Husqvarna TC449 Workshop Manual
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Husqvarna TC449 Workshop Manual

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Technical DVD
Technical DVD
Workshop Manual
My 2011
Ed. 11-2010
www.husqvarna-motorcycles.com

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Summary of Contents for Husqvarna TC449

  • Page 1 Technical DVD Technical DVD Workshop Manual My 2011 Ed. 11-2010 www.husqvarna-motorcycles.com...
  • Page 2 HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the ma- nual may differ from actual components. No reproduction in full or in part without written authorisation.

  • Page 3: Foreword, Table Of Contents

    FOREWORD, TABLE OF CONTENTS Workshop Manual TC - TE - TXC 449 2011 I.E. TE - TXC 511 2011 I.E. SMR 449 - 511 2011 I.E. Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.
  • Page 4 FOREWORD, TABLE OF CONTENTS Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.

  • Page 5: Table Of Contents

    FOREWORD, TABLE OF CONTENTS Table of Contents Title Section Foreword, Table of Contents ................a Important Notices ....................b General Information .....................A Maintenance ......................B Troubleshooting ....................C Settings and Adjustments ................... D General Procedures ....................E Adjustments - Engine ..................F Engine Disassembly /Reassembly ..............F1 Front Suspension ....................

  • Page 7: Important Notices

    IMPORTANT NOTICES Section edition (08-2010) _Rev. 11-2010...
  • Page 8 * 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.

  • Page 9: General Information

    GENERAL INFORMATION Section edition (08-2010) _Rev. 11-2010...
  • Page 10 GENERAL INFORMATION Engine ......................A.3 Timing system ....................A.3 Fuel system ....................A.3 Lubrication ....................A.3 Cooling ......................A.3 Ignition system....................A.3 Starter ......................A.3 Drive and Transmission ................A.3 Chassis ......................A.4 Suspension ....................A.4 Brakes ......................A.4 Wheels......................A.4 Tyres ......................A.4 Electrical components location ..............A.5 Supplies ......................A.6 Overall dimensions - Weight .................A.7 edition (08-2010) _Rev.

  • Page 11: Engine

    GENERAL INFORMATION Engine Single cylinder, 4 stroke TC-TE-TXC-SMR 449 Bore ..................3.86 in (98 mm) Stroke ..................2.35 in (59.6 mm) Displacement ............. 27.44 cu.in (449.6 cu.cm) Compression ratio (TC) ................13:1 Compression ratio (TE-TXC-SMR) .............12:1 TE-TXC-SMR 511 Bore ..................3.98 in (101 mm) Stroke ..................

  • Page 12: Chassis

    GENERAL INFORMATION Gear ratios (TE - TXC - SMR) 1st gear..................2.286 (32/14) 2nd gear ..................1.875 (30/16) 3rd gear ..................1.533 (23/15) 4th gear ..................1.250 (25/20) 5th gear ..................1.043 (24/23) 6th gear ..................0.917 (24/23) Secondary drive Motion is transmitted from gearbox to rear wheel through 5/8" x 1/4" chain Transmission sprocket ................

  • Page 13: Brakes

    GENERAL INFORMATION Brakes Front (TC - TE - TXC) Fixed disc type “WAVE” Ø 10.24 in (260 mm) with hydraulic control and floating calliper. Brake pad surface area ........2.56 sq.in (16.50 sq.cm) x 2 Front (SMR) “WAVE” Ø 9.45 in (240 mm) with hydraulic control and floating calliper. Brake pad surface area ..........

  • Page 14: Electrical Components Location

    GENERAL INFORMATION Electrical components location (TC) The ignition system includes the following elements: Generator on the inner side of L.H. crankcase half cover; Electronic ignition coil with integrated spark plug cap positioned on cylinder head; Electronic control unit under the saddle; Spark plug on cylinder head;...

  • Page 15: Supplies

    GENERAL INFORMATION Supplies (reserve included) Type Quantity Fuel tank (TC) Unleaded fuel 95R0Z/R0N 2.25 gal (8.5 litres) Fuel tank (TE-SMR 499/511) Unleaded fuel 95R0Z/R0N 2.25 gal (8.5 litres) Fuel tank (TE-SMR 499/511 USA) Unleaded fuel 95R0Z/R0N 2.51 gal (9.5 litres) Fuel tank (TXC) Unleaded fuel 95R0Z/R0N 2.51 gal (9.5 litres)

  • Page 16: Overall Dimensions - Weight

    GENERAL INFORMATION Overall dimensions - Weight Kerb weight, without fuel (TC): ..........108 Kg (238.1 lb) Kerb weight, without fuel (TE): ..........113 Kg (249.12 lb) Kerb weight, without fuel (TXC): ..........110 Kg (242.51 lb) Kerb weight, without fuel (SMR): ........123,5 Kg (272,27 Ib) *: max.
  • Page 17 GENERAL INFORMATION ������ ��������������������� �������������������� �������������������� ������� edition (08-2010) _Rev. 11-2010...
  • Page 18 GENERAL INFORMATION 820 mm (32,28 inch) * 1460 mm (57,48 inch) 2170 mm (85,43 inch) H06375 A.10 edition (08-2010) _Rev. 11-2010...

