Related Manuals for Husqvarna SM 610 2006
Summary of Contents for Husqvarna SM 610 2006
- Page 1 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com T o the best kno w ledge of M V A gu sta M otorc ycles S .p.A . - V arese, Inc. the m aterial contained herein is accurate as of the date this publication w as approved for printing.
- Page 3 All manuals and user guides at all-guides.com F o rew o rd T his publication intended fo r H U S Q V A R N A W orks hops has been p repare d for th e p urpose of helping the authorized p ersonnel in the m aintenance and repair w ork of the m otorc ycle s here w ith dealt w ith.
- Page 4 All manuals and user guides at all-guides.com T E 6 1 0 S M 6 1 0 - W here no t othe rw ise specified, data and instructions refer to all m o dels.
- Page 5 All manuals and user guides at all-guides.com 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...
- Page 6 All manuals and user guides at all-guides.com...
- Page 7 All manuals and user guides at all-guides.com G E N E R A L S ection...
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Page 8: Table Of Contents
All manuals and user guides at all-guides.com G E N E R A L T able of C ontents 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
All manuals and user guides at all-guides.com G E N E R A L E N G IN E 4-stroke, single cylinde r B ore 3.85 in. S troke 3.01 in. D isplacem ent 35.15 cu. in. C om pression ratio 11.1:1 T IM IN G S Y S T E M S ingle overhead cam shaft;... -
Page 10: T Ra N S M Is S Io N
All manuals and user guides at all-guides.com G E N E R A L T R A N S M IS S IO N M ulti-plate clutch in oil bath 6-speed gearbo x, cons tant m esh gear type D rive betw een e ngine and gea rb ox m ain shaft b y straight toothed gea rs P rim ary d rive D rive pinion gear... -
Page 11: * F R A M E
All manuals and user guides at all-guides.com G E N E R A L * F R A M E W H E E L S S ingle-beam in steel tubes of circular section splitting appro x. R im s on line w ith the e xhaust;... -
Page 12: Ig N Itio N S Ys Te M - E Le C Tric S Ys Te M
All manuals and user guides at all-guides.com 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 ele m en ts: - G en erato r;... -
Page 13: W E Ig H Ts
All manuals and user guides at all-guides.com 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 610 .....kg 142 (31 3 lbs) T E 610 ..... -
Page 14: C A P Ac Itie S
All manuals and user guides at all-guides.com G E N E R A L C A PA C IT IE S F uel tank (rese rve included) U nleaded gasoline (98 R .O .N .) 2.64 Im p. G all./ 3.17 U .S . G all. F uel reserve 2.64 Im p. - Page 15 All manuals and user guides at all-guides.com M A IN T E N A N C E S ection...
- Page 16 All manuals and user guides at all-guides.com 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 escrip tio n O p era tio n P re-d elivery E ngine oil C oolant...
- Page 17 All manuals and user guides at all-guides.com 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 -...
- Page 18 All manuals and user guides at all-guides.com 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 -...
- Page 19 All manuals and user guides at all-guides.com T R O U B L E S H O O T IN G S ection...
- Page 20 All manuals and user guides at all-guides.com 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 em e d y E n g in e d o n t s tart o r starts w ith d iffic u lty In ad e q u a te co m p ressio n 1.
- Page 21 All manuals and user guides at all-guides.com T R O U B L E S H O O T IN G T ro u b le C au se R em e d y E n g in e cu ts o u t easily 1.
- Page 22 All manuals and user guides at all-guides.com T R O U B L E S H O O T IN G T ro u b le C au se R em e d y C lu tc h d ra g 1.
- Page 23 All manuals and user guides at all-guides.com 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...
- Page 24 All manuals and user guides at all-guides.com T R O U B L E S H O O T IN G T ro u b le C au se R em e d y P o o r (fro n t an d rear) b rakin g 1.
- Page 25 All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S S ection...
- Page 26 All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S T able of C ontents 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...
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Page 27: A D Ju Stm E N T O F Va Lve S P La Y
All manuals and user guides at all-guides.com 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 em ove seat, spoilers, fuel tank, coolers and expa nsion tank as show n at chapter G ene ral O perations . -
Page 28: C Arb U Reto R Ad Ju Stm En T
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S C arb u re to r a d ju stm e n t A djust the carburetor w ith w a rm e ngine and w ith th e throttle control in closed position. -
Page 29: O Il Ch An G E, Clean In G An D Ch An G In G O Il Filters D
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S O il ch an g e , cle an in g an d ch a n g in g o il filters D rain th e o il w ith w arm en g in e . -
Page 30: C Lean In G Th E B Ag Filters
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S C lean in g th e b a g filters T he filters (1) et (2) are set o n the right side betw ee n the cover and the sum p (transm ission to the scavenge pum p), and on the left sum p (tw in-filter, transm ission to the pressure pum p). -
Page 31: R Ep Lace M En T O F Co O Lan T
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S R ep lace m e n t o f co o la n t S et a vessel under the engine an d w ork as follow s : - rem ove the righ t radiator cap a n d the cooling fluid drain scre w (A ) set on the right of the c ylind er. -
Page 32: A Ir Filter Ch E C K An D Clean In G
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S A ir filter c h eck an d cle an in g R em ove the sad dle. R em ove the R .H . -
Page 33: T H Ro Ttle Cab Le Ad Ju Stm En T
All manuals and user guides at all-guides.com 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 ad ju stm en t T o check the correct adjustm ent o f the throttle op erate as follow s: - rem ove the upp er rubb er cap (1);... -
Page 34: C Lu Tch Ad Ju Stm En T
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S C lu tc h ad ju stm en t T he control Iever m ust have a 0.1 2 ÷ 0.20 in. idle stroke before beginning to disenga ge the clutch. - Page 35 All manuals and user guides at all-guides.com 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 ver a n d flu id le vel c h eck O n the S M 6 10 m odel the lever p osition can be adjusted (4 adjustm ents) for an y driver ha nd size.
