TM RACING 250Fi EN Workshop Manual
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TM RACING 250Fi EN Workshop Manual

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Workshop Manual
250 - 300
EN
450
www.tmracing.it

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Summary of Contents for TM RACING 250Fi EN

  • Page 1 Workshop Manual 250 - 300 www.tmracing.it...
  • Page 2 TM Racing SPA, declines all liability for any errors in the compilation of this manual, and reserves the right to make any modifications required for the development of its products. Illustrations shown are approximate and, in some cases, may not precisely correspond with the part...
  • Page 3 Foreword This publication, to be used by TM Racing workshops, has been drawn-up to assist authorised personnel in the maintenance and repair of motorcycles handled. Perfect knowledge of the technical data stated herein is decisive for the most complete professional training of the operator.

  • Page 5: Table Of Contents

    INDEX IDENTIFICATION OF THE VEHICLE ............3 TECHNICAL SPECIFICATIONS ..............7 DIAGNOSIS ..................19 REGISTRATIONS/ADJUSTMENTS ............21 CheCking Coolant level ..............23 Draining, Filling anD BleeDing Cooling SyStem .........24 hyDrauliC ClutCh PumP ...............24 BleeDing hyDrauliC ClutCh ..............25 niSSin Front Brake PumP ..............26 BremBo Front Brake PumP ..............27 BremBo raDial Front Brake PumP ............28 BremBo 16X18 raDial Front Brake PumP .........29 Changing BaSe PoSition oF rear Brake PeDal .........30...
  • Page 6 INDEX PARTS REMOVAL ................51 muD guarDS removal ................53 rear muD guarD removal ComPlete With liCenCe Plate holDer anD DireCtion inDiCatorS ....55 rear PoSition inDiCator light rePlaCement ........57 tail light rePlaCement ................58 liCenCe Plate holDer removal ............60 6.6 FRonT headLighT ReMoVaL/RePLaCeMenT .........62 Front DireCtion inDiCator light rePlaCement ......63 eXhauSt unit ..................64 eXhauSt unit removal .................65...

  • Page 7: Identification Of The Vehicle

    1. IDENTIFICATION OF THE VEHICLE...
  • Page 8 1. IDENTIFICATION OF THE VEHICLE...
  • Page 9 1. IDENTIFICATION OF THE VEHICLE RICONOSCERE I MODELLI DI MOTO TM RACING ESEMPIO DI MODELLO MOTO 300Fi MX E.S. CILINDRATA TIPO DI ALIMENTAZIONE TIPO DI USO TIPO DI AVVIAMENTO (Solo QuanDo inSerito Come oPtional) 250 = 250cc Fi = inieZione en = enDuro e.S.
  • Page 10 1. IDENTIFICATION OF THE VEHICLE ENGINE SERIAL NUMBER The engine serial number (1) is embossed into the rear part of the engine, near to the shock absorber. Make a note of this number in the relevant space at the beginning of the manual. KAYABA FORK CODE The fork code (2) is a capital letter printed on the inside of each foot. TM SHOCK ABSORBER CODE The shock absorber code (3) is printed on an adhesive label applied near to the compression braking valve.

  • Page 11: Technical Specifications

    2. TECHNICAL SPECIFICATIONS...
  • Page 12 2. TECHNICAL SPECIFICATIONS...
  • Page 13 2. TECHNICAL SPECIFICATIONS FRAME TECHNICAL DATA 250Fi-300Fi-450Fi EN EU4 - 250Fi-300Fi-450Fi-530Fi EN MOTORCYCLE MODEL Frame high resistance aluminium alloy perimeter Front suspension kayaba Usd Fork Ø 48 mm Front/rear suspension run front 310mm -rear 320 mm rear suspension aluminium swing arm, Progressive linkage, TM Racing shock absorber Front disc brake Ø 270 mm floating calliper Rear disc brake Ø 245 mm floating calliper Front/rear brake disc wear limit min 3.5 mm Front tyre 90/90 - 21” (100/80 - 21 oPT) air pressure 1.0 bar (off-road) / 1.5 bar (on road) rear tyre 120/90 - 18” (140/80 - 18” opt.) 140/80 - 18”...
  • Page 14 2. TECHNICAL SPECIFICATIONS 250Fi - 300Fi EN MAINTENANCE TABLE A CLEAN MOTORCYCLE CAN BE INSPECTED FASTER AND AT A LOWER COST Check steering bearings and play adjustment • • • Clean and grease steering bearings and relative sealing elements • bleed telescopic fork • • Clean dust scraper • Check seal and operation of fork and shock absorber • Full fork maintenance • • Full shock absorber maintenance •...
  • Page 15 2. TECHNICAL SPECIFICATIONS 250Fi - 300Fi EN MAINTENANCE TABLE A CLEAN MOTORCYCLE CAN BE INSPECTED FASTER AND AT A LOWER COST Check cooling system seal and coolant level • • • Check condition and arrangement of rubber pipes without bends • • • Check condition and arrangement of bleed hoses without bends • • • Check electric fan operation (if installed) • • • Replace silencer soundproofing material • Check exhaust system sealing and fixing •...
  • Page 16 2. TECHNICAL SPECIFICATIONS The hour meter is integrated inside the dashboard. 450FI EN MAINTENANCE TABLE A CLEAN MOTORCYCLE CAN BE INSPECTED FASTER AND AT A LOWER COST Check steering bearings and play adjustment • • • Clean and grease steering bearings and relative sealing elements • bleed telescopic fork • • Clean dust scraper • Check seal and operation of fork and shock absorber • Full fork maintenance • • Full shock absorber maintenance • •...
  • Page 17 2. TECHNICAL SPECIFICATIONS 450FI EN MAINTENANCE TABLE A CLEAN MOTORCYCLE CAN BE INSPECTED FASTER AND AT A LOWER COST Check electrical system operation (low beam, high beam, stop light, turn • • indicator signals, control indicators, horn, safety button/switch) Check cooling system seal and coolant level • • • Check condition and arrangement of rubber pipes without bends • • • Check condition and arrangement of bleed hoses without bends • • • Check electrovalve operation (if installed) • • • Replace silencer soundproofing material •...
  • Page 19 3. DIAGNOSIS...
  • Page 20 3. DIAGNOSIS...
  • Page 21 3. DIAGNOSIS Performing the scheduled maintenance on your motorcycle will make problems unlikely. however, should a problem occur, check the trou- bleshooting table and follow the instructions provided to solve the problem. The table has two columns indicating who should perform the intervention: • the symbol indicates that the intervention must be performed by the user: • the symbol indicates that the intervention must be performed by a technician or at an authorised TM workshop. Therefore, for your safety, have such work performed only at a specialised TM workshop, where your motorcycle will be serviced optimally by specifically trained personnel. Contact a TM dealer if you have any questions. For anything not covered in this paragraph, consult the “Pda” section. PROBLEM CAUSE SOLUTION Incorrect command Correctly repeat the procedure to activate the • (EN/SMR/SMM). starter motor according to the motorcycle model. Ignition key not inserted or •...
  • Page 22 3. DIAGNOSIS PROBLEM CAUSE SOLUTION Correctly repeat the engine start procedure Incorrect command according to the motorcycle model. • Refuel. No fuel supply to the • Check the petrol pump and fuel pipe connections. engine. Check fuel pressure. • I n c o r r e c t i d l e s p e e d •...