  • Page 19: Maintenance

    MAINTENANCE Section edition (08-2010) _Rev. 11-2010...
  • Page 20 MAINTENANCE TE -TXC 449 /511 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF EVERY 10 h EVERY 20 h EVERY 30 h EVERY 70 h NECESSARY...
  • Page 21 MAINTENANCE TC 449 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE ENGINE REPLACE IF EVERY 10 h EVERY 25 h EVERY 50 h EVERY 70 h NECESSARY ENGINE OIL FILTRES à...
  • Page 22 MAINTENANCE TE-SMR 449/511 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) ENGINE CHECKS SERVICE COUPON SERVICE COUPON SERVICE COUPON EVERY AFTER THE FIRST EVERY EVERY REPLACE IF 1000 Km...
  • Page 23 MAINTENANCE TC 449 _TE -TXC 449 /511 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) COMPETITION MOTORCYCLE, RACING USE: WITH FULL POWER ENGINE CHASSIS AFTER FIRST 3 HOURS EVERY 4h EVERY 8h EVERY 16h REPLACE IF (150 Km)
  • Page 24 MAINTENANCE TE-SMR 449/511 SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) STANDARD MOTORCYCLE, STREET LEGAL (WITH LIMITED POWER ENGINE) CHASSIS CHECKS SERVICE COUPON SERVICE COUPON SERVICE COUPON EVERY AFTER THE FIRST EVERY EVERY REPLACE IF 1000 Km...

  • Page 25: Troubleshooting

    TROUBLESHOOTING Section edition (08-2010) _Rev. 11-2010...
  • Page 26 TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston rings Replace 4. Worn cylinder Replace 5. Cylinder head loosely tightened Tighten 6.
  • Page 27 TROUBLESHOOTING Noise seems to come from gearbox 1. Worn gears Replace 2. Worn gear grooves Replace Noise seems to come 1. Chain stretched (worn) or improperly adjusted Replace or adjust from secondary drive 2. Worn transmission sprocket and rear chain sprocket Replace chain Clutch slips...
  • Page 28 TROUBLESHOOTING CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut overtightened Adjust 3. Bent steering stem Replace bottom yoke 4. Worn or seized steering bearings Replace Handlebar vibration 1.
  • Page 29 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1. Dirty air filter Clean easily 2. Worn piston rings Replace 3. Worn piston or cylinder liner Replace Spark plug electrodes 1. Spark plug electrode gap too close Adjust overheat 2.

  • Page 31: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS Section edition (08-2010) _Rev. 11-2010...
  • Page 32 SETTINGS AND ADJUSTMENTS Saddle removal.....................D.4 Side panel removal ..................D.4 Scoop removal....................D.6 Engine guard removal ..................D.6 Idle adjustment (TC) ..................D.8 Idle adjustment (TE - TXC - SMR) ..............D.8 Hydraulic clutch lever adjustment and fluid level check ......D.9 Front brake lever adjustment and fluid level check (TC - TE - TXC) ...D.9 Front brake lever adjustment and fluid level check (SMR) ......D.10 Rear brake pedal position adjustment ............D.11 Rear brake pedal free play adjustment............D.11...
  • Page 33 SETTINGS AND ADJUSTMENTS H006104 H006106 H006105 H06374 edition (08-2010) _Rev. 11-2010...

  • Page 34: Saddle Removal

    SETTINGS AND ADJUSTMENTS Saddle removal Turn pin (1) counter clockwise, and remove saddle (2) from central retaining screw. H006109 H006110 Side panel removal Remove the saddle as described in the relevant paragraph. Left-hand side panel: Loosen the four screws (1) using an 8 mm wrench, and remove the side panel (2).
  • Page 35 SETTINGS AND ADJUSTMENTS Right-hand side panel: Loosen the five screws (3) using an 8 mm wrench, release side panel (4) from scoop (5) by disengaging retaining tabs (6). H006113 H006114 edition (08-2010) _Rev. 11-2010...

