Introduction

Dear MZ Owner,

we appreciate your purchase of a MZ motorcycle and thank you for your confidence in us.

The MZ 125 SX/SM motorcycles are based on 80 years of motorcycle construction experience in Zschopau. Both types have been developed for use according to the provisions of the road traffic regulations. These motorcycles are not suitable for hard off-road usage. You should keep this fact in mind when using your MZ 125 SX/SM.

Before you start riding your new motorcycle, please read all the information in this manual. This will provide you with important advice and information about the correct operation and handling of your motorcycle, as well as giving you useful information about regular care and maintenance.

Following these instructions and information is not just important for maintaining your vehicle in good condition, but is also in many cases a prerequisite for any claim under the warranty.

The owner's manual should always be kept with the motorcycle so that you can refer to them at any time. These owner's manual form an important part of the vehicle accessories and must remain with the motorcycle if it is resold.

Should a scheduled inspection be due, please bear in mind that the maintenance crew at your MZ workshop have been specially trained for this purpose.

Should you have problems or questions concerning your MZ 125 SX/SM, please refer to your MZ dealership for assistance. The crew there will always be pleased to assist you.

May you always enjoy riding your motorcycle!

MOTORRAD-UND ZWEIRADWERK GmbH
Alte Marienberger Straße 30 - 35
D-09405 Zschopau-Hohndorf

Explanation or the notes

The notes on safety and warnings included in these owner's manual are marked as shown below. Please pay special attention to these statements and instructions.

DANGER Immediate danger causing serious injury to persons or death.

WARNING Possible danger which may cause serious injury to persons or death.

ATTENTION Possible danger or risky handling of the vehicle which may cause injury to persons or damage to property.

Each one of these safety precautions informs you of the following:

• what kind of danger is at hand,
• what may happen,
• what you can do to avoid or reduce the risk of injury or damage to equipment.

Symbols used and their meaning:

	DANGER in general
	WARNING, ATTENTION in general
	Important notices on environmental protection
	Warning against hazardous voltage
	Warning against crushing by the driving chain
	Danger of crushing
	Warning against corrosive liquids
	Danger of fire
	Warning against hot surfaces

Table of Contents

Safe driving and health

ATTENTION Riding a motorcycle requires you to observe specific safety precautions to ensure your personal safety. Please familiarise yourself with these precautionary measures before you start riding.

Rules for safe riding

• Always make a pre-ride inspection before you start the engine
  (see "&Pre-ride inspection", page 18).
  By doing this you protect the machine from damage and may prevent an accident.
• The motorcycle must only be driven by persons in possession of a valid motorcycle driver's license.
• Make yourself easy to see to avoid an accident which is not your fault:
  • Wear bright or reflective clothing.
  • Do not ride in the blind spot of other motorists.
• Be especially alert at crossroads, exits and entrances and at side street junctions.
• Observe the local laws and regulations of the country you are riding in:
  • Keep within the speed limits and never ride faster than conditions warrant.
  • Signal well before you make a turn or change lanes. Your size and manoeuvrability could surprise other motorists.
• When driving, keep both hands on the handlebars and keep both feet on the foot rests. The passenger must always hold onto the motorcycle or the driver with both hands and have both feet on the pillion foot rests.

Protective clothing

• Always wear a helmet. As well as boots, gloves and protective clothing you should also wear a face shield or protective goggles. Passengers should wear the same protective clothing.
• Do not wear any loose clothing! This could get caught in the operating elements, the foot rests, the driving chain or the wheels.
• The exhaust system becomes very hot when the engine is running and remains hot for a while after the engine has been switched off. Be careful not to touch any parts of the hot exhaust system. Only wear clothing that fully covers your legs.

Amendments

WARNING Modifications to the motorcycle, removal of original parts, or the fitting of non-MZ spare parts and accessories may render the motorcycle unsafe and illegal. The installation of a performance enhancing kit results in the loss of warranty and road traffic admission. Any manipulation of the governor kit entails the loss of the warranty and all manufacturer product liabilities.

Operation

Vehicle identification

Key number:

The motorcycle comes with two keys for the ignition lock. There is a tag bearing the key number on the key-ring.

Keep this tag and the second key in a safe place, away from the motorcycle.

The key number must be stated when ordering a replacement key.

Vehicle identification number:

The vehicle identification number (1) is a unique identification of the motorcycle and must be given when registering it with the proper authorities.

This number is imprinted on the right side of the steering head column.



Enter the identification number of your vehicle here:

Engine number:

The engine serial number (1) is imprinted in the right-hand side of the engine.



Enter the engine number of your vehicle here:

Operating elements

Ignition lock

1.	Parking position Ignition off, Parking lights on Steering locked to the left
2.	Ignition off, Lights off, Steering locked to the left
3.	Ignition off
4.	Ignition on

Instrument panel

1. Reset knob for trip-mileage counter
2. Left/right indicator
3. Headlight control
4. Idler control
5. Warning light for cooling system
6. Warning light "0il pressure too low"
7. Tachometer
8. Trip-mileage counter
9. Odometer (kilometres)
10. Speedometer (km/h or m.p.h.)

ATTENTION Risk of engine failure! The warning lamp (5) flashes when the cooling system is overloaded. The warning light (6) must go out by the time the engine reaches 2000 rpm. It remains on at higher speeds then the oil pressure is too low. Pay attention to maintenance instructions, or see a MZ dealer for this service!

