Husqvarna SM 610 2006 Workshop Manual
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Husqvarna SM 610 2006 Workshop Manual

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W orkshop M an u al
S M 6 10, T E 61 0/ 2 0 06
P a rt. N . 8 0 0 0 A 4 6 4 0 (0 4 -2 00 5 )
1

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Summary of Contents for Husqvarna SM 610 2006

  • Page 1 W orkshop M an u al S M 6 10, T E 61 0/ 2 0 06 P a rt. N . 8 0 0 0 A 4 6 4 0 (0 4 -2 00 5 )
  • Page 2 T o the b est kno w led ge o f M V A gu sta M oto rc ycles S .p .A . - V a re se , In c. the m a teria l con tain ed h ere in is a ccu rate as o f the d ate this p ub licatio n w a s a pp roved for prin ting.
  • Page 3 F o rew o rd T his p ub licatio n in ten de d fo r H U S Q V A R N A W orks h o p s h a s b e e n p re pa re d fo r th e p u rpo se of h elp ing the a utho rize d p e rsonn el in the m a in te na nce a nd re pair w ork of the m otorc ycle s h e re w ith d e a lt w ith.
  • Page 4 T E 6 1 0 S M 6 1 0 - W h ere n o t oth e rw ise specified, d ata an d instructio n s re fe r to a ll m o d e ls.
  • Page 5 S u m m a ry C h a p te r S ectio n G e n e ra l M ain ten an ce T ro u b les an d rem ed ies S ettin g s an d ad ju stm en ts G en eral o p era tio n s E n g in e d isass em b ly E n g in e o ve rh au lin g...
  • Page 7 G E N E R A L S e ctio n...

  • Page 8: Table Of Contents

    G E N E R A L T ab le o f C o nten ts E n g in e A .3 T im in g s ys te m A .3 F u e l fe e d in g A .3 L u b ric atio n A .3...

  • Page 9: E N G In E A

    G E N E R A L E N G IN E 4-stro ke, sin gle cylin de r B ore 3.8 5 in . S troke 3.0 1 in . D isplace m e nt 3 5.1 5 cu. in. C o m p ressio n ra tio 11 .1 :1 T IM IN G S Y S T E M...

  • Page 10: T Ra N S M Is S Io N

    G E N E R A L T R A N S M IS S IO N M ulti-plate clu tch in oil b ath 6-spe ed gea rbo x, co ns ta n t m esh g ea r typ e D rive be tw ee n e n g ine and gea rb ox m a in sha ft b y stra ig h t to oth e d g e a rs P rim a ry d rive...

  • Page 11: * F R A M E

    G E N E R A L * F R A M E W H E E L S S in gle -b e am in ste el tu bes of circu la r sectio n splittin g a p p ro x. R im s on lin e w ith the e xha ust;...

  • Page 12: Ig N Itio N S Ys Te M - E Le C Tric S Ys Te M

    G E N E R A L IG N IT IO N S Y S T E M - E L E C T R IC S Y S T E M T h e ig n itio n s ys tem in clu d es th e fo llo w in g e le m e n ts : - G e n e rato r;...

  • Page 13: W E Ig H Ts

    G E N E R A L W E IG H T S (§ )/ D IM E N S IO N S m m S M 610 T E 610 (§): C u rb w eig h t, w ith o u t fu el S M 6 10 .....kg 1 42 (31 3 lbs) T E 6 10 .....

  • Page 14: C A P Ac Itie S

    G E N E R A L C A PA C IT IE S F ue l tan k (rese rve inclu ded) U n lea de d g a so lin e (9 8 R .O .N .) 2.6 4 Im p . G a ll./ 3 .17 U .S . G all. F ue l re serve 2.6 4 Im p .
  • Page 15 M A IN T E N A N C E S e ctio n...
  • Page 16 M A IN T E N A N C E P R E -D E L IV E R Y IN S P E C T IO N D e sc rip tio n O p e ra tio n P re -d e live ry E ng in e oil C o olan t...
  • Page 17 M A IN T E N A N C E P E R IO D IC M A IN T E N A N C E S C H E D U L E S E E P A G E C O U P O N A - C O U P O N B - C O U P O N C -...
  • Page 18 M A IN T E N A N C E P E R IO D IC M A IN T E N A N C E S C H E D U L E S E E P A G E C O U P O N A - C O U P O N B - C O U P O N C -...
  • Page 19 T R O U B L E S H O O T IN G S e ctio n...
  • Page 20 T R O U B L E S H O O T IN G E N G IN E T ro u b le C au se R e m e d y E n g in e d o n t s ta rt o r s ta rts w ith d iffic u lty In ad e q u a te co m p re ss io n 1.
  • Page 21 T R O U B L E S H O O T IN G T ro u b le C au se R e m e d y E n g in e cu ts o u t e as ily 1.
  • Page 22 T R O U B L E S H O O T IN G T ro u b le C au se R e m e d y C lu tc h d ra g 1. E xcessive clu tch a d ju ste r fre e p la y A d just 2.
  • Page 23 T R O U B L E S H O O T IN G F R A M E W H E E L S A N D S U S P E N - S IO N T ro u b le C au se R e m e d y D iffic u lt to tu rn h a n d leb a rs...
  • Page 24 T R O U B L E S H O O T IN G T ro u b le C au se R e m e d y P o o r (fro n t a n d re ar) b ra kin g 1.
  • Page 25 S E T T IN G S A N D A D JU S T M E N T S S e ctio n...
  • Page 26 S E T T IN G S A N D A D JU S T M E N T S T ab le o f C o nten ts A d ju stm e n t o f va lve s p la y D .3 C o m p res sio n ch eck D .3...

  • Page 27: C O M P Res Sio N Ch Eck

    S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f valve s p la y R e m o ve se at, sp oile rs, fue l ta nk, coo lers and e xpa nsio n ta n k a s sh o w n at cha pter G e ne ra l O p era tio ns .

  • Page 28: C Arb U Reto R Ad Ju Stm En T D

    S E T T IN G S A N D A D JU S T M E N T S C a rb u re to r a d ju s tm e n t A djust th e ca rb u re to r w ith w a rm e n gine a nd w ith th e th rottle con tro l in close d p ositio n .

  • Page 29: O Il Ch An G E, Clean In G An D Ch An G In G O Il Filters D

    S E T T IN G S A N D A D JU S T M E N T S O il ch a n g e , c le an in g a n d ch a n g in g o il filte rs D ra in th e o il w ith w a rm en g in e .

  • Page 30: C Lean In G Th E B Ag Filters

    S E T T IN G S A N D A D JU S T M E N T S C le a n in g th e b a g filte rs T he filte rs (1 ) e t (2 ) a re se t o n the righ t sid e be tw ee n th e cover an d the su m p (transm issio n to th e scave ng e pu m p), an d on th e left sum p (tw in-filte r, tra nsm issio n to th e p re ssu re pu m p ).

  • Page 31: R Ep Lace M En T O F Co O Lan T

    S E T T IN G S A N D A D JU S T M E N T S R e p la ce m e n t o f co o la n t S et a vessel u n d er the engine a n d w o rk a s follow s : - rem o ve th e rig h t ra d iator ca p a n d the coo lin g fluid d ra in scre w (A ) se t on the rig ht of th e c ylin d er.

  • Page 32: A Ir Filter Ch E C K An D Clean In G

    S E T T IN G S A N D A D JU S T M E N T S A ir filte r c h e c k a n d c le an in g R e m o ve th e sa d d le . R e m o ve th e R .H .

  • Page 33: T H Ro Ttle Cab Le Ad Ju Stm En T

    S E T T IN G S A N D A D JU S T M E N T S T h ro ttle cab le a d ju s tm en t T o che ck th e co rrect a dju stm ent o f the throttle op era te a s fo llo w s: - rem o ve th e up p er ru bb er cap (1);...