  • Page 36: Scoop Removal

    SETTINGS AND ADJUSTMENTS Scoop removal Remove the saddle and side panels, as described in the relevant para- graphs. Left-hand side scoop: Loosen the three screws (1) using an 8 mm wrench, and remove the scoop (2). H006115 H006117 H006116 Right-hand side scoop: Loosen the two screws (3) (using an 8 mm wrench) and remove horn (4) and scoop (5).
  • Page 37 SETTINGS AND ADJUSTMENTS Throttle cable adjustment To check the correct adjustment of the throttle control cable, operate as follows: - loosen screws (1) and remove protective cap (2); - turn throttle twistgrip (3) and make sure that there is a clearance of approx. 2 mm (0.08 in);...

  • Page 38: Idle Adjustment (Tc)

    SETTINGS AND ADJUSTMENTS Idle adjustment (TC) Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: - Turn knob (1) clockwise until fully closed position, then turn anticlockwise through 33 clicks until obtaining an idle speed of 1,850 - 1,950 rpm, which can be read using the suitable diagnosis instrument.

  • Page 39: Hydraulic Clutch Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS Hydraulic clutch lever adjustment and fluid level check Free play (A) shall be of at least 3 mm (0.12 in). The lever position can be adjusted to suit the rider hand size. To decrease the lever distance from the handgrip, rotate the adjuster (B) CLOCKWISE.

  • Page 40: Front Brake Lever Adjustment And Fluid Level Check (Smr)

    SETTINGS AND ADJUSTMENTS Front brake lever adjustment and fluid level check (SMR) The lever (1) can be adjusted (4 settings available) to suit the rider's hand size. To decrease the lever (1) distance from the handgrip, turn the adjuster screw (2) COUNTER CLOCKWISE “A”.

  • Page 41: Rear Brake Pedal Position Adjustment

    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 within the range available (A).

  • Page 42: Rear Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS Rear brake fluid level check Level (A) must be between the MIN and MAX notches visible on the master cylinder reservoir. H006134 Engine oil level check Oil level depends on oil temperature. The higher the temperature, the higher the oil level inside oil sump.

  • Page 43: Engine Oil Replacement And Mesh Filters-Filter Cartridge Cleaning Or Replacement

    SETTINGS AND ADJUSTMENTS Engine oil replacement and mesh filters-filter cartridge cleaning or replacement Be careful not to touch hot engine oil. Drain the oil with WARM ENGINE; proceed as follows: - Remove the engine guard as described under the relevant paragraph; - Remove the oil filler cap (1).

  • Page 44: Coolant Level Check

    SETTINGS AND ADJUSTMENTS - reassembly is a reverse of removal; - undo cap (7) and remove cartridge filter (8); (on reassembly, tighten plug (7) to a torque of 15 Nm / 1.5 Kgm / 11.6 ft/lb) - replace filter (8), lubricate O-ring (9), and screw cap (7); - once filter has been replaced, refit oil drainage plug (2), and pour the recom- mended quantity of oil.

  • Page 45: Coolant Replacement

    SETTINGS AND ADJUSTMENTS Coolant replacement Coolant shall be replaced with cold engine and coolant. - Remove the engine guard as indicated under the relevant paragraph. - Place a vessel on the R.H. side of the cylinder, under the coolant drain screw (1).

  • Page 46: Air Filter Check

    SETTINGS AND ADJUSTMENTS Air filter check - Remove the saddle and right-hand side panel, as described in the relevant paragraphs. - release retaining clips (1), and slide filter (2) out of vehicle right side, taking special care not to damage the two retaining hooks; - widen the two retaining tabs (3) and remove subframe (4) with sponge (5);...

  • Page 47: Chain Adjustment

    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.

  • Page 48: Chain Lubrication

    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.

  • Page 49: Suspension Setup According To Track Condition

    SETTINGS AND ADJUSTMENTS Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain. Always start from the suspensions standard set- ting before making any change. Afterwards, increase or decrease the adjusting clicks, one at a time.

  • Page 50: Shock Absorber Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain conditions. Proceed as follows: 1. With the motorcycle on the stand and the rear wheel lifted from the ground, measure dimension (A); 2.

  • Page 51: Shock Absorber Spring Preload Adjustment (Te-Tc-Txc)

    SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment (TE-TC-TXC) Proceed as follows: 1. Remove the saddle and right-hand side panel, as described in the relevant paragraph. 2. Clean lock ring nut (1) and adjuster ring nut (2) of the spring (3). 3.

  • Page 52: Shock Absorber Spring Preload Adjustment (Smr)

    SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment (SMR) Proceed as follows: 1. Remove the saddle and right-hand side panel, as described in the relevant paragraph. 2. Clean lock ring nut (1) and adjuster ring nut (2) of the spring (3). 3.

