function instrument cluster includes:
Speedometer, Odometer, Tripometer, L/R Turn
signal indicators, Hi beam indicator, Water
temperature alarm and indicator, EFI indicator
1
¢2Ù
3. Ignition switch and cover ¢3á
[Ignition Switch Function]
The ignition switch on the middle of the fuel tank or just below the right side of the fuel tank depending on model.
A. When the ignition switch is on the vertical position, the circuit is cut off; the engine can't be operated; Key can
be removed.
B. Open the cover, insert the key and turn it counterclockwise; the lock is off (the circuit is still cut off; after the
lock is moved on, the key can be removed,
C. At this time, move the ignition lock counterclockwise or clockwise to the internal gear position, the circuit is
closed, the neutral gear indicator is on, the odometer is on, the engine can start.(remark:move the lock
counterclockwise, the circuit is closed, but the front position light and the rear position light is off; move the lock
clockwise, the circuit is closed, but the front position light and the rear position light is on).
D. Move the ignition switch to the vertical position, the circuit is off and the engine is on the state of flameout,
insert the key to lock it.
10
STEERING LOCK
The lock is below the steering
stem.To lock the steering, turn the
handlebars all the way to the left,
turn the ignition key clockwise to
lock while pushing in, and then
remove the key.
¢1Ù
Caution: Always lock the steering
when the motorcycle is parked.
LEFT HANDLEBAR CONTROLS
1.
Horn button
2.
Turn signal switch
3.
Passing switch
4.
Headlight dimmer switch
¢4Ü
¢3Û
¢2Ú
[Horn Button]
¢1Ù
Press the horn button
to sound the horn if necessary.
[Headlight Dimmer Switch]
select
D
for low beam and
D
(blue) for high beam.
11
Continued from previous page
2. [Turn Signal Light Switch]
The turn signal light switch has three positions. If need to turn left, move the turn signal light
switch to " ",both front and rear left turn signal lights on, and if you need to turn right, move the turn
signal light switch to "
", both front and rear right turn signal lights on; press turn signal off with
both signal lights off. The switch will automatically return to mid position.
3. [Passing Switch]
Note: The passing switch is on the left handlebar .
Select for low beam and press the "passing" switch, and then both low beam and high beam lights
will turn on. Release the switch and only low beam light is on. While overtaking another vehicle at
night, use the "passing" switch instead of constantly turning on and off the (4) headlight dimmer switch.
RIGHT HANDLEBAR CONTROLS
¢3Û
1. Electric starter button
2. Headlight switch
3. Engine cut-off switch
¢Ú2
¢1Ù
12
[Electric Starter Button]
The starter button is on the right handlebar controls.
1.Make sure that the gear is shifted to neutral and the fuel switch is in the position of "
", or grasp
the clutch lever to separate the clutch when the motorcycle remains in any other gear.
2. Open the cover of the ignition switch lock, insert the key into switch and turn it 90 degrees
counterclockwise, remove the key and close the lock cover, move the ignition switch 30 degrees
counterclockwise to the internal gear position.
3.Turn the engine cut-off switch to " " and press the electric starter button "
",at the same time,
slightly opening the throttle and the engine will start.
[Emergency Engine Cut-off Switch]
Engine Cut-off is on the right handlebar controls.
"
"
¡Á
":In this position the engine will turn over but not start.
":This is the engine run position.
To start the engine, the engine cut-off switch must be turned to "
13
".
[Rear shock absorber]
It is recommended that your PAGSTA dealer make the following adjustments.
There are 2 Rear shock absorbers located under the middle of the frame.
The rear shocks have four adjusting positions for different road and driving conditions. By
adjusting the spring force, the riders comfort is affected. Ride height is affected by adjusting the
bolt length.
14
CAUTION
Do not overfill the fuel tank!
The tank is full when the fuel is 1/4" below the lip. Overfilling the tank may cause damage to the
bike and/or cause a fire hazard.
After fueling, make sure that fuel cap is closed securely.
While refueling, fuel should be filtered through the filter at the mouth of the tank.
[How to Open the Fuel Cap]
The right cap is the actual fuel cap, turn it 90 degree counter clockwise and open it.
To closed the cap, push the cap down and turn it clockwise.
FUEL TANK AND CAP
Fuel tank capacity is 3.7 gallons.