Left handlebar controls

1.	Choke
	1a Cold starting position, turn 2 stages in arrow direction (depending on outside temperature)
	1b Travelling position, turn as far as the stop
2.	Headlight flasher
3.	Light switch
	Off
	Parking light
	Headlight
4.	Horn
5.	Indicator switch
	Left indicator
	Right indicator
6.	Dipper switch
	Full beam ON
	Dipped beam ON

Right handlebar controls

1.	Engine stop button
	Ignition interrupted
	Ignition, ON (Function is active if the corresponding symbol is covered by the switch.)
2.	Starter button

Gear change pedal

Adjusting the angle of the gear change pedal:

1. Loosen the clamping screw (2).
2. Pull off the gear change pedal (1) and put it on again in the desired position.
3. Tighten the clamping screw (2).

Fuel tank cap

ATTENTION Fuel can leak out. Before you start your ride make sure that the fuel tank is closed tightly.

Fuel cock

Seat lock

Removing the seat:

1. Turn the bayonet socket (1) an 1/4 turn anti-clockwise.
2. Lift the seat up to the rear and remove it.

Mount the seat:

1. Slide the seat below the screw at the tank, and simultaneously press the holding clip on the rear frame and hold it pressed.
2. Turn the bayonet socket (1) an 1/4 turn anti-clockwise.

WARNING Danger of falling! Check the safe retention of the seat before you drive! Never ride with a helmet hanging from the motorcycle! So the helmet can cause an accident.

Rear wheel suspension

The spring preload has been preset in the factory for a person of approximately 75 kg. An adjustment is necessary if the motorcycle predominantly carries two people or the permissibie overall weight.

L = 175 mm:

• 75 kg (1 person)

L = 175 - 172 mm:

• 2 persons or permissible overall weight (172 mm for heavy pillion-rider and for long and bad stretch)

Intermediate positions are possible.

ATTENTION Risk of dazzling by modified headlight aiming! The headlight setting must be corrected after the spring preload has been changed.

The damping effect of the spring shaft is not adjustable.

Front wheel suspension

The damping effect of the telescopic forks is not adjustable.

It must always move easily.

Therefore, always ensure that it is well maintained.

After dismounting and remounting the wheel, check the parallelity of both forks and correct if necessary.

Side stand

The side stand is equipped with a switch that breaks the ignition circuit when the side stand is extended and the engine is put in gear. This makes it impossible to ride off when the stand is extended.

Foot brake pedal

The angular adjustment of the foot brake lever can be changed with the setting cam (1), which simultaneously serves as an end stop.

The adjustment of the angle must be completed by readjusting the play in the foot brake pedal:

1. Loosen the nut (2) on the pressure rod.
2. Turn the pressure rod until a play of 1 mm has been set.
3. Tighten the nut (2) again.

Handlebar adjustments

1. Loosen the screws of the handlebar holding shells (1) until the handlebars can be rotated.
2. Turn the handlebars into the desired position.
3. Retighten the screws of the handlebar holding shells.

Tightening torque Screws for the handlebar holding shells 25+5 Nm

ATTENTION Danger of crushing! When the handlebar are fully turned there must still be a gap of at least 3 cm between handlebar and tank.

Accessories

The only accessories which may be used are those which have been authorised by MZ for the MZ 125 SX/SM, or which do not detract from operating and road safety.

In this connection, please pay regard to the warranty conditions and the legal requirements.

ATTENTION No warranty and road traffic admission when installing performance increasing components!

The following accessories are available through MZ's authorized dealers:

• Engine protection
• Top case carrier set
• Roll bar set
• Hand protection set
• Assembly aid set
• Fork protector set

Driving instructions

Running in

DANGER Risk of accident! New tyres do not have their optimal roadholding at first, therefore they must be run in. Ride cautiously for the first 100 km (60 miles)! Even run-in tyres have to warm up before they reach their maximal roadholding.

During the first few hours of operation the engine has a higher degree of internal friction. All the moving parts have worn in.

Therefore, observe the following instructions while running in during the first 1000 km (600 mi):

0 to 150 km (0 to 90 miles):

• Vary the speed and the revs from time to time.
• Keep the revs below 6000 rpm.
  Recommended speed:

  gear	1	2	3	4	5	6
  km/h	20	30	40	50	60	70

150 to 500 km (90 to 300 miles):

• Keep the revs below 8000 rpm.
  Recommended speed:

  gear	1	2	3	4	5	6
  km/h	25	40	55	65	80	95

• You can use the full engine speed range in all gears up to 8000 rpm. Do not ride at full throttle!

DANGER Risk of accident! New brake blocks do not reach their optimal frictional force for the first 200 km (120 miles). They must be worn in. You can compensate for the somewhat reduced braking effect by exerting more force on the brake pedal or hand-brake. The same applies after the brake blocks have been changed.

500 to 800 km (300 to 480 miles):

• Do not ride for long distances at full throttle or longer stretches at over 8000 rpm.

After 800 km (480 miles):

• The engine load can be increased to maximum for short periods.

ATTENTION The engine oil and oil filter must be changed after the first 1000 km (600 mi), see the maintenance schedule.

After 1000 km (600 miles):

• You can ride at full throttle.

If the RPM exceed 10500, the ignition box switches off the ignition current (rev limiter).

ATTENTION Risk of engine and transmission damage! The revs may not go into the area of the rev limiter.

If any problems become evident during the running-in period contact an authorised MZ Workshop without delay.

Safe driving

DANGER Risk of accident! Check the operational safety and roadworthiness of your motorcycle before every journey. If you notice any irregularities, the necessary repairs must be made before starting the motorcycle!

Pre-ride checks:

The following list of checks does not take very long. The increased safety gained is worth much more than the few moments needed for the checks.

• Front and rear brakes:
  Check the braking effect and brake fluid level.
• Lights and horn:
  Check that the headlight, rear and brake lights, indicators, warning lights and horn are functioning properly.
• Tyres:
  Check the condition and pressure of the tyres (see section Maintenance - Tyres).
• Fuel level:
  Check the fuel level and fill up if necessary (see section Operation instructions - Refuelling).