  • Page 34: C Lu Tch Ad Ju Stm En T

    S E T T IN G S A N D A D JU S T M E N T S C lu tc h a d ju s tm e n t T he co n tro l Ie ve r m u st h a ve a 0.1 2 ÷ 0 .2 0 in. id le stro ke be fore be gin nin g to d ise ng a g e the clutch .
  • Page 35 S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f fro n t b rake c o n tro l le ve r a n d flu id le ve l c h e c k O n th e S M 6 10 m od el th e le ver p o sitio n ca n be adjuste d (4 a d ju stm e n ts) fo r an y d river ha nd size .

  • Page 36: A D Ju Stm En T O F Rear Co N Tro L P Ed Al

    S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f rea r c o n tro l p ed a l T h e p o sitio n o f th e re a r b rake p ed a l as reg a rd s the fo o tre st can be ad- ju ste d a cco rd ing to th e p erson al re q uire m en ts.

  • Page 37: S Teerin G B Earin G S P Lay Ad Ju Stm En T

    S E T T IN G S A N D A D JU S T M E N T S S tee rin g b ea rin g s p la y ad ju stm e n t T o en sure m a xim u m sa fety, th e stee ring sh ould alw a ys b e a d ju ste d so tha t th e h a nd le ba rs ro ta te fre ely w itho ut pla y.
  • Page 38 S E T T IN G S A N D A D JU S T M E N T S A d ju stin g th e fo rk a ) C O M P R E S S IO N (L O W E R R E G IS T E R ) S ta nd a rd ca lib ra tio n : -1 2 clicks.

  • Page 39: A D Ju Stin G Th E Sh O Ck Ab So Rb Er D

    S E T T IN G S A N D A D JU S T M E N T S A d ju stin g th e sh o ck ab so rb er sag T he re a r sh ock a b sorb er m ust be a dju sted a ccordin g to th e rid er w e ig h t a nd tra ck conditions.
  • Page 40 S E T T IN G S A N D A D JU S T M E N T S D rive ch ain a d ju stm en t C a rry o u t th e cle a n in g o p era tio n s a s de scribe d in the pe riod ica l m a in ten an ce ca rd .
  • Page 41 G E N E R A L O P E R AT IO N S S e ctio n...
  • Page 42 G E N E R A L O P E R AT IO N S T ab le o f C o nten ts E . 3 F O R E W O R D R em o val o f sa d d le E .
  • Page 43 G E N E R A L O P E R AT IO N S F o rew o rd T he o pe ratio ns d e scrib ed in th is section are refe rre d to th e re m o va l o f th e en gine fro m the m o torc ycle ; fu rth er o p era tion s no t di- rectly con n ecte d to th is scope are located at the en d o f th e ch a p te r.

  • Page 44: R Em O Val O F Sa D D Le

    G E N E R A L O P E R AT IO N S R e m o va l o f s a d d le T urn co u n te rclo ckw ise the re a r fa sten in g p in (1) a nd re m ove th e s a dd le. R e m o va l o f s id e p a n e ls - R .H .

  • Page 45: R Em O Val O F Air Filter B O X An D Carb U Reto R

    G E N E R A L O P E R AT IO N S R e m o va l o f a ir filter b o x a n d ca rb u reto r Lo ose n on the L .H . side the m anifo ld cla m p (1 ) o n th e ca rb u re to r th e n the fron t cla m p (2 ) o n the c ylinde r h e a d;...

  • Page 46: R Em O Val O F C O N Ve Yo Rs An D Fu El Tan K

    G E N E R A L O P E R AT IO N S R e m o va l o f c o n ve yo rs a n d fu e l ta n k C lo se th e L .H . side fue l cock a nd p lace th e R .H . fu e l cock (2 ) o n O F F p o sitio n ;...

  • Page 47: R Em O Val O F Ex H Au St S Yste M

    G E N E R A L O P E R AT IO N S R e m o va l o f e xh au st s ys te m R e m o ve the scre w s (1 ), (2) and th e tw o g ua rds (3) a n d (4 ) fro m th e fro nt e xh au st pipe s a nd fro m th e cen tral e xhau st pipe (N O T E : re a sse m b le th e scre w s (1) a nd (2 ) w ith "LO C T IT E 243 ").

  • Page 48: R Em O Val O F C O O Lin G Syste M H O Ses

    G E N E R A L O P E R AT IO N S R e m o va l o f e le c tric a l c o n n e c tio n s an d sp ark p lu g ca p D e ta ch th e e le ctrical co n ne ction s from the e ng ine to th e m ain w iring harn ess (sta rtin g m o to r cab le, gro un d cab le ba tte ry-e n g in e, ge n era to r cab le s, ne utra l sw itch ca b le ) a n d th e sp a rk p lu g ca p.
  • Page 49 G E N E R A L O P E R AT IO N S O n the L.H . of the en gine, rem ove the bre ath er hose (1), the clutch cable (2), the pin io n guard (3), the m aster link a nd the rear cha in (4).
  • Page 50 G E N E R A L O P E R AT IO N S C o o lin g fa n , ra d iato rs a n d c o o la n t e x p a n sio n ta n k rem o val D isco n n e ct th e co oling fan (1 ) fro m th e m ain w irin g h a rn e ss;...
  • Page 51 G E N E R A L O P E R AT IO N S E n g in e re m o va l fro m th e fram e R e m o ve the u pp e r en gine fa ste ning scre w (1) the n th e p la te (2 ) fro m th e en gin e.

  • Page 52: R Em O Val O F Re Ar Fra M E W Ith Fen D Er

    G E N E R A L O P E R AT IO N S R e m o va l o f re a r fram e w ith fen d e r T h is o p e ra tio n d o esn t con cern th e e ng in e re m o val fro m the m oto rc ycle . R e m o ve th e sa d d le , th e side p an els, the a ir filte r bo x, the fu el tan k, th e ex- h a u st sile n ce r a n d the re a r b rake pu m p gu ard as sh o w n o n pa ge s E .4 , E .5 , E .7 , E .9 , E .1 3 .
  • Page 53 E N G IN E D IS A S S E M B LY S e ctio n...
  • Page 54 E N G IN E D IS A S S E M B LY T ab le o f C o nten ts F .4 D is a ss e m b ly o f g e a r le ve r D isas sem b ly o f altern ato r sid e co ve r F .5 D isas sem b ly o f altern ato r...
  • Page 55 E N G IN E D IS A S S E M B LY S P E C IF IC T O O L S 800 0 89 743 C ran k cas e p u ller 800 0 39 523 F lyw h eel p u ller 800 0 90 662 E n g in e h o ld er...

  • Page 56: D Is Ass E M B Ly O F G E A R Le Ve R

    E N G IN E D IS A S S E M B LY T o facilita te th e jo b , d ra in th e oil fro m th e en gine (a s de scrib ed in the ch ap ter S e ttin g s a n d A d ju stm e nts , p ag e D .5).

  • Page 57: D Isas Sem B Ly O F Altern Ato R Sid E Co Ve R

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f a ltern a to r sid e co ver R e m o ve the cover (1 ) w ith the sta tor (8 m m w re n ch ) a n d w ith th e g a ske t. E xtract th e g e ar w ith clutch (2).

  • Page 58: D Isas Sem B Ly O F Altern Ato R

    E N G IN E D IS A S S E M B LY D is ass e m b ly o f a lte rn a to r a) K ee p th e fly w h e e l (1 ) ste ad y u sing the too l (2) c od e 80 00 39 5 22 , rem ove th e 2 4 m m n u t a nd its w a she r.

