HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from actual components. No reproduction in full or in part without written authorisation.
FOREWORD, TABLE OF CONTENTS Workshop Manual TE 250 - 310 2011 I.E. WRE 125 2011 SMS 125 2011 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com...
FOREWORD, TABLE OF CONTENTS Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.
FOREWORD, TABLE OF CONTENTS Table of Contents Title Section Foreword, Table of Contents ................a Important Notices ....................b General Information .....................A Maintenance ......................B Troubleshooting ....................C Settings and Adjustments ................... D General Procedures ....................E Engine Disassembly ....................F Engine Overhaul ....................G Engine Assembly ....................
* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client.
GENERAL INFORMATION Cold tire pressure Front Rider only ............... 1,2 Kg/cm (17.07 Psi) Rider and passenger ............1,5 Kg/cm (21.33 Psi) Rear Rider only ...............1,5 Kg/cm (21.33 Psi) Rider and passenger ............1,8 Kg/cm (25.60 Psi) Electrical components location The ignition system includes the following elements: Generator, on the inner side of L.H.
GENERAL INFORMATION WRE 125 H02633 Overall dimensions Wheelbase A (WRE) ................mm 1462 (57.56 in.) (SMS) ................mm 1462 (57.56 in.) Overall length B (WRE) ................mm 2208 (86.93 in.) (SMS) ................mm 2145 (84.49 in.) Overall width C ..............mm 825 (32.48 in.) Overall height D (WRE) ................
GENERAL INFORMATION SMS 125 H02634 Capacities Type Quantity Fuel tank capacity (reserve included) 98 octane unleaded fuel 9,5 l - 2.09 Imp. Gall 2.51 U.S. Gall Fuel reserve 2 l - 0.44 Imp. Gall 0.53 U.S. Gall Oil tank capacity 0.176 Imp.
MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) WRE - SMS 125 ENGINE PART EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE 500 km (310 mi) 1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi) 20000 Km (12427 mi)
MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) WRE - SMS 125 CHASSIS PART EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE 3 HOURS 1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi) 20000 Km (12427 mi) AS REQUIRED...
TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or has starting trou- Insufficient compression bles 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston ring Replace 4. Worn cylinder Replace 5. Cylinder head loosely tightened Tighten 6.
TROUBLESHOOTING Trouble Cause Remedy Engine is noisy Noise seems to come from piston 1. Too much piston-to-cylinder clearance Replace 2. Worn piston rings or piston grooves Replace 3. Too much carbon build-up in combustion chamber Clean or on piston crown Noise seems to come from crankshaft 1.
TROUBLESHOOTING Trouble Cause Remedy Gear shift pedal does not return to original 1. Weak or broken selector return spring Replace position 2. Worn shifter forks Replace Transmission jumps out of gear 1. Worn sliding gear dogs Replace 2. Worn gear grooves Replace 3.
TROUBLESHOOTING CHASSIS Trouble Cause Remedy The handlebar is hard to turn 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut Adjust overtightened 3. Bent steering stem Replace bottom yoke 4. Worn or seized steering bearings Replace Handlebar vibration 1.
TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy The spark plug gets dirty easily 1. Dirty air filter Clean 2. Worn piston rings Replace 3. Worn piston or cylinder liner Replace 4. Mixture too rich Adjust carburettor Spark plug electrodes overheat 1.
SETTINGS AND ADJUSTMENTS Saddle removal Turn the rear fixing (1) counter clockwise, remove it and extract the saddle. Tank removal Remove the saddle as described in the relevant paragraph. Remove the screws (1) and the side panels. (8 mm Allen wrench) H02635 Remove the tank retaining screw (2).
SETTINGS AND ADJUSTMENTS Lift the front part of the tank (6) and remove it from the bike with the scoops. H02638 Ed. 05-2011...
SETTINGS AND ADJUSTMENTS Throttle cable adjustment The throttle cable may be adjusted using the adjuster screw on the cable itself or the adjuster screw on the carburettor cover. To check for proper adjustment of throttle cable, proceed as follows: move the rubber cap (1) aside; move transmission sheath to and fro to ensure a play of approx.
SETTINGS AND ADJUSTMENTS Idle adjustment Idling should be adjusted only when the engine is hot and throttle is closed, as follows: turn the idle speed adjuster screw (1) until setting 1500 RPM ± 100 (turn clock- wise to increase the speed and counter clockwise to reduce the speed). Exhaust gas contains poisonous carbon monoxide gas.
SETTINGS AND ADJUSTMENTS Clutch plate replacement Drain transmission oil as outlined in the relevant paragraph. Remove the brake pedal (1). Remove the five retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the five screws (4) securing the clutch springs.
SETTINGS AND ADJUSTMENTS Adjustment of the clutch control lever To adjust the clutch control lever, you will need to adjust cable tension using the adjuster on the lever. Remove the rubber protection (1). Loosen the lock ring nut (3) and turn the tensioner (2). There should be at least 10 mm (0.39 in.) free play (A) before the clutch begins to disengage.
SETTINGS AND ADJUSTMENTS Front brake fluid level check The level of the fluid in master cylinder reservoir must never be below the minimum value, which can be checked from the sight glass (1) on the side of master cylinder body. A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.
SETTINGS AND ADJUSTMENTS Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs. For adjusting, proceed as follows: Loosen the screw (1). Turn the cam (2) in order to raise or lower the brake pedal (3) within the range available (A).
SETTINGS AND ADJUSTMENTS Rear brake fluid level check Master cylinder fluid level - visible through sight glass (1) - must be above the minimum notch on master cylinder reservoir. A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.
SETTINGS AND ADJUSTMENTS Changing transmission/gearbox oil Remove the engine guard (1) by undoing the screws (2). H02653 To completely replace the oil, unscrew the plug (3) under the oil sump and let oil come out, then screw the plug again with its gasket and pour fresh oil from the hole of the loading plug.
SETTINGS AND ADJUSTMENTS Engine lubrication oil level Remove the saddle, turning the rear pin (1) counterclockwise. Remove the cap (2). Visually check that the oil level in the tank is sufficient; if necessary, top up with the oil type indicated in the lubricant table. H02655 H06642 Exhaust valve cleaning / oil drainage...
SETTINGS AND ADJUSTMENTS Lubricating oil pump drainage Remove the saddle and side panel, as outlined in the relevant paragraph. Drainage is to be done with the engine off. Using the special pliers, loosen clamp onto pump (5) to carburettor pipe (4), and disconnect pipe.