  • Page 23: Diagnosis

    3. DIAGNOSIS PROBLEM CAUSE SOLUTION • Air filter clogged. Clean or replace the air filter. • Faulty injection system. Check the injection system (PDA). E x h a u s t s y s t e m n o t sealed, deformed or Check the faulty parts on the exhaust system, •...
  • Page 24 3. DIAGNOSIS in order to allow authorised workshops and the most demanding users to work directly on the eFi system, TM Racing has an (optional) Pda for TM Racing motorcycles equipped with a fuel injection system. This instrument, with dimensions of 228 x 168 x 45, is suitable for any op- erating conditions, in the workshop, on the track and on the test bench. it has an internal rechargeable battery. which can power the control unit and is able to communicate even when the engine is off. alternatively, it is possible to connect the instrument to an external 12V battery and communicate with the control unit using the same procedures. The 7’’ colour display is a touch-screen that can also interact with a pen, track ball or mouse connected via the instrument Usb port, which can also be used for uSB pendrives. The instrument is also equipped for ethernet, has CoM port, mini Usb port and power supply connections. When connected via Can to the control unit, the instrument allows the following to be performed: - Check the motorcycle eFi system operation (electronic diagnosis) - Check some engine functions (Mechanical diagnosis) - Check the data entered in the control unit - Change the maps in the control unit (only Racing models) - display the engine operating hours - Upload new maps provided by TM Racing (Racing models only) - acquire data in real time in 2d and numerical format. The instrument receives continuous software and firmware updates allowed by the specific hardware configuration without additional costs, and is available for sale to all TM Racing Clients.

  • Page 25: Registrations/Adjustments

    4. REGISTRATIONS/ADJUSTMENTS...
  • Page 26 4. REGISTRATIONS/ADJUSTMENTS...

  • Page 27: Checking Coolant Level

    4. REGISTRATIONS/ADJUSTMENTS CHECKING COOLANT LEVEL With the engine cold, open the radiator filler cap. The fluid must cover the channels by approximately 10 mm. if the level is too low, top up immediately with more fluid mix and bleed the air. Use water only if strictly necessary and in small amounts, to avoid reducing the properties of the fluid. DANGER IF POSSIBLE, ChECk ThE COOLANT LEvEL whILE ThE ENgINE IS COLD. IF IT IS NECESSARY TO OPEN THE RADIATOR FILLER CAP WHILE IT IS HOT, FIRST COVER IT WITH A CLOTH AND THEN SLOWLY OPEN IT TO DISCHARGE THE OVERPRESSURE.

  • Page 28: Draining, Filling And Bleeding Cooling System

    4. REGISTRATIONS/ADJUSTMENTS 250/300 D R A I N I N G , F I L L I N G A N D B L E E D I N G COOLING SYSTEM Coolant can be drained by removing the screw (1) from the water pump cover on the right side of the engine. Prepare a suitable recipient to collect the fluid drained. The radiator cap must be open to drain the fluid. once finished, screw in the drain screw and tighten to 12 nm. NOTE: Replace the aluminium sealing washer. To fill the cooling system, pour the amount of coolant indicated in the “Technical data” table through the filler neck (2). Close the radiator filling cap and start the engine for a few seconds. switch off the engine, open the...

  • Page 29: Bleeding Hydraulic Clutch

    4. REGISTRATIONS/ADJUSTMENTS CHECKING AND TOPPING UP THE HYDRAULIC FLUID LEVEL The fluid tank is part of the clutch pump located on the handlebar. Remove screws (3), cover (4) and membrane (5). The fluid level must be 5 mm below the edge with the tank in horizontal position. Top-up if required. Use doT4 brake hydraulic fluid. Re-mount the membrane, cover and screws and tighten. Use water to wash away any hydraulic fluid that overflowed or was spilled. DANGER IF ThE LEvEL OF ThE hydRAULIC FLUId dROPS BELOw ThE PRE- ESTABLISHED MEASUREMENT, THERE MIGHT BE LEAKS IN THE SYSTEM OR A MECHANICAL PROBLEM. kEEP ThE hydRAULIC FLUId OUT OF ThE REACh OF ChILdREN.

  • Page 30: Nissin Front Brake Pump

    4. REGISTRATIONS/ADJUSTMENTS NISSIN FRONT BRAKE PUMP ADJUSTING THE LEVER POSITION The position of front brake lever with respect to the grip can be changed with the adjusting screw (1). Remove the rubber protection (2). Loosen counter-nut (3) and rotate the screw clockwise to move the lever away or anticlockwise to move the lever closer. Tighten the counter-nut again (3). WARNING When the operation is complete, make sure that the front brake lever has free travel of 3 mm before engaging the brake and that the front wheel can rotate freely with the lever at rest. if there is no free travel, pressure forms in the brake system, and as a result, the front wheel brake may fail due to overheating or to the wheel itself locking. CHECKING BRAKE FLUID LEVEL The fluid tank is part of the front brake pump located on the handlebar and has an inspection indicator (4). With the tank in horizontal position, the fluid level must never drop below the indicator centreline. DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE, IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED.

  • Page 31: Brembo Front Brake Pump

    4. REGISTRATIONS/ADJUSTMENTS BREMBO FRONT BRAKE PUMP ADJUSTING THE LEVER POSITION The position of front brake lever with respect to the grip can be changed with the adjusting screw (1). Turn the knob (1) clockwise to move the lever away or anticlockwise to move the lever closer. WARNING When the operation is complete, make sure that the front brake lever has free travel of 3 mm before engaging the brake and that the front wheel can rotate freely with the lever at rest. if there is no free travel, pressure forms in the brake system, and as a result, the front wheel brake may fail due to overheating or to the wheel itself locking. CHECKING BRAKE FLUID LEVEL The fluid tank is part of the front brake pump located on the handlebar and has an inspection indicator (2). With the tank in horizontal position, the fluid level must never drop below the indicator centreline. DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE, IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED.

  • Page 32: Brembo Radial Front Brake Pump

    4. REGISTRATIONS/ADJUSTMENTS BREMBO RADIAL FRONT BRAKE PUMP ADJUSTING THE LEVER POSITION The position of front brake lever with respect to the grip can be changed with the adjusting ring nut (1). Rotating clockwise, the lever moves away, rotating anticlockwise, to move it closer. WARNING When the operation is complete, make sure that the front brake lever has free travel of at least 3 mm before engaging the brake and that the front wheel can rotate freely with the lever at rest. if there is no free travel, pressure forms in the brake system, and as a result, the front wheel brake may fail due to overheating or to the wheel itself locking. CHECKING BRAKE FLUID LEVEL The fluid tank (2) is transparent to allow you to inspect the fluid level. With the tank in an upright position the fluid level must always be within the MaX and Min indexes. DANGER IF ThE BRAkE FLUId LEvEL dROPS BELOw ThE mINImUm vALUE, IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED.

  • Page 33: Brembo 16X18 Radial Front Brake Pump

    4. REGISTRATIONS/ADJUSTMENTS BREMBO 16X18 RADIAL FRONT BRAKE PUMP ADJUSTING THE LEVER POSITION The position of front brake lever with respect to the grip can be changed with the adjusting wheel (1). Rotating clockwise, the lever moves away, rotating anticlockwise, to move it closer. WARNING When the operation is complete, make sure that the front brake lever has free travel of 3 mm before engaging the brake and that the front wheel can rotate freely with the lever at rest. if there is no free travel, pressure forms in the brake system, and as a result, the front wheel brake may fail due to overheating or to the wheel itself locking. CHECKING BRAKE FLUID LEVEL The fluid tank (2) is transparent to allow you to inspect the fluid level. With the tank in an upright position the fluid level must always be within the MaX and Min indexes. DANGER IF ThE BRAkE FLUId LEvEL dROPS BELOw ThE mINImUm vALUE, IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED.