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Page 36: A D Ju Stm En T O F Rear Co N Tro L P Ed Al
All manuals and user guides at all-guides.com 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 rear co n tro l p ed al T he position of th e rear b rake ped al as regards the footrest can be ad- justed according to the personal requirem ents. -
Page 37: S Teerin G B Earin G S P Lay Ad Ju Stm En T
All manuals and user guides at all-guides.com S E T T IN G S A N D A D JU S T M E N T S S teerin g b earin g s p la y ad ju stm en t T o ensure m axim um safety, the steering should alw a ys be adjuste d so that the handlebars rotate freely w itho ut pla y. - Page 38 All manuals and user guides at all-guides.com 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 (LO W E R R E G IS T E R ) S tandard calibration: -12 clicks.
- Page 39 All manuals and user guides at all-guides.com 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 rea r shock absorber m ust be adjusted according to the rider w eight a nd track conditions.
- Page 40 All manuals and user guides at all-guides.com 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 arry out the cleaning operations as described in the periodical m a intenance card .
- Page 41 All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S S ection...
- Page 42 All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S T able of C ontents E . 3 F O R E W O R D R em o val o f sa d d le E .
- Page 43 All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S F o rew o rd T he ope rations d escribed in this section are refe rre d to the rem oval of the engine fro m the m otorc ycle ; further opera tions not di- rectly connected to this scope are located at the en d of the chapte r.
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Page 44: R Em O Val O F Sa D D Le
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f sad d le T urn counte rclockw ise the re ar fa stening pin (1) a nd rem ove the s addle. R em o va l o f sid e p an els - R .H . -
Page 45: R Em O Val O F Air Filter B O X An D Carb U Reto R
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f air filter b o x an d ca rb u reto r Loosen on the L.H . -
Page 46: R Em O Val O F C O N Ve Yo Rs An D Fu El Tan K
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f co n ve yo rs a n d fu el tan k C lose the L.H . -
Page 47: R Em O Val O F Ex H Au St S Yste M
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f exh au st s ys te m R em ove the scre w s (1), (2) and th e tw o gua rds (3) and (4) from th e front e xhaust pipes and from the central exhau st pipe (N O T E : reassem ble the screw s (1) and (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
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f elec trical co n n ec tio n s an d sp ark p lu g ca p D etach the electrical connections from the engine to the m ain w iring harness (starting m otor cable, ground cable battery-en gine, generato r cable s, neutral sw itch cable) an d the spark plug cap. - Page 49 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S C o o lin g fan , ra d iato rs a n d c o o la n t ex p an sio n ta n k rem o val D isconnect the cooling fan (1) fro m the m ain w irin g harness;...
- Page 51 All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S E n g in e rem o val fro m th e fram e R em ove the upp er engine fastening scre w (1) the n the plate (2 ) fro m the engine.
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Page 52: R Em O Va L O F Rear Fram E W Ith Fen D Er
All manuals and user guides at all-guides.com G E N E R A L O P E R AT IO N S R em o va l o f rear fram e w ith fen d er T his operation d oesn t concern the engine rem oval from the m otorc ycle. R em ove the sad dle, the side panels, the air filter box, the fu el tank, the ex- haust silencer and the rea r brake pum p guard as sho w n on pa ges E .4, E .5, E .7, E .9, E .13. - Page 53 All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY S ection...
- Page 54 All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY T able of C ontents 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 All manuals and user guides at all-guides.com 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...