SETTINGS AND ADJUSTMENTS Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 0.39 in. above the cells. The radiator cap features two locking positions: the first one is for prior discharge of pressure from the cooling system.
SETTINGS AND ADJUSTMENTS Coolant replacement Place the vehicle on a flat ground and in horizontal position. Place a vessel of adequate capacity on the right side of the vehicle under the water pump (1). Loosen the exhaust screw (2) using an 8 mm wrench. Slowly open the RH radiator cap (3) and let the liquid drain.
SETTINGS AND ADJUSTMENTS Air filter check Remove the saddle as outlined in the relevant paragraph. Disconnect the battery cables (1) and (2) and remove the battery (3). H06646 Lift the engine oil reservoir (4). Undo the screw (5) and remove the filter (6). Detach the filter (6) from the subframe (7).
SETTINGS AND ADJUSTMENTS Assembly To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece (A) is turned up- wards and edge (B) is on the left lower side of the filter case. Reassemble the parts previously removed.
SETTINGS AND ADJUSTMENTS Chain adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break.
SETTINGS AND ADJUSTMENTS Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets. Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication.
SETTINGS AND ADJUSTMENTS Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions. Proceed as follows: 1. Place the motorcycle on the stand and measure distance (A). 2. Sit on the motorcycle in normal riding position with full riding gear on. 3.
SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment Proceed as follows: 1. Turn the rear fixing (1) counter clockwise and remove the saddle, unscrew the retaining screws (2) and remove the right-hand side panel (3). 2. Clean lock ring nut (4) and adjuster ring nut (5) of the spring (6). 3.
SETTINGS AND ADJUSTMENTS Front fork adjustment Front fork has no adjustment. Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground.
SETTINGS AND ADJUSTMENTS Fuel supply hose inspection Check the pipe (1) starting from tank cock and reaching the carburettor. If cracked, replace it by releasing the two clamps (2). H02683 H02658 Engine lubrication oil piping check Remove the saddle and right-hand side panel, as outlined in the relevant paragraph.
SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section "E". Ensure that pipe (1) and silencer (2) do not show any sign of failure or damage: replace if cracked or damaged. Remove the right-hand side panel (3) and check the conditions of the silent-blocks (4).
Exhaust valve position check H02846 H02848 The cylinder has a double exhaust valve system called H.T.S. (HUSQVARNA TORQUE SYSTEM), ensuring engine top performance. These valves are con- trolled by a centrifugal governor making them open at approx. 7500 rpm ± 200.
GENERAL PROCEDURES Foreword This section describes the operations preliminary to engine removal. Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts. H02702 H02704 H02703...
GENERAL PROCEDURES Saddle removal - Turn the rear fixing (1) counter clockwise and remove the saddle. H02655 Side panel removal Remove the saddle as described in the relevant paragraph. Using an 8 mm wrench, loosen retaining screws (1) and remove side panels (2) and (3). H02708 H02709 Battery removal Remove the saddle as outlined in the relevant paragraph. - Using an 8 mm Allen wrench, first remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable); remove the battery (1) from its hous-...
GENERAL PROCEDURES Oil reservoir removal Remove saddle, side panels and tank as outlined in the relevant para- graphs. Disconnect the oil pump supply connector (1). Using an 8 mm wrench, loosen screw (2), and remove oil pump (3) with its mount.
GENERAL PROCEDURES Electronic control unit removal Remove the saddle as outlined in the relevant paragraph. Remove control unit (1) from the special vibration mount (2). Release connector (3) from control unit (1) H02715 H02716 Ed. 05-2011...
GENERAL PROCEDURES Rear chassis complete with mudguard and air box removal Remove saddle, side panels, tank, silencer, battery, oil reservoir and control unit (in this order), as outlined in the relevant paragraphs. Shear the plastic clips securing wiring to rear chassis. H02718 - Disconnect air temperature sensor connector (1) positioned inside filter box (widen tabs, and pull).
GENERAL PROCEDURES To remove upper pin (7), loosen nut with a 12 mm wrench and pin with a 13 mm wrench. H02722 - Lift chassis (8) complete with filter box (9). H02717 Ed. 05-2011...
GENERAL PROCEDURES Exhaust system removal H02723 Remove the saddle as described in the relevant paragraph. Remove the right-hand side panel as described in the relevant paragraph. Using an 8 mm T-wrench, remove silencer (2) retaining screws (1), and remove silencer from vehicle. H02724 E.10 Ed.
GENERAL PROCEDURES Remove clamp (3) and disconnect secondary air circuit pipe (4) from exhaust manifold (5). H02725 Release the two springs (6). H02726 To remove manifold (5), loosen screw (7) with an 8 mm wrench. Check seal (8) and metal gasket (9) for wear. Change, if damaged. H02727 H02728 H02729...
GENERAL PROCEDURES Fuel tank and scoop removal H02730 Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Remove the breather hose (1). H02731 E.12 Ed. 05-2011...
GENERAL PROCEDURES Loosen tank retaining screw (2) (with an 8 mm Allen wrench). H02732 Close fuel cock (3), release clamp (5), and disconnect pipe (4). H02637 Raise the tank (6) from the front end, and remove it from bike complete with scoops (7).
GENERAL PROCEDURES Scoop removal Remove the saddle and side panels, as outlined in the relevant para- graphs. Using an 8 mm wrench, loosen front screw (8) between scoop (7) and tank. H02734 Using an 8 mm wrench, loosen side screw (9) and upper screws (10) with a Phillips screwdriver; then remove scoop (7).
GENERAL PROCEDURES Voltage regulator removal Disconnect the connector (1). Loosen the two retaining screws (2) and remove the regulator (3). (8 mm wrench) H02738 Ignition coil removal Remove: saddle and fuel tank as described in the relevant paragraphs. Remove the spark plug cap (1). H02739 Remove the retaining screws (2) and then the coil (3).
GENERAL PROCEDURES Horn removal Loosen the upper screw (1) securing the spoiler to the right-hand radiator. H02741 Disconnect the two connectors (2) and remove the horn (3) with its brack- H02742 Number plate holder removal Remove tail light as outlined in section M. Disconnect rear turning indicator connectors (1) and (2).
