The provided document is a service manual for the Vertigo Combat motorcycle, detailing its various models, technical specifications, and maintenance procedures.
The Vertigo Combat is described as a powerful, lightweight, and versatile motorcycle, expertly designed for both pleasure and performance. Its core principles emphasize lightness, power, and versatility, alongside reliability and a strong Trial pedigree. All components, including the gearbox, starter, water pump, and chassis, have undergone rigorous testing in demanding conditions for over two years to ensure reliability. A critical design aspect was its compact size, which enhances control, maneuverability, and the ability to tackle challenging sections. This was achieved through a specially designed fan, radiator, water pump, and a compact engine, all contributing to reduced overall dimensions.
Important Technical Specifications:
The manual details three main models: Camo Works, Combat Ice Hell, and Combat Titanium R, each with specific variations.
Engine:
- Type: 2-stroke engine across all models.
- Engine Size: Available in 247cc EFI, 250cc EFI (Titanium R only), and 300cc EFI.
- Power:
- 247cc/250cc EFI: 25 hp at 9200 rpm
- 300cc EFI: 31 hp at 9200 rpm
- Torque:
- 247cc/250cc EFI: 4.0 kg.m at 4500 rpm
- 300cc EFI: 4.9 kg.m at 4500 rpm
- Compression:
- 247cc/250cc EFI: 8.8:1
- 300cc EFI: 8.7:1
- Stroke:
- 247cc/250cc EFI: 72.5x60mm
- 300cc EFI: 79x60mm
- Crankcase: Aluminium (Camo Works, Combat Ice Hell) or Magnesium (Combat Titanium R).
- Gearbox: 6-speed gearbox, with 4 trial-developed gears, each ECU controlled.
- Transmission: 9z/38 (Camo Works) or 10z/42 (Combat Ice Hell, Combat Titanium R).
- Clutch: Multi-disc oil wet.
- Exhaust Muffler: Symmetric and centered silencer.
- Manifold: Stainless steel (Camo Works, Combat Ice Hell) or Titanium (Combat Titanium R).
- Radiator: Vertigo special design, adapted to frame shape.
- Control Unit: Vertigo design, controlling gear position, engine temperature, pressure, petrol pump, water pump, and electric timing. Integrated injection driver.
- Engine Sensors: Barrel gearbox sensor (controls each engaged gear), Protocol CAN 2.0 B, TPS (Throttle Position Sensor), PWM water pump control.
- Powerbox ECU: Vertigo design, controls all electrical power, protects components from short circuits.
Frame:
- Materials:
- Camo Works: 25CRMO4 steel + aluminium 6082
- Combat Ice Hell: 15CDV6 steel + aluminium 6082
- Combat Titanium R: Titanium GR5 + aluminium 6082
- Swingarm: Aluminium cast (Camo Works, Combat Ice Hell) or Magnesium cast (Combat Titanium R).
Suspension:
- Front Suspension: Tech Alu black 170mm stroke (Camo Works) or Tech Alu gold 170mm stroke (Combat Ice Hell, Combat Titanium R).
- Rear Suspension: Monoshock/swingarm, Vertigo special swingarm combined with multi-regulation REIGER monoshock with rebound adjustment (Camo Works, Combat Ice Hell). Combat Titanium R adds high/low speed compression adjustment. All have 170mm stroke.
Other Specifications:
- Airbox: High capacity 1.1L upper airbox.
- Petrol Tank: 2.3L, low and centered gravity position, hidden from damage.
- Handlebar: Vertigo (Camo Works, Combat Ice Hell) or Renthal Fatbar (Combat Titanium R).
- Front Brake: Hydraulic Braktec system with 185mm disc, 4 pistons.
- Front Rim: Morad 1.60 x 21".
- Rear Brake: Hydraulic Braktec system with 150mm disc, 2 pistons.