  • Page 59: D Isas Sem B Ly O F Th E W Ater P U M P B O D Y

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f th e w a ter p u m p b o d y R e m o ve five scre w s (1 ) (8 m m w rench) re taining th e p u m p h o u sin g (2 ). R em o ve th e b u sh e s (6).

  • Page 60: D Isas Sem B Ly O F Cylin D Er H Ead Co Ve R

    E N G IN E D IS A S S E M B LY D is ass e m b ly o f c ylin d e r - h e a d co ve r R em ove th e u n io n p ip e (1) a nd th e carb ure to r. R e m o ve the va lve reg ister co vers (2) (8 m m w re n ch ).

  • Page 61: D Isas Sem B Ly O F Cylin D Er H Ead

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f c ylin d er h ea d R e m o ve the tw o ca m sh aft g ear scre w s (1) (5 m m w re n ch ). R o ta te th e g e ar (1 );...

  • Page 62: D Isas Sem B Ly O F Valve S

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f va lve s U se va lve sp rin g com p resso r 80 0 0 3 95 2 1 to rem o ve the va lves. B e care ful n o t to d a m a g e th e g aske t surfaces o r the co m b ustio n cha m be r o f th e c ylin- d e r h e a d .

  • Page 63: D Isas Sem B Ly O F P Isto N

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f p isto n H o ld the p isto n a nd co ver th e cra n kcase w ith a cle a n ra g . T he p iston (1 ) is m a rke d w ith a n a rro w o n the e xha u st sid e , in o rd e r to co rre ctly rea sse m b le it.

  • Page 64: D Isas Sem B Ly Clu Tch Co Ve R

    E N G IN E D IS A S S E M B LY D isa sse m b ly c lu tc h c o ve r R em ove all screw s (1 3 p cs.) h o ld in g th e clu tch cove r (1 ). R e m o ve the clutch cover (in ord er to re m o ve th e co ve r, u se a scre w drive r).

  • Page 65: R Em O Val O F Th E Starter M O To R An D H O Ld In G Flan G E

    E N G IN E D IS A S S E M B LY R e m o va l o f th e sta rtin g m o to r a n d h o ld in g flan g e R e m o ve the tw o fa sten ing screw s (8 m m w rench) a n d th e sta rtin g m o to r (1 ).

  • Page 66: D Isas Sem B Ly O F Clu Tch

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c lu tc h S e t a n a lu m in u m sh im a m on g p rim a ry tra nsm ission te eth (in o rd er to preve nt its ro ta tio n ).

  • Page 67: D Isas Sem B Ly If Th E G Earb O X Co N Tro L Sh Aft

    E N G IN E D IS A S S E M B LY D isa ss e m b ly if th e g ea rb o x c o n tro l s h aft W ithd ra w the ra ck an d th e co nne c te d shaft (1) R e m o ve the tw o 4 m m A llen screw s (2 ) an d rem o ve th e p la te (3 ) s p ro cke t o f th e g e ar se ctor (4 ).
  • Page 68 E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c ra n kc as e, c ran k sh a ft a n d la y s h aft P e rfo rm th e fo llo w in g o n th e R .H .
  • Page 69 E N G IN E D IS A S S E M B LY R e m o ve the see ge r ring (7) an d w ith d ra w the pin io n, o p e ra tin g o n th e L.H . cra n kca se.
  • Page 70 E N G IN E D IS A S S E M B LY R em ove th e scre w s lo cking the L .H . to th e R .H . cran kca se. In sta ll th e sp e cia l to o l (A ) n° 8 0 00 89 74 3 an d o p en the cra nkca se s, le verin g on the cra n ksh a ft S e para te th e cra n kca se s w ith the ge arb o x a sse m bly o n th e left o n e.

  • Page 71: D Isas Sem B Ly O F Th E G Earb O X

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f th e g earb o x U sing p lie rs re m ove th e rods (1 ) on w hich the fork s a re h in g e d . R e m o ve the fo rk s.

  • Page 72: D Isas Sem B Ly O F Th E O Il P U M P

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f th e o il p u m p F ro m th e p re vio u sly re m ove d clutch co ve r, rem o ve th e fou r o il pu m p fasten - in g scre w s (1 ) (8 m m w re nch ) th a t se cu re th e cove r, the n rem o ve all the p a rts u p to th e o il pu m p drive sha ft (2 ).

  • Page 73: D Isas Sem B Ly O F Th E Cran Ks H Aft Co M P O N En Ts

    E N G IN E D IS A S S E M B LY D isa ss e m b ly o f c ra n ks h aft c o m p o n e n ts In se rt a p la te (1 ) be tw ee n th e tw o flyw h eel h alve s. U sing a p ress, re m o ve th e co nne cting rod pin, from o n e o f th e flyw h e el ha lve s.
  • Page 75 E N G IN E O V E R H A U L IN G S e ctio n...
  • Page 76 E N G IN E O V E R H A U L IN G T ab le o f C o nten ts G .4 C le a n in g o f c o m p o n e n ts A s s e m b lies G .4 C ylin d er h ead...
  • Page 77 E N G IN E O V E R H A U L IN G T ab le o f C o nten ts C ran k sh aft G .15 C ran k sh aft ru n -o u t G .15 R ep lacin g th e sm all en d b u sh G .16...
  • Page 78 E N G IN E O V E R H A U L IN G C lea n in g o f c o m p o n en ts A ll co m po ne n ts m ust be cle ane d w ith gaso line an d d rie d w ith co m p re sse d air. D u rin g th is o p eratio n in flam m ab le vap o rs b u rst an d m etal p articles m a y b e vio len tly ejected .
  • Page 79 E N G IN E O V E R H A U L IN G C ylin d e r h ea d R e m o ve ca rbo n de po sits from the com bustio n cham b e r u sin g a ro u n d e d scra pe r.
  • Page 80 E N G IN E O V E R H A U L IN G R e p la c in g o ve rsize valve s R e m o ve th e se a ts b y m illin g th e ring s. T a ke gre at ca re n ot to da m a g e the se a t lo ca tio n s in th e he ad .
  • Page 81 E N G IN E O V E R H A U L IN G R e p la cin g th e va lve g u id e C h an g e the va lv e g uid e as follo w s: - P ut th e he a d in a n o ve n hea ted at a te m peratu re a f 2 0 0 °C (3 9 2 °...
  • Page 82 E N G IN E O V E R H A U L IN G V alve sp rin g C h eck the fre e le n g th "L ". If this d oe s no t co rresp o nd to th e p re scrib ed lim its th en substitute th e sp rin g s.
  • Page 83 E N G IN E O V E R H A U L IN G In s p ec tio n o f ro ck er a rm C h eck the clea ran ce be tw een the rocke r arm an d th e ro cke r a rm sha ft.
  • Page 84 E N G IN E O V E R H A U L IN G C a m ro lle r re p la ce m e n t R e p la c e th e ca m ro lle r if, in c o n se q u en c e o f th e rad ial p la y im - p ro ve m e n t (th e n e ed le b ea rin g p in is w o rn ), th e valve p la y exce e d 0 .0 0 6 -0 .0 0 8 in ., b o th fo r th e in ta ke a n d e xh a u s t s id e s.
  • Page 85 E N G IN E O V E R H A U L IN G T im in g c h ain a n d g e ars R e pla ce the chain in pre sence of noisin ess and if th e ch a in te n sio n e r on the cylind er is a t 1 0 clicks of its stroke (A ).
  • Page 86 E N G IN E O V E R H A U L IN G C ylin d e r T h e c ylin d e r lin e r bo re sho uld b e c om p lete ly sm o oth , w ith ou t g ro ovin g o r sco rin g .
  • Page 87 E N G IN E O V E R H A U L IN G G u d g e o n p in -c o n n e c tin g ro d s m all e n d clea ra n c e C lea ran ce at a ssem b ly should be: 0.000 47÷0 .0010 6 in .
  • Page 88 E N G IN E O V E R H A U L IN G P is to n rin g s -c ylin d e r c le a ran c e In tro d u ce th e rin g in to th e lo w er p a rt o f th e c ylin d e r (i.e . w h e re th e re is le a s t w e a r);...