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Page 56: D Isasse M B Ly O F G Ear Le Ver
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY T o facilitate the job, drain the oil from the engine (as described in the chapter S ettings and A djustm ents , page D .5). R em ove th e spark plug and the gear control lever. -
Page 57: D Isas Sem B Ly O F Altern Ato R Sid E Co Ve R
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f altern a to r sid e co ver R em ove the cover (1 ) w ith the stator (8 m m w re n ch) and w ith the gasket. E xtract the g ear w ith clutch (2). -
Page 58: D Isas Sem B Ly O F Altern Ato R
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f altern a to r a) K eep the fly w heel (1) stead y u sing the tool (2) c ode 800039 522, rem ove the 24 m m nut and its w a sher. -
Page 59: D Isas Sem B Ly O F Th E W Ater P U M P B O D Y
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f th e w ater p u m p b o d y R em ove five screw s (1) (8 m m w rench) retaining the pum p housing (2). -
Page 60: D Isas Sem B Ly O F Cylin D Er H Ead Co Ve R
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f c ylin d er - h e ad co ver R em ove the unio n pipe (1) a nd th e carbureto r. R e m ove the valve register covers (2) (8 m m w rench). -
Page 61: D Isas Sem B Ly O F Cylin D Er H Ead
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f c ylin d er h ea d R em ove the tw o cam shaft gear scre w s (1) (5 m m w rench). R otate the g ear (1);... -
Page 62: D Isas Sem B Ly O F Valve S
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f va lve s U se valve spring com pressor 800 0 39521 to rem o ve the valves. B e careful not to dam age th e gasket surfaces or the com bustion cham ber of th e c ylin- der head. -
Page 63: D Isas Sem B Ly O F P Isto N
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f p isto n H old the piston a nd cover the cra nkcase w ith a clean rag. T he piston (1 ) is m arked w ith an a rro w o n the e xha ust side, in order to correctly reassem ble it. -
Page 64: D Isas Sem B Ly Clu Tch Co Ve R
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly c lu tch co ver R em ove all screw s (13 pcs.) hold ing the clutch cover (1). R em ove the clutch cover (in order to rem o ve the cover, use a screw driver). -
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
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY R em o va l o f th e startin g m o to r a n d h o ld in g flan g e R em ove the tw o fastening screw s (8 m m w rench) and the starting m otor (1 ). -
Page 66: D Isas Sem B Ly O F Clu Tch
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f clu tc h S et an alum inum shim am ong prim ary transm ission teeth (in o rder to prevent its rotation). -
Page 67: D Isas Sem B Ly If Th E G Earb O X Co N Tro L Sh Aft
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly if th e g earb o x c o n tro l sh aft W ithdra w the rack and the connec ted shaft (1) R em ove the tw o 4 m m A llen screw s (2) and rem o ve the plate (3) s procket of the gear sector (4). - Page 68 All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f cran kcase, cran ksh aft an d la y s h aft P erform th e follow ing o n the R .H .
- Page 69 All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY R em ove the see ger ring (7) an d w ithd ra w the pinion, operating on the L.H . crankcase.
- Page 70 All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY R em ove the scre w s locking the L.H . to the R .H . crankcase. Install the special tool (A ) n° 8 000 89743 and o pen the crankcases, levering on the crankshaft S eparate th e cra nkcases w ith the gearbo x assem bly on the left o ne.
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Page 71: D Isas Sem B Ly O F Th E G Earb O X
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f th e g earb o x U sing pliers rem ove the rods (1 ) on w hich the fork s are hinged. R em ove the fork s. -
Page 72: D Isas Sem B Ly O F Th E O Il P U M P
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f th e o il p u m p F rom the previou sly rem oved clutch cover, rem ove the four oil pum p fasten- ing screw s (1 ) (8 m m w rench) that secure the cover, then rem ove all the parts up to the oil pum p drive shaft (2). -
Page 73: D Isas Sem B Ly O F Th E Cran Ks H Aft Co M P O N En Ts
All manuals and user guides at all-guides.com E N G IN E D IS A S S E M B LY D isasse m b ly o f cran ksh aft co m p o n e n ts Insert a plate (1 ) betw een the tw o flyw heel halves. U sing a press, re m ove the connecting rod pin, from one of the flyw h eel halves. - Page 74 All manuals and user guides at all-guides.com...
- Page 75 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G S ection...
- Page 76 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G T able of C ontents 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 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G T able of C ontents 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 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C lean in g o f c o m p o n en ts A ll com ponents m ust be cleaned w ith gasoline an d dried w ith com pressed 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 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C ylin d er h ea d R em ove carbon deposits from the com bustion cham ber using a rou nded scraper.
- Page 80 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G R ep lacin g o versize valve s R em ove the seats b y m illing the rings. T ake great care not to dam a ge the seat locations in the head.
- Page 81 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G R ep lacin g th e valve g u id e C hange the valv e guide as follow s: - P ut the hea d in an oven heated at a tem perature af 200 °C (392 °...
- Page 82 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G V alve sp rin g C heck the free le ngth "L". If this does not correspo nd to the p rescribed lim its then substitute the springs.
- Page 83 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G In sp ec tio n o f ro cker arm C heck the clearance betw een the rocker arm an d the rocker arm shaft.
- Page 84 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C am ro ller rep la cem en t R ep lace th e ca m ro ller if, in c o n seq u en c e o f th e rad ial p la y im - p ro ve m en t (th e n eed le b earin g p in is w o rn ), th e valve p la y exce ed 0.006-0.0 08 in ., b o th fo r th e in ta ke an d exh a u st sid es.
- Page 85 All manuals and user guides at all-guides.com 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 ears R eplace the chain in presence of noisiness and if the chain tensioner on the cylinder is at 10 clicks of its stroke (A ).
- Page 86 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C ylin d er T he c ylinder liner bore should be c om pletely sm ooth, w ithout gro oving or scoring.
- Page 87 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G G u d g e o n p in -co n n ec tin g ro d s m all en d cleara n ce C learance at assem bly should be: 0.00047÷0.0010 6 in.