WARNING Risk of being scalded! Hot oil can spray out. Never open the cap on the oil tank while the engine is running.

• Engine oil level:
  Check the oil level when the engine is cold, top up when necessary (see section Maintenance - Check oil level).

WARNING Risk of being scalded! Never open the cooler cap while the engine is running.

• Coolant level:
  Check the coolant level and top up if necessary (see section Maintenance - Coolant).
• Driving chain:
  Check the condition and slack of the chain (see section Maintenance - Driving chain).
• Throttle twist grip:
  Check for smooth opening and closing in all steering positions.
• Clutch:
  Check efficiency, condition and free play (see section Maintenance - Clutch).

Individual riding styles:

ATTENTION Your safety on the road is very much determined by your personal conduct and the way you drive.

Therefore:

• Do not drive when you are tired.
• Never drive when you are not fit to ride (for instance, when you are under the influence of alcohol, drugs or medication).
• Always adjust your speed to road and traffic conditions.
• Always observe traffic regulations strictly, especially the speed limits.
• Ride your motorcycle in accordance with your riding ability.

Loading:

WARNING Risk of accident! Carrying baggage affects the motor-cycle's performance and stability. Adjust your way of riding and speed accordingly! Do not exceed the maximum authorised load.

If you want to take baggage with you, please observe the following instructions:

• Keep the baggage weight as low as possible.
• Place the baggage as near as possible to the centre of gravity of the motorcycle.
• Distribute the weight as evenly as possible.
• Check regularly that the baggage is secure. No part of the baggage or its securing gear may come into contact with any of the motorcycle's moving parts, e.g. a wheel.

Drive economically and protect the engine and the environment

WARNING Increased engine wear! The engine should not be warmed up while stationary! First warm up the engine before riding at higher speeds.

When the engine is idling it takes a very long time for it to reach operating temperature. During the warm-up period the wear is especially high. Therefore, ride off with a low engine speed shortly after starting the engine. When the engine had warmed up a higher performance could be retrieved.

ATTENTION Risk of environmental damage! Do not accelerate at full throttle! Try to avoid driving at maximum speed!

Using moderate acceleration reduces the fuel consumption, environmental damage and engine wear considerably.

Fuel consumption, exhaust gases and vehicle noise increase disproportionately at high speeds.

ATTENTION Risk of environmental damage! Do not run the engine at higher revs than necessary. Shift up as soon as possible and shift down only if the engine no longer runs smoothly.

The fuel consumption in second gear is more than double that in top gear. Reducing the engine speed also reduces the noise emission.

ATTENTION Risk of environmental damage! Drive at a steady speed and be alert!

Unnecessary acceleration and braking manoeuvres result in higher fuel consumption.

Operating instructions

Starting the engine

WARNING Risk of poisoning! There is a danger of poisoning if the engine is run in enclosed spaces.

A battery in good working condition is the prerequisite for a sure starting procedure.

Starting a cold engine:

1. Open the fuel cock or switch to reserve, depending upon tank fuel level (see section Operation - Fuel cock).
2. Fold side stand up, put the motorcycle in vertical position.
3. Turn on the ignition.
   If the lights are on, switch the light on the left handlebar controls off (see section Operation).
   Thus all the battery power is available.

WARNING Risk of accident! The motorcycle can move off when you start the engine Always make sure that the transmission is in neutral gear.

4. Change the transmission into neutral gear (the control light for neutral must come on).
5. Slide the motor stop switch to (left position).
6. Open the choke in arrow direction. There are two choke positions. The lower the outside temperature, the bigger must be the choke opening (see section Operation).
7. Do not open the throttle!
   Open the throttle somewhat if the motor does not start.

ATTENTION Never press the starter button for longer than 5 seconds. If the engine does not start immediately, release the starter button, wait for 20 to 30 seconds and then press it again.

8. Press the "START" button in the right handlebar controls (the starter starts the engine).
9. Partially dose the choke.
10. Close the choke contrary to arrow direction when the engine starts to run.

Starting a warm engine

1. Open the fuel cock or switch to reserve, depending upon tank fuel level.
2. Fold side stand up.
3. Turn on the ignition.
   If the lights are on, switch the light on the left handlebar controls off (see section Operation - Handlebar control, left).
   Thus all the battery power is available.

WARNING Risk of accident! The motorcycle can move off when you start the engine Always make sure that the transmission is in neutral gear.

4. Change the transmission into neutral gear (the control light for neutral must come on).
5. Slide the motor stop switch to (left position).
6. Do not use the choke.
7. Open the throttle max. 1/4 turn.
8. Press the "START" button in the right handlebar controls (the starter starts the engine).

The engine stop switch on the right-hand handlebar serves to switch off the engine in cases of danger without operating the ignition lock.

Otherwise use the ignition lock to switch the engine on and off.

9. After the engine has started, the driver and passenger can get on.
10. Switch the light on.
11. Ride off in first gear.

ATTENTION Risk of damage to the regulator, rectifier and ignition box. Never start the engine without a or with a flat battery by pushing the motorcycle. Only use external batteries as a starting aid when the nominal voltage of the external battery is between >12 V and a maximum of 13.8 V, and if the capacity is not higher than your motorcycle's own battery!

Changing gear

ATTENTION Risk of damage to the gear box, engine and transmission. Never try to change gears without disengaging the clutch.

The gear change pattern is shown in Operation section.

To shift up or down, pull the clutch lever completely to the stop, change to the next gear and then release the clutch lever slowly.

To change into neutral gear, activate the clutch while repeatedly pressing down the foot pedal (some resistance will be noticed in first gear), then let the foot pedal up gently.

ATTENTION When starting an 125 SX/SM governed to 80 km/h, keep the engine speed below 6500 rpm. Otherwise a quick start is impossible.