  • Page 53: Shock Absorber Damping Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber damping adjustment TC - TE - TXC Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: TC - TE - TXC -11 turns -11 click (± 2 click) (adjuster 1) 2) High damping speed: TC - TE - TXC...

  • Page 54: Kayaba Fork Adjustment (Tc - Te - Txc)

    SETTINGS AND ADJUSTMENTS KAYABA fork adjustment (TC - TE - TXC) COMPRESSION (Fig. a) (TC - TXC: TOP ADJUSTER; TE: LOWER ADJUSTER) TC-TXC= -11 clicks TE= -10 clicks To reset standard calibration, turn adjuster screw (A) clockwise to reach the fully closed position;...

  • Page 55: Marzocchi Fork Adjustment (Smr)

    SETTINGS AND ADJUSTMENTS Marzocchi fork adjustment (SMR) a) COMPRESSION (LOWER ADJUSTER) Standard setting: -16 clicks (± 1 click) To reset standard calibration, turn adjuster screw (A) clockwise to reach the fully closed position; then turn it back by the mentioned clicks. In order to obtain a smooth braking action, turn the adjuster counter clockwise.

  • Page 56: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS 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. Press lightly on the handlebar grips to cause the front end to rotate;...

  • Page 57: Fuel Supply Hose Inspection

    SETTINGS AND ADJUSTMENTS Fuel supply hose inspection Check fuel supply hose conditions; if cracked, swollen etc. it is necessary to change it as follows: - Remove the saddle and left-hand side panel, as described in the relevant paragraphs. - Release the control unit (1) off its mounts and remove it from its housing. H006166 - Using a Phillips screwdriver, loosen the clamp (2) connecting the tube (3) to throttle body (4).

  • Page 58: Exhaust System Check

    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. H006170 D.28 edition (08-2010) _Rev. 11-2010...

  • Page 59: General Procedures

    GENERAL PROCEDURES Section edition (08-2010) _Rev. 11-2010...
  • Page 60 GENERAL PROCEDURES Saddle removal.....................E.3 Side panel removal ..................E.3 Front Mudguard Removal ................E.5 Number Plate Holder Removal (TE - SMR)..........E.5 Rear Mudguard Removal ................E.6 Battery removal ....................E.7 Tank Removal ....................E.7 Fuel Pump Removal................... E.11 Cock Removal.................... E.11 Throttle body removal.................E.12 Exhaust System Removal (SMR) ...............E.15 Exhaust System Removal (TE - TXC) ............E.16 Exhaust system removal (TC).

  • Page 61: Saddle Removal

    GENERAL PROCEDURES Saddle removal Turn pin (1) counter clockwise, and remove saddle (2) from chassis fastening. H006109 H006110 Side panel removal Remove the saddle as described in the relevant paragraph. Left-hand side panel: Loosen the four screws (1) using an 8 mm wrench, and remove the side panel (2).
  • Page 62 GENERAL PROCEDURES Right-hand side panel: Loosen the five screws (3) using an 8 mm wrench, release side panel (4) from scoop (5) by disengaging retaining tabs (6). H006113 H006114 edition (08-2010) _Rev. 11-2010...

  • Page 63: Front Mudguard Removal

    GENERAL PROCEDURES Front Mudguard Removal Loosen the two screws (1) securing headlamp fairing/number plate holder and mudguard. Loosen the four screws (2) with a 8 mm wrench, and remove front mudguard (3). H02403 Number Plate Holder Removal (TE - SMR) Remove rear turning indicators, as described in the relevant section.

  • Page 64: Rear Mudguard Removal

    GENERAL PROCEDURES Rear Mudguard Removal Remove the saddle, the two side panels and the number plate holder (TE - SMR) as described in the relevant paragraphs. Using a 8 mm wrench, loosen the two screws (1) positioned under rear mudguard, disconnect connector (2) (TE - SMR), and remove tail light. H02407 H02408 Using a 8 mm wrench, loosen the two front retaining screws (3), and remove...