- Page 88 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G P isto n rin g s -c ylin d er cle aran ce Introduce the rin g into th e lo w er p art o f th e c ylin d er (i.e. w h ere th ere is least w ear);...
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Page 89: C Ran K Sh Aft
All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C o n n ectin g ro d b ig e n d ra d ial clearan ce S T A N D A R D W E A R L IM IT 0,26-0,36 m m... -
Page 90: R Ep Lacin G Th E Sm All En D B U Sh
All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G R ep lacin g th e s m all en d b u sh T he bush should be replaced using a correct size punch and drift. B efore the reassem bly apply on the bush 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
All manuals and user guides at all-guides.com 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 aran ce S T A N D A R D W E A R L IM IT 0,55-0,75 m m 0,09 m m... - Page 92 All manuals and user guides at all-guides.com 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 heck the clearance betw een the selector pin and the selector drum groove b y m easuring the tw o clearances w ith a g auge.
- Page 93 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G O il p u m p T here a re th ree c learances w hich have to be checked to establish w hether the oil pum p needs cha nging or not;...
- Page 94 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G "K E IH IN " c arb u reto r o verh au lin g T horou ghly w ash w ith pe trol and d ry w ith com p ressed air all carbure tor com ponets. T horoughly clean all jets and ducts w ith com pressed air o nly.
- Page 95 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G C arb u re to r a d ju stm e n t A djust the carburetor w ith w a rm e ngine and w ith th e throttle in closed posi- tion.
- Page 96 All manuals and user guides at all-guides.com 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 Inspect needle valve (9) and valve seat (c) G rooved w ear (a ): R eplace.
- Page 97 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G JE T N E E D L E Inspect jet needle (6). B ends/W ear: R e place. S tandard clip po sition: 4th G roov e.
- Page 98 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G F L O A T E R Inspect: - F loat (1 0). D am age: R e place. A C C E L E R A T O R P U M P Inspect: - D iaphra gm (accelerator pum p 11 ) (a).
- Page 99 All manuals and user guides at all-guides.com E N G IN E O V E R H A U L IN G F u el d rain in g T o drain the fuel from the carb uretor float cham ber, close the L.H . side fuel cock (1, fig.
- Page 100 All manuals and user guides at all-guides.com...
- Page 101 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY S ection...
- Page 102 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY T able of C ontents H .4 G e n e ra l d ire c tio n s R eassem b ly o f cran ksh aft H .5 R eassem b ly o f tran sm issio n...
- Page 103 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY N O T E : If not oth erw ise specified, standard tightening torques fo r th e follow 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...
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Page 104: G En Era L D Irec Tio N S
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY G en era l d irec tio n s F or a correct re -assem bly follo w in the adverse se nse w h at sho w n for dism antling, how ever pa ying a special attention to every operation w e spe cifically m ention. -
Page 105: R Eassem B Ly O F Cran Ksh Aft
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f cran ksh aft Lubricate the cra nkpin w ith m oto r oil and place it in the flyw heel. A lig n th e flo w tro u g h h o les o f th e en g in e o il. - Page 106 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY...
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Page 107: R Eassem B Ly O F Tran Sm Issio N
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f tran sm is sio n If the gear shafts have been disassem bled, the follow ing paragraphs sho w the reassem bly sequence. - Page 108 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY ¤ A uxiliary shaft Install 2nd speed gear bushing an d lubricate w ith e ngine oil. M ount: 2nd ge ar and put graphite grease on it (th e side w ith slots should face 3rd speed gear), w as her and circlip.
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Page 109: R Eassem B Ly O F Cran Kcase
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R eassem b ly o f cran kcase P osition the L.H . crankcase on the holding plate (service tool code 8000 90662);... - Page 110 All manuals and user guides at all-guides.com 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 = 25m m /0.98 in . A U X ILIA R Y S H A F T...
- Page 111 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY A s s em b ly o f g e ar fixin g clip an d g earb o x c o n tro l sh a ft R eassem ble the drum (1 ) w ith the screw (2) (28 N m -2,85 K gm -20.6 ft/ Lb + LO C T IT E 2 4 2).
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Page 112: A Ssem B Ly O F C O U N Terw Eig H T An D Laysh Aft G Ear
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY A s s em b ly o f co u n terw eig h t an d la ysh aft g ear Install the counterw eight (1 ) on th e la y shaft using the related ke y (the flat surface m ust be faced outw ard );... -
Page 113: R Eassem B Ly O F Flyw H Eel
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f flyw h eel Install the tim ing system chain (1) on the crankshaft; - degre ase w ith solvent the crankcase cone and the corresponding fitting surface on the flyw h eel;... -
Page 114: R Eassem B Ly O F Stato R An D P Ick-U P
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f stato r an d p ick -u p M ount the stator so that the cable holding plate is in front of th e pick-up location;... - Page 115 All manuals and user guides at all-guides.com 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 startin g in term e d iate g ear Install on the crankcase the centering bushings and the flange (1 );...
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Page 116: R Eassem B Ly O F P Isto N An D Cylin D Er
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY * "d" cut position R easse m b ly o f p isto n a n d c ylin d er F it the piston ring s as show n in fig ure. -
Page 117: R Eassem B Ly O F Cylin D Er H Ead
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f c ylin d er h ea d A lw a ys use a ne w h ead gasket (1 ) w hen assem bling. A ssem ble the cylinder head;... -
Page 118: R Eassem B Ly O F Cam Sh Aft
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f cam sh aft F it the chain into the gear (1) w hile resting the gea r on the inside w all of the head and w ith the notc h on the outside and aligned w ith the head cover m ating surface;... -
Page 119: R Eassem B Ly O F Cam -Ch Ain Ten Sio N Er
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f cam -c h ain te n sio n er B ack the cam chain tensioner pin; - reassem ble the cam chain tensioner w ith the screw s (1) (4,5 N m -0.46 K gm - 3.2 ft/lb);... -
Page 120: R Eassem B Ly O F W Ater P U M P Im P Eller
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f w ater p u m p im p eller M ount the im peller (1 ) on cam sha ft (3) w ith n ut (2 ) (5 N m -0 ,5 K gm -3 .7 ft/lb). R easse m b ly o f c ylin d er h ea d c o ver M ount the rocker arm and push in the rocker arm shaft ;... - Page 121 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY C lean the gasket surfaces on both the c ylinder hea d and the c ylinde r head cover w ith solvent.
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Page 122: R Eassem B Ly O F P U M P H O U Sin G
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f p u m p h o u sin g G rease a nd assem ble tw o ne w O -R ings (1) on th e spacer (2) h ousing. M ount the space r then assem ble a ne w e xtern al O -R ing (3 ) on the spacer end. -
Page 123: L Ay-Sh Aft Tim In G
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY L a y-s h aft tim in g Install the key o n the crankshaft a nd place the driving gear in position. O perate analog y for the la y-shaft. -
Page 124: R Eassem B Ly O F Clu Tch
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f clu tc h P lace an alum inum shim betw e en the teeth of th e p rim ary d rive gears, in order to prevent its rotation. -
Page 125: R Eassem B Ly O F O Il P U M P An D O Il Filter Cartrid G E
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f o il p u m p an d o il filter cartrid g e A ssem ble the oil pum p in orde r show n in the picture. -
Page 126: R Eassem B Ly O F Altern Ato R Co Ver
All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f altern a to r c o ver R eassem ble the ignition cover (2), w ith th e stator , b y inserting the c entering pin (1) and a ne w g asket;... - Page 127 All manuals and user guides at all-guides.com E N G IN E R E A S S E M B LY R easse m b ly o f rear p in io n , n eu tral sen s o r an d g ear sh ift p ed al Install the rear pinion (1) w ith a ne w retaining ring.
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Page 128: In Stru Ctio N S Fo R Lu B Ricatio N
All manuals and user guides at all-guides.com 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 stru ctio n s fo r assem b ly C O M P O N E N T P R O C E D U R E... - Page 129 All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N S ection...
- Page 130 All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N T able of C ontents 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...
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Page 131: F Ro N T S U S P En S Io N
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N F ro n t su s p en sio n T he fro nt suspen sion unit is a M A R Z O C C H I U .S .D . telescopic h ydraulic fork w ith advanced axle; 1 .77 in. diam eter s tanchions. W heel travel along the legs is 9.84 in. -
Page 132: In Stru Ctio N S Fo R U Se O F Ø 45U S D Fo Rk
All manuals and user guides at all-guides.com 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 em ote h ydra ulic fork w ith revers ed legs w ith static load spring and cartridge m ulti-valve dam ping system . -
Page 133: F O Rkw O Rkin G
All manuals and user guides at all-guides.com 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 ydraulic s ystem of this fork relies on m ultivalves; a system alre ad y tested in the past M A G N U M but w ith different featu res as both legs have the sam e setting. -
Page 134: G En Eral Ru Les Fo R A P Ro P Er O Ve Rh Au Lin G
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N Let s see w hat h appens in each leg during R E B O U N D . S pring rebou nd a ction pushes the stanchion dow n w ards, thus causing an oil need into the cartridge (see F IG . -
Page 135: M Aintenance Rec Om M Endations
All manuals and user guides at all-guides.com 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 aintenance rec om m endations T his fork is the result of years of e xperience m a de on the m ost im po rtant racing tracks. - Page 136 All manuals and user guides at all-guides.com 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 rem oving the fork legs fro m the steering crow n and the stee ring head, loosen the upper plug (48) of eac h slider (7) w ith the 19-m m w renc h.
- Page 137 All manuals and user guides at all-guides.com 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 the slider (7) to its end of stroke against the stanchion tube (5-6). P our 2/3 of th e indicated oil quantity into the stanch ion.
- Page 138 All manuals and user guides at all-guides.com 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 ollow the instru ctions from F IG .6 to F IG . 9, as indicated in the abov e paragraph.
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Page 139: S Lid Er D Isasse M B Ly
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N 4- A ir b le ed in g (F IG .2 3) N O T E P erform this ope ration w ith legs fully in rebound (fro nt w heel up from the soil), still fitted in the m otorc ycle. -
Page 140: R Eb O U N D Settin G Ch An G E
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N 2- S ta n ch io n d isassem b ly F IG . 24 F ix the slider of the stanchion tube (5-6 ) into a vice equipped w ith protection jaw s. -
Page 141: D Am P In G U N It Rea Sse M B Ly
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N Insert the adjusting scre w (19 ) into the plug seat (48); push it do w n w hile tu rning counter clockw ise until it locks. -
Page 142: A D Ju Stm En T
All manuals and user guides at all-guides.com 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 setting for C O M P R E S S IO N : w h en in "com pletely closed" position, unscrew b y 12 clicks (F IG .37) S T A N D A R D setting for R E B O U N D : w hen in com pletely closed p osition, unscrew b y 12 clicks (F IG . -
Page 143: R Em O Vin G Th E Fro N T Fo Rk
All manuals and user guides at all-guides.com F R O N T S U S P E N S IO N R em o vin g th e fro n t fo rk T ake note of m e asure A w hich m ust be restored w h en re assem bling. S et a support und er the engine to lift the front w heel from the grou nd, w o rking as follow s: -rem ove,on the L .H . - Page 144 All manuals and user guides at all-guides.com...
- Page 145 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N S ection...
- Page 146 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N T able of C ontents 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...
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Page 147: R E A R Su S P En S Io N
All manuals and user guides at all-guides.com R E A R S U S P E N S IO N R ear su s p en sio n T he suspension of this m otorc ycle is of the progre ssive type and c onsists of a shock absorber, a series of linkages and a sw ing a rm . -
Page 148: C H Eckin G Th E Sh O Ck Ab So Rb Er
All manuals and user guides at all-guides.com R E A R S U S P E N S IO N D isasse m b ly, o ve rh au lin g , a n d reassem b ly o f th e rear sh o ck a b so rb er A ccurately clean the shock absorber before disassem bly. - Page 149 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N B leed the gas b y pressing on the reservoir valve. T o protect his e yes from possible particles, the operator m ust tu rn the valve aw a y from his e yes.
- Page 150 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N O nce the plug is rem oved, push a nd drive the fork rod guide inside the bod y so as to free snap ring housing.
- Page 151 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N G rip the shock a bsorber up per side in a vice using alum inum or bronze jaw s. Insert a rod or a screw d river into the connecting ho le, and rem ove the piston and fork rod unit from the shock absorber bod y.
- Page 152 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N C h eckin g th e a d ju stm e n t In case of com pression adjustm ent for ope rating d efect, it is necessary to unscrew the kno b stopping do w el (before unscre w ing, heat w ith w arm air).
- Page 153 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N...
- Page 154 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N A fter having com pleted the check, insert again the piston, the disk, the spring and the ring w ith slots. R em ove the cone h olding shaft from the plug, screw th e ring an d insert it in the slot applying a light pressure.
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Page 155: R Ea Sse M B Lin G Th E Sh O Ck Ab So Rb Er
All manuals and user guides at all-guides.com R E A R S U S P E N S IO N D isasse m b lin g th e air/o il d iap h rag m o f th e rese rvo ir A lw a ys replace the diaphragm w h en changing the oil inside the shock absorber. - Page 156 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N P repare the diap hragm w ith asse m bled O R (w e a dvise using a new o ne for each replacem ent).
- Page 157 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N R eassem ble the reservoir plug an d the valve, fit it inside the reservo ir, then fit the snap ring into the throat. Insert the nitrogen valve - or the air valve if the nitrogen valve is not an hand - using 10-1 2 bar pressure.
- Page 158 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N L = 234,5÷23 7,5 m m (9.23÷9.35 in .)
- Page 159 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N S h o ck a b so rb er d am p in g ad ju stm en t A djustm ent of the com pression stroke is independent from the rebo und stroke.
- Page 160 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N D isasse m b lin g an d o verh a u lin g th e rear sw in g arm (p ag es J.2 6-J.27) S et a stand or a block under the e ngine and see th at the rea r w he el is lifted from the g round.
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Page 161: O Verh A U Lin G Th E Rear Sw In G Arm Axle
All manuals and user guides at all-guides.com R E A R S U S P E N S IO N O verh a u lin g th e rear sw in g arm axle U sing a com para tor, check the sw ing arm axle fo r distortion. P osition the axle on tw o identical contacts. - Page 162 All manuals and user guides at all-guides.com R E A R S U S P E N S IO N C h ain ten sio n ro llers, ch ain d rivin g ro ller, ch ain g u id e, c h ain ru n n er C heck the w ear of the above m e ntioned elem ents and replace the m w hen necessary.
- Page 163 All manuals and user guides at all-guides.com B R A K E S S ection...
- Page 164 All manuals and user guides at all-guides.com B R A K E S T able of C ontents 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 All manuals and user guides at all-guides.com B R A K E S B R A K IN G S Y S T E M T he braking s ystem s is divided into tw o com pletely independent circuits. E ach system is provid ed w ith a caliper connected to a h ydra ulic control pum p w ith tank for the fluid.
- Page 166 All manuals and user guides at all-guides.com B R A K E S D isc b rake A regular check of brake disc condition is m ost im portant; th e disc should be absolutely clean w ithout an y trace s of rust, oil, grea se or dirt and sh ould not be excessively scored.
- Page 167 All manuals and user guides at all-guides.com B R A K E S W ear ch eck a n d rep lace m en t o f b rake p a d s Inspect pads for w e ar. S ervice lim it A a) T he front p ad thickness m ust not be lo w er th an 3,5 m m (S M ) or 3.8 m m (T E ).
- Page 168 All manuals and user guides at all-guides.com B R A K E S F ro n t b rakin g s ys tem b lee d in g T he braking s ystem m ust be blee d w hen, due to air in the circuit, the lever stroke is long and spong y.
- Page 169 All manuals and user guides at all-guides.com B R A K E S B leed in g th e re ar b reakin g s ys tem T he braking s ystem m ust be bled w h en, due to air in the circuit, the pedal stroke is long and spong y.
- Page 170 All manuals and user guides at all-guides.com B R A K E S F lu id ch a n g e T he brake fluid s hould be checked and changed in accordance w ith the P eriodic M aintenance C hart (pag es B ..) or w h enever it is contam inated w ith dirt or w ate r.
- Page 171 All manuals and user guides at all-guides.com B R A K E S P eriodically check the connecting hoses (A ) and (B ): if the hoses are w orn or cracked, their replacem ent is advised.
- Page 172 All manuals and user guides at all-guides.com...
- Page 173 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M S ection...
- Page 174 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M T able of C ontents 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 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M T able of C ontents 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 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M...
- Page 177 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 en erato r (1 ), in oil bath, on the inner side of L.H .
- Page 179 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M...
- Page 180 All manuals and user guides at all-guides.com 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 charging s ys tem consists of: - A lternator (2);...
- Page 181 All manuals and user guides at all-guides.com 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 rren t leakag e T o gain access to the batte ry, re m ove the saddle (see page E .4 ).
- Page 182 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M G en era to r s tato r co il co n tin u ity ch eck R em ove the stator coil-m ain w irin g harness conne ctor then check the continuity using a tester.
- Page 183 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M V o ltag e reg u lato r-rectifier ch ec kin g W ith the ignition definitely fu nctional, w hilst the ba ttery is charged (12.5V -13V ), start the engine: if the battery tension does not incre ase (14.5V ) after about four m inutes, substitute the regulato r.
- Page 184 All manuals and user guides at all-guides.com 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 he starte r s yste m consists of: - B attery (1 6);...
- Page 185 All manuals and user guides at all-guides.com 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 tarter m o to r d isassem b ly U se a 10 m m w rench to rem ove the nut (1 ) unde r the rubbe r cap an d a 8 m m w rench to rem ove the starting m otor and ground cable screw s (2).
- Page 186 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M S tarter m o to r te st d ia g ram 1- O u tp u t 2- T o rq u e 3- R e vo lu tio n 4- term in al vo lta g e 5- L o ad c u rren t...
- Page 187 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M E lectric start re m o te co n tro l sw itch c h eck D isconnect the starter rela y coupling (A ). D isconne ct the cables from the positive and negative poles of the battery to avoid short circuits during assem bly.
- Page 188 All manuals and user guides at all-guides.com 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 the C .D .I.
- Page 189 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M Ig n itio n c o il resistan ce ch ec k T o gain access to the electronic coil (1) rem ove th e saddle and the fuel tank (see page E .16-E .2 3).
- Page 190 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M E lectro n ic u n it T he electronic un it (1) is fastened under the sad dle. T he ope ration is characterized b y the presence of a condenser that is loaded b y the generato r and th at then release the charge to th e coil in accord w ith the pick-up signal and the program m ed tim in g value.
- Page 191 All manuals and user guides at all-guides.com 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 8E spark plug. C heck distance "A " (0,6÷0,7 m m / 0.022÷0.026 in.) betw een electrod es.
- Page 192 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M T h ro ttle P o sitio n S en s o r ch ec kin g (T P S ) S et the tester in O hm position then detach the th rottle position sensor cable (1) from the m ain w iring harness.
- Page 193 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M B A T T E R Y T he sealed batte ry (1) do es not re quire an y m ainte nance w ork. If th e vehicle re- m ains unused for long periods, it is recom m ended to rem ove batte ry from electri- cal system and s tore it in a dry pla ce.
- Page 194 All manuals and user guides at all-guides.com 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 rning light L ig h ts 2- G R E E N w a rning light N eu tral 3- B A T T E R Y C H A R G E w a rnin g light (the w arning light com es on, contem pora rily w ith th e vertical LE D indicator 1 0, w hen the...
- Page 195 All manuals and user guides at all-guides.com 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 operation allow s you to set th e param ete rs of the instrum ent for use on m otorc ycles w ith different characteristics (S M -T E ).
- Page 196 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M A d d in g / R em o vin g S cree n s T his operation allow s you to add a nd rem ove different screens (func tions) to the unit. T he com pute r contains 9 screens in all. T he screens m a y be show n w ith the b ar grap h acting a s a tachom eter o r a batte ry m e ter.
- Page 197 All manuals and user guides at all-guides.com 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...
- Page 198 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M In stru m e n t rep lacem e n t - M odel T E : rem ove the four elastic 1 fig.1 and rem ove the headlam p holder 2; - M odel S M : rem ove the scre w 3 fig.
- Page 199 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M H E A D L A M P H ead la m p a d ju s tm e n t (T E - S M ) T he fro nt headla m p is fitted a dipping bulb for m ain and dipped be am s and a pilot/side lam p bulb.
- Page 200 All manuals and user guides at all-guides.com E L E C T R IC S Y S T E M R ear tail lig h t b u lb rep lacem en t (T E -S M ) T o gain access to the tail light bulb (12V -5/21W ), p roceed as follow s: - rem ove the tw o fastening screw s (1) and th e rea r lens (2);...
- Page 201 All manuals and user guides at all-guides.com 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 easure the co m m utators contin uity using a teste r.
- Page 202 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 order to facilitate the tank and saddle assem bling, hold do w n w a rd the sheath 2: M ake attention to correctly positioning the conne ctor rubbe r of the instrum ent A ssem ble the clam ps as show n in the figure.
- Page 204 All manuals and user guides at all-guides.com 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 hen a connector is connected, check that it clicks into position. C heck the connector for corrosion, dirt or a b roke n cover.
- Page 205 All manuals and user guides at all-guides.com E N G IN E C O O L IN G S Y S T E M S ection...
- Page 206 All manuals and user guides at all-guides.com E N G IN E C O O L IN G S Y S T E M T able of C ontents 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 All manuals and user guides at all-guides.com E N G IN E C O O L IN G S Y S T E M 1. C entrifugal pu m p 2. R .H . cooler 3. L.H . cooler 4. T herm ostat 5.
- Page 208 All manuals and user guides at all-guides.com...
- Page 209 All manuals and user guides at all-guides.com L U B R IC AT IO N C IR C U IT S ection...
- Page 210 All manuals and user guides at all-guides.com L U B R IC AT IO N C IR C U IT L u b ric atio n s ys tem T he engine lub rication is of the forced type, w ith d u al lobe pum p located inside the R .H .
- Page 211 All manuals and user guides at all-guides.com S P E C IF IC TO O L S S ection...
- Page 212 All manuals and user guides at all-guides.com S P E C IF IC TO O L S S P E C IA L T O O L S 1- (800 0 89743 ) C rankcase 2- (800 0 39523 ) F lyw heel puller 3- (800 0 90662 ) E ngine holder 4- (151 4 13401 ) S w ing a rm puller 5- (800 0 39524 ) C lutch hub retain ing...
- Page 213 All manuals and user guides at all-guides.com TO R Q U E W R E N C H S E T T IN G S S ection T ighten all nuts and bolts w ith a to rque w rench at the correct setting . Insufficient tightening of nuts or bolts can cause them to becom e dam a ged or loose lead ing to vehicle dam age or injury to the rider.
- Page 214 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S S ection...
- Page 220 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S T able of C ontents 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...
- Page 221 All manuals and user guides at all-guides.com 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 single-beam w ith d ouble-cradle type closed in steel tubes. Light allo y rear fram e. F or a rough check, please see the picture (page Y .
- Page 222 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S F ro n t w h eel H ub and rim in light allo y w ith hig h tensile steel spokes. R im m ake, type and dim ension (T E ) "T A K A S A G O E xcel in light alloy: 1,6x2 1 (S M ) "S A N R E M O "...
- Page 223 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S R em o vin g th e fro n t w h eel S et a stand or a block under the e ngine and see th at the front w heel is lifted from the ground. L oosen the bolts (1) holding the w h eel axle (2) to the front fo rk stanchions.
- Page 224 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S R ear w h eel H ub and rim in light allo y w ith hig h tensile steel spokes. R im m ake, type and dim ension (T E ) "T A K A S A G O E xcel in light alloy: 2,15x18 (T C ) "T A K A S A G O E xcel in light alloy: 1,85x19 (2 50);...
- Page 225 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S R em o vin g th e rear w h eel U nscre w the nut (1) of th e w heel pin (3) and extra ct it. It is not neces- sary to unloose the chain adjusters (2);...
- Page 226 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S W h eels o verh au lin g C heck the w ear state of the hub bearings. In case of excessive clearance (radial and a xial), operate as follo w s: - la y the h ub on a flat holder w ith hole, allow ing fo r the passage of the rem oved bearing;...
- Page 227 All manuals and user guides at all-guides.com F R A M E A N D W H E E L S R im s w arp ag e T he table belo w show s the contro l value that the w heel rim m ust be checked. T oo m uch skid and eccentricity are ge nerally caused b y an y w o rn bea rings.
- Page 228 All manuals and user guides at all-guides.com 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 roceed as follow s: - F ully stretch the chain w ith the a djusting screw s.
- Page 229 All manuals and user guides at all-guides.com N O T E S F O R U S A /C D N -A U S M O D E L S S ection...
- Page 230 All manuals and user guides at all-guides.com 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 erin g w arn in g T am pering w ith N oise C ontrol S ystem P rohibited. F ederal la w p rohibits the follow ing acts or causing thereof: (1) T he rem oval or rend ering inop erative b y an y pe rson other than for purp oses of m aintenance, repair, or replacem ent, of an y d evice or elem ent of design incorporated in to an y n e w vehicle for the p urpose of noise control prior...