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Husqvarna TE 125 Workshop Manual

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Workshop Manual
TE 125 2011
SMS4 2011
Part. N. 8000H4704 (07-2010)

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  • Page 1 Workshop Manual TE 125 2011 SMS4 2011 Part. N. 8000H4704 (07-2010)
  • Page 2 HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the ma- nual may differ from actual components. No reproduction in full or in part without written authorisation.

  • Page 3: Foreword, Table Of Contents

    FOREWORD, TABLE OF CONTENTS Workshop Manual TE 125 2011 SMS4 2011 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com 1st edition (07-2010) Printed in Italy Print no.
  • Page 4 FOREWORD, TABLE OF CONTENTS Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.

  • Page 5: Table Of Contents

    FOREWORD, TABLE OF CONTENTS Table of Contents Title Section Foreword, table of contents ................. a Important notices ....................b General information .....................A Engine Technical data ..................F Engine overhaul....................F1 Engine Maintenance ..................F2 Engine cooling ....................F3 Carburettor ......................F4 NOTES Unless otherwise specified, data and specifications apply to all models. Part.
  • Page 7 GENERAL INFORMATION Section Part. N. 8000 H4704 (07-2010)
  • Page 8 GENERAL INFORMATION Engine ......................A.3 Timing system ....................A.3 Fuel system ....................A.3 Lubrication ....................A.3 Cooling ......................A.3 Ignition system....................A.3 Starter ......................A.3 Drive and Transmission ................A.3 Chassis ......................A.4 Suspension ....................A.4 Brakes ......................A.4 Wheels......................A.4 Tyres ......................A.4 Electrical components location ..............A.5 Overall dimensions - Weight .................A.6 Capacities .....................A.7 Part.

  • Page 9: Timing System

    GENERAL INFORMATION Engine Single cylinder, 4 stroke Bore ......................2.05 In. Stroke .....................2.05 In. Displacement ...................7,591 cu.In. Compression ratio ..................11,2:1 Timing system Type........single overhead camshaft; chain operated 4 valve Valve clearance (with engine cold) INTAKE................0.0039 ÷ 0.0055 Inches EXHAUST..............0.0079 ÷ 0.0094 Inches Fuel system Type..................

  • Page 10: Suspension

    GENERAL INFORMATION Final ratios (TE) 1st gear...................... 36,32 2nd gear ....................24,03 3rd gear ..................... 17,48 4th gear ..................... 14,65 5Th gear ....................12,26 6Th gear ....................10,77 Final ratios (SMS) 1st gear...................... 33,24 2nd gear ....................22,00 3rd gear ..................... 16,00 4th gear .....................

  • Page 11: General Information

    GENERAL INFORMATION Cold tyre pressure (TE) Front Rider only .................... 17.07 Psi Rider and passenger ................21.5 Psi Rear Rider only .................... 21.33 Psi Rider and passenger ................25.5 Psi Cold tyre pressure (SMS) Front Rider only .................... 21.33 Psi Rider and passenger ................

  • Page 12: Overall Dimensions - Weight

    GENERAL INFORMATION Overall dimensions - Weight Kerb weight, without fuel (TE-SMS): ........117 Kg (257.94 lb) 800 mm (31,50 inch) * 1450 mm (57,09 inch) 2235 mm (87,99 inch) H02401 *: Max. Width Part. N. 8000 H4704 (07-2010)

  • Page 13: Capacities

    GENERAL INFORMATION 800 mm (31,50 inch) * 1465 mm (57,68 inch) 2200 mm (86,61 inch) H02402 *: Max. Width Capacities Type Quantity Fuel tank, reserve included 98 octane unleaded fuel 9,5 litres (2,09 gal.) Reserve fuel 2 litres (0,44 gal.) Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 1,15 litres (0,3 gal.)

  • Page 15: Important Notices

    IMPORTANT NOTICES Section Part. N. 8000 H4704 (07-2010)
  • Page 16 Section B by having the required SMS4 maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client. The warranty becomes NULL AND VOID if the motorcycle is rented.
  • Page 17 TECHNICAL DATA Section Part. N. 8000 H4704 (07-2010)
  • Page 18 TECHNICAL DATA Technical data: Engine ................. F.3 Technical data: Electrical system..............F.9 Technical data: Tightening torque figures ..........F.10 Technical data: Engine torque figures ............F.11 Technical data: Lubrication points and types of Lubricant ......F.14 Technical data: Diagrams and Tables about the Lubrication System ..F.16 Part.