GENERAL PROCEDURES Air box removal Remove saddle, side panels, fuel tank, oil reservoir and silencer (in this order), as outlined in the relevant paragraphs. - Disconnect air temperature sensor connector (1) positioned inside filter box (widen tabs, and pull). H02718 - Loosen clamp (2) securing filter box to carburettor. H02745 Loosen the screws (3) using a 10 mm wrench. H02746 Loosen upper pin (4) using a 12 mm wrench on nut, and a 13 mm wrench on pin.
GENERAL PROCEDURES - Overturn chassis (5) with filter box (6) without removing control unit and fuse and flasher holder bracket. H02751 - Using an 8 mm wrench, loosen the four screws (7), and remove filter box (6) from chassis. H02750 H02748 Using a 2.5 mm Allen wrench, loosen the two screws (8), and remove tem- perature sensor (9). H02752 E.18 Ed. 05-2011...
GENERAL PROCEDURES Using an 8 mm wrench, loosen the two screws (10), and remove shock absorber protection (11). H02753 Remove rivets (13), and remove upper rubber protection (12). - Remove the air filter. H02754 Front mudguard removal Using an 8 mm wrench, loosen the four screws (1), and remove mudguard (2).
GENERAL PROCEDURES Rear brake removal Using a 6 mm Allen wrench, loosen screw (1), and remove lever (2) complete with pump pushrod (3). H02756 Carburettor removal Close fuel cock (1), release clamp (3), and disconnect pipe (2). H02765 Disconnect TPS sensor connector (4). Important - Do not remove TPS from carburettor in order not to lose calibration.
GENERAL PROCEDURES Loosen clamps (6), and disconnect mixture oil hose (5). H02749 H02764 Slightly turn carburettor (8) to the left, loosen screw (9), and remove starter control (10). H02762 H02761 Ed. 05-2011 E.21...
GENERAL PROCEDURES Loosen the two screws (11), and remove carburettor valve cover (12). H02760 H02759 Detach carburettor (8), and remove it. H02758 On reassembly, take care that carburettor breather hoses (13) are correctly positioned inside their seats and that they are not kinked.
GENERAL PROCEDURES Secondary drive chain removal To remove chain, proceed as follows: Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5). H02673 H02767 Engine removal Remove the saddle as described in the relevant paragraph. Remove the fuel tank as described in the relevant paragraph. Remove the exhaust system as described in the relevant paragraph.
GENERAL PROCEDURES Engine removal Lift retaining tab, and disconnect clutch cable (1). H02768 - Disconnect ignition connector (2), PICKUP connector (3), and coolant tem- perature sensor (4). H02769 H02770 Take off the spark plug cap (5). H02771 E.24 Ed. 05-2011...
GENERAL PROCEDURES Loosen clamp (6), and praise carburettor (7) off the intake duct. H02772 Open clamps (8), and disconnect pipes (9) from engine (10). H02773 Using a 27 mm wrench, loosen nut (11) on swinging arm shaft then, work- ing on the right side, remove swinging arm shaft until releasing engine, but without removing swinging arm.
GENERAL PROCEDURES Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs. Drain all coolant as outlined in the relevant paragraph. Using an 8 mm wrench, loosen screws (2), and remove radiator protections (1).
GENERAL PROCEDURES Open clamps (8), and disconnect hoses (9) from left-hand radiator (10). H06649 Open clamp (11), and disconnect the radiator connecting hose (12). H02780 Using an 8 mm wrench, loosen screws (13), and remove left-hand radiator (10). H02781 H02782 Ed.
GENERAL PROCEDURES Using an 8 mm wrench, loosen screws (14), and remove right-hand radiator (7). H02784 H02783 Thermostat removal Remove fuel tank, and drain all coolant as outlined in the relevant para- graph. Open the three clamps (1) securing the thermostat (2). Disconnect the hoses (3) and remove the thermostat (2).
ENGINE DISASSEMBLY Right-hand side component and cover disassembly 14 13 20 17 H06625 To make disassembly operations easier, it is recommended to place engine block onto a rotating support, securing it on the upper side. Loosen screw (1), and remove the kick start lever (2). (8 mm wrench) Loosen the two screws (3), and remove regulator cover (4).
ENGINE DISASSEMBLY Clutch-side crankcase half component disassembly Working crossways, loosen the five retaining screws (1) on clutch springs, and remove them together with the relevant washers (2) and springs (3). H06528 Remove pressure plate (4) and clutch plates pack (5) from hub. Slide thrust washer (6), axial roller bearing (7) and retainer (8) out of pri- mary shaft end.
ENGINE DISASSEMBLY Carry out this operation using special tool part no. 8000 79015 with the ends inserted inside the two opposite grooves on clutch hub. Lock clutch hub in place with tool, and loosen locking nut (13) with a 22 mm socket wrench.
ENGINE DISASSEMBLY Countershaft nut (16) has a left-hand thread. Loosen countershaft nut (16) placing a 1/2 gear or an aluminium shim be- tween clutch housing gear (17) and countershaft gear (18). H06534 Slide clutch housing (17), the two needle roller cages (18) with spacer (19), the inner spacer (20) and three-tab washer (21) out of primary shaft.
ENGINE DISASSEMBLY Remove the Woodruff key from crankshaft. H06536 Slide countershaft idle gear (24) with the relevant shims (25) out of right crankcase half. H06537 Slide selector shaft (26) out of right crankcase half rear side. H06538 Ed. 05-2011...
ENGINE DISASSEMBLY Disengage return spring (27) on starter shaft (28) from its retainer on right crankcase half. H06539 Working on the inner side, slide out starter shaft (28) assembly complete with control gear, and collect washer (29). H06540 Sprocket-side component and cover disassembly Loosen the three retaining screws (1), and remove cover (2).
ENGINE DISASSEMBLY Using a chisel and a hammer, straighten the bent sections of lock washer (5) on sprocket sealing screw. H06542 Lock sprocket (6) in place using tool part no. 00YA2273 and then, with a 13 mm socket wrench, loosen sprocket sealing screw on output shaft. Slide out this screw, lock washer, large washer and sprocket.
ENGINE DISASSEMBLY Prevent rotor rotation using a suitable tool. Using a 17 mm socket wrench, loosen rotor sealing nut. Remove lock washer. H06544 Use tool (7) part no. 8000 51614, and secure it onto rotor with three screws having a suitable length. Holding the tool in place with a 19 mm Allen wrench and working clockwise on the central screw, remove rotor from crankshaft with a 17 mm Allen wrench.