  • Page 34: Changing Base Position Of Rear Brake Pedal

    4. REGISTRATIONS/ADJUSTMENTS C H A N G I N G B A S E P O S I T I O N O F R EA R BRAKE PEDAL Loosen the low M6 counter-nut (1) and rotate the adjustment screw using the hex head (2). once the ideal position has been found, tighten the counter-nut.

  • Page 35: Cleaning The Air Filter

    4. REGISTRATIONS/ADJUSTMENTS 4.11 CLEANING THE AIR FILTER Clean the air filter and perform maintenance on a regular basis. a dirty air filter affects air flow, reduces engine power, and increases fuel consumption. in some cases dust may enter the engine causing serious damage. Maintenance must therefore be performed on the air filter on a regular basis. Rotate the screw (1) by 1/4 of a turn. Lift the filter cover (2) and remove it. Loosen the butterfly screw (3) and remove it. Carefully remove the filter (4) from its housing.

  • Page 36: Starter Auxiliary Device

    4. REGISTRATIONS/ADJUSTMENTS separate the sponge element (5) from the plastic cage (6). Carefully wash the sponge element with a special cleaning solution and let it air dry thoroughly. if necessary, squeeze the sponge gently but never wring it. Clean the plastic cage and the filter case and check that the sleeve that connects the throttle body to the filter case is intact and positioned correctly. Reassemble the sponge and the cage. making sure it has been previously oiled using filter oil. Re-mount the air filter, positioning it correctly on the support surface. Make sure none of the sponge edges are lifted or are non-adherent to the support surface. Tighten the butterfly screw (3) again. Re-mount the filter cover (2). WARNING do not clean the sponge element with petrol or petroleum, which may corrode it. For correct maintenance, use specific products available on the market for cleaning and lubrication. never start the motorcycle without the air filter. The infiltration of dust and dirt may cause damage and serious wear. Make sure that the seal between the rubber sleeve and filter case is perfect and make sure that the sponge element has been correctly assembled on the plastic cage. any leaks can take sand or dirt into the engine. 4.12 STARTER AUXILIARY DEVICE The starter auxiliary lever must have free travel of 1 - 15 mm. operate as follows to adjust play: Move the protection cap (1) onto the throttle body;...

  • Page 37: Accelerator Command Cables Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.13 ACCELERATOR COMMAND CABLES ADJUSTMENT THROTTLE BODY The accelerator grip must be adjusted according to the preference of the rider, but must always have at least 4-5 mm play. To adjust the play, move the protective caps (1). First, adjust the opening cable (upper) and then the closing cable (lower). Refer also to the wording on the sheaths. Opening cable Loosen the counter-nut (2) and tighten or loosen the adjuster (3) until the play required is obtained. Tightening the adjuster free travel increases. by loosening the adjuster free travel decreases. Tighten the counter-nut and make sure the grip rotates smoothly. Closing cable Loosen the counter-nut (4) and tighten or loosen the adjuster (5) until the play required is obtained. Tightening the adjuster free travel increases. by loosening the adjuster free travel decreases. Tighten the counter-nut and make sure the grip rotates smoothly. When adjustment has been completed, re-position the protective caps. WARNING With the engine running, make sure that the minimum idle speed is correct and that it does not increase when you steer to the right or left up to stopping. 4.14 ADJUSTING IDLE SPEED adjusting the idle speed greatly affects engine start-up, i.e. an engine with correctly adjusted idle speed will be easier to start than an engine with incorrect idle speed adjustment.

  • Page 38: Checking Chain Tension

    4. REGISTRATIONS/ADJUSTMENTS 4.15 CHECKING CHAIN TENSION 10 - 15 Put the motorcycle up on the centre stand to check the chain tension. Push the chain upwards at the end of the drive chain runner. the upper part of the chain must be taut. The distance between the swing arm and the lower part of the chain (a) must be approx. 10-15 mm. adjust the tension, if required. DANGER - I F T h E C h A I N I S TO O T I g h T, T h E F I N A L T R A N S m I S S I O N COmPONENTS (ChAIN, PINION ANd SPROCkET, BEARINgS, gEARBOx ANd REAR whEEL) ARE gREATLy STRESSEd.

  • Page 39: Chain Maintenance

    4. REGISTRATIONS/ADJUSTMENTS 4.17 CHAIN MAINTENANCE duration of the chain depends above all on maintenance. Chains without an o-ring must be regularly cleaned with petroleum and then immersed in hot oil (specific for chains) or be treated with spray (specific for chains). Maintenance of chains with o-ring is minimised. The best cleaning method is using plenty of water. never use brushes or solvents to clean the chain. When the chain is dry, use a spray specific for chains with o-ring. DANGER PREVENT THE LUBRICANT FROM REACHING THE REAR TYRE AND THE BRAKE DISC, OTHERWISE THE TYRE'S ADHERENCE TO THE GROUND AND THE REAR BRAKE ACTION COULD BE CONSIDERABLY REDUCED AND CONTROL OF YOUR MOTORCYCLE COULD BE LOST EASILY.

  • Page 40: Checking Shock Absorber Static Sag

    4. REGISTRATIONS/ADJUSTMENTS 4.19 CHECKING SHOCK ABSORBER STATIC SAG Correct shock absorber static sag should correspond to static lowering of the motorcycle of approx. 35 mm. Variations exceeding 2 mm may greatly affect motorcycle performance. Procedure: Place the motorcycle on a stand so that the rear wheel does not touch the ground. Measure the distance between the rear wheel pin and a fixed point (e.g. a reference on the side panel), making sure that the straight line that connects the wheel pin to the fixed point is as perpendicular to the ground as possible and make note of the value as measurement a. Place the motorcycle back on the ground. ask someone to keep the motorcycle in an upright position. Measure the distance between the rear wheel pin and the fixed point again and make note of the value as measurement b. The static sag is the difference between the two measurements a and Example: Motorcycle on stand (measurement a): ...... 600 mm Motorcycle on the ground without load (measurement b): ............565 mm static sag: ..............35 mm if static sag is lower, the shock absorber spring pre-load must be decreased. if static sag is greater, spring pre-load must be increased. see “Varying pre-load and replacing shock absorber spring” chapter. 4.20 CHECKING SHOCK ABSORBER RIDER SAG Correct shock absorber rider sag should correspond to a lowering of the motorcycle of approx. 90÷105 mm.

  • Page 41: Shock Absorber Compression Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.21 S H O C K A B S O R B E R C O M P R E S S I O N ADJUSTMENT TM SHOCK ABSORBER access the adjustment screw from the right part of the motorcycle. • Low speeds The adjustment screw (1) is positioned on the top of the shock absorber gas tank. Use a 5 mm allen wrench. by rotating clockwise, braking increases, or anticlockwise it decreases. a total number of 24 clicks are available.