- Rear Rim: Morad 2.15x18" (Camo Works, Combat Ice Hell) or Morad 2.15x18" lightweight mechanized (Combat Titanium R).
- Rear Axle: Standard chain adjustment (Camo Works, Combat Ice Hell) or Single action snail-cam chain adjustment (Combat Titanium R).
- Weight: 69 kg (Camo Works), 68 kg (Combat Ice Hell), 65 kg (Combat Titanium R).
- Total Length: 2010mm.
- Distance Between Axes: 1310mm.
- Seat Height: 680mm.
Usage Features:
The motorcycle's engine performance is highlighted as spectacular, delivering 31 hp at 9200 rpm with impressive torque and power delivery, instilling confidence on demanding terrain. The 6-speed gearbox features 4 trial-specific ratios and 2 top gears for road or trails (top speed limited to 110 km/h), with each gear having 4 different and unique injection maps for diverse power options. The suspension is designed for both pleasure and performance, offering incredible traction. The large diameter clutch diaphragm provides smooth and progressive action, ensuring good rider control and instant response.
Maintenance Features:
The manual provides detailed maintenance charts and procedures, emphasizing safety and the use of authorized Vertigo dealers for complex tasks.
- General Maintenance: Includes periodical checks for tires, wheels, braking system, brake pads, brake fluid, suspension forks, rear shock absorber, drive sprockets, drive chain, frame, steering bearing, nuts and bolts, clutch system, clutch fluid, transmission oil, cooling system, coolant, cylinder-piston, cylinder head, electrical connections, battery, throttle cable, air filter, spark plug, and fuel circuit.
- Suspension System Maintenance: Rear suspension maintenance is recommended to be performed by the manufacturer. Front suspension maintenance involves oil seal changes, oil replacement (using OJ 01 (SAE 5) oil), and specific torque values for reassembly (e.g., 19.6 ÷ 23.5 Nm for end cap, 10 ÷ 12 Nm for end cap screw). Oil level tolerance is ± 1 mm.
- Suspension Adjustments: Models vary in adjustment capabilities. Camo, Ice, and Titanium R all have preload spring, extension, and slow response compression adjustments. Ice and Titanium R also feature high response compression adjustment. Compression can be adjusted for low and high speed, with a maximum of 24 clicks. Rebound adjustment offers about 50 clicks. Spring preload can be adjusted based on driver weight.
- Brake System Maintenance: Brake fluid type is DOT 4. Procedures for front and rear brake lever adjustment are provided, including loosening/tightening screws and adjusting free play. Brake fluid level verification is done via spy-holes. Brake pads should have a minimum of 2mm thickness.
- Frame Maintenance: Regular inspection for damage after accidents and periodic screw checks are recommended.
- Engine System Maintenance: Tightening torques must be checked periodically. Engine oil capacity is 375 ml, using CASTROL TRANSMAX Z. Spark plug type is BPMR6A, with an electrode gap of 0.7 mm.
- Cooling System Maintenance: Total coolant capacity is 600ml. Castrol Radicool SF Premix is recommended for Camo and Ice Hell models, with specific magnesium crankcase coolant for magnesium crankcases.
- ECU Tunning: The dealer kit includes Winjall Software, Biker Software, Tuneware file, USB Dongle with a yearly renewable license, and a USB-FTDI serial interface cable. Software installation involves specific steps, including copying files and connecting an external 12V battery to prevent ECU damage during updates. Winjall allows monitoring engine state, calibrating gear position and throttle position sensors, and modifying ignition advance and injection maps within specified ranges. The software also features a control panel with various graphs (bargraphs, panels, meters, scopes, ledgraphs) for real-time data display.
- Maps Selection: The ECU offers 4 different maps, each with a distinct flash frequency on the LED MAP indicator: Map 1 (standard), Map 2 (drier), Map 3 (medium altitude), and Map 4 (high mountains). The map selection resets to Map 1 when the motorbike is shut down or the engine stops unintentionally.
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