ENGINE DISASSEMBLY Loose the three retaining screws (8) on stator. Slide rubber block and plate (9) out of left crankcase half, and remove the complete stator (10). Remove the Woodruff key from crankshaft. H06546 Intake valve disassembly Using the special wrench part no. 8000 98431 loosen the four sealing screws (1) on intake valve unit (2).
ENGINE DISASSEMBLY Remove intake valve (2) from crankcase, and collect gasket (3). H06548 Exhaust valve disassembly - Remove exhaust valve control unit (1) ad described in the relevant paragraph. - Loosen screw (2), and remove parts (3), (4), (5) and (6). Remove screws (7) and cover (8).
ENGINE DISASSEMBLY Piston-cylinder-and-head assy disassembly Head, cylinder and piston can be disassembled also at an earlier stage, as this procedure is independent of the disassembly operations carried out so far. The piston-cylinder-and-head assy removal proves now necessary in order to separate the crankcase halves.
ENGINE DISASSEMBLY Slide cylinder (6) out of crankcase stud bolts, by duly supporting piston with your hands when it is separated from cylinder. WARNING - When removing the cylinder, do not let it rotate as piston ring end could enter gaps thus preventing piston removal and causing damage to the piston ring itself.
ENGINE DISASSEMBLY Splitting the crankcase Loosen the 12 retaining screws on left crankcase half. H06624 H06624 With the gearbox in neutral position, fit tool part no. 8000 79016 on left crank- case half (with 3 duly-sized "A" screws), work on the central pin and separate crankcase halves.
ENGINE DISASSEMBLY Using pliers, counteract spring action and turn ratchet to allow selector shaft removal. Slide out selector shaft from the left side. H06556 Crankshaft removal Should it be necessary to remove crankshaft from right crankcase half, use the same tool part no. 8000 79016 already used for crankcase splitting. Align tool holes with those on right crankcase half outer side, and secure tool with three screws of a suitable length.
ENGINE OVERHAUL Cleaning parts All parts must be cleaned with gasoline and dried with compressed air. During this procedure flammable vapours develop and metal particles may be blown at high speed, it is therefore recommended to perform this procedure away from open flames or sources of ignition, and to wear goggles. Ed.
ENGINE OVERHAUL Compression ratio check To check if the compression ratio is correct, proceed as follows: a) remove the cylinder together with the head from the crankcase ; b) remove the piston from the connecting rod, carefully clean it and install it in- side cylinder until it rests against the corresponding sector on the combustion chamber (such part, as well, has to be cleaned from deposits) c) screw a dial gauge into the spark plug hole, and reset it on the piston position...
ENGINE OVERHAUL Cylinder Light alloy cylinder with "NIKASIL"-coated liner. Once the cylinder has been activated, the max. allowed out-of-round value is 0.015 mm (0.0006 in.). In case of damages or excessive wear the cylinder shall be replaced. Cylinders are marked by a letter or a colour referring to the class they belong to. Cylinder measuring Check that the internal surface is perfectly smooth and free from scuffing.
ENGINE OVERHAUL Clearances To ensure the best operating conditions and maximum performance, all clearances must be within the specified tolerance. A tight fit will lead to seizure as moving parts heat up; whereas a loose fit will cause annoying vibration resulting in early wear of moving parts.
ENGINE OVERHAUL Cylinder to piston clearance The piston-cylinder units are supplied already coupled; should the cylinders and pistons of some units have been accidentally mixed up, it will be necessary to measure the diameters as outlined in the previous paragraphs. Take these measurements at a stabilised temperature of 20°C.
ENGINE OVERHAUL Piston rings Visually check the piston ring and the relevant seat in the piston. If the piston ring is worn or damaged, it has to be replaced (the set is available as spare part). If the piston ring seat is worn or damaged as well, both piston and piston ring shall be replaced.
ENGINE OVERHAUL Piston pin-piston-connecting rod small end clearance The table below is a list of the possible clearances allowing to reach the right radial clearance of 0.002÷0.010 mm (0.000078÷0.000393 in.). If, during engine overhaul, a radial clearance higher than the max. allowed value of 0.015 (0.00059 in.) is found and the colour mark (C) is no longer vis- ible on the connecting rod, it will be necessary to measure the diameter "A"...
ENGINE OVERHAUL Pin-flywheel-connecting rod big end clearance The table below is a list of the possible clearances allowing to reach the right radial clearance of 0.20÷0.028 mm. If, during engine overhaul, a radial clear- ance higher than the max. allowed value of 0.050 is found, it will not be neces- sary to measure the diameter "E"...
ENGINE OVERHAUL Connecting rod Due to the stresses the connecting rod is subject to, its original dimensions change in a more or less noticeable way. The connecting rod tests are meant to check its wholeness. Should readings not comply with the max. allowed wear limits, it will be neces- sary to replace it.
ENGINE OVERHAUL Head Remove carbon deposits from the combustion chamber. Make sure that there is no cracking and that the sealing surfaces do not feature scoring, dents or any other kind of damages. Flatness must be perfect as well as spark plug seat threading.
ENGINE OVERHAUL Various crankshaft straightness check Place the crankshaft between centres and take the measurement with a dial gauge, checking that the detected value does not exceed 0.05 mm (0.00196 in.). H06578 Bearings Carefully wash bearings with mixture and dry with compressed air without turn- ing them.
ENGINE OVERHAUL Needle roller bearing replacement To remove the needle roller bearing of the water pump shaft, use special tool part no. 8000 43824. H06581 Oil seal replacement Replace the oil seals at each engine overhaul. To install the new oil seals, in- sert them squarely into their housings and use suitable driver tools.
ENGINE OVERHAUL Clutch unit Inspect all clutch components to make sure they are in the best conditions. Clutch plates should show no signs of bluing, scoring or distortion; the plates fitted with friction material shall have a thickness complying with the values indicated in the table.
ENGINE OVERHAUL Gear change Check that the gear front coupling teeth are in perfect conditions, make sure that the idle gears rotate freely on their shafts and that their clearance is not higher than 0.10 mm (0.004 in.). The shaft threading and grooves must be in perfect conditions. Moreover, make sure that the gear selector components are in good conditions.