  • Page 42: Shock Absorber Rebound Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.22 SHOCK ABSORBER REBOUND ADJUSTMENT TM SHOCK ABSORBER access the adjustment screw from the left part of the motorcycle. The adjustment screw (1) is located on the fork coupling, connecting the shock absorber to the linkage. Use a screwdriver. by rotating clockwise, braking increases, or anticlockwise it decreases. a total number of 34 clicks are available. WARNING before starting, it is recommended to tighten the adjuster from the standard position to the “all closed” position and counting the clicks. Make note of the number of clicks in order to be able to restore standard adjustment. it is normal to count the clicks starting from the “all closed” position. STANDARD ADJUSTMENT 250-300 mx 22 clicks from all closed 450 MX 18 clicks from all closed 250-300 EN 18 clicks from all closed 450 EN 28 clicks from all closed...

  • Page 43: Fork Compression Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.24 FORK COMPRESSION ADJUSTMENT The compression hydraulic brake system determines how the fork behaves in the compression phase. The degree of compression hydraulic braking can be adjusted on the basis of the rider’s preference and/or installed spring rate. MARZOCCHI USD FORK The adjustment screw (1) is positioned on the upper part of the fork cap. Use a screwdriver. by rotating clockwise, braking increases, or anticlockwise it decreases. a total number of 28 clicks are available. WARNING do not touch the lateral bleed screw (2). do not operate on the red hex screw (3) since brake compression variation is not required . WARNING before starting, it is recommended to tighten the adjuster from the standard position to the “all closed” position and counting the clicks. Make note of the number of clicks in order to be able to restore standard adjustment. it is normal to count the clicks starting from the “all closed” position. both rods must be adjusted the same way. standard adjustment: 16 clicks from all closed. KAYABA USD FORK The adjustment screw (1) is positioned on the upper part of the fork cap.

  • Page 44: Fork Rebound Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.25 FORK REBOUND ADJUSTMENT The rebound hydraulic brake system determines how the fork behaves in the rebound phase. The degree of rebound hydraulic braking can be adjusted on the basis of the rider’s preference and/or installed spring rate. MARZOCCHI USD FORK The adjustment screw (1) is positioned on the lower part of the fork foot. Use a screwdriver. by rotating clockwise, braking increases, or anticlockwise it decreases. a total number of 28 clicks are available. WARNING do not operate on the hex nut (2) since brake rebound variation is not required .

  • Page 45: Varying Pre-Load And Replacing Fork Springs

    4. REGISTRATIONS/ADJUSTMENTS 4.26 vARyINg PRE-LOAd ANd REPLACINg FORk SPRINGS Partially disassemble the springs to vary the spring pre-load (see the specific manual regarding the fork fitted on the motorcycle). It is NOT recommended to vary the pre-load of the springs on forks fitted by Tm Racing. Replace the springs with others featuring different rates if required. WARNING For further and more detailed information regarding the forks, refer to the instructions supplied by the fork manufacturer. 4.27 BLEEDING TELESCOPIC FORK every 5 hours of use during competitions, operate on the bleeder screws or valves to release any over-pressure inside the fork. MARZOCCHI USD FORK Marzocchi forks are equipped with a valve (1), which is protected by a rubber cap (2). Remove the rubber cap and gently press the valve stem.

  • Page 46: Checking Steering Bearings And Play Adjustment

    4. REGISTRATIONS/ADJUSTMENTS 4.28 CHECKING STEERING BEARINGS AND PLAY ADJUSTMENT Periodically check steering bearing play. To check, position the motorcycle so that the front wheel is lifted. Turn the handlebar in both directions and move the fork back and forth. if the steering is hard to turn, the bearings are too tight and the ring-nut (3) must be loosened. if the steering vibrates, the bearings have play and the ring-nut (3) must be tightened. To adjust, loosen the four M8 screws (1) and nut (2) of the fork head and tighten or loosen the ring-nut (3) as necessary. do not tighten the ring nut (3) beyond the play elimination point; this prevents damage to the bearings. Tighten the fork head nut and then the four x M8 17 nm screws. Make sure steering is smooth, without jamming or play. DANGER IF THE STEERING BEARINGS ARE TOO TIGHT OR HAVE PLAY, PERFORMANCE ON THE ROAD MAY BE IRREGULAR AND CONTROL OF YOUR MOTORCYCLE COULD BE EASILY LOST.

  • Page 47: Adjusting The Main Light Height

    4. REGISTRATIONS/ADJUSTMENTS 4.29 ADJUSTING MAIN LIGHT HEIGHT The front headlight is height-adjustable. after having adjusted the fixing plastic straps to the forks in order to level the headlight frontally, the front screw (1) can be used to adjust the height of the headlight. Turn it clockwise to lift it or anti-clockwise to lower it. 4.30 HEADLIGHT HEIGHT ADJUSTMENT To check whether the headlight is positioned correctly, position the motorcycle, with the tyres inflated to the right pressure and with a person sitting on the seat, perfectly perpendicular with the longitudinal axis. Facing a wall or screen at a distance of 10 metres, trace a horizontal line corresponding to the height of the centre of the headlight, and a vertical in line with the longitudinal axis of the vehicle. Perform the check, possibly in the penumbra. When switching the high beam on, the upper demarcation limit between the dark and illuminated area must result at a height not exceeding 9/10 of the height from the ground of the centre of the projector.

  • Page 49: General Operations

    5. GENERAL OPERATIONS...
  • Page 50 5. GENERAL OPERATIONS...

  • Page 51: Seat Removal

    5. GENERAL OPERATIONS SEAT REMOVAL Loosen the screws (1) on both sides. Lift the rear part of the seat (2). slide the seat (2) out towards the rear of the motorcycle. LATERAL PANELS DETACHMENT Remove the seat as described in the relative paragraph. Unscrew the screw (1) and remove the panel (2). Proceed in the same manner for the left panel. NOTE: On re-mounting, position the bushes correctly under the screws.

  • Page 52: Radiator Conveyors Removal

    5. GENERAL OPERATIONS RADIATOR CONVEYORS REMOVAL Remove the seat as described in the relative paragraph. Rotate the airbox (2) fixing screw (1) by 1/2 turn and remove it. Unscrew the four screws (3) and remove the right conveyor (4). Proceed in the same way for the left conveyor. NOTE: On re-mounting, position the bushes correctly under the screws. RADIATOR FINS REMOVAL Remove the radiator conveyors as described in the relative paragraph. Use a screwdriver to press on the clamps (1), until the fins (2) are released. Remove the fins (2), releasing the pegs (3). NOTE: On re-mounting, insert the pegs (3) correctly into the relative holes (4).

  • Page 53: Disassembly And Mounting The Front Wheel

    5. GENERAL OPERATIONS DISASSEMBLY AND MOUNTING THE FRONT WHEEL Position the motorcycle with the frame cradle on a stand to keep the front wheel off the ground. Loosen the aluminium flanged screw (1), loosen fixing screws (2) and (3) on the left and right fork feet, and finish unscrewing the flanged screw (1). keep the front wheel still and slide out the wheel pin (4). if necessary, to help the wheel pin escape, lightly tap the threaded end of the pin with a mallet (hammer with plastic head). alternatively, use a normal hammer and a plastic punch. WARNING never use the hammer directly on the pin; the pin could be irreversibly damaged. Carefully remove the front wheel from the fork. WARNING never activate the brake lever when the front wheel has been removed. always position the wheel on the level with the brake disc upwards to prevent damage. To re-mount the front wheel, carefully insert it into the fork, inserting the disc between the brake pads without damaging them. Position the wheel correctly and mount the wheel pin (4), positioning the spacer (5) on the left part of the wheel. Temporarily screw and tighten the flanged screw (1) until the wheel spacer is blocked. Tighten the locking screws (2) onto the right fork foot to prevent the wheel pin from turning, and tighten the flanged screw to 40 nm. Tighten the locking screws (3) on the left fork foot to 12 nm. Loosen the locking screws (2) again on the right foot and remove the motorcycle from the stand. engage the front brake and force the fork down several times to align the rods. end by tightening the locking screws (2) on the left fork foot to 12 nm.