  • Page 65: Battery Removal

    GENERAL PROCEDURES Battery removal Remove the saddle as described in the relevant paragraph. First remove the BLACK negative cable (1), then the RED positive cable (2) (when reassembling, first connect the RED positive cable, then the BLACK negative cable); release retaining elastic strap (3), and remove battery (4) from its compartment.
  • Page 66 GENERAL PROCEDURES Undo the upper clamp (3) connecting fuel pump to throttle body. H06516 Disconnect pump supply connector (4). H02416 Slacken clamp (5) with long nose pliers, and disconnect breather hose (6) from tank. H02417 edition (08-2010) _Rev. 11-2010...
  • Page 67 GENERAL PROCEDURES Slacken clamp (7) with long nose pliers, and disconnect hose (8) between the two tanks. H02418 Loosen upper screw (8) using a 14 mm wrench; undo and remove lower bolt (9) with two 14 mm wrenches, then remove engine left connecting rod (10).
  • Page 68 GENERAL PROCEDURES With a 8 mm socket wrench, undo screw (11), and remove the screw with rubbers and spacers. On reassembly, tighten screw (11) to 10 Nm - 1.0 Kgm - 7.38 ft/lb. H02424 Remove tank (12) and drain any residual fuel through cock. For upper tank removal, refer to the rear chassis removal paragraph.

  • Page 69: Fuel Pump Removal

    GENERAL PROCEDURES Fuel Pump Removal. Remove lower fuel tank as described in the relevant paragraph. - Using a 8 mm Allen wrench, loosen the five screws (1) securing pump (2) to tank. To replace throttle body supply hose (3), open metal clamp (4) and then, after hose replacement, close clamp again using the special pliers. H02426 On reassembly, tighten screws (1) to a torque of 7 Nm - 0.7 Kgm - 5.16 ft/lb checking that the O-ring (8) is correctly positioned in its seat and it is not...

  • Page 70: Throttle Body Removal

    GENERAL PROCEDURES Throttle body removal. Remove lower fuel tank as described in the relevant paragraph. Remove the air filter as described in the relevant paragraph. Use a 4 mm Allen wrench to loosen the screw (1) and remove the cover (2) of the throttle body.
  • Page 71 GENERAL PROCEDURES Disconnect injector connector (9). H02435 Detach the pressure sensor (10). H02436 H02437 From the right side: TE - TXC - SMR; remove second throttle connector (11), second throttle TPS connector (12), and TPS connector (13). H02438 E.13 edition (08-2010) _Rev. 11-2010...
  • Page 72 GENERAL PROCEDURES disconnect TPS connector (14). H02439 Loosen intake manifold (16) upper screw (15). H02440 Working on bike right side, slightly lift throttle body and turn it clockwise by 90°, then remove it from bike left side. H02441 edition (08-2010) _Rev. 11-2010 E.14...

  • Page 73: Exhaust System Removal (Smr)

    GENERAL PROCEDURES Exhaust System Removal (SMR) H06518 Key (SMR) Silencer Clamp Seal Lambda sensor Manifold Seal E.15 edition (08-2010) _Rev. 11-2010...

  • Page 74: Exhaust System Removal (Te - Txc)

    GENERAL PROCEDURES Exhaust System Removal (TE - TXC) TE-TXC H06517 Key (TE - TXC) 1. Silencer (Lanfranconi) 1a. Silencer (Krapovic) 2. Clamp 3. Seal 4. Lambda sensor 5. Manifold 6. Seal edition (08-2010) _Rev. 11-2010 E.16...
  • Page 75 GENERAL PROCEDURES Working on the right side, loosen upper screw (1) using a 12 mm T- wrench. H06372 Working on the left side, loosen screw (2) using a 12 mm T-wrench. H02444 Loosen clamp (4) screw (3) (with a 13 mm wrench), and move it onto the exhaust manifold.
  • Page 76 GENERAL PROCEDURES Cut Lambda sensor cable clamps, and remove connector (6). H02446 Loosen the two screws (7) using a 12 mm Allen wrench, then remove manifold H02447 On reassembly, replace seal (9) H02449 edition (08-2010) _Rev. 11-2010 E.18...

  • Page 77: Exhaust System Removal (Tc)

    GENERAL PROCEDURES Exhaust system removal (TC). H02450 Silencer Spring Manifold Spring Flange Bushing Seal E.19 edition (08-2010) _Rev. 11-2010...
  • Page 78 GENERAL PROCEDURES Working on the right side, loosen support clamp upper screw (1) using a 12 H02518 mm T-wrench. Working on the left side, loosen screw (2) using a 12 mm T-wrench. H02444 Release spring (3). H02519 Remove silencer (4). H02520 edition (08-2010) _Rev.

  • Page 79: Rear Chassis Removal

    GENERAL PROCEDURES Release springs (5), and remove manifold (6). Using a 12 mm Allen wrench, loosen the two nuts (7), then remove flange (8), bushing (9), and gasket (10). On reassembly, screw nuts (7) to a torque of 26 Nm - 2.65 Kgm - 19.18 ft/ H02521 H02522 H02523...
  • Page 80 GENERAL PROCEDURES Cut clamps (5) of the rear wiring harness. H02453 Make sure that fuel tank cocks are closed, then disconnect hose (6) from rear tank cock (7). H02454 Using a 10 mm wrench, loosen the four screws (8), and remove the chassis (9) with tank (10).