ENGINE OVERHAUL Shifter forks Visually inspect the shifter forks and replace any bent fork. A bent fork will make gears hard to engage and let the transmission jump out of gear unex- pectedly under loading. Fork slider thickness Standard Max. size limit 3.35÷3.43 mm 3.31 mm (0.132÷0.135 in.)
ENGINE OVERHAUL Carburettor H06593 NOTE adjuster screws are on the left side of the motorcycle. Description Ref. Dell'Orto PHBH 28 1 Throttle valve D 48/2 groove (*) 2 Taper needle U 38 3 Idle diffuser N° 2 6.5 gr 4 Floater 5 Jet at maximum HN 268 6 Main nozzle...
ENGINE OVERHAUL Carburettor overhaul Clean all carburettor components thoroughly with gasoline and dry them with compressed air. Clean all jets and holes thoroughly blowing them with com- pressed air. Never use tool bits or metal wire. Check that the slide valve is in good condition.
ENGINE OVERHAUL Main jet correction factor The main jet strongly affects carburetion, hence the general performance of the engine. Climate factors such as external tem- perature and altitude greatly affect the behaviour of the air-fuel mixture within the carburettor. It is thus necessary to modify the original jet size, inferring the correction factor on the graph below.
ENGINE OVERHAUL Washer valve Make sure that plates are neither worn nor broken. Should this be the case, replace the plates and the plate stops. When refitting the removed parts, apply Loctite on the screws. H06597 Exhaust valve Clean the valves with a spark plug cleaner brush or with thin sand paper. Clean and replace them following the intervals indicated in section "B".
ENGINE ASSEMBLY General instructions..................H.3 Items summary and general assembly notes ..........H.4 Crankshaft reassembly .................H.4 Gear shift part reassembly ................H.5 Piston-cylinder-and-head reassembly ............H.9 Primary drive and countershaft gears line up ..........H.12 Clutch reassembly ..................H.13 Right cover reassembly ................H.15 Exhaust valve reassembly ................H.17 Ed.
ENGINE ASSEMBLY General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly operations are expressly high- lighted in the text. Gaskets, oil seals, metal clips, sealing washers in deformable material (copper, aluminium, fibre etc.) and self- locking nuts must always be replaced. Bearing specifications and dimensions have been calculated for a certain operating life.
ENGINE ASSEMBLY Item summary and general assembly notes PARTS PROCEDURES Flywheel - Crankshaft taper end Degrease with suitable degreasers Crankcase crankshaft Fit the shaft inside the pre-heated bearings Starter drive shaft Press with "Loctite 648" Crankshaft - Bearings Pre-heating seat at 100°C/125°C Piston pin - Connecting rod - Cage Check selection colours coupling (see Sect.
ENGINE ASSEMBLY Gear shift part reassembly Fit the original shim at the end of the output shaft. If the selector shaft or the gear shafts are replaced, it will be necessary to determine the thickness of the shims to be fitted in order to achieve the correct axial clearance. Selector shaft and gear shafts axial clearance: 0.3÷0.4 mm (0.012÷.015 in.).
ENGINE ASSEMBLY Fit the selector shaft with its bearing and sector gear well lubricated with engine oil in the right half crankcase. If the ratchet is already assembled on the outer side of the crankcase half, use pliers to counteract the action of the spring so as to allow the insertion of the selector shaft.
ENGINE ASSEMBLY WARNING - In case of incorrect sealing, the following operating failures may occur: Air seepage causing a leaner mixture and possible engine seizure. Oil leak from gearbox area to crankshaft area; this may lead to a fast consumption of lubricant causing gearbox overheating and seizure.
ENGINE ASSEMBLY Fit the original shim (4) on starter shaft end, and insert it in the right crankcase half seat. Mind the positioning of the clutch spring end, it must be fitted between the rear end of the crankcase half and the protruding tooth (D). Pre-charge the lever return spring by turning its end clockwise until it is fitted inside the special crankcase half hole.
ENGINE ASSEMBLY Fit the countershaft drive gear (5) with the original shims (6). H06608 Fit the spacer (9) and the tab in the crankshaft seat, and install the primary drive gear (7) and the water pump control gear (8). H06609 To correctly line up the primary drive and countershaft gears, the position of the crankshaft gear must correspond to that of the piston at TDC.
ENGINE ASSEMBLY Lubricate all the parts to be assembled with engine oil and fit the cylinder into the piston by compressing the ends of the piston rings with your fingers (or us- ing a universal piston installation tool). During installation, avoid rotating the cylinder since piston ring ends could enter ducts.
ENGINE ASSEMBLY Rotate the crankshaft and check that the piston (1) slides freely inside cylin- der. Tighten the nuts (2) between cylinder and crankcase to the recommended torque, working crossways. Fit the duly greased external (3) and internal (4) O-rings in the cylinder seats and insert the head inside cylinder stud bolts.
ENGINE ASSEMBLY Primary drive and countershaft gears line up Fit a dial gauge on the head to determine the condition of the piston at the top dead centre. Insert on the primary shaft the three-tab washer (1), the inner spacer and the two roller cages (2) with spacer (3).
ENGINE ASSEMBLY Clutch reassembly Fit bushing, spring and clutch control lever shaft inside L.H. crankcase half seat. Fit the washer (1) and the disengagement group into the primary shaft in the following order: the fist rod and the ball. All these parts must be greased before reassembly.
ENGINE ASSEMBLY Install the lock washer and hub locking nut. While locking the hub with tool part no. 8000 79015, lock the nut with a 22 mm socket wrench to the specified tightening torque. Rivet washer onto nut. H06617 Fit the friction plates starting by one of the seven line steel plates (3) and alternate it with one of the six friction plates (4);...
ENGINE ASSEMBLY Fit the bearing thrust washer (7) and assemble the pressure plate (8). H06618 Fit the clutch springs (9) and lock them onto hub with the suitable washers and screws. H06619 Right cover reassembly Install the original shim at the ends of water pump control shaft (A) and intro- duce it inside its seat on RH crankcase half.
ENGINE ASSEMBLY Install the gasket on the crankcase half, and check the correct position of the centring bushings; proceed to RH cover reassembly, taking care that the water pump control shaft end can be easily installed inside its special cover seat. H06638 Insert the eight retaining screws, taking care that the one at the rear centring bushing (white arrow) is longer than the other ones.