  • Page 54: Disassembly And Mounting The Rear Wheel

    5. GENERAL OPERATIONS DISASSEMBLY AND MOUNTING THE REAR WHEEL Position the motorcycle with the frame cradle on a stand to keep the rear wheel off the ground. Unscrew the flanged nut (1) and, supporting the wheel, slide out the wheel pin (2), remove the chain tensioner slide (3), the calliper (4) with its support, take the chain off the sprocket and carefully remove the rear wheel from the swing arm. Pay attention to the sprocket side and brake side wheel spacers (5). WARNING never activate the brake pedal when the rear wheel has been removed. always position the wheel on the level with the brake disc upwards to prevent damage. When the wheel pin has been removed, clean the threading of both the wheel pin and the flanged nut. Re-grease them to prevent the threading from seizing. WARNING Re-mount the spacers (5) as indicated in table “A”. Table- A 9 mm 8.5 mm 6 mm 8.5 mm Mx/EN/FT 13.7 mm 13.7 mm To re-mount the rear wheel, insert the spacer (sprocket side) in the hub, insert the wheel into the swing arm and, supporting the wheel, mount the chain on the sprocket and position the calliper (4) with its support.

  • Page 55: Parts Removal

    6. PARTS REMOVAL...
  • Page 56 6. PARTS REMOVAL...

  • Page 57: Mud Guards Removal

    6. PARTS REMOVAL MUD GUARDS REMOVAL FRONT MUD GUARD REMOVAL Loosen the screws (1) from below with relative washer and remove the mud guard (2). NOTE: On re-mounting, insert thicker spacers (3) onto the rear screws and thinner spacers (4) onto the front screws. REAR MUD GUARD REMOVAL Remove the seat, the right and left side pods and the licence plate holder as described in the relevant paragraphs. Loosen the silencer fixing screws (1) and (2) (10 mm internal wrench and 8 mm external). Loosen the screws (3) (4 mm internal allen wrench and 10 mm external) that fix the mud guard support subframe and remove the latter (4).
  • Page 58 6. PARTS REMOVAL Loosen the screws (5), with relative washer, which fix the mud guard to the tank. Remove the mud guard (6). NOTE: Re-mount everything in reverse order to disassembly, paying attention to position the wide spacer (7) on the lower support and the narrow one (8) on the rear support, when mounting the silencer.

  • Page 59: Rear Mud Guard Removal Complete

    6. PARTS REMOVAL REAR MUD GUARD REMOVAL COMPLETE W I T H L I C E N C E P L AT E H O L D E R A N D DIRECTION INDICATORS Remove the seat, the right and left side pods as described in the relevant paragraphs. Cut the straps (1). disconnect the tail light wires (2). disconnect the wires (3) of the rear direction indicators. Loosen the silencer fixing screws (4) and (5) (10 mm internal wrench and 8 mm external).
  • Page 60 6. PARTS REMOVAL Loosen the screws (6) (4 mm internal allen wrench and 10 mm external) that fix the mud guard (7) support subframe to the motorcycle rear subframe (8). Loosen the screws (9), with relative washer, which fix the mud guard to the tank. Remove the complete mud guard (10). NOTE: Re-mount everything in reverse order to disassembly, paying attention to position the wide spacer (11) on the lower support and the narrow one (12) on the rear support, when mounting the silencer.

  • Page 61: Rear Position Indicator Light Replacement

    6. PARTS REMOVAL R E A R P O S I T I O N I N D I C AT O R L I G H T REPLACEMENT Remove the seat and left lateral panel as described in the relevant paragraphs.

  • Page 62: Tail Light Replacement

    6. PARTS REMOVAL TAIL LIGHT REPLACEMENT Remove the seat and left lateral panel as described in the relevant paragraphs. Cut the straps (1). disconnect the wires (2). Cut the straps (3). Unscrew the screws (4) with nut (5) in the lower part.
  • Page 63 6. PARTS REMOVAL slide the cable (6) out from the hole in the mud guard. Unscrew the screws (7) of the tail light (8). slide the licence plate holder (9) from the support subframe. Cut the strap (10) and remove the tail light. NOTE: Re-mount everything proceeding in reverse order to disassembly, fix the cabling with plastic straps, positioning them as originally and connect the tail light colour with colour:...

  • Page 64: Licence Plate Holder Removal

    6. PARTS REMOVAL LICENCE PLATE HOLDER REMOVAL Remove the seat and left lateral panel as described in the relevant paragraphs. Cut the straps (1). disconnect the tail light wires (2). disconnect the wires (3) of the rear direction indicators. Cut the straps (4).
  • Page 65 6. PARTS REMOVAL Unscrew the screws (5) with nut (6) in the lower part. slide the cable (7) out from the hole in the mud guard. Remove the licence plate holder (8) complete with tail light and direction indicators. Cut the strap (9). Remove the direction indicators and tail light by unscrewing the relative screws. NOTE: Re-mount everything proceeding in reverse order to disassembly, fix the cabling with plastic straps, positioning them as originally and connect the tail light and the direction indicators colour with colour:...

  • Page 66: Front Headlight Removal/Replacement

    6. PARTS REMOVAL HEADLIGHT REMOVAL/REPLACEMENT Release the four elastics (1) that block the headlight (2) onto the fork rods. disconnect the connector (3) from the headlight. disconnect the connectors (4) of the front direction indicators. Unscrew the two screws (5) that fix the headlight (6) to the mask. Unscrew the headlight adjustment screw (7) completely and remove the headlight (6).

  • Page 67: Front Direction Indicator Light Replacement

    6. PARTS REMOVAL NOTE: Re-mount the headlight, proceeding in reverse order to disassembly, paying attention to correctly position the spring (8) and the nut (9) and connect the direction indicator connectors (4) colour with colour. Right indicator = red/black wire + black wire Left indicator = red/yellow wire + black wire adjust the height of the headlight as described in the relative paragraph.

  • Page 68: Exhaust Unit

    6. PARTS REMOVAL EXHAUST UNIT 1) Silencer 2) Silencer support straps 3) Spacer 4) Spacer 5) springs 6) extension 7) manifold 8) springs 9) manifold on cylinder...

  • Page 69: Exhaust Unit Removal

    6. PARTS REMOVAL EXHAUST UNIT REMOVAL Remove the seat and right side pod as described in the relevant paragraphs. Loosen the silencer fixing screws (1) and (2) (10 mm internal wrench and 8 mm external). Release the spring (3) that blocks the silencer (4) and extension (5) in position. Remove the silencer (4). Release the spring (3) that blocks the extension (5) and exhaust manifold (6) in position.
  • Page 70 6. PARTS REMOVAL slide out the extension (5). Release the two springs (7) that connect the exhaust manifold (6) to the manifold on the cylinder. Remove the manifold (6). Loosen the manifold (9) fixing nuts (8) on the cylinder.
  • Page 71 6. PARTS REMOVAL Remove the manifold (9). NOTE: Re-mount everything, proceeding in the opposite order, paying attention: - when re-mounting the manifold (9), to clean the contact surfaces (10) of the manifold and cylinder from residues of Threebond 1215 sealant and tighten the nuts (8) with a torque of 12 Nm/ 1.2 kgm/ 8.85 ft/lb + Loxeal 82-33 - To position the wide spacer (11) on the lower support and the narrow one (12) on the rear support, when mounting the silencer.