We recommend you to use unleaded
87 Octane fuel or higher.
91 Octane or better for best performance.
Decorative
fuel cap
Actual fuel cap
15
WARNING: DO NOT USE SYNTHETIC ENGINE OIL. THE CLUTCH WILL BE DAMAGED IF
USED AND YOU WILL VOID YOUR WARRANTY!
ENGINE OIL
Engine oil quality is the chief factor affecting
engine performance and service life.
Your PAGSTA motorcycle uses standard engine
oil SAE10w/40 API SG. Use only quality engine oil
certified to meet or exceed requirements for service
SG. The viscosity grade of engine oil should be based
on the atmospheric temperature in your riding area as
shown at right.
Your first oil change should be performed at 500
miles and every 3,000 miles thereafter.
TUBELESS TIRES
Proper air pressure will provide the maximum stability, riding comfort and tire life.
KENDA 160/80-16
Load
KENDA 80/90-21
Driver only
Front: 32psi
Rear: 32psi
Driver and a passenger
Front: 32si
Rear: 32psi
16
We recommend
KENDA tires.
WARNING
Operation with excessively worn tires is hazardous and will adversely affect
traction, stability and handling. Improper tire inflation will cause abnormal tread
wear and create a safety hazard. Under inflation may result in the tire slipping on
or coming off the rim and causing an accident.
NOTE:
Tire pressure should be checked before you ride while the tires are cold. Check tires
for cuts, embedded nails or other sharp objects. Check tires for dents or deformation.
If there is any damage, see your authorized PAGSTA dealer for repair or replacement.
Replace tires before tread depth at the center of the tire reaches the following limit:
Minimum tread depth(mm)
Front: 1/16"
Rear: 5/64"
We recommend
KENDA tires.
17
OPERATION
PRE-RIDE INSPECTION
Inspect your motorcycle before you ride.
1.
2.
3.
4.
5.
6.
Oil level: Check the level and if necessary, add oil. And check for oil leaks
Front and rear brakes: Check operation.
Tires: Check condition and pressure of both front and rear tires. If necessary, charge or repair.
Throttle: Check for smooth opening and full closing in all steering positions.
Lights and signals: Check that the headlight, taillight, turn signals and horn function properly.
Chain: Check that the chain is properly adjusted and is lubricated properly.
If it is severely worn or damaged it should be changed.
7. Steering: Move the handles bars from side to side and check for binding or stiffness.
STARTING OF ENGINE
WARNING
NEVER run the engine in an enclosed area do to exhaust gases.
NEVER start the engine when the engine is in gear.
18
STARTING PROCEDURE 2016 AND LATER MODEL YEARS
1. Position yourself on motorcycle in a safe manner. (both feet on the ground and hands on hands on grips)
2. Position motorcycle in riding stance (horizontal) and dis-engage kick stand.
(Motorcycle will crank, but will not start if kick stand is in the down position)
3. Flip open rain cover on ignition switch exposing lock cylinder, using round key unlock ignition switch.
(Turn clockwise)
Remove key from ignition.
4. Using shifter on left side put transmission in neutral.
(Neutral light will illuminate green (N) up on instrument cluster)
5. Put engine kill switch into run position. At this time the fuel pump will prime fuel system.
(EFI light will illuminate orange up on instrument cluster)
6. While holding clutch lever in, press starter button.
(Do not hold starter button longer than 3-5 seconds at a time).
Release starter button immediately after engine starts.
7. If motorcycle does not start after (3) consecutive tries, turn ignition switch off and allow bike to sit for at
least for 1-3 minutes.
(Review starting procedure before trying to restart motorcycle)
8. If motorcycle still does not start, call your local dealer
NOTES:
1. Do not roll the throttle before starting.
Rolling the throttle before starting the motorcycle is unnecessary.
Close the throttle.
2. Disengage the clutch (pull the clutch lever in).
3. Lift the gear shift lever up to the end of its travel and release.
4. Ease out the clutch lever and gradually open the throttle.
5. Repeat the previous steps to engage remaining gears.
Remember...
 Disengage the clutch completely before each gear change.
 Partially open the throttle so the engine does not drag when the
clutch lever is released.
19
[Preparing to ride]
Insert the ignition key and turn it clockwise 90 degrees to unlock the lock, and turn the ignition
", and turn engine cut-off switch to "
".
switch(left/right). Turn the fuel switch handle to "
Shift the gear to the neutral position with neutral gear indicator on (green), or shift to any gear,
grasp the clutch lever and start the engine.