ENGINE ASSEMBLY Exhaust valve reassembly To reassemble the exhaust valves, simply reverse the removal procedure minding that with completely closed valves, the min. distance from the piston must be equal to or grater than 0.4÷0.5 mm (0.0157÷0.0197 in.). On bushings (A), check the wear of the seats holes for pin (B); if worn, replace the parts.
FRONT SUSPENSION Front fork removal Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: H02787 H02786 remove the screws (1) and the brake line clamp on the left-hand side;...
FRONT SUSPENSION remove the brake calliper from the L.H. fork leg loosening the two retaining screws (3); remove the front wheel as described in Section "Y"; H02789 loosen the bolts (4) that secure the fork legs to steering head and bottom yoke;...
FRONT SUSPENSION Front fork overhaul H06650 1) Bottom yoke with pin 2) Steering head 3) Nut 4) Tube spacer 5) Cap 6) Outer tube 7) LH damper unit 8) RH damper unit 9) Ring nut 10) Clamp 11) Leg protection Ed.
FRONT SUSPENSION Disassembly Using a 30 mm Allen wrench, loosen upper cap (1) Completely loosen cap and remove it. Push slider (2) downwards onto inner tube. H02792 Screw a threaded bar (A) onto inner shock absorber rod. Pull absorber rod upwards using the bar and, at the same time, push upper retainer (3) downwards with your hand so as to slide out the two split rings (4).
FRONT SUSPENSION Remove dust seal (5) prising it off with a screwdriver (take care not to dam- age inner seal lip). H02795 Using a thin screwdriver, remove slider inner retaining ring (6). When removing the sealing ring (7), it is advisable to protect its lip with a special bush (B).
FRONT SUSPENSION Assembly Install lower retainer (8), with the discharged side pointing outwards. H02799 Slide sealing ring (7) inside the special bumper (C), and drive it fully home inside slider. Lock it inside slider with the retaining ring (6). H02800 Install it on the duly-lubricated dust seal tube (5), and move it downwards along tube.
FRONT SUSPENSION Lubricate inner tube and insert it inside slider (2). This operation is made easier thanks to pipe tapered end. Install the previously-assembled dust seal onto slider, and drive this latter fully home onto tube. H02802 Oil replacement Pour 520 cc of recommended oil inside inner tube, pumping rod to full travel several times to allow oil distribution inside shock absorber.
FRONT SUSPENSION Pull rod outwards and, at the same time, push retainer (3) downwards so as to allow split rings (4) correct insertion. Leave bar and retainer, and check that split rings are correctly installed onto rod. H02805 Grease the O-ring (9) positioned onto cap (1) Screw cap (1) onto slider (2).
REAR SUSPENSION Rear suspension The rising-rate rear suspension is made up of a shock absorber, a linkage system and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions. Periodically check all components for wear. Type of suspension Steel swinging arm suspension with hydraulic single shock absorber.
REAR SUSPENSION Rear shock absorber removal Fit a support under the engine so that the rear wheel is raised off the ground. Remove rear chassis, as described in paragraph E - General Procedures. Using a 14 mm wrench, loosen nut (1) on bike left side. H02812 Slightly raise rear swinging arm, and remove lower pin (2) from the right side.
REAR SUSPENSION Disassembling and servicing the swinging arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove secondary drive chain (1), release rear brake line (3) from swinging arm (2), and remove chain guard (4) as outlined in the relevant paragraphs (see section E).
REAR SUSPENSION Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion. Service limit: 0.30 mm. H00428 Servicing the rear suspension drop and drag link With drop link (1) and drag link (2) still in place (connected to swinging arm and...
REAR SUSPENSION Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary. Check the chain guide alignment, and remember that a bent element can cause chain early wear. In this case, chain might unwrap from the sprocket.
BRAKES Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Bleeding the front braking system ..............L.6 Bleeding the rear braking system ..............L.7 Changing the fluid..................L.8 Removal of the rear braking system ............L.11 Removal of the front braking system ............
BRAKES Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 4.
BRAKES Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: 260 mm Front brake disc thickness (when new): 3.0 mm Wear limit: 2.5 mm Rear brake disc diameter: 240 mm Rear brake disc thickness (when new): 4.0 mm...
BRAKES Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 3.8 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs. Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.
BRAKES Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).
BRAKES Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Remove reservoir cap (A) (21 mm wrench) and diaphragm and fill with fluid (DOT 4).
BRAKES Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind. Use only fluid taken from a sealed container (DOT 4).
BRAKES Remove the reservoir cap (2) or (2A) 21 mm wrench and the rubber gaiter. Loosen the bleed valve on the calliper. Pump the brake lever (3) or the brake pedal (3A) until draining all fluid. Tighten the bleed valve and fill the reservoir with fresh fluid. Loosen the bleed valve, operate lever or pedal, tighten the valve keeping lever or pedal pressed and then release quickly.
BRAKES Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses. H02836 H02837 L.10 Ed. 05-2011...
BRAKES Removal of the rear braking system Remove the rear wheel as outlined in the paragraph (see chapter Y). Remove the hose (2) supports (1) by loosening the screws (3) using an 8 mm wrench. H02838 Loosen the two screws (4) and remove the pump (5) by disconnecting the STOP micro switch connector (6).
BRAKES Removal of the front braking system Remove the front wheel (1) as outlined in the relevant paragraph (see sec- tion Y). Loosen the screws (3) and remove the block (2). H02842 Loosen the two screws (5) and disconnect the brake calliper (6). H02841 Release the hose (7) from the support (8).
ELECTRICAL SYSTEM TROUBLESHOOTING ................M.35 CHARGING SYSTEM ................M.35 ELECTRONIC IGNITION SYSTEM ............M.35 Connector positioning ................M.36 Bike left-hand side ..................M.36 Bike right-hand side .................. M.37 Front side, under headlamp fairing ............M.38 Under the saddle ..................M.38 Rear side, under tail light .................
ELECTRICAL SYSTEM Wiring diagram 22 23 H02524 Key to wiring diagram 24. Water temperature sensor Gr/B ....Grey/Blue 25. Alternator Gr/Bk .... Grey/Black 1. Battery 26. Voltage regulator O ....Orange 2. Electronic control unit 27. Rear L.H. turning indicator O/B ....
ELECTRICAL SYSTEM Electrical component location The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H02525 Electronic ignition coil (2) under the fuel tank; H02526 Electronic control unit (3) under the saddle; H06651 Voltage regulator (4) on steering tube left side;...