Braking

Always apply both brakes simultaneously. Just using one brake reduces the braking effect.

DANGER Risk of accident! Never brake too hard! This can lead to the wheels locking and the motorcycle going out of control

Please observe the following instructions:

1. Reduce speed when approaching a curve. Braking in a curve may cause skidding.
2. Apply the brakes with care on wet roads.
3. On long, steep, downhill stretches use the braking effect of the engine by shifting down. You can supplement this by applying both brakes intermittently.

Stopping the engine

WARNING Danger of burning! The exhaust silencer and pipes can become very hot. Always park the motorcycle so that pedestrians and children cannot come into contact with these parts!

Switch off the ignition.

To be able to switch the ignition key to or press it in (thus unlocking it) and turn it.

Lock the steering to prevent theft. Close the fuel cock.

ATTENTION Do not park the motorcycle on soft or sloping ground. If the motorcycle is left unattended (even for a short period) always remove the ignition key and close the fuel cock.

Refuelling

DANGER Risk of fire and explosion. Never refuel in an enclosed space!

Recommended fuel:

Non-leaded, regular petrol with an octane rating of 95 (ROZ) or higher.

WARNING Do not overfill the fuel tank! Make sure that no fuel is spilled onto the hot engine. After refuelling, screw the tank cap on tightly.

Fill the tank so that at least 20 mm space remain between the lower edge of the filier neck (1) and the fuel level when the motorcycle is resting on its side stand.

The fuel corrodes the paintwork and plastic parts. Wipe up spilt fuel immediately.

Winter driving instructions

ATTENTION Risk of accident! The standard fitted tyres have restricted suitability for riding on snow and ice.

If you also drive your motorcycle in winter and live in a country with a moderate or cold climate, please observe the following instructions:

• Before winter starts, protect the chromium-plated and unprotected metal and painted parts with a corrosion protection agent recommended by a specialist dealer.
• Apply this corrosion protection agent to the motorcycle as specified in the maintenance schedule.
• Before the winter period Starts, treat the ignition lock with a commercially available lock lubricant.
• Remove all superfluous preservative measures at the end of the winter period.
  This does not apply to the electric plug connections.
• Let your MZ dealer:
  • treat plug and socket parts of the cable harness with a contact care substance,
  • wipe excess contact spray off carefully,
  • check the antifreeze content of the coolant.

Maintenance

General remarks

ATTENTION If you do not possess the necessary tools or knowledge to carry out repairs or maintenance you are advised to get this work done by your authorised MZ dealer!

Improperly performed repairs and maintenance work may lead to the loss of warranty claims.

Regular maintenance work, adjustments and lubrication carried out at by your authorized MZ dealer provide the basis for many years of safe and efficient operation of your motorcycle.

All maintenance work should be carried out at regular intervals.

The distance intervals specified in the maintenance schedule are guidelines. They may be affected by the following factors:

• How you ride
• Weather conditions
• Surface conditions
• Geographie location.

WARNING Do not make any of your own adjustments or changes to the engine or chassis components. In so doing you put yourself and others at risk.

Depending on the severity of the abovementioned factors, even shorter intervals may be necessary.

The instructions in this chapter provide you with information on how to perform small maintenance tasks and help in the event of a break down.

The on-board tool kit supplied is primarily intended for use in case of a break down.


During the warranty period, all work should be carried out by your MZ dealer.

Fire and safety at work regulations must be observed during all care and maintenance work!

Only use the fuel and lubricants recommended by us!

Top up lubricants or brake fluid only with the original fluids. Mixtures can have adverse effects or cause damage.

ATTENTION Risk of environmental damage! Please observe the environment and fire protection regulations when handling fuel and lubricants! Dispose of used oil according to the legal regulations!

Let your MZ dealer determine the cause of losses of fuel, lubricants and brake fluid - there could be a leak!

Maintenance schedule

Engine and gearbox

Electrical Installation

Chassis

Lubrication points

Checking the oil level

The engine has pump circulation lubrication. Oil is supplied by a feed pump to the parts of the engine and transmission to be lubricated.

WARNING Risk of being scalded! Hot oil can spray out. Never remove the oil filler plug while the engine is running.

Checking the oil level:

Check the oil level after every 1,000 km while the engine is cold.

1. Stand the vehicle in an upright position on level ground.
2. Screw the oil filler plug, together with the dipstick, out of the oil filler nozzle and wipe the stick.
3. Screw in the oil tank cap until it stops and read the oil level after screwing it out again.
4. The oil level must be maintained between the MIN and MAX marks. Top up the oil if necessary, but never above the MAX mark.

Top up about 200 cm³ (0,2 l) of oil is the MIN level is reached.

ATTENTION Risk of engine failure and increased wear and tear! Never run the engine with insufficient oil!

Changing the oil

Let your MZ dealer change the oil and oil filter generally.

The workshop fulfils the requirements for disposing of the used oil in an environmentally safe way and also offers an expert service.

The oil is to be changed at the intervals shown in the maintenance schedule. The following points are to be observed:

1. Warm the engine (oil) up or change the oil after having driven the motorcycle.
2. Place the motorcycle on a flat, level surface in vertical position.
3. Place a container underneath the engine to collect the oil.
4. Loosen the oil return plug (4).

WARNING Danger of burning! Hot oil can spray out. Never remove the oil filler plug immediately after running the engine under heavy load.

5. Screw out the oil filler plug (5).
6. Screw out the oil drain plug (1).
7. Screw out the screw plug (2) together with the oil screen, be careful with the seal.
8. Let the oil drain out completely.
9. Dismount the oil filter cap. (screws 3 and 4).
10. Remove the oil filter.

ATTENTION Damaged seals and sealing rings are to be renewed before reassembly!