  • Page 89: C Ran K Sh Aft

    E N G IN E O V E R H A U L IN G C o n n e ctin g ro d b ig e n d ra d ial c leara n c e S T A N D A R D W E A R L IM IT 0,2 6-0 ,3 6 m m 0 ,08 0 m m...

  • Page 90: R Ep Lacin G Th E Sm All En D B U Sh

    E N G IN E O V E R H A U L IN G R ep la cin g th e s m a ll e n d b u sh T he bush sh o u ld b e re p la ce d usin g a corre ct size p un ch an d drift. B e fore th e re a sse m b ly a pp ly on the b ush M O L Y B D E N U M B IS U LP H ID E G R E A S E .

  • Page 91: C Lu Tch H O U Sin G -Frictio N D Isc Clearan C E

    E N G IN E O V E R H A U L IN G C lu tc h h o u sin g -frictio n d is c cle a ran ce S T A N D A R D W E A R L IM IT 0,5 5-0 ,7 5 m m 0 ,09 m m...
  • Page 92 E N G IN E O V E R H A U L IN G F o rk c o n tro l d ru m - fo rk p in s c o u p lin g C h e ck th e cle a rance b etw e en the se lecto r pin a nd the se lecto r dru m g roo ve b y m e a su rin g th e tw o cle ara nces w ith a g a ug e.
  • Page 93 E N G IN E O V E R H A U L IN G O il p u m p T he re a re th ree c lea ran ces w hich h ave to b e ch ecke d to e sta b lish w h ethe r th e oil pu m p ne e ds ch a n gin g or no t;...
  • Page 94 E N G IN E O V E R H A U L IN G "K E IH IN " c arb u re to r o ve rh au lin g T ho rou g hly w a sh w ith p e tro l and d ry w ith com p resse d a ir a ll ca rb u re tor co m po ne ts. T h o ro u gh ly cle an a ll je ts a nd d ucts w ith com p resse d a ir o n ly.
  • Page 95 E N G IN E O V E R H A U L IN G C a rb u re to r a d ju stm e n t A djust th e ca rbure tor w ith w a rm e ngine an d w ith th e th ro ttle in clo se d p osi- tion .
  • Page 96 E N G IN E O V E R H A U L IN G N E E D L E V A L V E In spect n e e d le va lve (9 ) a nd va lve sea t (c) G roo ved w e a r (a ): R e p la ce.
  • Page 97 E N G IN E O V E R H A U L IN G JE T N E E D L E In sp e ct je t ne ed le (6). B en ds/W ea r: R e pla ce . S ta nd ard clip po sition : 4th G roov e.
  • Page 98 E N G IN E O V E R H A U L IN G F L O A T E R In sp e ct: - F lo a t (1 0 ). D a m a g e : R e p la ce . A C C E L E R A T O R P U M P In sp e ct: - D ia p h ra g m (a ccelera to r pu m p 1 1 ) (a ).
  • Page 99 E N G IN E O V E R H A U L IN G F u e l d ra in in g T o dra in the fu e l fro m the carb uretor float cham ber, clo se th e L .H . sid e fu el cock (1 , fig.
  • Page 101 E N G IN E R E A S S E M B LY S e ctio n...
  • Page 102 E N G IN E R E A S S E M B LY T ab le o f C o nten ts H .4 G e n e ra l d ire c tio n s R ea sse m b ly o f c ra n k s h a ft H .5 R ea sse m b ly o f tra n s m is s io n H .7...
  • Page 103 E N G IN E R E A S S E M B LY N O T E : If not o th erw ise specifie d , sta n d a rd tig h te nin g to rqu es fo r th e follo w ing th rea d - M 5 x0 ,8 : 5 ,9 N m - 0 ,6 K g m - 4 .3 ft/lb - M 6 x1 : 9 ,3 N m - 0 ,9 5 K g m - 6 .8 ft/lb - M 8 x1 ,2 5 : 2 2 N m - 2 ,3 K g m - 1 6 .6 ft/lb...
  • Page 104 E N G IN E R E A S S E M B LY G en era l d ire c tio n s F or a co rrect re -assem bly follo w in the ad verse se nse w h a t sh o w n fo r dism a ntlin g , h ow e ver pa yin g a sp ecia l atten tion to eve ry op era tion w e spe cifically m entio n.
  • Page 105 E N G IN E R E A S S E M B LY R e as s e m b ly o f cran k sh a ft Lu bricate the cra nkpin w ith m oto r oil an d p lace it in th e flyw h e e l. A lig n th e flo w tro u g h h o le s o f th e en g in e o il.
  • Page 106 E N G IN E R E A S S E M B LY...
  • Page 107 E N G IN E R E A S S E M B LY R e as s e m b ly o f tra n s m is sio n If the g ea r sh afts h ave b een disassem bled, the follo w in g pa rag rap hs sh o w the re assem bly seq uence .
  • Page 108 E N G IN E R E A S S E M B LY ¤ A u xilia ry sha ft In sta ll 2n d spe ed g ea r bu shin g an d lu brica te w ith e ng ine o il. M o u n t: 2 nd ge a r an d pu t g rap hite gre ase o n it (th e sid e w ith slo ts sh o u ld fa ce 3 rd sp ee d ge ar), w as he r an d circlip .
  • Page 109 E N G IN E R E A S S E M B LY R ea sse m b ly o f c ra n k c a s e P osition the L.H . cra n kca se o n th e h o ldin g pla te (se rvice to o l cod e 800 0 906 62 );...
  • Page 110 E N G IN E R E A S S E M B LY A = 28 m m / 1.1 in. M A IN S H A F T B = 25 m m /0.98 in . A U X ILIA R Y S H A F T...
  • Page 111 E N G IN E R E A S S E M B LY A s s em b ly o f g e a r fixin g clip an d g e arb o x c o n tro l s h a ft R e asse m ble th e dru m (1 ) w ith th e screw (2) (2 8 N m -2 ,8 5 K g m -2 0 .6 ft/ Lb + LO C T IT E 2 4 2 ).

  • Page 112: A S Sem B Ly O F C O U N Te Rw Eig H T An D La Ys H A Ft G Ea R

    E N G IN E R E A S S E M B LY A s s em b ly o f c o u n te rw eig h t an d la ysh a ft g e ar Install th e co u n te rw e ig h t (1 ) o n th e la y sha ft u sin g the re late d ke y (th e fla t su rfa ce m u st b e fa ce d o utw a rd );...

  • Page 113: R Ea Sse M B Ly O F Flyw H E E L

    E N G IN E R E A S S E M B LY R e as s e m b ly o f flyw h e el In stall the tim in g system cha in (1 ) on the cra nksha ft; - de g re a se w ith solve nt the cran kcase cone a nd th e co rre sp o n d in g fittin g surfa ce on th e flyw h e el;...

  • Page 114: R Ea Sse M B Ly O F S Ta To R A N D P Ick -U P

    E N G IN E R E A S S E M B LY R e ass e m b ly o f s ta to r a n d p ick -u p M o unt th e sta to r so th a t the ca ble h old in g p la te is in fron t o f th e pick-u p locatio n ;...

  • Page 115: A S Sem B Ly O F S Ta Rtin G M O To R An D S Ta Rtin G

    E N G IN E R E A S S E M B LY A s s em b ly o f sta rtin g m o to r a n d sta rtin g in te rm e d ia te g e a r In stall on th e cra nkca se th e centerin g bushing s an d th e fla n g e (1 );...