  • Page 72: Tank Removal

    6. PARTS REMOVAL 6.10 TANK REMOVAL Remove the complete mud guard and the splash guard as described in the relevant paragraphs. Loosen the two screws (1) that fix the control unit (2) to the tank (3). Lift the contactor (4) releasing it from the support bracket (5). Loosen the screws (6) from both sides and remove the rear subframe (7), while supporting the tank (3).
  • Page 73 6. PARTS REMOVAL Remove the hoses protection sheath (8). disconnect the fuel pump connector (9). Push the quick coupling ring nut (10) towards the fitting (11) and disconnect the hose (12) from the tank. NOTE: Re-mount everything proceeding in reverse order to disassembly, paying attention to wrap the sheath (8) around the fuel hose (12) and the pump electric connection cable.

  • Page 74: Tank Dismantling

    6. PARTS REMOVAL 6.11 TANK DISMANTLING Remove the tank as described in the relative paragraph. Unscrew the screw (1) and remove the contactor support plate (2). Loosen the screws (3) and remove the fins (4). stretch the strap (5) and remove the bleeder hose (6). Unscrew and remove the cap (7).

  • Page 75: Injector Replacement

    6. PARTS REMOVAL Loosen the screws (8) and remove the pump (9). NOTE: On re-mounting the pump, check that the fitting (10) is positioned as in the figure. Check that the gasket (11) is not ruined and is positioned correctly, then tighten the screws (8) gradually cross-wise, until they are fully home on the plastic of the pump (9) compressing the gasket (11).
  • Page 76 6. PARTS REMOVAL Unscrew the screw (3) that fixes the idle speed adjustment knob (4). Lift the throttle body (5) detaching it from the coupling and disconnect the injector connector (6). Loosen the screw (7) of the injector supply fitting (8). extract the injector (9) from the throttle body. slide the injector (9) out and replace it. NOTE: when re-mounting the injector, pay attention not to invert it.

  • Page 77: Swing Arm Rear Shock Absorber

    6. PARTS REMOVAL 6.13 SWING RM REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL Remove the rear subframe complete with tank and mud guard as described in the relevant paragraph. Unscrew the nut (1) of the shock absorber lower pin (2). slide the pin (2) out. Loosen the nut (3) pin (4) fixing the tie-rod (5) to the rocker (6). slide the pin (4) out.
  • Page 78 6. PARTS REMOVAL Unscrew the nut (7) of the shock absorber upper pin (8). Remove the pin (8). Lift the rear swing arm (9), so that it is parallel to the ground and then lower the shock absorber (10) in a way to slide it from the upper attachment. Remove the shock absorber (10) from the frame. NOTE: Re-mount everything in reverse order, paying attention to re- mount the pins (2), (4) and (8) from the left side of the motorcycle and the relative nuts from the right side.

  • Page 79: Rear Shock Absorber Rockers And Tie-Rod Removal

    6. PARTS REMOVAL 6.14 REAR SHOCK ABSORBER ROCKERS AND TIE-ROd REmOvAL Unscrew the nut (1) of the shock absorber lower pin. slide the pin (2) out. Loosen the nut (3) pin (4) fixing the tie-rod (5) to the rocker (6). Remove the pin (4).
  • Page 80 6. PARTS REMOVAL Loosen the nut (7) of the pin (8) that fixes the rocker (6) to the rear swing arm and then remove the rocker. Loosen the nut (9) and remove the pin (10) with the chain roll (11) and the tie-rod (5). NOTE: Re-mount everything in reverse order, paying attention to re- mount the pins (2), (4) and (8) from the left side of the motorcycle and the relative nuts from the right side. Tighten the nut (1) with a torque of 35 Nm/ 3.5 kgm/ 25.81ft/lb Tighten the nut (3) with a torque of 60 Nm/ 6 kgm/ 44.25 ft/lb...

  • Page 81: Linkages

    6. PARTS REMOVAL 6.15 LINKAGES 1) Rocker 2) Roller cage 3) oil seal 4) bush cover 5) Chain wheel 6) nut 7) Screw 8) Front suspension rod 9) Spacer 10) Pin...

  • Page 82: Rear Swing Arm Removal

    6. PARTS REMOVAL 6.16 REAR SWING ARM REMOVAL Unscrew the nut (1) and slide the pin out from the opposite side. Remove the wheel (2). if the chain has a connecting link, remove it and remove the chain. if the chain does not have a connecting link, the chain runner must be removed to release the chain itself. Unscrew the screw (3). Loosen the two screws (4) blocking from the part opposite the nuts (5) and remove the chain guide (6).
  • Page 83 6. PARTS REMOVAL open the chain runner (7) and release the chain (8). NOTE: On re-mounting the chain runner, make sure the two spacers are re-positioned correctly (9). slide the calliper support (10) out from the attachment on the swing arm. Releases the hoses (11) from the supports (12).
  • Page 84 6. PARTS REMOVAL support the calliper (10) and the hoses (11) with a strap (13) fixed to the silencer. Loosen the nut (14) fixing the swing arm to the rocker (15). slide the rocker pin (16) out. NOTE: On re-mounting, insert the pin (16) from the left part and the nut from the right part. Lower the rocker (15) in a way to release the spring arm (17).
  • Page 85 6. PARTS REMOVAL Unscrew the screw (18) of the brake pedal lever (19). Release the spring (20) releasing the lever (19) in a way to access the swing arm pin. From one side loosen the nut (21) of the swing arm pin. slide the pin (22) out from the opposite side. Loosen the shock absorber upper fixing pin in a way that the frame widens.
  • Page 86 6. PARTS REMOVAL Remove the swing arm (17). Remove the bushes (24) and with relative “oR” gaskets (25) and the bushing (26); use an extractor to remove the roller bearing cages. NOTE: Re-mount everything, proceeding in the opposite order, pay attention to: - Correctly re-mount the swing arm pin (22); grease before inserting and then check that the nut (23) is tightened flush to the pin. Now, tighten the nut positioned from the opposite side with a torque of 40 Nm/ 4.0 kgm/ 29.5 ft/lb.

  • Page 87: Front Swing Arm Removal

    6. PARTS REMOVAL 6.17 FRONT SWING ARM REMOVAL Measure the distance between the upper part of the fork and the steering plate, in a way to position the rod correctly on re-mounting. NOTE: Normally the distance is approx. 13 mm on the first reference notch of the rod. Release the four elastics (1) that block the headlight (2) onto the fork rods. disconnect the connector (3) from the headlight.
  • Page 88 6. PARTS REMOVAL disconnect the connectors (4) of the front direction indicators. on the left rod, loosen the screws (5) and move the brake calliper (6), then loosen the screws (7) and strip the hose (8).
  • Page 89 6. PARTS REMOVAL Loosen the screws (9) and (10) and slide the fork rod (11) out. NOTE: On re-mounting, position the rods on the upper steering plate at the measurement obtained and then tighten the screws (9) with a torque of 20 Nm/ 2.0 kgm/ 14.75 ft/lb and the screws (10) with a torque of 15 Nm/ 1.5 kgm/ 11.06 ft/lb. Re-mount the brake calliper on the left fork, tightening the screws (5) to a torque value of 25 Nm 2.5 kgm - 18.44 ft/lb.