ATTENTION Risk of environmental damage! Oil must not be poured into the sewage system or onto the ground. The used oil must be disposed of according to the regulations.

11. Soak the new filter together with an 0-ring in oil, then insert it, renew the seal and screw the cap on tightly (screws 3, 4).
12. Clean the coarse screen of the screw plugs and the magnet of the oil drain plug.
13. Screw in the oil drain plug (1) and the screw plug with the coarse screen (2) and tighten.
14. Fill 1.4 l of oil into the engine and screw in the oil filler plug.

WARNING Danger of burning! Hot oil can spray out. Never remove the cap on the oil tank while the engine is running!

15. Check the oil level (see section Checking the oil level).

Check for leaks after changing the oil!

Oil quantities:

Oil types:

All the recommended oils can be used throughout the whole year.

SAE15 W-50 API SG/SH
SAE10 W-40 API SG/SH

Use only brand name oils are to be used. MZ's recommendations for types of oil must be observed.

ATTENTION Apply the correct torques to all bolts!

Torques Oil drain plug (1) 20+5 Nm Screw plug, oil screen (2) 30+5 Nm Oil filter cap screws (3) 8+2 Nm Oil return plug (4) 8+2 Nm

Clutch

The free play on the clutch can be adjusted either on the clutch hand lever or on the engine.


Adjustment:

1. Loosen the lock nut (1).
2. Make the setting with the adjusting screw (2):
3. Screw in:
   -> more clutch play.
   Screw out:
   -> less clutch play.
4. Screw the lock nut (1) on tightly.

The free play on the end ofthe lever should be between 5 and 10 mm (0.2 to 0.4 in.).

If it is no longer possible to set the required free play, an MZ dealer must check the internal clutch mechanism.

Braking

WARNING Risk of accident! Air in the brake system reduces the braking efficiency and is dangerous for you and others. Check the brake fluid level before every ride!

Please note that new brake blocks have to be worn in during the first 200 km (120 miles) in order to develop their optimal braking effect.

If there is not enough brake fluid, air may get into the braking system and reduce the braking efficiency.

For your own safety, bleeding the brakes should be carried out by your MZ dealer.

Checking the brake fluid level in the front wheel brake:

The brake fluid reservoir is situated next to the hand brake lever.

When the brake fluid reservoir (1) is horizontal, the level of brake fluid must not sink below the middle of the round viewing window (2).

Checking the brake fluid level in the rear wheel brake:

The brake fluid reservoir is on the right under the seat near the suction silencer.

The brake fluid level must be visible between the MIN and MAX marks.

WARNING Brake fluid is poisonous! Avoid contact with the skin! Keep brake fluid in the original container out of the reach of children! Brake fluid corrodes paint and plastic components.

Instructions:

Only use high quality brake fluid (DOT 4) as lower quality products do not have the chemical characteristics required and can corrode the rubber seals.

Old brake fluid tends to form vapour locks when put under heavy load (riding downhill and frequent braking). This leads to a serious reduction of the braking efficiency and a loss of safety on the road.

For your own safety, adjustments to the brakes should be carried out by your MZ dealer.

Let your MZ dealer determine and eliminate the cause of a loss of brake fluid. Your machine is not roadworthy if the brake blocks are worn (wear marks) or the brake system leaks!

Brake fluid corrodes paint and plastic components. Therefore, wipe up spilt brake fluid immediately.

Have the brake fluid and rubber seals renewed by your MZ dealer every 2 years.

The brake hoses should be replaced every 4 years by your MZ dealer.

Checking the brake pads:

The thickness of the brake pads at the front and rear must on no account be less than 2.0 mm (0.07 in) otherwise the brake discs can be damaged!

The brake pads must be replaced by your MZ dealer.

When the wear mark (2) is no longer visible, the brake pad must be replaced by a new one!

Checking the brake discs:

The minimum thickness of the brake disc is impressed on the brake disc.

The brake discs must be replaced by your MZ dealer.

Tyres

Check the tyre pressure before every journey while the tyres are cold

(tyre temperature = outside temperature).

The tyre pressure should correspond to the values in the table:

WARNING Risk of accident! Worn tyres reduce the motorcycle's stability and may lead to accidents. Replace worn tyres with new ones! Let your MZ dealer or authorised workshop perform tyre repairs and replacements! Always ride with the correct tyre pressure!

Observe the legal tread depth in your country.

In any case, the tyres should be changed, at the latest, when the tread depth is down to 2 mm (0.07 in).

ATTENTION Use only those tyres which are approved for your motorcycle (see the Technical Data section and the entries in the authorisation documentation)!

Air filter

The air filter (2) must be removed for cleaning:

1. Remove the intake pipe (1).
2. Lever out the body-bound rivet (4) with a suitable tool (e.g. screwdriver).
3. Lever out the body-bound rivet (3).
4. Clean the filter by knocking it out or blowing it out with compressed-air

WARNING Risk of fire and explosion! It is forbidden to smoke when handling fuel or cleaning fluids with similar properties.

Before refitting:

1. Wipe out the air filter casing.
2. If necessary, empty the condensate collector (5) on the underside of the air filter casing.
3. Reattach the condensate collector (5) with the clamp.
4. After the filter has been re-fitted, insert the intake pipe (1) with the circular groove tightly.

Fuel supply

WARNING Risk of fire and explosion. It is forbidden to smoke when handling fuel or cleaning fluids with similar properties.

Maintenance work on the fuel supply is required if there are any faults in the following components:

Tank:

If the tank is dirty it must be rinsed out. This work is best done by your MZ dealer.

Fuel cock:

A filter (1) is fitted inside the tank in front of the fuel cock. In order to clean it, the tank must be emptied and the fuel cock unscrewed.

Screw off the filter and clean it.

External fuel filter:

Clean this filter in the same intervals as the fuel cock filter.

Replace the filter if necessary.

Carburettor:

The cleaning of the carburettor, especially the jets must only be performed in a workshop.

For this purpose the carburettor must be dismounted from the engine.

The carburettor has been optimally adjusted by the manufacturer or during the inspection by your MZ dealer.

Any unauthohsed change of the settings has a negative effect on the following:

• Engine performance
• Petrol consumption
• Exhaust emissions
• Environment

Petrol hose and connections:

• Check that the clamps are tight.
• If required, replace the hose with an original hose from the MZ dealer.

Battery

WARNING Risk of acid burning! Battery fluid must not come into contact with eyes, skin or clothing. Acid splashes must be thoroughly rinsed off with water immediately. If necessary seek medical attention.

The battery (2) is located behind the left lateral lining. In the Standard model a normal lead accumulator is used.

• Keep the battery connections clean and always preserved with battery grease!
• Check the electrolyte level periodically. The level must be maintained between the MIN and MAX marks (two lines on the battery case).
• Only use distilled water to top up.

ATTENTION Risk of damage to the on-board electronics! Always keep the battery well charged!

• Ensure that the battery is securely fitted (2)! The fixing strap (3) of the battery fastenings must not be porous. It is to be fitted like in the illustration (alongside of the cover).

If the motorcycle is not going to be ridden for over 1 month, the following steps are to be undertaken before putting it in the garage:

1. Remove the battery and store in a dark place where the temperature is between 5°C/40°F and 20°C/68°F. If necessary, the battery must be re-charged first.
2. When removing the battery, first disconnect the negative lead and then the positive! Dismount the tank spoiler and partly the left lateral lining and cautiously pull it to the left in order to remove the battery.
3. When reinstalling, first connect the positive lead and then the negative! Insert bush (1) between cable lug and pole terminal. Ensure that the pole terminals are securely fitted!

The positive pole must be covered by a rubber cap.

WARNING Store the battery out of the reach of children! Remove the battery from the motorcycle before recharging.

Before driving the motorcycle again, check that the battery is charged.

WARNING Risk of fire and explosion. Ensure an adequate ventilation in the area where you are charging the battery! Smoking and naked lights are forbidden! Avoid making sparks!

Adjusting the headlights

Temporary adjustment to headlight may be made as follows:

1. Load the motorcycle with the weight it usually carries.
   The spring preload on the shock-absorber must correspond to this load (see section Operation - Rear wheel suspension).
2. Stand the motorcycle horizontally (not on the side stand) facing a vertical wall (do not put it on Stands) at a distance of 5 m (5.5 yards).
3. Measure the distance from the centre of the headlight to the ground.
4. When the headlight is correctly adjusted, the light-dark border of the luminous cone of the dipped headlight must appear 140 mm (5.6 in) below the centre point of the headlight marked on the wall.

Setting:

1. Loosen the headlight screws (1) by about two turns.
2. Tilt or swivel the headlight casing.
3. Retighten the screws (1).

Driving chain

The driving chain is one of the most important transmission components on your motorcycle.

Chain care

Keep the chain clean and lubricated! Wash periodically with copious water (non-pressurised) and then care is made with O-Ring chain spray.

Check the chain slop periodically.

ATTENTION If the chain slack is incor-rectly set, it overloads the engine and other important components. Keep the chain slack within the set limits (60 - 70 mm)!

To check the slack in the chain, stand the motorcycle up vertically.

The rear wheel must turn freely. To do this prop the motorcycle up with a suitable support (e.g. assembly aid of the accessories) under the front pari of the frame.

WARNING Risk of injury! Do not put your fingers between sprocket and chain!

Turn the rear wheel several times and measure the chain slack at various places in order to establish where it is tightest. The valid measurement is made at the tightest part of the chain. This is done by moving the chain up and down.

Correct the chain slack if it is too tight (slack < 60 mm) or to loose (slack > 70 mm):

1. Loosen the axle nuts (1) on the chain adjuster by about one turn on each side
2. To reduce the chain slack:
   Turn the nuts (2) to the right on both sides.
   To increase the chain slack:
   Turn the nuts (2) to the left on both sides and slide the wheel forwards. Turn the nuts (2) by the same amount on both sides so that the axle remains aligned.
3. Tighten the axle nuts (1) on both sides.
4. Once the adjustments have been made check the wheel tracking and correct if necessary.

Torques Axle nuts (1) 100+10 Nm

Coolant

Checking the coolant:

The coolant level should be checked after the first 1,000 km, and then after every 6,000 km by the MZ dealer.

WARNING Overpressure causes a risk of being scalded. Do not open the radiator cap when the engine is hot.

1. Remove the radiator cap (1) by turning it to the left.
2. Check the fluid level.
   When the engine is cold, the fluid level should bejust underneath the lower sealing surface of the radiator cap.

ATTENTION Insufficient coolant may result in engine damage. Get your MZ dealer to repair leaks of coolant immediately!

Refilling the coolant:

1. Stop the engine and let it cool down.
2. Open the radiator cap.
3. Fill the radiator system with a mixture of high quality proprietary coolant for aluminium engines and distilled water.

At least the proportion of mixture is to be designed for -20°C (-4°F).

This corresponds approximately to a 50/50 mixture anti-freeze and water (please observe the instructions of the coolant manufacturer).

If the recommended coolant is not available, water can be used temporarily. However, refill with the recommended coolant at the first opportunity.

Cleaning and preserving

Frequent and thorough cleaning not only improves the appearance of your motorcycle but also improves its overall operating performance.

The life expectancy of many engine components will be increased and corrosion prevented.

1. Seal the end pipe of the exhaust to prevent water entering.
   
   The following areas are to be protected from water getting in
   • carburettor and the intake area below the seat,
   • wheel hubs, brake caliper,
   • instruments, ignition switch,
   • driving chain.
   • exhaust outlet,
   • main brake cylinder,
   • handlebar switches.
   • space under the seat fairing (ignition box, fuse holder),
   • lower fixing eye of the shock absorber.
2. Make sure the spark plug and all filling caps are securely closed.
3. Soften up heavy soiling with copious water before the actual washing process.
4. Use detergents which do not attack the paintwork or other protective surface layers to remove dirt. Pay attention to the information provided by the manufacturer of the cleaning substance.
   A brush helps to clean heavily soiled places.
5. Thoroughly rinse dirt and cleaner off with water.

ATTENTION High pressure water, e.g. from a high-pressure cleaner, can damage components of the motorcycle. Therefore only clean with a low-pressure water jet!

6. Immediately after washing, dry all surfaces with compressed air or a soft cloth.
7. Dry the chain and lubricate it straight away with chain spray to prevent rust formation.
8. Clean the seat with a vinyl upholstery cleaner to keep the cover soft and shiny.
9. Car wax can be applied to all the painted and chromium-plated parts of the motorcycle. Compound cleaning and waxing agents should not be used.
10. Remove the end pipe seal.
11. Start the engine and go for a short test ride.
12. Treat the exhaust system with a care product for stainless steel.
13. Slide back the protective caps on the operating levers on the handlebars, dry the surfaces underneath and lubricate the joints.

WARNING Risk of accident! Directly after washing, the braking efficiency may be reduced. Until you have dried the brakes by light braking, keep a suff icient distant from the vehicles in front of you to allow for longer braking distances! Environment Ensure that you dispose of the waste water according to the regulations.

Storage

If you are going to störe your motorcycle for an extended period (30 days or more) then a number of precautionary measures must be taken to prevent any damage during this period. After the motorcycle has been thoroughly cleaned, prepare the motorcycle for storage as follows:

1. Empty the fuel tank, the fuel line and the float housing of the carburettor.
2. Check the level of the coolant and its antifreeze content, top up if necessary.

ATTENTION Avoid making sparks. When using the starter just to rotate the crankshaft, the spark plug cable must be removed and grounded so that there are no sparks.

3. Remove the spark plug, squirt a little engine oil SAE 10W40 or SAE 10W50 into the spark plug hole, then replace the spark plug. Turn the engine over a few times with the starter (ground the ignition cable) in order to distribute the oil over the cylinder walls.
4. Thoroughly clean the driving chain and grease it.
5. Lubricate the bowden cables.
6. Oil the joints of the operating levers and foot rests.
7. Adjust the tyre pressure to that correct for one rider.
8. Put the motorcycle on stands so that both wheels are off the ground.
9. When storing in humid or saity air, all exposed metal surfaces must be protected by a light film of oil. Do not allow oil to come into contact with rubber components or the seat.
10. Treat plug and socket parts of the cable tree with a contact care substance.
11. Remove the battery, recharge it and store it in a dry place. It must be recharged once a month. The battery must not be stored at either very high or very low temperatures (over 30°C/86°K or below 0°C/32°K).

ATTENTION All necessary repairs should be made before putting the motorcycle into storage. Do not start the engine during the storage period!

Recommissioning after storage

1. Charge the battery and install it ensuring that the polarity is correct (black cable without protective cap - minus, black cable with protective cap and thin red positive cable).
2. Fill the tank with new petrol.
3. Check the oil level.
4. Check the coolant level.
5. Check the brake fluid level.
6. Change the engine oil and the oil filter after a longer period of storage (more than one year.
7. Check the tyre pressure.
8. Check operating safety and roadworthiness in accordance with the road traffic regulations.

Self help

On-board tool kit

The on-board tool kit is located in a tool bag beyond the seat.

The on-board tool kit contains:

1. spark plug spanner ^* with rubber insert for fixing the loose spark plug
2. ring spanner 24, 2 items
   ring spanner 22, 1 item
3. open-jawed spanner 32, 2 items for adjusting the suspension spring preload
4. open spanner 13x17
5. hexagon socket head wrench 5
6. reversible screwdriver, also to be used as a pin for the spark plug spanner.

^* attaching to the ring spanner (2) or the open-jawed spanner 32 (3) ensures better lever

Changing the tyres

A tyre change can only be performed by an authorised workshop, because they have the necessary equipment.

Changing spark plugs

To change the spark plug please perform the following steps:

1. Switch off the ignition
2. Remove the spark plug cap (1)
3. Poke a wire through the spark plug space drain borehole (2) so that any water in the spark plug space drains out.
4. Screw the spark plug out with the spark plug spanner (with rubber insert) using the reversible screwdriver as a tommy bar.
5. Clean the spark plug if necessary, check the spark gap (0,7 mm, 0.027 in) or replace the spark plug.
6. Clean the plug gasket before reinserting.
7. Screw the spark plug in with a spark plug spanner.
8. Replace the spark plug cap.

Replacing fuses

The fuse box (1) is located under the seat. Remove the seat to gain access.

WARNING Danger of fire and risk of damages to the vehicle-borne electronics! Using another device as a bypass leads to serious damage to the electrical system or to fire. Never use a fuse with a higher current rating than that specified!

If a fuse blows, turn off the ignition and insert a new one with the correct amperage.

If the new fuse blows please contact an authorised MZ dealer.

Changing light bulbs

ATTENTION Only use light bulbs conforming to the technical specifications supplied. Do not touch the lamps with your bare hands but with a clean, soft towel!

Rear light:

1. Loosen the screws of the rear light and remove the casing.
2. Change the bulb (bayonet socket).
3. Refit the rear light casing.

Indicator light:

1. Remove the screw on the back of the indicator casing.
2. Remove the indicator light bowl.
3. Change the bulb (bayonet socket).
4. Reassemble in the reverse order.