[Electric Starting]
Press the electric starter button "
" Do not roll the throttle before starting. Rolling the
throttle before starting the motorcycle is unnecessary.
NOTE:
1. Don't press the start button "
may discharge prematurely
" for more than 3-5 seconds at a time, otherwise the battery
2. Release the starter button immediately after the engine has started.
3. Don't press the starter button while the engine is running, otherwise it may adversely affect the
engine.
4. Allow the motorcycle to sit for several minutes when the engine fails to start after three
consecutive attempts, otherwise the battery may be damaged or drained.
20
[Shifting Gears]
Your motorcycle has five forward gears in a one-down, four-up shift pattern which is coordinated with a cableoperated clutch system.Learning when to shift gears comes with experience.
Keep the following tips in mind:
• As a general rule, shift while moving in a straight line.
• Close the throttle and pull the clutch lever in completely before shifting. Improper shifting may damage the
engine, transmission, and drive train.
• Learn to recognize the engagement point as you release the clutch lever. It is at this point the transmission of
power to the rear wheel resumes.
• Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high.
• Learn the relationship between engine sound and the normal shifting points.
• Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm.
• Avoid downshifting to help slow your motorcycle when engine rpm is high. Downshifting when engine speed
is near its allowable maximum may over-rev the engine and cause possibledamage.
• To prevent transmission damage, do no tcoast or tow the motorcycle for long distances with the engine off.
Shifting Points
BREAKIN-IN
During the initial break in period of 500 miles, avoid full
throttle use and never labor the engine by shifting gears hard.
Strictly restrict the engine to less than 6000 rpm. During the
initial 100 miles, the maximum speed should not be more than
50 mph and during the first 500 miles, no more than 65 mph.
Timely performance of the break in maintenance period will
ensure optimum service life and performance from the engine.
Use the table at right to estimate the proper shifting points.
21
Gear
Speed
1st to 2nd gear
30km/h 19mph
2nd to 3rd gear
45km/h 28mph
3rd to 4th gear
60km/h 37mph
4th to 5th gear
75km/h 47mph
Warning
Never shift gears when the clutch is not engaged and the throttle is not decreased. Otherwise
you may damage the engine, the driving chain and other components. Shifting gears with out
properly engaging the clutch may cause an accident.
[Braking]
• While slowing the motorcycle down, decrease the throttle first and then apply both front and rear
brakes together to slow down or stop.
• To apply an emergency brake, close the throttle first, release the clutch and promptly use both
front and rear brakes at the same time.
• Independent use of only the front or rear brake reduces braking performance. Also rapidly
applying brakes may cause the front or rear wheel to lock immediately, resulting in loss of
control of the motorcycle and could possible cause and accident.
• When approaching a corner or turn, close the throttle fully, and slow the motorcycle down by
applying both front and rear brakes at the same time, otherwise it may cause loss of control.
• When riding on wet or loose surfaces, maneuver steadily. Immediately speeding up, rapidly
applying brakes and turning may result in a loss of motorcycle control.
[Stopping]
Gradually close the throttle, decelerate the motorcycle, and then gently apply both front and rear
brakes together to stop, turn off the ignition switch and lock the steering. In case of emergency, press
the engine cut-off switch to cut off the engine. Lastly use the kick stand to support the motorcycle and
turn the fuel switch to " ".
22
Maintenance
Checking and changing of engine
oil, and cleaning of FILTER.
[Engine Oil Lever Check]
Check the engine oil level each day before
riding the motorcycle. There is a dipstick
behind the left crankcase cap for checking
the oil level. The level must be maintained
between the upper and lower level
marks on the dipstick.
Put the motorcycle on the kick stand on level
ground, remove the dipstick, wipe it clean, and
reinsert the dipstick without screwing it in.
Remove the dipstick to check the oil level.
If required, add the oil certified to meet
requirements for service SAE10W/40 API SG.
up to the upper level mark. Do not overfill.
Reinstall the dipstick. Check for oil leaks.
CAUTION:
Running the engine with insufficient oil can
cause serious engine damage.
23
Dipstick
Upper level mark
Lower level mark
[Engine oil change and oil filter clean]
Warm up the engine and drain the engine oil after
cutting off the engine.
Place an empty container under the engine.