  • Page 116: R Ea Sse M B Ly O F P Is To N A N D C Ylin D E R

    E N G IN E R E A S S E M B LY * "d" cu t p osition R e a s s e m b ly o f p is to n a n d c ylin d er F it th e p isto n rin g s a s sho w n in fig u re.

  • Page 117: R Ea Sse M B Ly O F C Ylin D E R H E A D

    E N G IN E R E A S S E M B LY R e as s e m b ly o f c ylin d e r h ea d A lw a ys use a ne w h ea d gasket (1 ) w h en asse m b ling . A sse m b le th e cylind er hea d;...

  • Page 118: R Ea Sse M B Ly O F C A M S H A Ft

    E N G IN E R E A S S E M B LY R e ass e m b ly o f c a m s h aft F it th e ch a in in to th e g e ar (1) w h ile restin g the g ea r o n the in side w all o f th e he ad and w ith th e n o tc h o n th e o utsid e a nd a lig ne d w ith th e h e ad co ver m a ting su rface ;...

  • Page 119: R E As S E M B Ly O F Ca M -C H Ain Te N Sio N Er

    E N G IN E R E A S S E M B LY R e as s e m b ly o f ca m -c h ain te n sio n er B ack the cam ch ain te nsioner pin; - rea ssem b le the ca m chain ten sione r w ith th e screw s (1 ) (4 ,5 N m -0 .4 6 K g m - 3.2 ft/lb);...

  • Page 120: R Ea Sse M B Ly O F W A Te R P U M P Im P E Lle R

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f w ater p u m p im p e lle r M o u n t th e im p e ller (1 ) o n cam sha ft (3 ) w ith n ut (2 ) (5 N m -0 ,5 K g m -3 .7 ft/lb ). R e a s s e m b ly o f c ylin d er h ea d c o ve r M o u n t th e ro cke r a rm a nd p ush in the rocker arm sh aft ;...
  • Page 121 E N G IN E R E A S S E M B LY C lea n th e ga sket surfa ces on bo th the c ylin der hea d a n d th e c ylin d e r h ea d cove r w ith solve n t.

  • Page 122: R Ea Sse M B Ly O F P U M P H O U S In G

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f p u m p h o u sin g G re a se a n d a ssem b le tw o n e w O -R in gs (1 ) o n th e spa ce r (2 ) h o using . M o u n t th e sp a ce r the n asse m b le a n e w e xte rn al O -R ing (3 ) on the spa cer e n d .

  • Page 123: L A Y-Sh A Ft Tim In G

    E N G IN E R E A S S E M B LY L a y-s h aft tim in g In stall the ke y o n the cra nksha ft a n d p lace the drivin g g e a r in p o sitio n . O pe ra te an alo g y fo r th e la y-shaft.

  • Page 124: R Ea Sse M B Ly O F C Lu Tc H

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f clu tc h P la ce a n a lu m in um sh im be tw e en the tee th o f th e p rim ary d rive g e ars, in o rd e r to p re ve n t its rotatio n.

  • Page 125: R E As S E M B Ly O F O Il P U M P An D O Il Filter C Artrid G E

    E N G IN E R E A S S E M B LY R e as s e m b ly o f o il p u m p an d o il filter c artrid g e A sse m b le th e o il p um p in orde r show n in the p icture . F asten th e cove r w ith th e four scre w s (1) (9 N m -0 ,9 K g m -6 .5 ft/lb ).

  • Page 126: R Ea Sse M B Ly O F A Lte Rn A To R C O Ve R

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f altern a to r c o ver R e a sse m b le th e ig n ition co ver (2), w ith th e stato r , b y inse rting the c ente rin g p in (1 ) a n d a n e w g asket;...
  • Page 127 E N G IN E R E A S S E M B LY R e as s e m b ly o f re ar p in io n , n eu tral se n s o r a n d g e a r s h ift p e d a l In stall the re ar pinio n (1) w ith a ne w re ta ining rin g.

  • Page 128: In Stru Ctio N S Fo R Lu B Ric A Tio N

    E N G IN E R E A S S E M B LY IN S T R U C T IO N S F O R A S S E M B L Y A N D L U B R IC A T IO N In s tru c tio n s fo r as se m b ly C O M P O N E N T P R O C E D U R E...
  • Page 129 F R O N T S U S P E N S IO N S e ctio n...
  • Page 130 F R O N T S U S P E N S IO N T ab le o f C o nten ts F ro n t s u s p en s io n In stru ctio n s fo r u se o f Ø 45U S D fo rk G en eral S p rin g tab le F o rkw o rkin g...

  • Page 131: F Ro N T S U S P En S Io N

    F R O N T S U S P E N S IO N F ro n t s u s p en sio n T he fro n t su sp e n sio n u n it is a M A R Z O C C H I U .S .D . te le sco p ic h yd ra ulic fork w ith a dvan ced a xle; 1 .7 7 in. dia m ete r s ta nch ion s. W he e l trave l a lo ng th e legs is 9 .8 4 in.

  • Page 132: In Stru Ctio N S Fo R U Se O F Ø 45U S D Fo Rk

    F R O N T S U S P E N S IO N IN S T R U C T IO N S F O R U S E O F Ø 4 5U S D F O R K G E N E R A L R e m o te h yd ra u lic fork w ith reve rs ed legs w ith static lo a d sp rin g a n d ca rtrid g e m u lti-va lve da m pin g system .

  • Page 133: F O Rkw O Rkin G

    F R O N T S U S P E N S IO N F O R K W O R K IN G T he h ydra ulic s yste m of this fork relies on m ultiva lves; a syste m a lre a d y teste d in th e p ast M A G N U M bu t w ith diffe rent featu res as bo th le g s h a ve th e sa m e settin g.

  • Page 134: G En Eral Ru Les Fo R A P Ro P Er O Ve Rh Au Lin G

    F R O N T S U S P E N S IO N L et s see w h a t h a p p e n s in ea ch leg d urin g R E B O U N D . S prin g reb o u n d a ctio n p u she s the stan ch ion d ow n w ard s, th us ca usin g an o il ne ed in to th e ca rtrid g e (se e F IG .

  • Page 135: M Ain Ten An Ce Re C Om M En Dation S

    F R O N T S U S P E N S IO N M A IN T E N A N C E M ain ten an ce re c om m en dation s T his fo rk is th e re su lt of years of e xp erience m a de o n th e m o st im p o rtan t ra cin g tracks.
  • Page 136 F R O N T S U S P E N S IO N O IL D R A IN F IG .6 B efore re m o vin g th e fo rk le gs fro m th e stee ring cro w n a nd the stee rin g he ad , loosen th e u p p e r p lu g (4 8 ) o f ea c h slide r (7 ) w ith th e 19 -m m w re nc h.
  • Page 137 F R O N T S U S P E N S IO N O IL F IL L IN G F IG . 1 0 P osition th e slider (7) to its end of stroke aga inst the sta n ch io n tu b e (5 -6). P ou r 2 /3 of th e in d icate d oil quan tity into the stanch io n .
  • Page 138 F R O N T S U S P E N S IO N D IS A S S E M B L Y F o llo w th e in stru ction s fro m F IG .6 to F IG . 9, as in dicated in th e a b ov e p a ra g ra p h .

  • Page 139: S Lid Er D Isasse M B Ly

    F R O N T S U S P E N S IO N 4- A ir b le e d in g (F IG .2 3) N O T E P erfo rm this op e ra tion w ith legs fu lly in re bou nd (fro n t w h e e l u p fro m the so il), still fitte d in the m oto rc ycle.