Headlights:

1. Loosen the screws (1) on the right and left side of the headlight casing.
2. Remove the casing.

Do not damage the coating.

3. Pull the plug-in socket (2) off the headlight bulb or the plug-in socket (3) off the parking light bulb.
4. Change the bulb.
5. Reassemble in the reverse order.

Control lights:

1. Unscrew the fixing screws of the direction indicators (1) on either side.
2. Remove the indicator lights and pull off the plug, remove the headlight (2) and the parking light (3) cable.
3. Remove the headlight and lay it down safely.
4. Pull the defective control light out off the tachometer (do not pull on the cable).
5. Press in a new control light.
   Only use original spare lights.
6. Reassemble in the reverse order to that of removal.
7. Check the headlight adjustment.

Instrument illumination:

1. Unscrew the indicator holding screws (1) on either side.
2. Remove the indicator lights and pull off the plug, remove the headlight (2) and the parking light (3) cable.
3. Remove the headlight and lay it down safely.
4. Pull the defective light out off the speedometer (do not pull on the cable!).
5. Press in a new light.
   Only use original spare lights.
6. Reassemble in the reverse order to that of removal.
7. Check the headlight adjustment.

Troubleshooting

Although all MZ motorcycles are subject to strict inspections at the factory before dispatch and are made ready for the road by the dealer, some problems may still arise during operation.

Problems with the fuel system, compression or with the ignition system can impair the starting efficlency and cause a deterioration in performance.

The diagram of the troubleshooting guide shows the procedures that enable the functional areas to be checked easily.

If your motorcycle needs to be required, please take it to your authorised dealer. The qualified mechanics at an MZ dealer have the necessary tools, training and experience to be able to repair your motorcycle expertly.

Only genuine MZ spare parts are to be used for repairs!

DANGER Risk of an electric shock! When working on the ignition system there is danger from the high voltage. Therefore switch off the ignition!

ATTENTION Risk of fire and explosion! Work on the fuel system involves a risk of fire and explosion. Smoking, naked lights and sparks are forbidden. Ensure a sufficient ventilation.

Technical data

Dimensions and weights

Engine

Carburettor

Transmission

Chassis

Electrical installation

Filling amounts and driving performance

Index

A

Accessories
Adjusting the clutch play
Adjusting the headlights
Air filter

B

Baggage
Battery
Brakes
Braking
Bulbs

C

Carburettor
Carrying baggage
Chain care
Chain slack
Changing gear
Changing light bulbs
Changing spark plugs
Changing the oil
Changing the tyres
Chassis
Checking the brake discs
Checking the brake fluid level
Checking the brake pads
Checking the coolant
Checking the oil level
Choke
Cleaning
Cleaning the fuel cock

D

Dimensions
Dipped beam
Driving chain
Driving performance

E

Electrical installation
Engine number
Engine stop button

F

Filling amounts
Foot brake pedal
Front wheel suspension
Fuel cock
Fuel tank cap
Full beam
Fuses

G

Gear change pedal

H

Handlebar adjustments
Headlight
Headlight flasher

I

Ignition lock
Indicator switch
Instrument panel

K

Key number

L

Left handlebar controls

M

Maintenance schedule

O

Oil quantities
Oil types
On-board tool kit
Operating elements

P

Parking light
Protect the environment
Protective clothing

R

Rear wheel suspension
Recommissioning after storage
Refilling the coolant
Refuelling
Replacing fuses
Right handlebar controls
Running in

S

Safe driving
Safe riding
Seat lock
Side stand
Spark plug
Starter button
Starting the engine
Stopping the engine
Storage

T

Tool kit
Transmission
Troubleshooting
Tyre pressure
Tyres

V

Vehicle identification number

W

Weights
Winter driving instructions

Notes

Wiring Diagram

LEGEND

K1	39-34.009 Cable harness
K2	39-34.022 Positive cable
K3	39-34.023 Ground cable
K4	Starter cable
K5	Cable - pick up
K6	Sidestand cable
K7	Cable, handlebar controls, left
K8	Cable, handlebar controls, right
K9	Cable, ignition and steering lock
K10	Cable wireness for instruments
1	Headlight
1a	Low beam
1b	High beam
1c	Parking light
2	Front stop light switch
3	Instruments / Tachometer
3a	Oil pressure warning light
3b	Flasher control light
3c	Idling speed pilot lamp
3d	High beam pilot lamp
3e	Temperature warning light
3f	Tachometer lighting
4	Handlebar controls, left
4a	Light switch
4b	High beam / Low beam
4c	Headlight flasher
4d	Indicator lights
4e	Horn
5	Handlebars controls, right
5a	Engine stop switch
5b	Starter switch
6	Ignition switch
7	Front indicator, left
8	Front indicator, right
9	Sidestand switch
10	Horn
11	Fan
12	Thermoswitch
13	Ignition unit
14	Starter relay
15	Starter motor
16	Rectifier / regulator
17	Ignition coil
18	Spark plug
19	Cut-off relay
20	Flasher unit
21	Battery
22	Fuse box
23	Rear stop light switch
24	Engine
25	Neutral gear switch
26	Engine ground point
27	Rear light (BSKL)
28	Rear indicator, right
29	Rear indicator, left
30	Back current barrier diode 3A type
31	Back current barrier diode 3A type
32	Back current barrier diode 3A type
33	Oil pressure
34	Back current barrier diode 3A type
35	Speed sensor
A	Parallel connector 15 front
B	Parallel connector 15 rear
C	Parallel connector, ground front
D	Parallel connector, ground rear
F	Parallel connector, left indicator
G	Parallel connector, right indicator
H	Parallel connector, ground
	Detachable connection
	Permanent connection
	Flat plug connector
	Round plug connector

COLOR CODE