Unscrew the drain screw
to drain the oil
completely and then tighten the drain screw.
Add 1.9L of new oil.
If you go to a PAGSTA service dealer, you can ask
the servicemen to open the right crank case and
remove the oil filter screen for cleaning.
NOTE: When riding on dusty areas, you should
change the engine oil and clean the oil filter more
frequently.
¢ÙDrain screw
¢ÚOil filter screen
24
SPARK PLUG SELECTION AND REPLACEMENT
[Spark Plug Selection]
1.When riding usually at low speed or low
temperature in winter, you are recommended to select
CR5HSA spark plug of which the center electrode is
black plug of which center electrode is black.
2.When riding usually at high speed or under high
temperature in summer, you are recommended to select
CR7HSA spark plug of which center electrode is gray.
3.You are recommended to select CR7HSA(furnished
in the factory) under normal conditions.
[Spark Plug Inspection and Replacement]
Disconnect the spark plug cap from the spark plug.
Side electrode
Clean any dirt from around the spark plug bases.
Remove the spark plug using the spark plug wrench in the tool kit and clean deposits or carbon
fouling with a wire brush. Inspect the electrode and central porcelain for damage or erosion. If the
erosion or damage is heavy, replace the plug. Check the gap of spark plug side electrode using a
feeler gauge and adjust the gap to 0.6-0.7mm.
Make sure the plug washer is in good condition.
Thread the spark plug in by hand to prevent cross-threading and then tighten it with a spark plug wrench.
25
AIR CLEANER REPLACEMENT
The air cleaner should be serviced at regular intervals. Service more frequently when
riding in unusually wet or dusty areas.
Remove the protective cover, remove the screw , disassemble the air filter cover ,
and take off the air filter parts , and then assemble the new filter parts. Please use the new
filter or the high quality air filter of the same model according to the user's Manual,
otherwise the engine may be damaged.
¢Ù
Air filter cover
¢Û
Air filter parts
¢Ú
Screw
26
CLUTCH ADJUSTMENT
Free play at the tip of the left clutch lever is 10 to 20mm. If adjustment is necessary, unscrew
the lock nut
positioning the clutch cable on the locator
of the crankcase and adjust it. Turn
the lever as (A) shows to decrease free play. Turn as (B) shows to increase.
The same for the adaptor
on the left clutch lever.
3
A
Adjuster
1¢Ù
Locator
B
3Û
Adjuster
¢2Ú
Lock nut
27
DRIVING CHAIN CHECK, ADJUSTMENT AND LUBRICATION
[Driving Chain Cheek]
Check for wear of the drive chain . Lubricate it when
needed. Use the center stand to support the motorcycle, and step
on the gearshift pedal to shift into neutral. Place your finger
between both front and rear wheels, and swing the chain
up and down to adjust the chain to 10-20mm.
(Drive Chain Adjustment)
This motorcycle drive chain adjusts automatically with the
tension of the chain control by tension adapter. Spring will
automatically adjust to the location of the tension wheel. You
should change the tension wheel if it was damaged.
3
1
2
¢Û
Tension
¢Ú
¢Ù
[Driving Chain Lubrication]
Remove a chain lock clip with pliers carefully and disassemble the chain. Clean the
chain with detergent solvent and then dry it. Check for wear and damage of every part of the
chain. If necessary, replace it. Lubricate the chain with an appropriate amount of motor oil
or chain lubricant oil. Install the driving chain in the reverse order of disassembly and
adjust it.
NOTE: WHEN INSTALLING THE CHAIN LOCK CLIP, KEEP THE MOUTH OF THE
CLIP OPPOSITE TO THE NORMAL MOVING DIRECTION.
28
Wheel
FRONT LEFT AND RIGHT DISC BRAKE
[Brake Fluid]
Check the fluid level in the brake fluid reservoir of
the right brake lever. If the level is low, add brake
fluid, the fluid level will descend as the fluid
automatically flows into the brake lines. This is an
important part of regular disc brake maintenance.
Brake fluid reservoir
WARING
Brake fluid can be dangerous. If it gets in your mouth,
force to spit it out. If eyes or skin are contacted,
clean with plenty of water and see a doctor.
1.Never use the fluid that has been used or that in
an open container. Never use left over fluid or that has
been stored for a long period of time as the fluid may
have absorbed water from the air.