  • Page 140: R Eb O U N D Settin G Ch An G E

    F R O N T S U S P E N S IO N 2- S ta n ch io n d is as s e m b ly F IG . 2 4 F ix th e slider of th e sta n ch io n tu b e (5 -6 ) into a vice eq uip p ed w ith pro te ctio n jaw s.

  • Page 141: D Am P In G U N It Rea Sse M B Ly

    F R O N T S U S P E N S IO N In se rt the a djusting scre w (1 9 ) into th e plu g se at (4 8 ); p u sh it d o w n w hile tu rnin g cou nter clockw ise u ntil it locks.

  • Page 142: A D Ju Stm En T

    F R O N T S U S P E N S IO N A D J U S T M E N T S T A N D A R D settin g fo r C O M P R E S S IO N : w h e n in "co m ple tely clo sed " p ositio n, unscre w b y 12 clicks (F IG .3 7 ) S T A N D A R D settin g fo r R E B O U N D : w h e n in co m ple tely clo se d p o sitio n, unscrew b y 12 clicks (F IG .

  • Page 143: R Em O Vin G Th E Fro N T Fo Rk

    F R O N T S U S P E N S IO N R e m o vin g th e fro n t fo rk T ake n ote of m e a su re A w hich m u st be restore d w h e n re a sse m b lin g . S et a su pp ort un d er the en g ine to lift th e fron t w h eel from th e g ro u n d , w o rkin g a s follo w s: -re m ove ,o n the L .H .
  • Page 145 R E A R S U S P E N S IO N S e ctio n...
  • Page 146 R E A R S U S P E N S IO N T ab le o f C o nten ts R e a r su s p en s io n R em o val o f re ar sh o ck ab so rb er O ve rh au l o f rear sh o ck ab so rb er O ve rh au l th e sp rin g C h eckin g th e sh o ck ab so rb er...

  • Page 147: R E A R Su S P En S Io N

    R E A R S U S P E N S IO N R e ar su s p e n sio n T he su spe nsion of this m otorc ycle is of the prog re ssive typ e a n d c o n sists o f a sho ck ab sorb er, a serie s o f linkage s an d a sw in g a rm .

  • Page 148: C H Eckin G Th E Sh O Ck Ab So Rb Er

    R E A R S U S P E N S IO N D is a s s e m b ly, o ve rh au lin g , a n d rea ss em b ly o f th e re ar sh o c k a b so rb er A ccu ra te ly cle a n the sh ock a bso rbe r b e fo re d isa sse m bly.
  • Page 149 R E A R S U S P E N S IO N B le ed the g as b y pressing o n the reservo ir valve. T o p ro te ct h is e ye s from possible particles, the o p e ra to r m u st tu rn th e va lve a w a y from his e yes.
  • Page 150 R E A R S U S P E N S IO N O nce th e p lu g is re m o ve d , pu sh a n d drive th e fo rk ro d gu ide in sid e th e bo d y so a s to fre e sn a p rin g h o u sin g .
  • Page 151 R E A R S U S P E N S IO N G rip the sho ck a bso rb er up per sid e in a vice u sing alu m in u m o r b ro n ze ja w s. In se rt a ro d or a scre w d river into th e conne cting ho le , a n d re m o ve th e pisto n a n d fo rk ro d un it from th e shock abso rber bo d y.
  • Page 152 R E A R S U S P E N S IO N C h ec kin g th e a d ju s tm e n t In case of co m p re ssio n a d justm en t for o pe ratin g d e fect, it is n ece ssary to u nscrew th e kn o b sto p p in g do w el (be fo re u nscre w ing , h e at w ith w arm air).
  • Page 153 R E A R S U S P E N S IO N...
  • Page 154 R E A R S U S P E N S IO N A fte r h a vin g co m p le te d the ch eck, in sert ag ain th e p iston , th e d isk, th e sprin g a n d th e rin g w ith slo ts.

  • Page 155: R Ea Sse M B Lin G Th E Sh O Ck Ab So Rb Er

    R E A R S U S P E N S IO N D isa ss e m b lin g th e a ir/o il d ia p h rag m o f th e re se rvo ir A lw a ys re p la ce the d iap hragm w h en cha nging th e o il in sid e th e sh o ck ab so rbe r.
  • Page 156 R E A R S U S P E N S IO N P rep a re th e d ia p h ra g m w ith asse m b led O R (w e a dvise usin g a ne w o n e for ea ch re p la ce m e n t).
  • Page 157 R E A R S U S P E N S IO N R e asse m ble th e rese rvo ir plug an d th e va lve , fit it in sid e th e re se rvo ir, th en fit th e sna p rin g in to th e thro at.
  • Page 158 R E A R S U S P E N S IO N L = 23 4,5 ÷23 7 ,5 m m (9 .2 3 ÷9 .35 in .)
  • Page 159 R E A R S U S P E N S IO N S h o c k a b s o rb e r d am p in g ad ju stm en t A djustm en t o f th e co m pressio n stro ke is ind epen den t fro m th e re b o u n d stroke .
  • Page 160 R E A R S U S P E N S IO N D isa s s e m b lin g a n d o ve rh a u lin g th e re ar sw in g a rm (p a g es J.2 6-J .27 ) S et a sta n d o r a b lo ck u nd er the e ng in e an d see th a t th e rea r w he el is lifte d from th e g ro u n d .