ELECTRICAL SYSTEM Spark plug (5) on cylinder head; Spark plug cap (5a); H02529 TPS sensor (6) on carburettor; H02530 H06652 Oil pump (7) positioned on right-hand rear chassis; Air temperature sensor (8) positioned inside filter box, close to oil pump; Coolant temperature sensor (9);...
ELECTRICAL SYSTEM Electrical component location The electrical system includes the following elements: - 12V-4Ah Battery (11) under the saddle; H06653 Turning indicator flasher (12) on left side of rear chassis; Fuses (13) on utilities holder plate, on left side of rear chassis; H02535 Headlamp (14) with 12V-35/35W twin halogen bulb and 12V-3W parking light bulb;...
ELECTRICAL SYSTEM Checking generator stator windings resistance The generator consists of a 12 V alternator with a power of 160 at 6,000 rpm, positioned inside engine left side cover. Ignition current start (spark): approx. 350 rpm. H02539 Measure across the terminals of the connector (1); correct value is about 0.6 . If resistance is outside the specified limits, replace the complete generator.
ELECTRICAL SYSTEM Alternator inspection Disconnect the three yellow cables coming from the alternator from the regulator, taking care to properly insulate them so as not to let them contact each other. Take engine to approx. 3,000 rpm, and measure the open-circuit voltage using an alternate current voltmeter with a scale up to at least 50V.
ELECTRICAL SYSTEM CHARGING SYSTEM The charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2); - 20A fuse (3); - Battery (4). The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator/rectifier. The voltage regulator/rectifier serves a dual purpose: it provides overvoltage protection for the battery and converts alternated current into direct current.
ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTIONS Current loss at the battery Remove the saddle (as outlined in the relevant paragraph) to gain access to the battery (1). Disconnect the BLACK negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using a meter.
ELECTRICAL SYSTEM Checking coil windings resistance Remove saddle and fuel tank (see relevant paragraph) to gain access to the coil (1). Disconnect the coil connector from the wiring, remove retaining screws and coil, and measure resistance in the primary and secondary windings with a meter. Induction coil: Primary winding resistance: 4.5 ±15% at 20°C.
ELECTRICAL SYSTEM Electronic control unit (ECU) Remove the saddle as described in Section E to gain access to the electronic control unit (1). Capacitive injection, i.e the spark on spark plug is obtained thanks to the discharge of a condenser - positioned inside control unit - through a capacitive coil. Spark ignites based on an advance table relating to the RPM values and throt- tle position.
ELECTRICAL SYSTEM BATTERY The battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place. After an intensive use of the battery, it is advisable to carry out a standard slow charging cycle (12V-4Ah battery: 0.6A for 8 hours).
ELECTRICAL SYSTEM Carburettor throttle position sensor (TPS) inspection Disconnect pipe from TPS on carburettor and, with the tester in OHM mode, position terminals across poles B and C on sensor, turn throttle twistgrip from the fully closed to the fully open position. Check that the resistance value cor- responds to the one specified in the table.
ELECTRICAL SYSTEM The following operations must be carried out with the engine off. Turn the ignition key (3) to "ON", oil warning light (4) will flash to indicate that the self-learning mode is active. With the throttle control released, press Engine Stop key (6), and keep it pressed: oil warning light (4) will start flashing more quickly.
ELECTRICAL SYSTEM Checking coolant temperature sensor Remove cap (1), disconnect electric contacts, and remove thermostat from head. Connect coolant temperature sensor (2) to an ohmmeter, and dip it inside the oil contained inside a pan. Heat up oil to slowly increase its temperature, and observe the values shown by the thermometer and ohmmeter.
ELECTRICAL SYSTEM Headlight unit with front fairing removal Using an 8 mm wrench, loosen screw (1). H02558 Move headlamp fairing (2) forward, and lift it to release damping pads (3) from their mounts (4). H02559 Open pipe support (5), and slide out front brake pipe (6) and speed sensor cable (7).
ELECTRICAL SYSTEM Removing headlight from front fairing Remove the headlight unit complete with front fairing as outlined in the relevant paragraph. Loosen beam adjuster screw (1). H02565 Disconnect headlight connector (2). Widen the supporting tabs (3), and remove headlight (4) from the inside. H02564 M.20 Ed.
ELECTRICAL SYSTEM Front turning indicator removal Remove the headlight unit complete with front fairing as outlined in the relevant paragraph. Disconnect connectors (1) and (2) of right and left turn indicators, respec- tively. H02566 Using a 10 mm wrench on the inside and an 8 mm wrench on the outside, loosen screws (3) and remove turning indicators (4).
ELECTRICAL SYSTEM HEADLAMP, TAIL LIGHT Headlamp adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light. Beam setting needs to be performed accurately; proceed as follows: - Place the motorcycle 10 metres away from a vertical wall; - the motorcycle must be on level ground and the optical axis of the headlamp must be perpendicular to the wall;...
ELECTRICAL SYSTEM release the bulb holder clips (3) and take out bulb (4); H02570 Headlamp bulb (4) is of the halogen type (H4); be careful when replacing it since the glass part shall not be touched with bare hands. To replace the parking light bulb (5) extract it from the inside cover. Once the bulb has been replaced, reverse the above procedure to reassem- ble.
ELECTRICAL SYSTEM Number plate bulb replacement - Loosen screw (1) and remove the number plate bulb (2) from the mud- guard. H02574 - Extract the bulb holder (3) with the bulb (4) from the housing. - Pull the bulb (4) to detach it from bulb holder. Once the bulb has been replaced, reverse the above procedure to reassem- ble.
ELECTRICAL SYSTEM Rear turning indicator removal Remove the tail light as outlined in the relevant paragraph. Disconnect connectors (1) and (2) of right and left turn indicators, respec- tively. H02575 Slide turning indicator cables out of rubber gaiter (3). H02576 Using a 10 mm wrench on the inside and an 8 mm wrench on the outside, loosen screws (4) and remove turning indicators (5).
ELECTRICAL SYSTEM Rear wiring harness replacement Remove the left body panel as outlined in section E. Remove the tail light as outlined in the relevant paragraph. Disconnect connector (1) and cut clamps securing wiring harness to chas- sis. Disconnect rear turning indicator connectors, and remove wiring harness. TWO TYPES OF EqUIVALENT, FULLY INTERCHANGEABLE WIR- ING HARNESSES, BUT WITH A DIFFERENT SHAPE, ARE AVAIL- ABLE.