2.Brake fluid is strongly corrosive. Never allow the
fluid to spatter on painted or plastic surfaces.
(Right)Brake calipers
29
Brake disc
[Brake Disc]
The brake disc will incur normal wear after being used for a period of time. In order to ensure
that the brake system will function properly and reliably, replace the disc when it is extremely
worn. The limit of motorcycle brake disc is 3.5mm, which is marked on the brake disc.
WARNING
Do not ride your motorcycle after you have just
replaced the disc with a new one. Grasp and release
the front brake lever several times until the brake
disc fits the brake calipers well, thus returning the
front brake lever to normal free play.
[Brake System]
Pre-ride inspection must be performed
every day on the following item:
a)Check the fluid level in the fluid
reservoir;
b)Check the brake system for fluid
leakage;
c)Check the fluid line and the reservoir
for leaks or cracks;
d) Check wear of the brake disc;
e)Ensure the brake lever has the
correct amout of free play and
functions properly.
Brake disc
Wear £¨
mark
Brake calipers
WARNING
1. The fluid disc brake operates under high
pressure. Change the fluid at the frequency
interval as shown in the Maintenance schedule.
2. If it is necessary to repair the brake system or
the disc, have the work performed by an authorized
PAGSTA dealer or service center.
30
Brake Fluid
REAR DISC BRAKE
Brake Pedal
[Brake Fluid]
Check the fluid level in the rear brake fluid
reservoir. If the level is low, add brake fluid. The
brake fluid level of the rear brake fluid reservoir will
descend as the fluid automatically flows into the
system. Checking and adding brake fluid is an
important part of regular brake maintenance.
WARING
Brake fluid can be dangerous. If it gets in your mouth,
force to spit it out. If eyes or skin are contacted,
clean with plenty of water and see a doctor.
1. Never use the fluid that has been used or that in an open container. Never use left over fluid or
that has been stored for a long period of time as the fluid may have absorbed water from the air.
2. Brake fluid is strongly corrosive. Never allow the fluid to spatter on painted or plastic surfaces.
31
[Brake Disc]
The brake disc will incur normal wear after being used for a period of time. In order to ensure
that the brake system will function properly and reliably, replace the disc when it is extremely
worn. The limit of motorcycle brake disc is 3.5mm, which is marked on the brake disc.
WARNING
Do not ride your motorcycle after you have just
replaced the disc with a new one. Grasp and release
the front brake lever several times until the brake
disc fits the brake calipers well, thus returning the
front brake lever to normal free play.
[Brake System]
Pre-ride inspection must be performed
every day on the following item:
A. Check the brake system for fluid
leakage;
B. Check the fluid tube and the reserve
air for leaks or cracks;
C. Check wear of the brake disc
D. Ensure the brake lever has the correct
amout of free play and functions properly.
wear mark brake disc brake calipers
WARNING
1. The fluid disc brake operates under high
pressure. Change the fluid at the frequency
interval as shown in the Maintenance schedule.
2. If it is necessary to repair the brake system or
the disc, have the work performed by an authorized
PAGSTA dealer or service center.
32
FRONT WHEEL DISASSEMBLY AND REPLACEMENT
Unscrew the lock , disassemble speedometer cable,remove the axle nut ,unscrew the front wheel axle
and take off the front wheel (including brake disc).
To replace the front wheel or brake disc, unscrew the brake disc lock bolt ,and take off brake disc ,
replace in reverse order.
Axle nut Lock bolt Front wheel axle
Brake disc Brake disc lock bolt Speedometer cable
33
REAR WHEEL DISASSEMBLY AND REPLACEMENT
Use a jack to raise the motorcycle's rear wheel
off the ground. Unscrew the rear brake adjusting
nut . Hold the other side of rear wheel axle with
wrench, and remove the rear axle nut , and take
out the rear wheel axle .Move the rear wheel
forward and remove the driving chain from the
drive gear, and remove the rear wheel.
Rear brake disc adjusting nut
Rear wheel axle
Rear axle nut
Front/rear wheel axle nut torque is: 40-50Nm. Apply the brakes several times after adjusting the rear
brake, chain and installing the front and rear wheels. Then release both front and rear brakes to check
that the wheels rotate properly.
34
BATTERY MAINTENANCE
The motorcycle is supplied with 12V9ah DC lead-acid battery.
When riding the motorcycle, insufficient electrolyte in the battery will cause damage to the
cells.
If electrolyte in battery runs out quickly, insufficient electrolyte will lower strength of the
current thus making it hard to start the engine or causing other issues with the electrical system.
Should this occur you will need to replace your battery.
NOTE: Warranty issues are handled by the manufacturer of the battery.
Regularly check electrolyte in the accumulator that is under the right side frame cover. The
electrolyte level should be between the upper and lower levels marked on the front side face of the
accumulator, If the electrolyte is below the lower level, take the accumulator out of the motorcycle,
remove its cap and add distilled water carefully up to the upper level.
Caution
1. When checking electrolyte or adding distilled water, make sure that the air tube is well
connected with the air outlet of the battery if your battery is not sealed.
2. Use only distilled water. Tap water will shorten the service life of the battery.
3. Remove the battery from the motorcycle to prevent its discharge and leakage when you are not
using your motorcycle for a long period of time. When removing, take the negative wire off
first. After charging, store the battery in well-ventilated area free of direct sunlight. If you
want to store the accumulator in the motorcycle, you should remove the negative wire.
4. Regularly clean both positive and negative posts after removing the battery.
5. Replace with an equivalent specified accumulator.
6. Follow the battery manufacturer's instructions and warranty procedures.
35
COOLING SYSTEM
[Adding Coolant]
The coolant consists of refrigerant and distilled water, and has the function of anti-freezing. The coolant will prevent
the engine from overheating in neutral rotation or rotating in low speed.
We reccommend a 50/50 mix of Ethyl Glycol and distilled water. You will need about 1600ml for a complete flush.
1. Place the motorcycle on flat ground, unfold the kick stand. Drain the current fluid.
2. Unscrew the radiator cap, and pour the coolant into the radiator until it is filled.
3. Screw the cap on the radiator tightly.
4. Start the motorcycle . When the temperature of the coolant reaches about 180 degrees, stop the engine for 5
minutes, then open the radiator to pour more coolant until it is filled. Screw the cap tightly. Pour the coolant in this
way three times to make certain you have achevied the optimum level.
5. The total capacity of coolant will be about 1600ml.
Radiator cap
Overflow cap
Water pipe
36
Sensor
[replacement of coolant]
When the coolant is getting turbid, or it has finished a maintenance cycle, the coolant
should be replaced.
Procedures:
Place the motorcycle on the flat ground and unfold the side stand.
When the engine is under room temperature, put the vessel under the radiator, and
remove the cap of water tube to drain the coolant as show in picture #3 on the previous page.
Screw on the release-coolant bolt and replace the radiator cap.
Pour the coolant in according to the method discussed on the previous page.
[function of sensor]
When the temperature of engine reaches about 260 degrees F, the sensor will switch on, so
the coolant temperature alarm lamp in the instrument lights up, showing that the engine needs
cool down, otherwise the life of the engine will be affected because of overheating.
The position of sensor is as indicated in picture 4 on the previous page.
[caution]
Please use a 50/50 mix of Ethyl Glycol and distilled water
The coolant is poisonous so handle properly and dispove of in a legal manner.
It is dangerous to open the cap of radiator when the engine is at high temperature.
When repairing, please release all the coolant first to prevent coolant getting into the crankcase.
[servicing system maintenance]
Check for leaks every 600 miles.
Check whether there's a leak in the joint of water pump and water tube.
In order to check whether the radiator house is damaged and aging, you can squeeze the hose by
hand to see whether it has cracks. If there's a leak or crack it will need to be replaced.
In this case take the motorcycle to your PAGSTA dealer or service center.
37
FUSE REPLACEMENT
Remove the right guard board by loosening the hexangular bolt on the main seat and open the
fuse box (white) to check fuses. There are 2 spare fuses for your motorcycle included.
Reinstall the guard board in reverse order after replacement.
The specified fuses are 15A.
When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the
electrical system. See your authorized PAGSTA dealer or service center for repair.
Caution: Replace with the specified fuse. Never use other conductive materials for replacement.
Turn the ignition switch off before checking or replacing fuses to prevent accidental shortcircuiting. To replace the fuse in the fuse box, remove the fuse box cover. Pull the old fuse out of
clips. Push a new fuse into the clips and install the fuse box cover.
Fuse location
38
CLEANING
Clean your motorcycle regularly to protect the surface finishes and inspect it for damage, wear and oil leaks.
CAUTION:
1.
2.
3.
4.
High pressure water can damage certain parts of the motorcycle. Avoid spraying high
pressure water at the following areas: ignition switch, handlebar switches, instruments,
muffler outlet and under seat.
Prevent water from flowing into the muffler, spark plug and battery.
After cleaning, rinse the motorcycle thoroughly with plenty of clean water.
Dry the motorcycle thoroughly. Start the engine and let it run for several minutes.
Lubricate the driving chain.
Test the brakes before riding the motorcycle to insure the brakes a functioning properly.
WARNING: Braking performance may be impaired immediately after washing the Motorcycle.
STORAGE GUIDE
Extended storage, such as for winter (exceeding one month), requires that you take certain steps to reduce
the effects of deterioration from non-use of the motorcycle. In addition, necessary precautions should be made
BEFORE storing the motorcycle.
1. Clean and dry the motorcycle. Wax all painted surfaces.
2. Drain the fuel tank. Spray the inside of the tank with aerosol rust-inhibiting oil.
3. Remove the spark plugs and fog the cylinder with commercial fog oil.
Press the starter button several times after turning off the ignition switch to diffuse the engine oil evenly in the
cylinders, and then reinstall the spark plugs.
4. Remove the battery. Store in a well-ventilated, dry, and cool area protected from direct sunlight. NOTE: To
remove the accumulator, dismantle the negative wire and then positive wire.
5. When installing, fix the positive wire first and then negative and close the ignition switch.
6. Inflate the tires to their recommended pressures. Place the motorcycle on blocks to raise both tires off the ground.
7. Cover the motorcycle using cloth or other strongly air-permeable materials and store in a well-ventilated area,
free of rain and direct sunlight with a minimum of daily temperature variation.
39
REMOVAL FROM STORAGE
1.Uncover and clean the motorcycle.
2.Check the batter voltage. When the voltage is 12.3V or below, you will need to charge before use.
3.Drain any rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh fuel.
4.Perform all pre-ride inspection checks. Test ride the motorcycle in a safe area away from traffic.
MAINTENANCE
Clean the motorcycle off dust and mud with dry cloth regularly. Dry the motorcycle when it is wet.
Apply a little rust-inhibiting oil on zinc-coated and chrome-coated parts. Wax the painted parts to keep
them looking new. Lubricate all moving Parts.
Inflate both tires to their recommended pressures.
Che ck all bolts, nuts and screws to prevent a safety hazard resulting from loosening.
Check both front and rear brakes. Immediately adjust and replace if they are excessively worn or don't
function properly.
MAINTENANCE SCHEDULE
Perform the pre-ride inspection at each scheduled maintenance period.
Symbols in the table stand for as follows:
1.INSPECT, CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C:CLEAN R:REPLACE A: ADJUST L:LUBRICATE I:INSPECT
* Should be serviced by your authorized PAGSTA dealer.
** I n the interest of safe ty, we recommend these items be serviced only by your authorized service dealer.
40
NOTES
Service more frequently when riding in unusually dusty areas.
At higher odometer readings, repeat at the frequency interval established here.
Adjustment of the timing chain tension and the valve clearance should be
made only by your authorized PAGSTA dealer for warranty compliance.
MAINTENENCE SCHEDULE - For all maintenance inquiries, please contact your dealer
41
MAINTENENCE SCHEDULE - For all maintenance inquiries, please contact your dealer
42
PAGSTA 320CC CHOPPA MOTORCYCLE SPECIFICATIONS
Component
Engine
Item
Model
Unit
Type
Displacement
Minimum fuelconsuming ratio
Compression ratio
Minimum idle
speed
ml
g/kw.
h
Spark plug gap
mm
rpm
Transmission
Primary drive
ratio
First drive ratio
Second drive ratio
Third drive ratio
Fouth drive ratio
Fifth drive ratio
Final
Fan Start
Temperature
Cooling
system
43
Thermostat
Temperature
Coolant capacity
Coolant type
MODEL
DD262MP
Twin Cylinder 4 Stroke
Overhead Cam, Balanced
320cc
354
10.2:1
1500 100
0.6~0.7
International 5 Gears
3.631
2.846
1.777
1.333
1.083
0.913
2.429
185 F
165
L
1.6
Ethanol Glycol 50/50 Water
Br