  • Page 161: O Ve Rh Au Lin G Th E Rear Sw In G Arm A Xle

    R E A R S U S P E N S IO N O ve rh a u lin g th e re ar sw in g arm a xle U sing a co m pa ra tor, check the sw ing a rm axle fo r d isto rtio n . P osition th e axle on tw o iden tical con tacts.
  • Page 162 R E A R S U S P E N S IO N C h a in te n s io n ro lle rs, ch a in d rivin g ro lle r, c h a in g u id e , c h ain ru n n er C h e ck th e w e a r o f th e ab ove m e n tio n ed elem e nts an d rep lace th e m w h en n ece ssa ry.
  • Page 163 B R A K E S S e ctio n...
  • Page 164 B R A K E S T ab le o f C o nten ts L .3 B ra k in g s ys te m B ra ke d isc L .4 W ear ch ec k a n d b rake p ad s rep lacem en t L .5 F ro n t b rakin g s ystem b leed in g L .7...
  • Page 165 B R A K E S B R A K IN G S Y S T E M T he b raking s yste m s is divided into tw o com plete ly in d e p e n d e n t circu its. E a ch system is p rovid ed w ith a caliper con nected to a h yd ra u lic co n tro l p u m p w ith tan k fo r th e flu id .
  • Page 166 B R A K E S D isc b ra k e A re g u la r ch e ck o f b rake d isc co nd ition is m o st im p orta nt; th e disc sho uld b e a bso lu te ly cle a n w ith ou t a n y tra ce s o f ru st, o il, gre a se o r d irt an d sh o uld n ot b e e xce ssive ly sco re d .
  • Page 167 B R A K E S W ea r c h ec k a n d rep la c e m en t o f b ra ke p a d s In sp e ct pa d s fo r w e ar. S ervice lim it A a) T he fro nt p a d th ickne ss m u st not be lo w er th an 3 ,5 m m (S M ) o r 3 .8 m m (T E ).
  • Page 168 B R A K E S F ro n t b ra k in g s ys te m b le e d in g T he b ra kin g s yste m m u st b e ble e d w h en , d u e to air in th e circu it, the le ver stro ke is lo n g a n d sp on g y.
  • Page 169 B R A K E S B lee d in g th e re a r b re akin g s ys te m T he b raking s yste m m u st be b led w h en, due to air in th e circu it, th e p ed al stroke is lo ng an d sp o ng y.
  • Page 170 B R A K E S F lu id c h a n g e T he b ra ke flu id s h o u ld be ch ecked a nd ch an ge d in a cco rd a nce w ith the P erio d ic M a in te n a n ce C h art (pa g es B ..) or w h en e ver it is con tam in ate d w ith d irt o r w a te r.
  • Page 171 B R A K E S P eriod ica lly ch e ck th e conn ecting ho ses (A ) and (B ): if th e h o se s a re w orn or cra cke d , th e ir re p lace m ent is a dvised.
  • Page 173 E L E C T R IC S Y S T E M S e ctio n...
  • Page 174 E L E C T R IC S Y S T E M T ab le o f C o nten ts M .4 W IR IN G D IA G R A M (T E , S M ) K E Y T O W IR IN G D IA G R A M (T E , S M ) M .5 E L E C T R IC A L C O M P O N E N T S L O C A T IO N ( T E ,...
  • Page 175 E L E C T R IC S Y S T E M T ab le o f C o nten ts T A IL L A M P M .43 M .43 R e a r ta il lig h t b u lb re p la ce m e n t H A N D L E B A R C O M M U T A T O R S M .44 R .H .
  • Page 176 E L E C T R IC S Y S T E M...
  • Page 177 E L E C T R IC S Y S T E M K E Y T O E L E C T R IC D IA G R A M (T E -S M ) C a b le c o lo r c o d in g 1.
  • Page 178 E L E C T R IC S Y S T E M E L E C T R IC A L C O M P O N E N T S L O C A T IO N (T E -S M ) - G e n e ra to r (1 ), in o il b ath , o n th e in ne r sid e o f L .H .
  • Page 179 E L E C T R IC S Y S T E M...
  • Page 180 E L E C T R IC S Y S T E M C H A R G IN G S Y S T E M T he ch a rg in g s ys te m co nsists o f: - A lte rn a to r (2 );...
  • Page 181 E L E C T R IC S Y S T E M C H A R G IN G S Y S T E M C H E C K S B attery cu rre n t le ak ag e T o ga in a ccess to th e b atte ry, re m ove the sadd le (se e p a g e E .4 ).
  • Page 182 E L E C T R IC S Y S T E M G e n e ra to r s ta to r co il c o n tin u ity c h e ck R e m o ve th e sta to r co il-m ain w irin g ha rne ss con n e cto r th en ch eck th e co n tinu ity u sin g a te ste r.
  • Page 183 E L E C T R IC S Y S T E M V o lta g e reg u la to r-rec tifier ch e c k in g W ith the ig nitio n de finite ly fu n ctional, w h ilst th e b a tte ry is ch a rg e d (1 2 .5V -1 3V ), start th e en gine : if th e b attery ten sio n does not incre a se (1 4 .5 V ) a fte r ab ou t fo ur m in u tes, sub stitute the reg ula to r.
  • Page 184 E L E C T R IC S Y S T E M S T A R T E R S Y S T E M T h e sta rte r s yste m co nsists o f: - B a tte ry (1 6 ); - E le ctric sta rt re m ote con trol s w itch (1 7);...
  • Page 185 E L E C T R IC S Y S T E M S T A R T E R S Y S T E M C H E C K S S ta rte r m o to r d isa s se m b ly U se a 10 m m w re nch to rem ove th e nut (1 ) und e r th e ru b b e r ca p a n d a 8 m m w ren ch to re m o ve the startin g m otor a nd ground ca ble screw s (2 ).
  • Page 186 E L E C T R IC S Y S T E M S tarte r m o to r te s t d ia g ra m 1 - O u tp u t 2 - T o rq u e 3 - R e vo lu tio n 4 - te rm in a l vo lta g e 5 - L o ad c u rre n t...
  • Page 187 E L E C T R IC S Y S T E M E le ctric s ta rt re m o te c o n tro l sw itch c h ec k D iscon ne ct the sta rter re la y coup ling (A ). D iscon ne ct th e ca b le s fro m th e po sitive an d ne ga tive po le s of the b attery to avoid short circu its d u rin g a ssem b ly.
  • Page 188 E L E C T R IC S Y S T E M E L E C T R O N IC IG N IT IO N S Y S T E M In th e C .D .I. s ystem th e electrica l energ y g ene rate d b y th e a lte rn a to r cha rge s the c on de nser. T he e ne rg y is re le a sed in a single surge at the spe cifie d ig n itio n tim in g an d th e curre nt flow s th ro ug h the p rim ary side o f th e ig ni- tion coil.
  • Page 189 E L E C T R IC S Y S T E M Ig n itio n c o il res is tan c e ch e c k T o ga in a ccess to th e e lectronic coil (1 ) re m o ve th e sa d d le a n d th e fu el tan k (see pa ge E .16 -E .2 3).
  • Page 190 E L E C T R IC S Y S T E M E lectro n ic u n it T he e le ctro n ic u n it (1 ) is faste ne d u n de r th e sad dle . T he o p e ra tio n is ch a ra cte rized b y th e pre sen ce of a co nd en ser tha t is loa de d b y the gen era to r a n d th a t th e n rele ase th e cha rge to th e coil in a ccord w ith the pick-up sig na l a n d th e p ro g ra m m e d tim in g valu e.
  • Page 191 E L E C T R IC S Y S T E M S p ark p lu g U se "N G K " C P R 8 E spa rk p lu g. C he ck d istance "A " (0 ,6 ÷0 ,7 m m / 0.02 2÷0.02 6 in .) b etw e en electrod es.
  • Page 192 E L E C T R IC S Y S T E M T h ro ttle P o s itio n S e n s o r c h ec kin g (T P S ) S et th e te ste r in O h m p osition the n de ta ch the th ro ttle p o sition se nso r cab le (1 ) from th e m a in w irin g ha rne ss.
  • Page 193 E L E C T R IC S Y S T E M B A T T E R Y T he se aled b a tte ry (1) d o es not re q uire an y m ainte n a n ce w o rk. If th e ve hicle re - m ain s un use d fo r lo n g p erio ds, it is recom m end ed to re m o ve b a tte ry fro m e le ctri- cal system an d s tore it in a dry p la ce.
  • Page 194 E L E C T R IC S Y S T E M D IG IT A L IN S T R U M E N T , W A R N IN G L IG H T S 1- G R E E N w a rn ing lig ht L ig h ts 2- G R E E N w a rn ing lig ht N eu tral 3- B A T T E R Y C H A R G E w a rn in g light (the w arning lig h t co m e s o n , con te m po ra rily w ith th e ve rtical LE D in dicator 1 0, w he n the en gine is sto ppe d a nd the ignition ke y is on...