  • Page 81: Rear Tank Removal

    GENERAL PROCEDURES Rear tank removal Remove the rear chassis, as described in the relevant paragraph. Loosen the two screws (1) securing tank (2) to rear chassis (3), and remove tank. on reassembly, check the correct positioning of the bushings. H02457 Solenoid starter removal Remove the saddle as described in the relevant paragraph.

  • Page 82: Cdi Electronic Control Unit Removal

    GENERAL PROCEDURES CDI electronic control unit removal Remove the saddle as described in the relevant paragraph. Remove the connector (1) from the CDI electronic control unit (2) and take the control unit together with its anti-vibration mount out of the chassis. H02459 Voltage regulator removal Remove the saddle as described in the relevant paragraph.

  • Page 83: Coil Removal And Spark Plug Check

    GENERAL PROCEDURES Coil removal and spark plug check ÷ 0.031 in) Spark plug electrodes gap shall be 0.7 - 0.8 mm (0.028 A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed.
  • Page 84 GENERAL PROCEDURES turn spark plug cap (3) complete with coil through 90° and lift it to remove it; then remove spark plug. H02466 Carefully change the spark plug, if necessary, using one having the same rating. Before refitting the plug, thoroughly clean the electrodes and the insula- tor using a metal brush.

  • Page 85: Clutch Hose Removal

    GENERAL PROCEDURES Clutch hose removal Loosen screw (1) (with a 8 mm wrench), and move number plate holder or headlamp fairing. H02468 Loosen screw (2) (with a 8 mm wrench), and remove the cover (3). H02467 Loosen screw (4) (with a 8 mm wrench), and disconnect clamp (5) from engine.

  • Page 86: Horn Removal (Te - Smr)

    GENERAL PROCEDURES Horn removal (TE - SMR) Loosen the two screws (1) (using a 8 mm wrench) Disconnect connector (2) and remove horn (3). H02470 Electric cooling fan removal (TE - TXC - SMR) Remove saddle first, and then the left side panel. Disconnect the connector (1).

  • Page 87: Air Filter Box Removal

    GENERAL PROCEDURES Air filter box removal Remove saddle, left and right side panels, filter, and voltage regulator, as indicated in the relevant paragraphs. Loosen screw (1) (with a 8 mm wrench) securing left scoop. H02473 Loosen intake coupling (3) clamp (2), and slide coupling out from the front side.
  • Page 88 GENERAL PROCEDURES Disconnect Blow-by hose (5). H02475 Loosen the three screws (6) (with a 8 mm wrench) H02478 Lower filter box (7), and remove it from the bike right side. H02476 edition (08-2010) _Rev. 11-2010 E.30...

  • Page 89: Engine Guard Removal

    GENERAL PROCEDURES Engine guard removal Using a 8 mm socket wrench, loosen the three screws (1), and remove engine guard (2). H02479 Gear shift pedal removal Remove chain and engine guard as indicated in the relevant paragraph. Engage the 2nd gear with the gear shift pedal (1) Using a 8 mm socket wrench, loosen screw (2), and remove gear shift pedal (1).

  • Page 90: Chain Slider Removal

    GENERAL PROCEDURES Chain slider removal Remove chain and gear shift pedal as indicated in the relevant para- graphs. Loosen screw (2), and remove chain guard (1). Fit a support under the engine so that the rear wheel is raised off the ground.
  • Page 91 GENERAL PROCEDURES Loosen screw (7) with a Phillips screwdriver. H02485 Loosen screw (9) (with a 8 mm wrench) and remove chain roller (8). H02486 Loosen screws (11) (with a 8 mm wrench) and remove sprocket guard (10). H02487 Raise rear wheel (12) and keep it raised off the ground with a belt. H02488 E.33 edition (08-2010) _Rev.
  • Page 92 GENERAL PROCEDURES Slide out the chain slider (5) as shown in figures “A” and “B”. H02489 H02490 edition (08-2010) _Rev. 11-2010 E.34...

