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DB Motors · Two-stroke single, premix, chain drive

Pirat (50 cc)

Library entry covers 2005-2010

28 factory 52 guideline

Published source

DB Motor ZZ-Super Sport-Pirat Owner's Manual, Periodic Maintenance Operation List p.26

Factory owner's handbook. Covers DB Motor ZZ / Super Sport / Pirat owner's manual (names Pirat AC and Pirat LC).

80 items for a 2010 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2010 DB Motors Pirat (50 cc)

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,000 mi or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 mi or 12 months

11 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

8 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 12,000 mi or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 4 h

17 items

Change engine oil

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check exhaust is well fastened

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours; also annually or after 20 hours by dealer
Check the condition of the electrical wiring

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the engine oil level

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the spark plug and electrode gap / replace as necessary

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Make sure the screws are tight

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check air filters and filter housing

Fuel and air

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the carburetor is correctly fastened

Fuel and air

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours; also annually or after 20 hours by dealer
Check the chain, sprockets and chain guide

Final drive

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the efficiency of the front fork

Front end

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the steering play

Front end

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check and adjust the rear shock absorber

Rear suspension and frame

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours; also annually or after 20 hours by dealer
Check the rear swing arm

Rear suspension and frame

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours; also annually or after 20 hours by dealer
Check brake pad thickness

Brakes

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Check the integrity of wheel bearings

Wheels and tires

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours; also annually or after 20 hours by dealer
Check the spokes and rims

Wheels and tires

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours
Adjust and lubricate the cables

Controls and cables

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. After 4 hours

Every 20 h or 12 months

5 items

Check the exhaust muffler

Engine

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Annually or after 20 hours (dealer)
Check carburation with engine warm

Fuel and air

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Annually or after 20 hours (dealer)
Empty and clean the carburetor float chamber

Fuel and air

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Annually or after 20 hours (dealer)
Clean and grease the steering

Front end

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Annually or after 20 hours (dealer)
Clean and grease the rear swing arm/frame coupling areas

Rear suspension and frame

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Annually or after 20 hours (dealer)

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

6 items

Clutch (S6S and S6C engines only)

Primary and gearbox

Factory

Factory: Read the instructions carefully
Clean and lubricate the chain

Final drive

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Before each use
Correctly adjust the chain tension

Final drive

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Before each use
Check brake drum shoes

Brakes

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Before each use
Check the stroke and efficiency of the brake lever

Brakes

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Before each use
Check the tires and their pressure

Wheels and tires

Factory

Factory: Periodic maintenance operation list for race use (bikes used for fun can extend these periods): columns before each use, after 4 hours, annually/after 20 hours. Before each use

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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