  • Page 19: Engine Technical Data

    TECHNICAL DATA ENGINE TECHNICAL DATA Engine • Engine type ..........................4-stroke, liquid cooled, SOHC • Displacement ................................124.7 cm3. • Cylinders layout ..........................Single-cylinder tilted forward • Bore x stroke ..........................52.0 x 58.6 mm (2.05 x 2.31 in) • Compression ratio ................................11.20:1 •...
  • Page 20 TECHNICAL DATA Cylinder head • Volume ........................... 9.90-10.50 cm3 (0.60-0.64 cu.in) • Deformation limit ............................0.03 mm (0.0012 in) Camshaft • Transmission system ............................Chain-drive (left) Camshaft lobe dimensions • Intake A ...........................30.225-30.325 mm (1.1900-1.1939 in) • Limit ................................ 30.125 mm (1.1860 in) •...
  • Page 21 TECHNICAL DATA • (Intake) valve face B width ....................1.538-2.138 mm (0.0606-0.0842 in) • (Exhaust) valve face B width ....................1.538-2.138 mm (0.0606-0.0842 in) • (Intake) valve seat C width .....................0.90-1.10 mm (0.0354-0.0433 in) • Limit .................................. 1.6 mm (0.06 in) • (Exhaust) valve seat C width ....................0.90-1.10 mm (0.0354-0.0433 in) •...
  • Page 22 TECHNICAL DATA • Winding direction (intake) ............................Clockwise • Winding direction (exhaust) ............................Clockwise Cylinder • Bore ..........................52.000-52.010 mm (2.0472-2.0476 in) • Wear limit ............................... 52.110 mm (2.0516 in) • Taper limit ..............................0.050 mm (0.0020 in) • Out-of-round limit .............................
  • Page 23 TECHNICAL DATA Scraper ring • Dimensions (B x T) ........................1.50 x 1.95 mm (0.06 x 0.08 in) • Piston ring ends gap (when installed) ..................0.20-0.70 mm (0.0079-0.0276 in) • Ring side play ........................0.040-0.160 mm (0.0016-0.0063 in) Crankshaft • Width A ............................47.95-48.00 mm (1.888-1.890 in) •...
  • Page 24 TECHNICAL DATA • ..................................24/21 (1.143) • ..................................22/23 (0.957) • ..................................21/25 (0.840) • Input shaft offset limit ..........................0.08 mm (0.0032 in) • Output shaft offset limit ..........................0.08 mm (0.0032 in) Gear selector mechanism • Type of gear selector mechanism ....................Gear selector drum and shaft •...
  • Page 25 TECHNICAL DATA ELECTRICAL SYSTEM SPECIFICATIONS Voltage • System voltage ..................................12 V Ignition system • Ignition system .................................TCI (digital) • Ignition advance (BTDC) Ignition coil • Model/manufacturer ............................. 2JN/YAMAHA • Primary coil resistance ..........................1.92÷2.88 Ω at 20° • Secondary coil resistance ..........................
  • Page 26 TECHNICAL DATA TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES GENERAL SPECIFICATIONS The chart contains the tightening torque figures for the standard fasteners with standard ISO thread pitch. Tightening torque figures specifications for special assemblies or components can be found in the relevant chapters of this manual. To avoid deformations, gradually tighten the fasteners in a cross pattern, until reaching the specified tightening torque.
  • Page 27 TECHNICAL DATA ENGINE TORQUE FIGURES Cylinder head tightening sequence: Element Thread Quantity Tightening torque Remarks Cylinder head bolt 22 Nm (2.2 m·kg, 16 ft-lb) Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Spark plug 13 Nm (1.3 m·kg, 9.4 ft-lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Oil level inspection plug...
  • Page 28 TECHNICAL DATA Element Thread Quantity Tightening torque Remarks Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Clutch casing bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Clutch casing bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft-lb) Unidirectional starter bolt 14 Nm (1.4 m·kg, 10 ft-lb) Primary drive gear...
  • Page 29 TECHNICAL DATA Generator cover tightening sequence: Clutch casing tightening sequence: Crankcase tightening sequence: A. Left crankcase B. Right crankcase Part. N. 8000 H4704 (07-2010) F.13...
  • Page 30 TECHNICAL DATA LUBRICATION POINTS AND TYPES OF LUBRICANT ENGINE Lubrication point Lubricant Oil seal lips Bearings Cylinder head bolts seat, thread and washers Water pump assembly O-ring Cylinder head cover gasket Connecting rod big end Piston pin Cylinder inner surface, piston, piston rings grooves and piston rings Balance shaft O-ring Camshaft lobes and rocker arm rollers Decompression chamber cam...
  • Page 31 TECHNICAL DATA Lubrication point Lubricant Starter motor O-ring Unidirectional starter idle gear shaft and unidirectional starter idle gear inner surfa- Unidirectional starter idle gear washer and thrust surfaces Clutch control lever Primary driven gear inner surface Long clutch pushrod Ball and short clutch pushrod Clutch pushrod ball Clutch hub seat and thread Input shaft and sprockets...
  • Page 32 TECHNICAL DATA DIAGRAMS AND TABLES ABOUT THE LUBRICATION SYSTEM ENGINE OIL LUBRICATION CHART Oil pump Oil filter element Crankshaft Camshaft Input shaft Output shaft F.16 Part. N. 8000 H4707 (07-2010)
  • Page 33 TECHNICAL DATA LUBRICATION DIAGRAMS Clutch control lever Input shaft Output shaft Crankshaft Oil filter Oil pump assembly Oil filter To cylinder head Part. N. 8000 H4704 (07-2010) F.17...
  • Page 34 TECHNICAL DATA Camshaft Crankshaft Input shaft Output shaft F.18 Part. N. 8000 H4707 (07-2010)

  • Page 37: Engine Overhaul

    ENGINE OVERHAUL Section Part. N. 8000 H4704 (07-2010) F1.1...

  • Page 38: Engine

    ENGINE OVERHAUL CyLINdER HEAd Oil pump check ..............F1.52 Cylinder head removal..........F1.3 - F1.4 Oil pump assembly ..........F1.52 - F1.53 Cylinder head removal..........F1.5 - F1.6 Oil pump installation ............F1.53 Cylinder head check ............. F1.6 GEARbOx sHAft Camshaft sprocket and timing chain guide Gearbox shaft and stop lever removal F54 check ..................

  • Page 39: Cylinder Head

    ENGINE OVERHAUL CyLINdER HEAd REmOVAL New = part to be replaced upon reassembly Cylinder head removal quen- Operation/parts to remove Quantity Remarks Spark plug cap Disconnect Spark plug Crankshaft end access screw Timing mark access screw Engine assembly nut/bolt (front side) Cylinder head cover Cylinder head cover gasket Clutch cable support...
  • Page 40 ENGINE OVERHAUL CyLINdER HEAd REmOVAL New = Cylinder head removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Timing chain guide (exhaust side) Washer Head clamp screw Head cover clamp screw Reverse removal procedure to install. * Sealant Three Bond No.1215®...
  • Page 41 ENGINE OVERHAUL CyLINdER HEAd REmOVAL 1. Align: • Reference "I" "a" on generator rotor (with the stationary re- ference "b" on the generator cover). Keep the thermostat "1" suspended in a container "2" full of water. (see fig. 01) Rotate the crankshaft anticlockwise. b.

  • Page 42: Cylinder Head Check

    ENGINE OVERHAUL 4. Remove: • Cylinder head • NOTE: • Slacken the bolts in the correct indicated sequence. • Slacken each bolt of 1/2 turn at the time. Once all the bolts have been slackened, remove bolts 1, 2, 4 and 6, then remove the cylinder head with bolts 3 and 5 inserted in their holes. CyLINdER HEAd CHECk 1.