  • Page 93: Engine Removal

    GENERAL PROCEDURES Engine removal Remove lower tank, throttle body, chain, and exhaust system as described in the relevant paragraphs. Loosen screw (1) positioned onto pump body, and drain off cooling sys- tem. H02491 Loosen clamps (2), and remove engine cooling hoses (3), (4) and (5). H02492 H02493 Loosen screw (6) (with an 8 mm wrench), and detach ground cable (8).
  • Page 94 GENERAL PROCEDURES Loosen screw (10) (with a 8 mm wrench), and remove cover (11). H02495 Loosen screw (12) (with a 8 mm wrench), and disconnect clamp (13) from engine. H02496 Loosen the three screws (14) (with a 8 mm wrench), and disconnect clutch actuator (14a).
  • Page 95 GENERAL PROCEDURES Turn coil (16) by 90° so that connector is pointing to bike rear end, then remove it. H02499 Disconnect Blow-by hose (20). H02500 Loosen screw (21) and screw (22) (with a 14 mm wrench), and remove right connecting rod (23). Disconnect all engine wiring harnesses.
  • Page 96 GENERAL PROCEDURES Remove rear brake pedal (26) by loosening screw (27) (with a 6 mm Allen wrench), and releasing spring (28). H02503 Loosen rear engine mounting bolt (29) (with two 14 mm wrenches) and the two front screws (30) (with a 12 mm wrench); engine will rest on chassis cradle.

  • Page 97: Radiator Removal

    GENERAL PROCEDURES Radiator Removal Remove saddle, side panels, scoops, and radiator grids as described in the relevant paragraphs. Drain off all coolant as indicated in the relevant paragraph. Loosen clamps (1) and remove hoses (2). H02507 H02508 H02509 H02510 E.39 edition (08-2010) _Rev.
  • Page 98 GENERAL PROCEDURES Disconnect temperature sensor connector (3). H02511 Disconnect electric fan connector (4) (TE - TXC - SMR). Loosen the four screws (5) (with a 8 mm wrench), and remove left-hand ra- H02512 diator (6) complete with fan (TE - TXC - SMR), and right-hand radiator (7). H02513 H02514 H02515...

  • Page 99: Adjustments - Engine

    ADJUSTMENTS - ENGINE Section edition (08-2010) _Rev. 11-2010...
  • Page 100 ADJUSTMENTS - ENGINE Valve clearance check .................. F.3 Set valve clearance (cylinder head cover removed)........F.4 edition (08-2010) _Rev. 11-2010...
  • Page 101 ADJUSTMENTS - ENGINE Valve clearance check Remove head cover as described in section F1 Check • Check valve clearance using a feeler gauge (1). Technical specifications Intake valve clearance with cold engine 0,71...15,65 in TE - TXC Max. 35 °C (0,05...0,10 mm) - SMR Intake valve clearance...
  • Page 102 ADJUSTMENTS - ENGINE Set valve clearance (cylinder head cover removed). Engine positioning at ignition TDC • Turn engine until reaching TDC. • Reference marks (arrows) parallel with cylinder head. H01727 Securing crankshaft at TDC • Remove screw (1) with sealing ring. H01712 •...
  • Page 103 ADJUSTMENTS - ENGINE Valve clearance adjustment Bearing mount disassembly • Remove screws (1, 2). • Disassemble bearing mount (3). • Remove guide sleeves (4). H01843 Camshaft disassembly • Take special care to camshaft position: both shaft gears reference marks (ar- rows) shall be aligned with sealing surface.
  • Page 104 ADJUSTMENTS - ENGINE • Take special care to camshaft position: both shaft gears reference marks (ar- rows) shall be aligned with sealing surface. • Fit exhaust camshaft (3) taking special care that timing chain (4) is well ten- sioned between camshaft and crankshaft. •...
  • Page 105 ADJUSTMENTS - ENGINE Valve clearance check Check • Check valve clearance using a feeler gauge (1). Technical specifications Intake valve clearance with cold engine 0,71...15,65 in TE - TXC Max. 35 °C (0,05...0,10 mm) - SMR Intake valve clearance with cold engine 2,84...3,56 in Max.