  • Page 195 E L E C T R IC S Y S T E M In stru m e n t se ttin g s T his op era tion a llow s you to set th e p aram e te rs of th e in stru m e n t fo r u se on m o to rc ycles w ith d iffe rent cha racteristics (S M -T E ).
  • Page 196 E L E C T R IC S Y S T E M A d d in g / R e m o vin g S cre e n s T his op era tion a llow s yo u to a dd a nd rem ove differe n t scre e n s (fu n c tio ns) to th e un it. T h e com p ute r co n ta in s 9 scre en s in all. T h e scree n s m a y be sh ow n w ith th e b a r gra p h a cting a s a ta ch o m e te r o r a ba tte ry m e te r.
  • Page 197 E L E C T R IC S Y S T E M F ig .1 F ig .1 F ig .6 F ig .1 1 F ig .2 F ig .7 F ig .1 2 F ig .3 F ig .8 F ig .4 F ig .9 F ig .5...
  • Page 198 E L E C T R IC S Y S T E M In s tru m e n t re p la c em e n t - M o d e l T E : re m o ve th e fo ur e lastic 1 fig .1 a nd re m o ve the he a dla m p h olde r 2 ; - M o d e l S M : re m o ve the scre w 3 fig.
  • Page 199 E L E C T R IC S Y S T E M H E A D L A M P H ea d la m p a d ju s tm e n t (T E - S M ) T he fro nt he ad la m p is fitted a dipp ing bu lb for m a in a n d d ip p e d b e a m s an d a pilot/sid e la m p bu lb.
  • Page 200 E L E C T R IC S Y S T E M R e a r ta il lig h t b u lb re p la ce m e n t (T E -S M ) T o g a in a cce ss to the ta il ligh t bu lb (12 V -5 /21 W ), p ro ce ed as fo llow s: - re m o ve th e tw o faste nin g screw s (1) a nd th e re a r len s (2);...
  • Page 201 E L E C T R IC S Y S T E M H A N D L E B A R C O M M U T A T O R S M ea sure th e co m m uta to rs co ntin uity using a teste r. In ca se o f a n o m a lie s, re place th e de fe c tive p art.
  • Page 202 E L E C T R IC S Y S T E M L .H . C O M M U T A T O R T E -S M...
  • Page 203 E L E C T R IC S Y S T E M A R R A N G E M E N T O F W IR IN G H A R N E S S O N T H E F R A M E 1: in ord er to fa cilitate th e ta nk a nd sa ddle assem blin g , h o ld d o w n w a rd the sh ea th 2: M a ke atten tio n to correctly p osition ing the con ne cto r ru b b e r o f th e instru m en t A ssem b le th e clam ps as show n in the figu re.
  • Page 204 E L E C T R IC S Y S T E M N O T E S C O N N E C T O R S W h e n a co n n e cto r is co nn ecte d, che ck tha t it clicks into po sitio n. C heck th e co n n e cto r fo r co rrosio n , d irt o r a b roke n co ver.
  • Page 205 E N G IN E C O O L IN G S Y S T E M S e ctio n...
  • Page 206 E N G IN E C O O L IN G S Y S T E M T ab le o f C o nten ts C h e ck in g th e c o o lin g flu id le ve l N .2 C o o lin g syste m N .4...
  • Page 207 E N G IN E C O O L IN G S Y S T E M 1. C e n trifug al p u m p 2. R .H . coo ler 3. L.H . coo le r 4. T h erm o stat 5.
  • Page 209 L U B R IC AT IO N C IR C U IT S e ctio n...
  • Page 210 L U B R IC AT IO N C IR C U IT L u b ric atio n s ys te m T h e e ng ine lu b ricatio n is of th e force d typ e, w ith d u a l lob e pum p lo ca te d insid e the R .H .
  • Page 211 S P E C IF IC TO O L S S e ctio n...
  • Page 212 S P E C IF IC TO O L S S P E C IA L T O O L S 1- (8 00 0 89 7 43 ) C ran kcase 2- (8 00 0 39 5 23 ) F lyw he el pu ller 3- (8 00 0 90 6 62 ) E ng ine holder 4- (1 51 4 13 4 01 ) S w in g a rm puller 5- (8 00 0 39 5 24 ) C lutch hu b reta in in g...
  • Page 213 TO R Q U E W R E N C H S E T T IN G S S e ctio n T igh te n a ll nu ts a nd bolts w ith a to rque w rench a t th e co rre ct se ttin g . Insu fficien t tig hte n ing o f n uts or b o lts ca n cau se th em to b eco m e d am a ged o r loose lead in g to veh icle d a m a g e o r in ju ry to the rid er.
  • Page 214 TO R Q U E W R E N C H S E T T IN G S E N G IN E T IG H T E N IN G T O R Q U E S (+ /- 5 % ) C ylin der h ea d fastening n ut M 8x1,25 25 N m...
  • Page 215 TO R Q U E W R E N C H S E T T IN G S E N G IN E T IG H T E N IN G T O R Q U E S (+ /- 5 % ) E ngine oil dra in plu g M 14 x1,5 24 N m...
  • Page 216 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) R ear fram e lo w er fastenin g scre w M 8x1,25 25,5 N m...
  • Page 217 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) C hain gu id e bracket to rear sw ing arm fastenin g M 8x1,25 25 N m...
  • Page 218 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) F ront brake disc fastening scre w (S M )/ M 8x1,25 34,7 N m...
  • Page 219 F R A M E A N D W H E E L S S e ctio n...
  • Page 220 F R A M E A N D W H E E L S T ab le o f C o nten ts Y .3 F ra m e F ro n t w h eel Y .4 R em o vin g th e fro n t w h eel Y .5 R ea sse m b lin g th e fro n t w h eel Y .5...
  • Page 221 F R A M E A N D W H E E L S F R A M E T he fram e is a sing le-be am w ith d ou ble -cradle typ e clo se d in ste e l tu be s. Lig ht allo y re ar fram e . F o r a ro ug h che ck, p le ase se e the picture (p ag e Y .
  • Page 222 F R A M E A N D W H E E L S F ro n t w h e el H u b an d rim in ligh t a llo y w ith hig h ten sile stee l spoke s. R im m a ke, typ e a nd d im ension (T E ) "T A K A S A G O E xcel in lig h t a lloy: 1 ,6 x2 1 (S M ) "S A N R E M O "...
  • Page 223 F R A M E A N D W H E E L S R e m o vin g th e fro n t w h eel S et a stan d o r a blo ck und er the e ng in e a nd see th a t th e fro n t w h e e l is lifte d fro m th e gro un d. L oo sen th e bo lts (1 ) ho ldin g the w h ee l axle (2) to the fro nt fo rk sta nchions.
  • Page 224 F R A M E A N D W H E E L S R e a r w h e el H u b an d rim in ligh t a llo y w ith hig h ten sile stee l spoke s. R im m a ke, typ e a nd d im ension (T E ) "T A K A S A G O E xcel in ligh t a llo y: 2 ,15 x18 (T C ) "T A K A S A G O E xce l in ligh t allo y: 1 ,8 5x1 9 (2 50 );...
  • Page 225 F R A M E A N D W H E E L S R e m o vin g th e re a r w h eel U n scre w th e nu t (1 ) of th e w he el pin (3) and extra ct it. It is n o t n e ce s- sary to un lo ose th e cha in ad ju sters (2);...
  • Page 226 F R A M E A N D W H E E L S W h e e ls o ve rh a u lin g C he ck th e w e a r sta te of th e hu b b ea rin gs. In ca se o f e xce ssive clea ran ce (radia l a n d a xia l), o p e ra te a s fo llo w s: - la y th e h u b o n a fla t ho lde r w ith h ole , a llo w ing fo r th e pa ssa ge of the re m ove d bea rin g ;...
  • Page 227 F R A M E A N D W H E E L S R im s w a rp ag e T he tab le b elo w sh ow s the co ntro l value th at the w h e e l rim m u st b e ch ecke d. T oo m uch skid a nd ecce ntricity a re ge ne rally cause d b y a n y w o rn b e a rin g s.
  • Page 228 F R A M E A N D W H E E L S C H E C K IN G T H E W E A R O F C H A IN , P IN IO N A N D S P R O C K E T P rocee d a s fo llo w s: - F ully stre tch th e ch a in w ith the a d ju sting scre w s.
  • Page 229 N O T E S F O R U S A /C D N -A U S M O D E L S S e ctio n...
  • Page 230 N O T E S F O R U S A /C D N -A U S M O D E L S T am p e rin g w arn in g T am pe rin g w ith N oise C ontrol S ystem P roh ib ited. F ed e ra l la w p ro hib its the follow ing acts or cau sing th e re o f: (1) T he re m ova l or re n d erin g ino p erative b y a n y pe rso n o th e r th a n fo r p u rp o ses o f m a in te na nce, rep air, o r rep lace m en t, of an y d evice o r e lem e nt of de sign incorp orated in to a n y n e w ve h icle for the p urp ose of no ise co ntrol p rior...

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