  • Page 90: Front Swing Arm Dismantling

    6. PARTS REMOVAL 6.18 FRONT SWING ARM DISMANTLING The fork system uses a multi-valve damping system, which allows the rebound and compression to be checked and adjusted, and spring for the static load. hydraulic damping in compression is realised by a special valve positioned on the top of every rod. hydraulic damping of rebound takes place via the use of a cartridge sealed inside every load bearing pipe. every rod is fitted with external registers for adjustment of the compression and rebound phase. both rods have air bleeding valves inside the sleeve and screws for bleeding the oil in the cartridge. loaD Bearing PiPes: in special high-tensile steel, with chrome-plating. Rod-hoLdeRs: Made in aluminium alloy; machined with cnc. anodised and polished internally. running bUshes: with Teflon® coating; no first detachment friction. gaskeTs: sealing rings designed by computer ensure maximum sealing in compression and minimum friction in extension. sPRings: Made in steel and available with different stiffness constants (k). (For more detailed information, refer to the Table).
  • Page 91 6. PARTS REMOVAL 1) Compression valve 2) Right rod 3) Left rod 4) Lh leg 5) Rh leg 6) Rod-holder 7) extension adjuster 8) Lock ring 9) Bush 10) Bush 11) Washer 12) sealing ring 13) Lock ring 14) Dust scraper 15) Bush 16) Bush 17) spring 18) Complete pumping unit 19) steering wheel...
  • Page 92 6. PARTS REMOVAL Loosen the upper cap of every rod-holder. NOTE: It is good practice to slightly loosen the caps before removing the rods from the motor cycle. eliminate the oil from the shock absorber unit. block the wheel pin support and loosen the adjustment screw. Push the internal pipe downwards. Position the tool in the figure between the wheel pin support and the cartridge unit nut. hold the nut in its housing with a wrench and remove the adjustment screw. Pay attention not to injure fingers.
  • Page 93 6. PARTS REMOVAL Remove the cartridge assy from the external pipe. do not remove the nut in the lower part of the cartridge assy. Remove the foot valve unit from the cartridge assy. Use an appropriate tool to block the orthogonal external area of the cartridge assy. Use the same tool in the orthogonal internal area of the foot valve assy. Loosen the foot valve unit using a wrench. Check that the oR rings on the foot valve unit are not damaged. replace them, if necessary.
  • Page 94 6. PARTS REMOVAL if the internal and external pipes are not disassembled, turn the rod over for at least 20 minutes to eliminate the oil completely. Remove the dust scraper using a flat tip screwdriver. Remove the lock ring using a flat tip screwdriver. extract the internal pipe from the external one. NOTE: To facilitate the operation, make the pipes run quickly (but carefully) forwards and backwards several times, until they are separated.
  • Page 95 6. PARTS REMOVAL Remove the sealing rings and the metal rings mounted on the internal pipe. do not re-use metal parts that have been removed. replace them with new ones. Replace the damaged sealing rings. The washer and the lock ring can be re-used, if not damaged. Check that the internal rod has no distortions or damage. replace it, if necessary. Check the extension register. Replace the damaged oR rings. Replace the complete unit (do not re-use it). Check the spring. Replace it if: The external diameter is damaged or excessively worn. The free length is equal to or less than 475 mm (18.7 in.). Check the internal pipe. Replace it if distortions are detected. (do not repair or re-use a pipe with distortions). if the pipe has surface defects, clean the surface with sand paper. if repair is not possible, replace the pipe.
  • Page 96 6. PARTS REMOVAL Check the external pipe. Replace the pipe if distortions are detected or if the running surface is damaged. Mount the sealing rings and the metal parts on the internal pipe. For the mounting sequence, see the figure given below. NOTE: Apply grease to the edge of the sealing ring. when mounting the sealing ring on the internal pipe, cover the end part of the latter with a plastic casing, as shown in the figure. This will protect the lip of the ring, thus preventing damage.
  • Page 97 6. PARTS REMOVAL Mount the dust protector on the external pipe. Make sure there is no play between the dust protector and the external pipe. Re-mounting the cartridge assy Tighten the nut until it is locked on the internal rod. Make sure that the length of the threading on the internal rod is minimum 15 mm (0.6 in.). Fill the cartridge with specific oil (200 cm - 12.2 in eliminate the air from the cylinder by moving the piston rod up and down several times.
  • Page 98 6. PARTS REMOVAL Compress the piston rod completely and install the foot valve assy. With the foot valve assy mounted, check that the piston rod is completely extended. block the orthogonal external area of the cartridge assy. Use the same tool in the orthogonal internal area of the foot valve assy. Use a wrench to tighten the foot valve assy to 29 nm (21.4 ft/lb). hold the cartridge assy with the end part of the piston rod facing downwards, as shown in the figure. Pump the piston rod up and down approx. 10 times to distribute the oil evenly in all the assy. drain the excess oil from the cartridge by moving the shock absorber unit along its entire travel. Pay attention not to deform or damage the piston rod or the other parts.
  • Page 99 6. PARTS REMOVAL drain the excess oil from the tank. Clean the excess oil from the cartridge. Mount the spring guide and the spring on the cartridge assy. insert the cartridge assy into the internal pipe. Push the internal pipe downwards. Position the tool in the figure between the wheel pin support and the cartridge unit nut. insert the internal rod into the piston rod and tighten the adjustment screw. Pay attention not to injure fingers. Tighten the adjustment screw to the stop position. Make sure that there is play between the lower part of the adjustment screw and the upper limit of the nut.
  • Page 100 6. PARTS REMOVAL Use a wrench to tighten the nut and adjustment screw to 28 nm (20.6 ft/lb). block the wheel pin support and tighten the adjustment screw to it at 50 nm (36.8 ft/lb). Pour the envisioned amount of oil into the external pipe: 350 cm - 21.36 Tighten the cylinder onto the external pipe at 29 nm (21.4 ft/lb).

  • Page 101: Steering Plate/Steering Bearings Removal

    6. PARTS REMOVAL 6.19 STEERING PLATE/STEERING BEARINGS REMOVAL Remove the fork rods (1) as described in the relative paragraph. Unscrew the central nut (2). Move the upper steering plate (3) complete with handlebar.
  • Page 102 6. PARTS REMOVAL Using a spanner, loosen the ring nut (4) of the steering pin (5). slide the lower plate (6) out complete with bearing. heat the pin (5) and the plate (6) and use relevant tools to remove the bearing (7). Remove the oil seal (8) and the upper bearing (9).
  • Page 103 6. PARTS REMOVAL Remove the housing (10) and (11) using a punch. NOTE: On re-mounting, clean the inside of the steering head and the steering pin well. Insert the bearing housing using a punch. Re- mount the bearings, greasing both the housing and the bearings.

  • Page 104: Acoustic Signal Replacement

    6. PARTS REMOVAL 6.20 ACOUSTIC SIGNAL REPLACEMENT Release the four elastics that block the headlight onto the fork rods and move it without removing it. disconnect the two connectors (1) and loosen the nut (2). Replace the acoustic signal device and re-mount everything in reverse order to disassembly. 6.21 M A P C H A N G E S E L E C T O R S W I T C H REPLACEMENT Remove the left radiator conveyor as described in the relevant paragraph.

