This document is an owner's manual for the Braaap ST-160 and ST-250 motorcycles, providing essential information for safe operation, maintenance, and warranty servicing.
Function Description
The Braaap ST-160 and ST-250 are motorcycles designed for transport and riding pleasure. The manual covers their operation, from starting the engine and shifting gears to braking and parking. It also details various components and their functions, such as the handlebar instruments, fuel system, and lighting.
Important Technical Specifications
- Engine: 4-stroke engine.
- Transmission: The ST-250 model features a 5-speed gear transmission with a clutch grip. The ST-160 model has automatic transmission and does not require clutch action for start-up or operation.
- Fuel: Recommended fuel is 93 or 95 (GB17930-1999) unleaded petrol. Ethanol gasoline (90 or higher conforming to GB18351-2004) can be used, but methanol gasoline is not recommended.
- Engine Oil: High-quality 4-stroke engine oil is required. Recommended viscosity levels are SAE15W-40, SAE10W-30, and SAE5W-30, with SE or SF level SAE10W-30 4-stroke lubricant specifically recommended. Oil volume for replacement is 850ml, or 1300ml for regular servicing.
- Spark Plug: Gap should be between 0.6 - 0.8 mm.
- Valve Clearance: Intake valve clearance: 0.04-0.05 mm; Exhaust valve clearance: 0.05-0.06 mm.
- Brakes: Front brake is a disk brake. Rear brake pedal applies the rear wheel brake. Hydraulic brake system uses SAE J1703 brake fluid.
- Tyres: Tread pattern depth should be checked: front wheel 1.6mm or less, rear wheel 2mm or less, requiring replacement if below these limits.
- Electrical System: Equipped with a 15A fuse. Bulbs should be replaced with new ones of the same rating.
- Serial Numbers: Chassis number (VIN code) is on the riser pipe of the chassis. Engine number is on the left side of the crankcase. A metal nameplate on the riser pipe shows main technical parameters and production date.
Usage Features
- Safety: Emphasizes wearing a safety helmet and protective clothing, using safe driving techniques, understanding safe driving speeds, and exercising caution in wet weather. A pre-driving inspection checklist is provided.
- Ignition Switch: Three positions: OFF (circuits disconnected, key removable), ON (ignition on, engine startable, key not removable), and Parking (tail and front parking lights on, key removable, for roadside parking).
- Handlebar Controls:
- Clutch Grip (ST-250 only): Used to release the drive system for starting and shifting gears.
- Rear-view Mirrors: For visibility.
- Left Handlebar: Contains dimmer switch (high/low beam), turn signal switch (left/right), and horn button.
- Speedometer: Displays driving speed in km/h.
- Odometer: Records total distance traveled.
- Ignition Switch: As described above.
- Right Handlebar: Contains engine shutdown switch, front brake lever, electric start button, and headlight switch.
- Front Brake Lever: Applies the front wheel brake.
- Accelerator: Controls engine speed.
- Gear Lever: 5-speed transmission (ST-250 only). Neutral gear is between first and second.
- Side Stand: For parking the motorcycle.
- Carburettor Enrichment Lever: Used to start a cold engine. Plunger type is raised to highest position; wire type is pushed forward to end position.
- Kick Start Lever: Located on the right side of the engine, can start the engine in any gear if the clutch is released (ST-250 only).
- Fuel Switch: Manual fuel valve with three positions: OPEN (normal fuel flow), RESERVE (access to reserve fuel when low), and CLOSED (after engine shut down).
- Rear Shock Absorber: Adjustable with five options, default setting is 2.
- Tool Kit: Located on the rear left side of the vehicle.
Maintenance Features
- Regular Maintenance Schedule: Provided in a table based on odometer readings or months, whichever comes first. Key intervals include 300km, 1,000km, 3,000km, 5,000km, and 7,000km.
- Lubrication Schedule: Specific components like accelerator wire, clutch wire, speedometer wire, driving chain, brake cam shaft, accelerator grip, brake wire, speedometer gear case & wheel bearing, and steering gear have recommended lubrication intervals.
- Battery: Conventional batteries require electrolyte level checks monthly and refilling with distilled water if low. Maintenance-free batteries do not require topping up but need full recharging before use and monthly/bi-monthly recharging during storage.
- Spark Plug Maintenance: Clean carbon deposits every 3,000km, replace every 6,000km.
- Engine Oil and Oil Filter: Replace engine oil and oil filter after the first 300km and every 3,000km thereafter.
- Brake Adjustments: Front brake lever free play should be 5-10mm. Hydraulic brake system checked daily for leakage, cracks, and spring back force. Brake lining checked for wear. Brake fluid level checked and replenished with SAE J1703 brake fluid.
- Rear Brake Light Switch: Adjustable to ensure light comes on before pressure is felt.
- Muffler: Keep clear to avoid burns after driving.
- Fuse: Located in a fuse box on the right side of the chassis. Spare fuse (15A) provided.
- Bulb Replacement: Replace with new bulbs of the same rating.
- Air Filter: Cleaned every 3,000km, more frequently in dusty conditions. Instructions for cleaning foam and paper type filters are provided.
- Carburettor: Idle speed adjustment (1400 ± 100 rpm) and accelerator wire clearance adjustment (0.5 - 1.0mm) are detailed.
- Valve Clearance: Checked and adjusted while the engine is cool, especially after the first 1,000km.
- Clutch Adjustment (ST-250 only): Clutch grip cable clearance should be 4mm.
- Drive Chain: Tension adjusted every 1,000km, maintaining 20-30mm of slack. Cleaned and lubricated every 1,000km.
- Tyres: Pressure and tread pattern checked after the first 1,000km and every 3,000km, and regularly thereafter.
- Storage: Instructions for long-term storage, including cleaning, fuel tank emptying, tyre pressure maintenance, and battery removal/recharging. Post-storage maintenance steps are also outlined.
- Troubleshooting: A table lists common engine problems, possible causes, and remedies.
- Lifetime Warranty Logbook Servicing: A detailed logbook for recording service dates, kilometers/time from purchase, and service intervals/maintenance performed, with spaces for dealer stamps. This logbook extends up to 115,000 km or 120 weeks.
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