  • Page 43: Camshaft Sprocket And Timing Chain Guide Check

    ENGINE OVERHAUL CAmsHAft spROCkEt ANd tImING CHAIN GUIdE CHECk 1. Check: • Camshaft sprocket. • Over 1/4 of "a" wear tooth Replace as a block the camshaft sprocket, the timing chain and the crankshaft. (see fig. 07) a. 1/4 of tooth b.

  • Page 44: Decompression System Check

    ENGINE OVERHAUL dECOmpREssION systEm CHECk 1. Check: • Decompression system Check the decompression system with the camshaft sprocket and the decompression chamber cam installed in the camshaft. b. Check that the decompression chamber lever "1" moves easily. (see fig. 10) c.

  • Page 45: Cylinder Head Installation

    ENGINE OVERHAUL CyLINdER HEAd INstALLAtION 1. Install: • Cylinder head • Make the timing chain go through the timing chain notch. 2. tighten: • Cylinder head bolts "1" (see fig. 12) • Cylinder head bolts "2" (see fig. 12) • Cylinder head bolt 22 Nm - 2.2 kgm - 16 ft-lb • Lubricate cylinder head bolts and washers with engine oil.
  • Page 46 ENGINE OVERHAUL CyLINdER HEAd INstALLAtION 1. Install: • timing chain tensioner gasket • Timing chain tensioner Apply sealant to the timing chain tensioner bolt threading. • sealant three bond No.1215® b. Slightly press with your hands the timing chain tensioner rod and at the same time rotate it completely clockwise with a thin blade screwdriver "1"...
  • Page 47 ENGINE OVERHAUL 5. Rotate: • Crankshaft (various revolutions clockwise) 6. Check: • Reference " I " "a" • Align the reference " I " on the generator rotor to the stationary reference "b" on the generator cover. • Reference " I " "c" • Align the reference " I " on the camshaft sprocket to the statio- nary reference "d" on the cylinder head. • Misalignment Correct. • Make reference to installation operations mentioned above. 7. Tighten: • Camshaft sprocket bolt • Camshaft sprocket bolt 30 Nm (3.0 mkg, 22 ft-lb) WARNING! • Make sure the camshaft sprocket bolt is tighte- ned to the specified torque to avoid the bolt from loosening and damaging the engine. 8. Measure: • Valve clearance • Not conforming to specifications Adjust. Part.

  • Page 48: Rocker Arms And Camshaft Removal

    ENGINE OVERHAUL ROCkER ARms ANd CAmsHAft REmOVAL Rocker arms and camshaft removal quen- Operation/parts to remove Quantity Remarks Cylinder head Check nut Adjuster screw Camshaft stop Rocker arm shaft Intake rocker arm Exhaust rocker arm Camshaft Reverse removal procedure to install. F1.12 Part.

  • Page 49: Camshaft Check

    ENGINE OVERHAUL CAmsHAft CHECk 1. Check: • Camshaft lobes Discoloured blue/pittings/scratches Replace the camshaft. 2. measure: • Dimensions of camshaft lobes "a" and "b" Not conforming to specifications Replace the camshaft. (see fig. 17) • Camshaft lobe dimensions • Intake A 30.225-30.325mm (1.1900-1.1939 in) •...
  • Page 50 ENGINE OVERHAUL HAS23880 ROCkER ARm ANd ROCkER ARm sHAfts CHECk 5. Calculate: • Rocker arm - rocker arm shaft clearance • Calculate the clearance subtracting the outside diameter of the rocker arm shaft from the inside diameter of the rocker arm. • Not conforming to specifications Replace faulty part(s). •...
  • Page 51 ENGINE OVERHAUL VALVE ANd VALVE spRING REmOVAL New = Valve and valve spring removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Cylinder head Rocker arms/camshaft Valve collet Upper spring seat Valve spring Intake valve Exhaust valve Valve stem seal Lower spring seat Valve guide...

  • Page 52: Valves Removal

    ENGINE OVERHAUL VALVE REmOVAL • The following procedure is applied to all the valves and their components. • Before removing the inside components of the cylinder head (e.g. valves, valve springs and valve seats), check for correct valve sealing. 1. Check: • Valve sealing Loss of valve seal Check valve face, valve seat and width of the valve seat. Pour a clean solvent "a"...

  • Page 53: Valves And Valve Guides Check

    ENGINE OVERHAUL VALVEs ANd VALVE GUIdEs CHECk • The following procedure is applied to all the valves and valve guides. measure: • Valve stem - valve guides clearance Not conforming to specifications Replace valve guide. Valve stem - valve guides clearance = Inside diameter of valve guide "a"...
  • Page 54 ENGINE OVERHAUL After installation, ream the valve guide with its reamer "3" to get the correct valve stem - valve guide clearance.(see fig. 28) • After replacing the valve guide, grind the valve seat. to delete: • Scale deposits (from valve face and seat) Check: • Valve face Pittings/wear Ream valve face.

  • Page 55: Valve Seats Check

    ENGINE OVERHAUL VALVE sEAts CHECk • The following procedure is applied to all the valves and valve seat. 1. to delete: • Scale deposits (from valve face and seat) 2. Check: • Valve seat Pittings/wear Replace cylinder head. 3. measure: •...
  • Page 56 ENGINE OVERHAUL HAS24300 VALVE sEAts CHECk • To obtain the best results when lapping, slightly patter on the valve seat while rotating it back and forth with the hands. e. Apply a fine grain lapping abrasive agent to the valve face and repeat the previous procedures. f. After each lapping operation, remove every trace of lapping abrasive agent from the valve face and valve seat.

  • Page 57: Valve Springs Check

    ENGINE OVERHAUL VALVE SPRINGS CHECK • The following procedure is applied to all valve springs. 1. Measure: • Valve spring "a" free length Not conforming to specifications Replace valve spring. (see fig. 38) • (Intake) free length 41.71 mm (1.64 in) • Limit 39.62 mm (1.56 in) • (Exhaust) free length 41.71 mm (1.64 in) • Limit 39.62 mm (1.56 in) 2.

  • Page 58: Valves Installation

    ENGINE OVERHAUL VALVEs INstALLAtION • The following procedure is applied to all the valves and their components. 1. trim: • End of the valve stem (with the whetstone) 2. Lubricate: • Valve stem "1" • Valve stem seal "2" (with recommended lubricant) (see fig. 42) •...
  • Page 59 ENGINE OVERHAUL 4. Install: • Valve collets "1" • Install the valve collets compressing the valve spring with the suitable tool. 5. To fix the valve collets to the valve stem, slightly patter with a soft mallet on the end of the valve. WARNING! • If you hit valve tip too hard you could damage the valve.

  • Page 60: Piston And Cylinder Removal

    ENGINE OVERHAUL pIstON ANd CyLINdER REmOVAL piston and cylinder removal New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Cylinder head Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Upper piston ring Lower piston ring Scraper ring Reverse removal procedure to install.

  • Page 61: Piston Removal

    ENGINE OVERHAUL pIstON REmOVAL 1. Remove: • Piston pin clips "1" • Piston pin "2" • Piston "3" (see fig. 47) WARNING! • do not use a hammer to remove the piston pin. • Before removing the piston pin clip, cover the opening of the crankcase with a clean cloth to avoid the piston pin clip from falling into the crankcase.

  • Page 62: Piston And Cylinder Check

    ENGINE OVERHAUL pIstON ANd CyLINdER CHECk 1. Check: • Piston wall • Cylinder wall Vertical scratches Replace the cylinder and replace as a block piston and piston rings. 2. measure: • Cylinder - piston clearance Measure cylinder "C" bore with a bore meter. • Measure cylinder bore "C" at (three) different heights; at every height take two measurements at right angle.

  • Page 63: Piston Rings Check

    ENGINE OVERHAUL pIstON RINGs CHECk 1. measure: • Piston rings side clearance Not conforming to specifications Replace the piston and piston rings together. • Before measuring piston rings side clearance, eliminate carbon deposits from piston rings and their grooves. • piston ring •...

  • Page 64: Piston Pin Check

    ENGINE OVERHAUL pIstON pIN CHECk 1. Check: • Piston pin Discoloured blue/grooves Replace the piston pin, then check lubrication system. 2. measure: • Piston pin "a" outside diameter Not conforming to specifications Replace piston pin. (see fig. 54) • piston pin outside diameter 13.995-14.000 mm (0.5510-0.5512 in) •...

  • Page 65: Piston And Cylinder Installation

    ENGINE OVERHAUL pIstON ANd CyLINdER INstALLAtION 1. Install: • Upper piston ring "1" • Lower piston ring "2" • Scraper ring expander "3" • Lower scraper ring "4" • Upper scraper ring "5" (see fig. 56) • Make sure the piston rings are installed with manufacturer references or numbers facing upwards. 2.

  • Page 66: Generator And Unidirectional Starter Generator And Unidirectional Starter Removal

    ENGINE OVERHAUL GENERAtOR ANd UNIdIRECtIONAL stARtER New = part to be replaced upon reassembly Generator and unidirectional starter removal quen- Operation/parts to remove Quantity Remarks Engine oil Sprocket cover Stator coil connector Disconnect. 2 Crankshaft position sensor connector Disconnect. 3 Neutral switch cable connector Disconnect.
  • Page 67 ENGINE OVERHAUL New = Generator and unidirectional starter removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Stator coil Generator rotor Woodruff key Unidirectional starter gear Bearing Washer Unidirectional starter idle gear shaft Washer Snap ring Unidirectional starter idle gear Unidirectional starter unit Reverse removal procedure to install.

  • Page 68: Unidirectional Starter Removal

    ENGINE OVERHAUL GENERAtOR REmOVAL 1. Remove: • Generator rotor nut "1" (see fig. 60) • Washer • Holding the generator rotor "2" with suitable tool "3", slacken the generator rotor nut. • Do not allow the pulley support to touch the protrusion on the generator rotor. 2. Remove: • Generator rotor "1" (with flywheel puller "2") • Woodruff key WARNING! •...

  • Page 69: Unidirectional Starter Check

    ENGINE OVERHAUL UNIdIRECtIONAL stARtER CHECk 1. Check: (see fig. 63) • Unidirectional starter rollers "1" • Unidirectional starter spring caps "2" • Unidirectional starter springs "3" • Damage/wear Replace the unidirectional starter unit. 2. Check: • Unidirectional starter idle gear • Unidirectional starter gear Unevenness/splinters/roughness/wear Replace the faulty parts.

  • Page 70: Generator Installation

    ENGINE OVERHAUL GENERAtOR INstALLAtION 1. Install: • Woodruff key • Generator rotor • Washer • Generator rotor nut • Clean the tapered part of the crankshaft and the generator rotor hub. • When installing the generator rotor, make sure the Woodruff key is correctly fixed in the crankshaft keyway. 2. tighten: • Generator rotor nut "1" (see fig. 66) • Generator rotor nut 70 Nm (7.0 mkg, 50 ft-lb) • Blocking the generator rotor "2" with suitable tool "3", tighten the generator rotor bolt.

  • Page 71: Electric Starting Device

    ENGINE OVERHAUL ELECtRIC stARtING dEVICE starter motor removal quen- Operation/parts to remove Quantity Remarks Starter motor Starter motor cable Disconnect. Reverse removal procedure to install. Part. N. 8000 H4704 (07-2010) F1.35...

  • Page 72: Starter Motor Disassembly

    ENGINE OVERHAUL stARtER mOtOR dIsAssEmbLy starter motor removal New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks O-ring Starter motor rear cover O-ring Switch Starter motor front cover/brush support set Brush Brush spring Reverse removal procedure to install. F1.36 Part.

  • Page 73: Starter Motor Check

    ENGINE OVERHAUL STARTER MOTOR CHECK 1. Check: • Switch Impurity Clean with sand paper of 600 grain. 2. Measure: • switch "a" diameter Not conforming to specifications Replace the starter motor. (see fig. 69) • Limit 16.6 mm (0.65 in) 3. Measure: • Mica "a" coating Not conforming to specifications Scrape off the mica coating until the correct value with a saw blade appropriately grounded, to adapt it to the switch. • Mica coating (depth) 1.35 mm (0.05 in) • The switch mica coating must be made thin to assure the switch correct operation.

  • Page 74: Starter Motor Assembly

    ENGINE OVERHAUL stARtER mOtOR CHECk 5. measure: • Brush "a" length (see fig. 72) Not conforming to specifications Replace the starter motor front cover/brush support set. • Limit 3.50 mm (0.14 in) 6. measure: • Brush spring pressure Not conforming to specifications Replace the brush springs together.

  • Page 75: Clutch Casing Removal

    ENGINE OVERHAUL CLUtCH New = Clutch casing removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Engine oil Disconnect Clutch cable Disconnect Oil filter element cover Oil filter element Clutch casing Clutch casing gasket Dowel pin Oil seal Reverse removal procedure to install.

  • Page 76: Clutch Removal

    ENGINE OVERHAUL CLUtCH REmOVAL Clutch removal New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Check nut Clutch spring Pressure plate Short clutch pushrod Clutch pushrod support Ball Friction plate 1 Clutch plate Friction plate 3 (green) Friction plate 2 F1.40 Part.
  • Page 77 ENGINE OVERHAUL CLUtCH REmOVAL New = Clutch removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Clutch dished plate spring Clutch dished plate seat Clutch hub nut Lock washer Clutch hub Thrust washer Clutch housing Spring washer Reverse removal procedure to install.

  • Page 78: Control Lever Removal

    ENGINE OVERHAUL CONtROL LEVER REmOVAL New = Control lever removal part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Clutch control lever Clutch control lever spring Snap ring Oil seal Bearing Reverse removal procedure to install. F1.42 Part.

  • Page 79: Clutch Removal

    ENGINE OVERHAUL CLUtCH REmOVAL 1. Unbend the lock washer tab. 2. slacken: • Clutch hub nut "1" (see fig. 74) • Blocking the clutch hub "2" with suitable tool "3", slacken the clutch hub nut. fRICtION pLAtE CHECk • The following procedure applies to all friction plates. 1. Check: •...

  • Page 80: Clutch Plates Check

    ENGINE OVERHAUL CLUtCH pLAtE CHECk • The following procedure applies to all clutch plates. 1. Check: • Clutch plate Damage Replace the clutch plates together. 2. measure: • Clutch plate deformation (with a surface plane and a feeler gauge "1") Not conforming to specifications Replace clutch plates together.

  • Page 81: Clutch Housing Check

    ENGINE OVERHAUL CLUtCH HOUsING CHECk 1. Check: • Clutch housing teeth "1" • Damage/pittings/wear Trim the clutch housing teeth or replace the clutch housing. (see fig. 79) • The presence of pittings on clutch housing teeth will cause erratic clutch operation. 2. Check: • Bearing • Damage/wear Replace bearing seat and clutch housing. CLUtCH HUb CHECk 1.

  • Page 82: Clutch Control Lever And Short Clutch Pushrod Check

    ENGINE OVERHAUL CLUtCH CONtROL LEVER ANd sHORt CLUtCH pUsHROd CHECk 1. Check: • Clutch control lever • Short clutch pushrod Damage/wear Replace faulty part(s). pRImARy dRIVE GEAR CHECk 1. Remove: • Primary drive gear • Refer to "BALANCE SHAFT GEAR". 2.

  • Page 83: Clutch Installation

    ENGINE OVERHAUL CLUtCH INstALLAtION 1. Install: • Spring washer "1" (see fig. 82) • Install the spring washer as shown in the figure. 2. Install: • Clutch housing • Thrust washer "1" • Make sure the thrust washer is installed with sharp side "a" opposite to the clutch hub. 3. Install: • Clutch hub "1" • Lock washer "2" •...
  • Page 84 ENGINE OVERHAUL 7. Install: • Clutch dished plate seat "1" • Clutch dished plate "2" • Friction plate 2 • Clutch plates • Friction plates 3 • Friction plate 1 (see fig. 86) • Recommended lubricant • Engine oil • Install the clutch dished plate seat and the clutch dished plate as shown in the figure.
  • Page 85 ENGINE OVERHAUL 9. Adjust: • Clutch mechanism clearance Check that protrusion "a" on clutch control lever "1 " is aligned to reference "b" on the crankcase as shown in the figure, by manually pushing the clutch control lever in "c" direction until it stops.

  • Page 86: Oil Pump

    ENGINE OVERHAUL OIL pUmp Oil pump removal quen- Operation/parts to remove Quantity Remarks Clutch housing Balance shaft drive gear Oil baffle plate Oil pump unit Oil pump drive gear Reverse removal procedure to install. F1.50 Part. N. 8000 H4704 (07-2010)

  • Page 87: Oil Pump Disassembly

    ENGINE OVERHAUL OIL pUmp dIsAssEmbLy Oil pump disassembly quen- Operation/parts to remove Quantity Remarks Oil pump housing cover Oil pump driven gear Oil pump inside rotor Oil pump outside rotor Oil pump housing Reverse removal procedure to install. Part. N. 8000 H4704 (07-2010) F1.51...

  • Page 88: Oil Pump Check

    ENGINE OVERHAUL OIL pUmp CHECk 1. Check: • Oil pump drive gear • Oil pump driven gear • Oil pump housing • Oil pump housing cover Cracks/damage/wear Replace faulty part(s). 2. measure: • Inside rotor - outside rotor end "a" clearance •...

  • Page 89: Oil Pump Installation

    ENGINE OVERHAUL OIL pUmp AssEmbLy • When installing inside rotor, align pin "2" of the oil pump shaft with groove "a" of inside rotor " 1" . 3. Check: • Oil pump operation • Refer to "OIL PUMP CHECK". OIL pUmp INstALLAtION 1. Install: • Oil pump assembly • Oil pump unit screw 4 Nm (0.4 mkg, 2.9 ft-lb) WARNING! •...

  • Page 90: Gearbox Shaft

    ENGINE OVERHAUL GEARbOx sHAft Gearbox shaft and stop lever removal New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Clutch housing Gearbox transmission link Gearbox shaft Snap ring Gearbox shaft spring Stop lever Stop lever spring Oil seal Reverse removal procedure to install.

  • Page 91: Gearbox Shaft Check

    ENGINE OVERHAUL GEARbOx sHAft CHECk 1. Check: • Gearbox shaft Bending/damage/wear Replace. • Gearbox shaft spring Damage/wear Replace. stOp LEVER CHECk 1. Check: • Stop lever Bending/damage Replace. Difficult roller rotation Replace stop lever. • Stop lever spring Damage/wear Replace. GEARbOx sHAft INstALLAtION 1.

  • Page 92: Balance Shaft Gear

    ENGINE OVERHAUL bALANCE sHAft GEAR primary drive gear and balance shaft gears removal New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Clutch housing Primary drive gear nut Balance shaft driven gear nut Washer Primary drive gear Balance shaft drive gear Straight key Lock washer...

  • Page 93: Primary Drive Gear And Balance Shaft Gear Removal

    ENGINE OVERHAUL pRImARy dRIVE GEAR ANd bALANCE sHAft GEARs REmOVAL 1. slacken: • Primary drive gear nut "1" • Place the aluminium plate "a" between the balance shaft drive gear "2" and the balance shaft driven gear "3", then slacken the primary drive gear nut . 2. Unbend the lock washer tab. 3.

  • Page 94: Primary Drive Gear And Balance Shaft Gear Installation

    ENGINE OVERHAUL pRImARy dRIVE GEAR ANd bALANCE sHAft GEARs INstALLAtION 1. Install: • Balance shaft driven gear "1" • Lock washer • Balance shaft drive gear "2" • Primary drive gear • Washer "3" • Balance shaft driven gear nut •...

  • Page 95: Crankcase Separation

    ENGINE OVERHAUL CRANkCAsE New = Crankcase separation part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Engine Cylinder head Cylinder/Piston Clutch housing Oil pump unit Gearbox shaft Starter motor Balance shaft gears Generator rotor Reverse removal procedure to install.
  • Page 96 ENGINE OVERHAUL Crankcase separation New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Chain cover timing chain Oil drain plug spring Engine oil filter Neutral switch snap ring spacer Right crankcase dowel pin Left crankcase Reverse removal procedure to install.

  • Page 97: Bearings And Oil Seal Removal

    ENGINE OVERHAUL bearings and oil seal removal quen- Operation/parts to remove Quantity Remarks Crankshaft/balance shaft transmission Oil seal bearing stop bearing Reverse removal procedure to install. Part. N. 8000 H4704 (07-2010) F1.61...

  • Page 98: Crankcase Separation

    ENGINE OVERHAUL CRANkCAsE sEpARAtION 1. Remove: • Crankcase bolts • Gradually slacken each bolt of 1/4 turn at the time, as indicated in the sequence. 2. Rotate: • Gear selector drum section • Rotate the gear selector drum section "1" to the position shown in the figure. In this position, the gear selector drum section teeth do not touch the crankcase during crankcase separation.

  • Page 99: Timing Chain And Timing Chain Guide Check

    ENGINE OVERHAUL tImING CHAIN ANd tImING CHAIN GUIdE CHECk 1. Check: • Timing chain Damage/stiffness Replace the timing chain and the camshaft sprocket together. 2. Check: • Timing chain guide (intake side) Damage/wear Replace. OIL fILtER CHECk 1. Check: • Oil filter Damage Replace.

  • Page 100: Bearing Stop Installation

    ENGINE OVERHAUL bEARING stOp INstALLAtION 1. Install: • Bearing stop "1" (see fig. 106) • Install the bearing stop "1" with the reference "OUT" "a" facing outside. • Apply the threadlock (LOCTITE®) on the bearing stop bolt threadings. • bearing stop bolt 7 Nm (0.7 mkg, 5.1 ft-lb) LOCtItE® CRANkCAsE AssEmbLy 1. Accurately wash all gaskets and crankcase mating surfa- ces.
  • Page 101 ENGINE OVERHAUL CRANkCAsE AssEmbLy • Gradually tighten each bolt of 1/4 turn at the time, as indicated in the sequence. • M6x70 MM:"7-9", "11" • M6x55 MM:"14","15" • M6x45 MM:"1-5", "10" • A. LEFT CRANkCASE • B. RIGHT CRANkCASE Part. N. 8000 H4704 (07-2010) F1.65...
  • Page 102 ENGINE OVERHAUL CRANksHAft New = part to be replaced upon reassembly quen- Operation/parts to remove Quantity Remarks Crankcase balance shaft Crankshaft F1.66 Part. N. 8000 H4704 (07-2010)

  • Page 103: Crankshaft Check

    ENGINE OVERHAUL CRANksHAft CHECk 1. measure: • Crankshaft misalignment Not conforming to specifications Replace crankshaft, the bearing or both. • Slowly rotate the crankshaft. • Offset limit C 0.030 mm (0.0012 in) 2. measure: • Connecting rod big end side clearance Not conforming to specifications Replace crankshaft. •...
  • Page 104 ENGINE OVERHAUL tRANsmIssION Gear selector forks and drum assembly, transmission removal quen- Operation/parts to remove Quantity Remarks Crankcase Gearbox fork shaft spring Gear selector drum assembly Gear selector fork-R Gear selector fork-C Gear selector fork-L Output shaft assembly Complete input shaft Long clutch pushrod Reverse removal procedure to install.

  • Page 105: Output Shaft Disassembly

    ENGINE OVERHAUL Output shaft disassembly quen- Operation/parts to remove Quantity Remarks Washer 2nd speed gear 6th speed gear Washer 1st speed gear spacer 5th speed gear snap ring safety washer 4th speed gear 3rd speed gear Output shaft Reverse removal procedure to install.

  • Page 106: Gear Selector Forks Check

    ENGINE OVERHAUL GEAR sELECtOR fORks CHECk • The following procedure is applied to all gear selector forks. 1. Check: • Gear selector fork cam roller "1" • Gear selector fork tooth "2" Deformation/damage/scoring/wear Replace the gear selector fork. (see fig. 112) 2.

  • Page 107: Transmission Check

    ENGINE OVERHAUL tRANsmIssION CHECk 1. measure: • Primary shaft misalignment (use a centre square and a dial gauge "1") • Not conforming to specifications Replace the primary shaft. (see fig. 116) • Input shaft offset limit 0.08 mm (0.0032 in) 2. measure: • Output shaft misalignment (use a centre square and a dial gauge "1") •...

  • Page 108: Primary Shaft And Output Shaft Assembly

    ENGINE OVERHAUL PRIMARY SHAFT AND OUTPUT SHAFT ASSEMBLY 1. Install: • Safety washer "1" • Snap ring "2" (see fig. 119) • Make sure of installing a snap ring with the sharp side "a" fa- cing towards the opposite direction of the washer and gear. • Make sure that the ends of the snap ring "b" correspond to the grooves of the splined shaft "c". 2. Install: • Sprocket of 2a "1" • Push the second sprocket inside the primary shaft "2", as shown in the figure. • Mounting depth "a" 106.85-107.05 mm (4.207-4.215 in) GEAR SELECTOR FORKS AND GEAR SELECTOR DRUM UNIT INSTALLATION 1.
  • Page 109 MAINTENANCE Section Part. N. 8000 H4704 (07-2010) F2.1...
  • Page 110 MAINTENANCE Maintenance: scheduled maintenance and lubrication ................F2.3 Maintenance: valve clearance adjustment ....................F2.4 Maintenance: ignition advance check......................F2.7 Maintenance: measuring compression pressure ..................F2.8 Maintenance: engine oil level check ......................F2.9 Maintenance: engine oil change ......................... F2.10 Maintenance: clutch cable clearance adjustment ..................F2.12 F2.2 Part.

  • Page 111: Maintenance: Scheduled Maintenance And Lubrication

    MAINTENANCE INTRODUCTION • This chapter includes all information necessary to perform recommended inspections and adjustments. • Complying with these preventive maintenance procedures will ensure higher reliability and a long life of the vehicle while also minimising the need for costly overhaul interventions. This information applies to both vehicles in use or brand new ones being prepared for sale.

  • Page 112: Maintenance: Valve Clearance Adjustment

    MAINTENANCE VALVE CLEARANCE ADJUSTMENT • The following procedure applies to all valves. • Valve clearance shall be adjusted with cold engine, at ambient temperature. • When measuring or adjusting valve clearance, the piston shall be set at Top Dead Centre (TDC) during the compres- sion stroke.
  • Page 113 MAINTENANCE Measure valve clearance using a feeler gauge. (see fig.04) Not conforming to specs Adjust. Adjust: • Valve clearance Loosen check nut " 1 " . Fit the blade of a feeler gauge " 2" in-between the adjuster screw end and the valve stem tip. (see fig. 05) Turn adjuster screw " 3" in direction "a" or "b" until obtaining the specified valve clearance. (see fig. 06) • Direction "a": Valve clearance increases. • Direction "b": Valve clearance decreases. • Hold the adjuster screw in place and tighten the check nut as specified.
  • Page 114 MAINTENANCE Install: • Crankshaft end access screw (together with O-ring ) • Timing mark access screw (together with O-ring ) Install: • Cylinder head cover gasket. • Cylinder head cover • Spark plug lnstall: • Ignition coil " 4" • Ignition coil bolt: 7 Nm (0.7 m ·kg, 5.1 ft-lb) •...

  • Page 115: Maintenance: Ignition Advance Check

    MAINTENANCE Install: • Spark plug • Spark plug: 13 Nm (1.3 mkg, 9.4 ft-lb) • Before installing the spark plug, clean seal and spark plug mating surfaces. IGNITION ADVANCE CHECK • Before checking ignition advance, check electrical connec- tions of the whole ignition system. •...

  • Page 116: Maintenance: Measuring Compression Pressure

    MAINTENANCE Remove: • Digital rev meter • Stroboscopic lamp Install: • Timing mark access screw (together with O-ring) MEASURING COMPRESSION PRESSURE • An insufficient compression pressure would negatively affect performance. Measure: • Valve clearance • Not conforming to specs Adjust. • Refer to " VALVE CLEARANCE ADJUSTMENT" on page 3-4.

  • Page 117: Maintenance: Engine Oil Level Check

    MAINTENANCE If compression reading is higher than the maximum allowed va- lue, ensure there is no scale on cylinder head, on valve surface and piston crown. Scale Remove. If compression pressure is below minimum allowed value, pour one spoon of engine oil into spark plug bore and take measu- rement again. Refer to the table below. Compression pressure (applying oil to cylinder) Reading Diagnosis Value greater than the one measured with no Worn or damaged piston ring(s) Repair.

  • Page 118: Maintenance: Engine Oil Change

    MAINTENANCE (see fig.14) • Type: SAE 10W-30, SAE 10W-40, SAE 15W-40, SAE 20W-40 or SAE 20W-50 • Recommended engine oil grade: API service type SG or higher, JASO standard MA WARNING! • Engine oil also lubricates the clutch; a wrong type of oil or chemical additives could lead to clutch slipping.
  • Page 119 MAINTENANCE • Engine oil drain plug " 2"; • O-ring " 3"; • Spring " 4"; • Engine oil filter " 5". (see fig.18) Drain: • Engine oil (fully, from crankcase). If the oil filter needs replacing, too, proceed as follows. Remove oil filter element cover "1" and oil filter element "2". Install a new O-ring "3". (see fig.19) Install the new oil filter element and oil filter element cover. • Oil filter element cover bolt: 10 Nm (1.0 mkg, 7.2 ft-lb) Check: • Engine oil filter. Dirty Clean. Install: • Engine oil filter; • Spring • O-ring; • Oil drain plug. •...

  • Page 120: Maintenance: Clutch Cable Clearance Adjustment

    MAINTENANCE Check: • Engine oil level; • Refer to " ENGINE OIL LEVEL CHECK" • Check: • Engine oil pressure. Slightly loosen the oil level inspection plug " 1". (see fig.20) Start engine and let it idle until engine oil starts to filter through the oil level inspection plug. If engine oil does not come out after a minute, stop engine to avoid seizure. Check engine oil channels, the oil filter element and oil pump for damage or leaks. Refer to "OIL PUMP". Start engine after fixing the problem and check engine oil pres- sure again. Tighten the oil level inspection plug as specified. • Oil level inspection plug: 7 Nm (0.7 mkg, 5.1 ft-lb) CLUTCH CABLE CLEARANCE ADJUSTMENT Engine side Loosen check nut "...

  • Page 121: Engine Cooling

    ENGINE COOLING Section Part. N. 8000 H4704 (07-2010) F3.1...
  • Page 122 ENGINE COOLING Cool.: thermostat ............................F3.3 Cool.: water pump ............................F3.4 Cool.: thermostat check ..........................F3.5 Cool.: thermostat installation ........................F3.6 Cool.: water pump disassembly........................F3.7 Cool.: water pump check ..........................F3.8 Cool.: water pump assembly ........................F3.9 Cool.: water pump installation ........................F3.10 F3.2 Part.
  • Page 123 ENGINE COOLING thErmOstat New = thermostat removal part to be replaced upon reassembly quen- Operation/Parts to remove Quantity remarks Coolant temperature sensor connector Coolant temperature sensor Thermostat cover Thermostat Radiator inlet hose Reverse removal procedure to install. Part. N. 8000 H4704 (07-2010) F3.3...
  • Page 124 ENGINE COOLING WatEr PUmP New = Water pump removal part to be replaced upon reassembly quen- Operation/Parts to remove Quantity remarks It is not necessary to remove the water pump, unless coolant level is extremely low or coolant contains some engine oil.
  • Page 125 ENGINE COOLING thErmOstat ChECK Check: • Thermostat Does not open at 80.5-83.5 °C (176.9-182.3 °F) Replace. (see fig.01) Keep thermostat " 1" in a vessel "2" containing water. Slowly warm up the water " 3". Dip a thermometer " 4" in water. Stir water, then look at the thermostat and thermometer reading.

  • Page 126: Thermostat Installation

    ENGINE COOLING thErmOstat INstaLLatION Install: • Thermostat. Install the thermostat with breather hole "a" facing up. (see fig.03) Install; • Copper washer. • Coolant temperature sensor. • Coolant temperature sensor: 18 Nm (1.8 mkg, 13 ft-lb) WarNING! • Pay utmost attention when handling the coolant temperature sensor. • Change any part that has fallen or suffered a strong impact.
  • Page 127 ENGINE COOLING WatEr PUmP dIsassEmBLy New = Water pump disassembly part to be replaced upon reassembly quen- Operation/Parts to remove Quantity remarks Water pump housing cover Water pump housing cover gasket Impeller shaft retainer Impeller shaft Water pump housing plate Water pump housing seal Water pump seal Bearing...
  • Page 128 ENGINE COOLING WatEr PUmP dIsassEmBLy remove: • Water pump seal " 1". • remove the water pump seal from inside the water pump housing "2". (see fig.04) remove: • Bearing "1" • remove the bearing from outside the water pump housing "2".
  • Page 129 ENGINE COOLING WatEr PUmP assEmBLy Install: • Water pump seal " 1" UBI (inside water pump housing "2") • Install water pump seal using the suitable tools. WarNING! • Never lubricate the water pump seal surface with oil or grease. •...
  • Page 130 ENGINE COOLING • Before installing the impeller shaft retainer, lubricate the slit on impeller shaft end with a thin layer of lithium soap-base grease. • Install water pump housing seal, water pump housing plate and impeller shaft retainer as shown. •...

  • Page 131: Carburettor

    CARBURETTOR Section Part. N. 8000 H4704 (07-2010) F4.1...
  • Page 132 CARBURETTOR CARBURETTOR F4.2 Part. N. 8000 H4704 (07-2010)
  • Page 133 CARBURETTOR CARBURETTOR DISASSEMBLY 1. Remove: • floater pin "1" • needle valve "2" • floater "3" • NOTE: Take out the floater pin in the direction shown by the arrow. CARBURETTOR CHECK 1. Check: • carburettor body • float chamber • jet block Cracks/damage Replace 2. Check: • fuel passages • Obstruction Clean. Flush carburettor with a petroleum-base solvent. Do not use corrosive detergent solutions.
  • Page 134 CARBURETTOR 8. Check: • jet needle "1" • main jet "2" • needle jet support "3" • idle jet "4" • idle screw "5" • needle jet "6" Deformation/damage/wear Change Obstruction Clean Blow jets clean with compressed air. 9. Check: • piston valve movement Insert piston valve into carburettor body and move it up and down. Sealing Change piston valve. 10. Check: • fuel hoses Cracks/damage/wear Change. Obstruction Clean. Blow hoses clean with compressed air. CARBURETTOR ASSEMBLY WARNING! • Before assembling the carburettor, wash all parts with a petroleum-base solvent. •...
  • Page 135 CARBURETTOR 3. Install: • float chamber rubber seal • float chamber • idle air screw • Idle air screw loosened by ..turns. 4. Install: • accelerator pump assembly 5. Install: • enricher assembly in release stage CARBURETTOR INSTALLATION 1. Install: • carburettor NOTE: Align protruding part "a" on carburettor to chamfer "b" on intake manifold. 2. Adjust: • idle speed • Idle speed 1750 +/- 50 rpm. 3. Adjust: • accelerator cable clearance Part. N. 8000 H4704 (07-2010) F4.5...
  • Page 136 CARBURETTOR F4.6 Part. N. 8000 H4704 (07-2010)

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