ELECTRICAL SYSTEM Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty. Right-hand switch 1 Engine stop button COLOUR POSITION H02611 Left-hand switch High beam flasher (self-cancelling) High beam switch Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling) To deactivate the turning indicators, press the control lever after it is returned...
ELECTRICAL SYSTEM G-Bk Colour coding key B ....Blue Bk ....Black B-Bk ....Blue-Black B-W ....Blue-White G ....Green G-Bk ..... Green-Black G-W ....Green-White Gr ....Grey Y ....Yellow R ....Red B-Bk Sb ....Sky blue W ....
ELECTRICAL SYSTEM FUSES • When you find a blown fuse (1), always investigate and eliminate the cause before replacing it. • Never replace a fuse with another fuse with a different rating. • Never use a wire or other makeshift repair techniques instead of installing a new fuse.
ELECTRICAL SYSTEM DIGITAL DASHBOARD, WARNING LIGHTS The motorcycle is fitted with a digital dashboard on which 3 warning lights are also available: high beam, turning indicators and fuel reserve. 1 - BLUE warning light “High beam” 2 - GREEN warning light “Turning indicators” 3 - RED warning light "Engine lubricating oil reserve"...
ELECTRICAL SYSTEM 2 - SPEED / CLOCK - SPEED: speed - maximum value: 299 Km/h or 299 mph; - CLOCK: clock - reading from 0:00 to 23:59:59. To reset the clock, push the SCROLL button (A) and hold for more than 3 seconds in order to increase the hour value;...
ELECTRICAL SYSTEM 5- SPEED / HOUR COUNTER It counts engine operating hours every 30 minutes up to a max. of 30 hours (the figure will be lost once battery is removed). To delete the stored data, push the SCROLL button (A) and hold for more than 3 seconds.
ELECTRICAL SYSTEM Dashboard replacement Remove the headlamp fairing as outlined in the relevant paragraph. H02587 Remove the two retaining screws (1) securing the dashboard to its bracket, disconnect the connector (2) and remove the dashboard (3). To refit the dashboard, reverse the disassembly procedure. H02586 Instructions for the instrument setting Upon turning on the instrument, if the operation DID NOT already take place,...
ELECTRICAL SYSTEM Ignition switch removal Remove the headlight unit complete with front fairing as outlined in the relevant paragraph. Loosen ring nut (1) Disconnect connector (2) and remove ignition switch (3). H02588 TROUBLESHOOTING CHARGING SYSTEM A battery that does not hold charge might be a symptom of: 1) current loss (see paragraph "Current loss at the battery");...
ELECTRICAL SYSTEM Connector positioning Bike left-hand side Engine stop button connector (1) positioned under tank on chassis upper left-hand side, close to coil. H02589 H02591 Generator connector (2) positioned under tank on chassis upper left-hand side, close to coil. Pick-up connector (3) positioned under tank on chassis upper left-hand side, close to coil.
ELECTRICAL SYSTEM Fuse connectors (6) positioned on rear chassis left-hand side. Turning indicator flasher connector (7) positioned on rear chassis left-hand side. Main wiring harness to rear wiring harness connector (8) positioned on rear chassis left-hand side. Oil level sensor connector (9) positioned on rear chassis left-hand side. H02594 Voltage regulator connector (9a) positioned on steering tube left-hand side.
ELECTRICAL SYSTEM Front side, under headlamp fairing Ignition switch connector (14) Front stop sensor connector (15) Speed sensor connector (16) Dashboard connector (17) Left-hand switch connector (18) Front left-hand turning indicator connectors (19) Headlight connector (20) Front right-hand turning indicator connector (21) Horn connector (21a) H02598 H02597...
ELECTRICAL SYSTEM Securing the wiring harness Bike main wiring harness consists of a main branch connecting control unit, fuses, oil pump, flasher, dashboard, switches, TPS, generator and the various available (air, water, stop, etc...) sensors and of a rear branch connecting tail light, number plate light and rear turning indicators.
ELECTRICAL SYSTEM The wiring harness reaching stop microswitch is secured to chassis through clamps (7). H02606 On the front side, wiring harness (1) is secured to clips (8) and (9) to holder plate, and with clamp (10). H02607 On handlebar, left-hand switch, right-hand switch and stop microswitch wiring harness is secured on handlebar through rubber straps (11).
ENGINE COOLING Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system. Without cooling medium (water), no heat exchange occurs between cylinder head and radiator.
ENGINE COOLING Cooling circuit H02611 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Fitting Water pump Breather hose Radiator connecting pipe Water pump / radiator lower pipe Thermostat to connection pipe 10 Thermostat 11 Thermostat to head pipe...
ENGINE COOLING Engine cooling system overhaul If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air.
TIGHTENING TORQUE FIGURES Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent. Ed. 05-2011...
CHASSIS AND WHEELS Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Chassis parts check ..................Y.4 Front wheel ....................Y.5 Removing the front wheel ................Y.6 Reassembling the front wheel ..............Y.7 Speed sensor ....................Y.8 Rear wheel ....................Y.9 Removing the rear wheel................
CHASSIS AND WHEELS Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy. A badly damaged chassis must be replaced. Ed. 05-2011...
CHASSIS AND WHEELS Lubrication points (lubricant) 1 Steering bearings (grease) H02618 Chassis parts check H02617 Controllo componenti telaio Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER/BEARING D FOOTPEGS/PINS/SPRINGS...
CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. H02620 Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. H02621 Hold the head of the wheel axle in place, and unscrew the bolt (3) on the opposite side;...
CHASSIS AND WHEELS Reassembling the front wheel Fit the L.H. spacer on the wheel hub. H02621 Fit the wheel between the fork legs so as to set the brake disc into the calliper. Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully home against the L.H.
CHASSIS AND WHEELS Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. H02624 Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...
CHASSIS AND WHEELS Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...
CHASSIS AND WHEELS Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed. Improper tightening will affect motorcycle stability; for a quick check, simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear, crisp sound indicates proper tightening, a dull sound means that the spokes need to be tightened.
CHASSIS AND WHEELS Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket. 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn, replace it after loosening the six screws that retain it to the hub.
CHASSIS AND WHEELS Checking pinion and sprockets for wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced. Wheel misalignment causes abnormal wear, making the motorcycle unsafe to ride. Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension.