SWM SM 500 R E4 2018, Manual

Page 1: ...SM 500 R E4 2018 Manuale Uso Manutenzione Manual Operation Maintenance Manuel Utilisation Entretien Handbuch Gebrauch Wartung Manual Uso Mantenimiento...

Page 2: ...manuel et question et se r serve le droit d apporter tous les perfectionnements n cessaires sans avis pr alable Les illustrations grav es dans ce manuel ne sont qu titre idicatif et pourraient ne pas...

Page 3: ...e le prescrizioni si riferiscono a tutti i modelli Unless specified data and prescription are referred to all the models Sauf indications contraires les donn es et les instructions se r f rent tous l...

Page 4: ...EN EN 1 ENGLISH...

Page 5: ...rvice This Owner s Manual is part and parcel of the motorcycle hence it shall remain with the motorcycle even when sold to another user This motorcycle uses components designed thanks to systems and s...

Page 6: ...order to comply with the mainte nance plan is charged to the Client Note the warranty is NULL AND VOID if the motorcycle is rented Important Notice Readthismanualcarefullyandpayspecialattention to sta...

Page 7: ...Reduce speed if it is raining and especially if there are puddles of water on the road When riding on wet or low grip surfaces snow ice mud etc keep a moderate speed and avoid sudden braking and mano...

Page 8: ...passenger handle with both hands and keep both feet on the passenger footrests Never carry a passenger that is unable to firmly place both feet on the passenger footrests Never ride under the influenc...

Page 9: ...BETICAL INDEX 70 SCHEDULED MAINTENANCE APPENDIX A Note References to the left or right of the motor cycle are considered from the point of view of a person facing forward Z number of teeth A Austria A...

Page 10: ...ng head tube Always quote the number stamped on the frame when ordering spare parts or requesting further details about your vehicle and note it on this booklet CHASSIS NUMBER VEHICLE IDENTIFICATION N...

Page 11: ...Rear brake control pedal 4 Right handlebar switch 5 Digital instrument 6 Ignition switch 7 Left handlebar switch 8 Clutch control lever 9 Gearboxcontrolpedal toengagefirstgear push the lever down for...

Page 12: ...ntrol TRANSMISSION Type constant mesh gear type Transmission ratio 1st gear 2 000 z 28 14 2nd gear 1 611 z 29 18 3rd gear 1 333 z 24 18 4th gear 1 086 z 25 23 5 th gear 0 920 z 23 25 6 th gear 0 814 z...

Page 13: ...Coolant capacity 2 0 2 4 Imp Pints 2 3 2 7 U S Pints Transmission oil Oil and oil filter replacement Imp Quarts 1 5 U S Quarts 1 8 Oil replacement Imp Quarts 1 3 U S Quarts 1 6 TABLE FOR LUBRICATION...

Page 14: ...kickstand 1 is supplied with every motorcycle WARNING The stand is designed to support the weight of the MOTORCYCLE ONLY Do not sit on the motorcycle using the stand for sup port as this could cause...

Page 15: ...ion 5 ABS warning light ABS ORANGE Starts flashing when the rear wheel s ABS func tion is deactivated Remains on if an ABS system malfunction is de tected in this case it is recommended to visit an SW...

Page 16: ...key in the OFF position and push the knob SCROLL A 2 place the ignition key in the ON position while pressing the SCROLL wheel for 3 seconds A To confirm the conversion the SET and the Miles and mph o...

Page 17: ...ost after detaching battery If the STP 1 is set to zero the functions TRIP 1 and AVS1 will also be set to zero The function TRIP 1 is ON together with the function STP 1 see figure 5 5 SPEED STP 1 FUE...

Page 18: ...P 1 and AVS 1 data 7 SPEED V MAX FUEL figure 7 SPEED m 299 kmh or 299 mph V MAX Shows the maximum speed reached by the vehicle in kmh or mph Maximum value 299 kmh or 299 mph To set to zero V MAX push...

Page 19: ...for more than 3 seconds CLOCK Clock reading from 0 00 to 23 59 59 the data will be lost after detaching battery To reset the clock push the knob SCROLL A for more than 3 seconds in order to increase...

Page 20: ...ion of the throttle control can be adjusted by loosening the two retaining screws 4 CAUTION Do not forget to tighten the screws 4 after the adjustment IGNITION SWITCH The ignition switch has two posit...

Page 21: ...and turn counterclockwise Push the key inwards if necessary turntoandfrom Turnthekeyclockwise and remove it from the lock To unlock the steering lock reverse the above pro cedure WARNING Do not turn...

Page 22: ...deac tivated for circuit riding NOTE In order to activate or deactivate the ABS func tion on the rear wheel the motorcycle must be stationary Rear wheel ABS deactivation To deactivate the ABS functio...

Page 23: ...shaft can be varied as follows loosen the screw pull the lever out and place the lever in a new position on the shaft Tighten the screw once operation is completed CAUTION Do not shift gears without...

Page 24: ...the road surface is slippery In any case it provides the minimum distance required for that particular road surface TheABSsystemdoesnotengageatspeedsofless than 10 km h When the system operates during...

Page 25: ...park plug clean or replace The engine starts but it is erratic dirty or worn out spark plug clean or replace faulty spark plug electrode gap adjust The spark plug gets easily dirt unfit spark plug rep...

Page 26: ...while the passengers mounts and dismounts Do not get off the vehicle by jumping or extending your legs and always dismount by following the in structions given in the relevant section Mounting of rid...

Page 27: ...the rider must not pull out or attempt to pull out the rear passenger footrests since this may un balance the vehicle Place your left hand on the rider s shoulder your left foot on the footrest and th...

Page 28: ...cycle as described in the rel evant section Using your left leg fully extend the stand Allow the passenger to dismount first from the left side of the vehicle In order to dismount the passenger must p...

Page 29: ...an adequate oil warm up and circulation NOTE A safety switch is mounted on the clutch lever s support which ONLY allows the engine to be start ed with the clutch lever pulled With the stand lowered th...

Page 30: ...THE MOTOR IN AN EMERGENCY Press the red button 7 to stop the motor after use bring it back to the out position When the bike is off place it on its side stand WARNING Independent use of the front or r...

Page 31: ...soperationmadewithwarmengine WARNING Becarefulnottotouchhotengineoil ENGINE OIL REPLACEMENT AND BAG FILTERS FILTER CARTRIDGE CLEANING OR REPLACEMENT WARNING Be careful not to touch hot engine oil Drai...

Page 32: ...and replace them if worn Refit everything operating in reverse order from removal taking care to correctly position the O rings 11 and 12 coupling torque 8 Nm 0 8 kgm 5 9 ft lb with loctite 243 Once...

Page 33: ...d place the motorbike fully upright The coolant must be 10 mm above the elements The coolant must always be present in the expansion tank 2 its level must always be above the MIN mark indicated in the...

Page 34: ...Filling procedure Pour the mount of liquid prescribed into the radiator and re position the cap 4 Take the motor to temperature to eliminate any air bubbles Allow the coolant to cool down then remove...

Page 35: ...the pipe 3 move the upper rubber cap 4 Unscrew the counter nuts 5 and appropriately rotate the adjusting screws 6 unscrew to decrease play tighten to increase it tighten back the lock nuts 5 re mount...

Page 36: ...nsulator should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the spark plug ha...

Page 37: ...kwise in order to release the saddle 2 from the locking position Lift the saddle from the rear part 3 and release it from the locking positions by pulling it towards the motorcycle rear part 4 RIGHT L...

Page 38: ...amping screw 2 and detach the tank vent hose 3 Position a rag under the quick coupling 4 of the fuel pipe press the coupling 4 and detach the fuel pipe Lift the reservoir slightly from the rear and di...

Page 39: ...rews 2 and remove the pro tection 3 Unscrew the two screws 4 and remove the plate 5 Unscrew the two screws 6 Remove the aspiration sleeve 7 Remove the filter 8 from the filter box Check that it s not...

Page 40: ...n front of the motorcycle and grasp the low er end of the fork rods sliders moving them in the direction of their axis Se si avverte gioco occorrer eseguire la regolazione operando come segue loosen s...

Page 41: ...the rear brake pedal with respect to the footrest may be adjusted according to the individual needs For adjusting proceed as follows loosen the screw 1 turn the cam 2 in order to raise or lower the b...

Page 42: ...nce it is dangerous to operate the motorcycle under such conditions have the brake system im mediately checked by the SWM Dealer CAUTION Do not spill brake fluid onto any painted surface or light lens...

Page 43: ...D LEVEL CHECK To check the fluid level proceed as follows remove screws 1 cover 2 and rubber 3 pump diaphragm on the handlebar clutch control by keeping the master cylinder 4 in horizontal position ch...

Page 44: ...sive demanding tests in various usage condi tions of the vehicles If you intend to use them on more specific ground following are a few guidelines forsetup Alwaysstartfromthesuspensionsstand ard setti...

Page 45: ...carry out monthly Set the motorcycle on a central stand release the fork fully extended and loosen the air vent valve D Once this operation is over tighten the valve Note Never force the adjusting sc...

Page 46: ...SAG is 0 98 1 18 25 30 mm 5 To get the right SAG according to your weight adjust the shock absorber spring preload as de scribed at side B rear mudguard top height C rear wheel axle height WARNING Th...

Page 47: ...ion stroke is independ ent from the rebound stroke A COMPRESSION Standard setting 1 Low damping speed 10 clicks adjuster 7 2 High damping speed 1 turn adjuster 8 To reset the standard setting turn upp...

Page 48: ...han let turn three times the rear wheel Now the chain should not be tight FAST ADJUSTMENT FIG B In the point shown in the figure fit a bush a 1 37 in 30 mm diameter or alternatively a shim in the same...

Page 49: ...center and 21st pin center Check the pinion damages or wear and replace it should the wear degree be as the one shown in fig ure Remove the wheel and check the wear of the rear sproket teeth The below...

Page 50: ...catethemetalandrubberparts OR bothinternally and externally alternatively use engine oil with SAE 80 90 viscosity CAUTION The chain lubricant shall NEVER get in contact with the tyres or the rear bra...

Page 51: ...per 2 Loosen the bolts 2 holding the wheel axle 3 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 4 on the opposite side draw the wheel axle out Note Do not oper...

Page 52: ...ile pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 3 on the R H leg 7 67 ft lb the screw 2 on the L H side 37 95 ft lb the screws 3 on the...

Page 53: ...orque of the nut 1 142 Nm 14 48 Kgm 104 73 ft lb Note Do not operate the rear brake pedal when the wheel has been removed this causes the cal liper pistons to move outwards After removal lay down the...

Page 54: ...pedal rear brake lines calliper assembly and disc LEGEND 1 Front brake control lever 2 Front brake master cylinder 2A Fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Re...

Page 55: ...out pins 4 Remove clips 3 Remove pads WARNING Donotworkthebrakeleverorped al while removing the pads PADS WEAR Check brake pad wear Respect the service limit A indicated in the relative figures If se...

Page 56: ...Install new brake pads Reassemble the two pins 2 and the clips 1 FRONT Install new brake pads Install clips 3 by pushing them toward the cal liper Install the pins 4 Pull clips 3 out to make sure the...

Page 57: ...the thickness of each disc at the point where it has worn the most Replace the disc if it has worn past the service limit Disc thickness DISC CLEANING Poor braking can also be caused by oil on the di...

Page 58: ...sture contami nation of the fluid Handle brake fluid with care because it can damage paint Don t mix two types of fluid for use in the brake This lowers the brake fluid boiling point and could cause t...

Page 59: ...out of the plastic hose now close the bleeding valve Restorethebrakefluidlevel A or B thenreas semble the rubber and the fluid reservoir cap After changing the fluid bleed the system as de scribed in...

Page 60: ...ing valve 1A positioned on the brake cal liper Restore the brake fluid level A then reassem ble the rubber and the fluid reservoir cap 2 WARNING During the bleed operation the fluid level inside the r...

Page 61: ...g the union slightly Release the pedal and wait for a few seconds before repeating the operation until only fluid come out of the tube Close the bleed union to the prescribed torque and check the flui...

Page 62: ...that the deadening material set on the holed tube inside the muffler is deteriorated ELECTRICAL COMPONENTS LOCATION The ignition system includes the following elements Generator 1 in oil bath on the i...

Page 63: ...ents Battery 12V 6Ah 10 under the saddle Direction indicators blinker device 11 positioned on the left of the rear subframe Fuses 12 positioned on the utilities holder plate under the saddle Relay 13...

Page 64: ...28 26 22 23 EN EN 61 Air pressure temperature sensor 19 Coolant temperature sensor 20 Lambda probe 21 Stepper motor 22 Injector 23 ABS 24 Power off switch 25 LED SW projector 26 W LED tail light 27 L...

Page 65: ...S 5A 12V Locked with key 8 Fuse 4 POWER 15A POWER RELAY Injector Coil Gas pump Lambda Probe Heater Canister Valve 9 Fuse 5 MAIN 15A ECU POWER PLUG DASHBOARD MAIN SWITCH Dc relay Power relay Fan relay...

Page 66: ...2 1 3 4 5 6 7 8 9 10 11 EN EN 63...

Page 67: ...EN 64...

Page 68: ...eadlight 20 Front right direction indicator 21 Dashboard 43 ABS Control unit 22 Auxiliary Socket 44 K line Connector 23 Left switch 24 Key 25 Blinker 26 Horn 27 DC Relay 28 Fan 29 Fan Relay 30 Stepper...

Page 69: ...G Violet Green Br P Brown Pink W White Br V Brown Violet W Bk White Black Br W Brown White W Bl White Blue G Bk Green Black W G White Green G Bl Green Blue W P White Pink G Br Green Brown W R White R...

Page 70: ...t voltage first connect the RED positive cable to the battery positive terminal then the BLACK or BLUE negative cable to the battery negative terminal The voltage reaches a constant value only after a...

Page 71: ...is a LED light Replace it when it does not function REPLACING THE NUMBER PLATE BULB loosen screw 1 and remove the number plate bulb 2 from the mudguard take bulb holder 3 and bulb 4 out of the sup po...

Page 72: ...s at 33 ft from a wall or screen Then trace a hori zontal line at the height of headlight centre and a vertical one in line with vehicle longitudinal axis If possible execute this operation in a shade...

Page 73: ...uide rapide Kurzanleitung Gu a r pida Cope_retro QUICK SM_codA000P02069_1ed_02 2018 indd 1 27 04 18 10 23 EN 70 EQUIPMENT Pos No Part no DESCRIPTION 1 A000P02069 MULTILANGUAGE QUICK MANUAL 1 2 FA00P01...

Page 74: ...ready for use after stor age Make sure the spark plug is tight Fill the fuel tank Run the engine to warm the oil up then drain the oil Refill with fresh oil Check all the points listed under the insp...

Page 75: ...Adjust play Flexible controls and transm Check Adjust Drive chain Check Adjust Description Operation Pre delivery Tyres Check pressure Side stand Check operation Side stand switch Check operation Ele...

Page 76: ...NTROL LEVER AND FRONT BRAKE FLUID LEVEL CHECK 39 AIR FILTER CHECK CLEANING AND OR REPLACEMENT 36 ANTI LOCK BRAKING SYSTEM ABS 21 B BATTERY 67 BATTERY CHARGER 67 BRAKE DISC WEAR 54 BRAKE PADS REMOVAL 5...

Page 77: ...VAL 35 R H HANDLEBAR SWITCH 18 RIGHT LATERAL PANEL REMOVAL 34 S SADDLE REMOVAL 34 SIDESTAND 11 SOSTITUZIONE LIQUIDO DI RAFFREDDAMENTO 31 SPARK PLUG CHECK 33 STARTING THE ENGINE 26 STEERING LOCK 18 STE...

Page 78: ...A A 1 APPENDICE A APPENDIX A ANNEXE A ANHANG A AP NDICE A...

Page 79: ...ES C GIOCO CLEA RANCE JEAU C GIOCO CLEA RANCE JEAU S MOLLE VALVOLE VALVE SPRING RESSORT SOUPAPES C X SCODELLINI SEMICONI VALVOLE VALVE CUP VALVE HALF CONE CUVETTES DEMI C NE SOUPAPES C X BILANCIERI DI...

Page 80: ...IRE RACCORDO DI ASPIRAZIONE INTAKE MANIFOLD RACCORD ADMISSION C S CILINDRO COMPLETO CYLINDER ASSY CYLINDRE COMPL C X PISTONE COMPLETO PISTON ASSY PISTON COMPL C S BIELLA MOTORE COMPLETA CONNECTING ROD...

Page 81: ...N CESSAIRE MOLLE FRIZIONE CLUTCH SPRING RESSORT EMBRAYAGE C X CAMPANA FRIZIONE CLUTCH DISCS HOUSING CAGE EMBRAYAGE C ASTINA DISINNESTO FRIZIONE CLUTCH DISENGAGEMENT ROD BILLE COILESSAU D BRAYAGE EMBR...

Page 82: ...SADDLE FRAME FASTENING BOLTS ENGINE FASTENING BOLTS PIVOTS DE FIXATION CADRE SIEGE PIVOTS DE FIXATION MOTEUR C C CAVALLETTO LATERALE SIDE STAND BEQUILLE LAT RALE RULLO GUIDACATENA CUSCINETTO CHAIN GU...

Page 83: ...M PIVOT NEEDLE BEA RINGS CAGE AIGUILLES PIVOT FOURCHE ARRI RE L AMMORTIZZATORE POSTERIORE REAR SHOCK ABSORBER AMMORTISSEUR ARRI RE R GABBIE A RULLI SPINOTTI LEVERAGGI SOSPENSIONE POST REAR SUSPENSION...

Page 84: ...RE TUBAZIONI POMPA PINZA IMPIANTI FRENANTI BRAKE SYSTEM PUMP CALI PER HOSES TUYAYU POMPE ETRIER SYST ME DE FREINAGE TUBAZIONI CARBURANTE FUEL HOSES TUYAU CARBURANT S X MATERIALE FONOASSORBENTE SILENZI...

Page 85: ...FER TO MANUAL WORKSHOP REPORTER AU MANUEL D ATELIER NOTE NOTE NOTE SOSTITUIRE LE GUARNIZIONI IN OCCASIONE DI OGNI SMONTAGGIO EVERY REMOVAL REPLACE ALL GASKETS TOUTES LES D MONTAGES REMPLACER LES GARNI...

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