  • Page 105: Combination Switch Replacement

    6. PARTS REMOVAL 6.22 COMBINATION SWITCH REPLACEMENT Release the four elastics that block the headlight onto the fork rods and move it without removing it. disconnect the cable (1) of the starter auxiliary lever (2). Loosen the two screws (3) to detach the switch from the handlebar. disconnect connectors (4) and (5), cut the straps and remove the switch. Replace the switch, re-mount everything in reverse order and fix the cabling with plastic straps, as described previously.

  • Page 106: Start Command Replacement

    6. PARTS REMOVAL 6.23 START COMMAND REPLACEMENT Remove the airbox as described in the relevant paragraph. Loosen the two screws (1) and detach the start command (2) from the handlebar. Cut the plastic straps that fix the cabling. disconnect the connector (3) and replace the start command. NOTE: On re-mounting, fix the cabling as previously, using plastic straps. 6.24 INSTRUMENT REPLACEMENT Release the four elastics that block the headlight onto the fork rods and move it without removing it. disconnect the fuel reserve connector (1). disconnect the odometer sensor connector (2).
  • Page 107 6. PARTS REMOVAL disconnect the instrument lighting connector (3). disconnect the direction indicators connector (4). Unscrew the two screws (3) and replace the instrument (4).

  • Page 108: Tension Adjuster Replacement

    6. PARTS REMOVAL 6.25 VOLTAGE ADJUSTER REPLACEMENT Remove the left conveyor as described in the relevant paragraph. disconnect the connector (1). Unscrew the screws (2) and remove the adjuster (3). 6.26 START CONTACTOR REPLACEMENT Remove the seat as described in the relative section. disconnect the connector (1). Loosen the two screws (2) connecting the battery positive cable (3) and the starter motor cable (4). Remove the contactor (5). NOTE: Replace the contactor and re-mount the cables (3) and (4) in the same position. dO NOT INvERT. 6.27 INDICATOR LIGHT REPLACEMENT Remove the seat as described in the relative section.

  • Page 109: Speed Sensor Replacement

    6. PARTS REMOVAL 6.29 SPEED SENSOR REPLACEMENT Remove the headlight, seat and airbox as described in the relevant paragraphs. Unscrew the screw (1) and disconnect the sensor (2). disconnect the connector (3). Cut the straps that fix the cabling and replace the sensor. NOTE: On re-mounting, fix the cabling using plastic straps, as previously described. 6.30 REAR STOP SENSOR REPLACEMENT disconnect the connector (1). Cut the plastic straps that fix the cabling.

  • Page 110: Front Stop Sensor Replacement

    6. PARTS REMOVAL 6.31 FRONT STOP SENSOR REPLACEMENT Remove the headlight as described in the relative paragraph. disconnect the connector (1). Unscrew the sensor (2) from the front brake pump and replace it with a new one. NOTE: dO NOT press the brake lever with the sensor removed. After replacing the front stop sensor it is necessary to perform the function of the front brake and, if necessary, bleed it as described in the relevant paragraph.

  • Page 111: Cooling System

    6. PARTS REMOVAL 6.32 COOLING SYSTEM 1) radiator cap 2) Strap 3) Radiators connection hose 4) Bleeder hose 5) Strap 6) upper hose 7) Strap 8) lower hose 9) Screw 10) Right radiator 11) Washer 12) Vibration damper 13) Left radiator...

  • Page 112: Radiators Removal

    6. PARTS REMOVAL 6.33 RADIATORS REMOVAL Remove the right and left conveyor as described in the relevant paragraph. Loosen the screw (1), remove the radiator cap and drain all of the coolant contained in the radiators. NOTE: On re-mounting the screw (1) replace the aluminium washer. Right radiator on the right radiator, loosen the strap (2) of the connection hose (3) of the two radiators. Use a screwdriver to detach the bleeder hose (4). Loosen the strap (5) and disconnect the upper hose (6).
  • Page 113 6. PARTS REMOVAL Unscrew the two screws (9) and remove the right radiator (10). Left radiator Loosen the strap (11) and strap (12) and detach the relevant hoses. Loosen the strap (13) and disconnect the hose (14). Unscrew the two screws (15) and remove the right radiator (16).

  • Page 114: Engine Removal From The Motorcycle

    6. PARTS REMOVAL 6.34 ENGINE REMOVAL FROM THE MOTORCYCLE disconnect the cables from the battery Remove the seat, the conveyors and the airbox as described in the relevant paragraphs. drain the coolant from the radiators as described in the relevant paragraphs. Loosen the straps (1) and disconnect the radiator hoses (2) from the head. Cut the straps (3), which fix the bleeder hose (4). Loosen the strap (5) and disconnect the radiators connection hose (6). Unscrew the two screws (7).
  • Page 115 6. PARTS REMOVAL Remove the right radiator (8) complete with hoses. Unscrew the two screws (9) and remove the left radiator (10) complete with hoses. Remove the drain hose (11) as described in the relative paragraph. Unscrew the screw (12) and remove the kick start lever (13).
  • Page 116 6. PARTS REMOVAL Unscrew the pin (14) of the brake pedal (15). Release the spring (16) and move the brake pedal. disconnect the starter motor electric connections (17). Unwind the sheath cover (18).
  • Page 117 6. PARTS REMOVAL Loosen the screws (19) and detach the clutch actuator (20) with the pinion cover casing (21). Unscrew the screw (22) and remove the pinion cover support (23). Remove the seeger ring (24). slide out the pinion (25) with the chain.
  • Page 118 6. PARTS REMOVAL detach the voltage adjuster connection connector (26). disconnect the engine electric connection connectors (27). detach the spark plug cap (28). disconnect the fuel hose (29) from the pump.
  • Page 119 6. PARTS REMOVAL Loosen the strap between the throttle body and the coupling. Unscrew the screw (30) that fixes the idle speed adjustment knob (31). detach the throttle body (32) from the engine. disconnect the temperature sensor connector (33).
  • Page 120 6. PARTS REMOVAL Unscrew the three screws (34) of the bracket (35) and remove it. Unscrew the three screws (36) of the bracket (37) and remove it. NOTE: The two brackets are the same; mark them in order to re-mount them correctly. Loosen the engine lower fixing pin (38); block the pin using a 12 mm socket wrench (39) and loosen the nut (40) using a 14 mm closed-end spanner. Loosen the engine upper fixing pin (41); block the pin using a 12 mm socket wrench (42) and loosen the nut (43) using a 14 mm closed-end spanner.
  • Page 121 6. PARTS REMOVAL slide the upper pin (41) out and leave the lower pin (38) mounted. Unscrew the swing arm pin (43). slide out the swing arm pin (43). slide out the lower pin (38).
  • Page 122 6. PARTS REMOVAL Move the swing arm (44) back as much as possible and the engine (45) forward as much as possible in a way to detach it from the swing arm. Loosen the strap (46), mark the manifold (47) in order to re-mount it in the same direction and then remove it. Rotate the engine (45) and remove it from the right side of the motorcycle.

  • Page 123: Engine Re-Mounting

    6. PARTS REMOVAL 6.35 ENgINE RE-mOUNTINg Re-mount the engine, proceeding in reverse order to disassembly. Re-mount the engine support brackets (35) and (37), tightening the screws (34) and (36) with a torque of 22 nm, 2.2 kgm, 16.22 ft/lb. Tighten the pins (38) and (41) with a torque of 45 nm/ 4.5 kgm/ 33.19 ft/ Tighten the swing arm pin (43) with a torque of 70 nm/ 7.0 kgm/ 51.6 ft/lb following that indicated in the “swing arm Removal” paragraph.

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