  • Page 107: Engine Disassembly/Reassembly

    ENGINE DISASSEMBLY/REASSEMBLY Section edition (08-2010) _Rev. 11-2010 F1.1...
  • Page 108 ENGINE DISASSEMBLY/REASSEMBLY Table of Contents Oil filters replacement..................7 Oil filter disassembly .................. 7 Oil filter assembly ..................7 Oil filter cover on crankcase ................. 7 Engine oil filter disassembly ..............8 Engine oil filter assembly ................9 Spark plug recess ignition coil..............10 Spark plug recess ignition coil disassembly ...........10 Spark plug recess ignition coil assembly ..........10 Spark plug recess..................
  • Page 109 ENGINE DISASSEMBLY/REASSEMBLY Clutch housing clearance reading ............28 Clutch housing assembly ................30 Clutch hub assembly ................30 Removing clutch plates ................30 Pressure plate assembly ................31 Clutch cover assembly ................31 Replacing clutch disengagement bearing..........32 Clutch disengagement bearing disassembly ..........32 Clutch disengagement bearing assembly ..........32 Checking the clutch pack thickness ............
  • Page 110 ENGINE DISASSEMBLY/REASSEMBLY Chain tensioning slider disassembly ............52 Slider disassembly .................52 Chain sliding and tensioning slider check ..........52 Slider assembly ..................53 Chain tensioner assembly ..............53 Cylinders disassembly and reassembly or replacement......54 Cylinder disassembly ................54 Piston disassembly ................55 Cylinder check ..................55 Piston assembly..................56 Piston diameter check ................
  • Page 111 ENGINE DISASSEMBLY/REASSEMBLY Crankshaft, countershaft, and relevant bearings........74 Crankcase left half disassembly .............74 Control gear disassembly ...............75 Removing crankshaft and countershaft ..........75 Crankshaft right bearing bushing disassembly ........76 Crankshaft for countershaft gear disassembly ........76 Crankshaft left bearing bushing disassembly .........77 Crankshaft axial clearance adjustment ...........77 Crankshaft wear check ................78 Connecting rod wear check ..............78...
  • Page 112 ENGINE DISASSEMBLY/REASSEMBLY Gear selector lock replacement ..............103 Gear selector disassembly ..............103 Gear selector assembly ................103 F1.6 edition (08-2010) _Rev. 11-2010...

  • Page 113: Oil Filters Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Oil filter replacement. Oil filter disassembly • Remove plug (1) with O-Ring (2). • Disassemble oil filter (3). H01732 Oil filter assembly • Assemble oil filter (3). • Assemble screw (1) with the O-Ring (2) slightly greased. Tightening torque figures Oil filter cover on crankcase M45 x 1.5, with O-Ring Grease 15 Nm / 1,5 Kgm / 11,06 ft/lb...

  • Page 114: Engine Oil Filter Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Engine oil filter disassembly • Disassemble front oil mesh filter. • Disassemble the following parts: - screw (1) - Filter (3) - O-Rings (2, 4, 5) H01722 • Disassemble rear oil mesh filter. • Disassemble the following parts: - screw (1) - Filter (3) - O-Rings (2, 4, 5)

  • Page 115: Engine Oil Filter Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Engine oil filter assembly • Assemble rear oil mesh filter. • Assemble the following parts: - O-Rings (5, 4, 2) - Filter (3) • Fit screw (1). Tightening torque figures Oil mesh filter screw plug on crankcase M20 x 1.5, with O-Ring Grease 10 Nm / 1 Kgm / 7,38 ft/lb thread H01855...

  • Page 116: Spark Plug Recess Ignition Coil

    ENGINE DISASSEMBLY/REASSEMBLY Spark plug recess ignition coil Spark plug recess ignition coil disassembly • Disassemble the following parts: - Screw (1) - Spark plug recess ignition coil (2) H01714 Spark plug recess ignition coil assembly • Fit spark plug recess ignition coil (2). •...

  • Page 117: Spark Plug Recess

    ENGINE DISASSEMBLY/REASSEMBLY Spark plug recess Spark plug recess disassembly • Remove seal (1) and spark plug recess (2). H01728 Spark plug recess assembly • Check lower O-Ring inside cylinder head recess for damages. • Assemble spark plug recess (2), and seal (1). H01868 edition (08-2010) _Rev.

  • Page 118: Spark Plug

    ENGINE DISASSEMBLY/REASSEMBLY Spark plug Spark plug disassembly • Disassemble spark plug using a wrench / suitable tool H01729 Spark plug assembly • Fit spark plug (1) using the 16 mm spark plug bushing Tightening torque figures Spark plug inside cylinder head 12 Nm / 1,2 Kgm / 8,85 ft/lb Lubrication, Copper paste H01729...

  • Page 119: Oil Pressure Adjustment Valve Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Oil pressure adjustment valve replacement Oil pressure adjustment valve disassembly • Disassemble the following parts: - screw (1) - Seal (2) - Spring (3) - Adjuster piston (1) H01909 Oil pressure adjustment valve assembly • Grease adjuster piston and spring Consumables Castrol GPS SAE 10W-40 Engine oil...

  • Page 120: Cylinder Head Cover

    ENGINE DISASSEMBLY/REASSEMBLY Cylinder head cover Removing cylinder head cover • Remove screws with seal (1), and washers. • Remove cylinder head cover (2) with gasket (3). H01719 Fitting cylinder head cover • Clean gasket (3) and cylinder head and cylinder head cover (2) sealing sur- face.

  • Page 121: Engine Positioning At Ignition Tdc

    ENGINE DISASSEMBLY/REASSEMBLY Engine positioning at ignition TDC • Turn engine until reaching TDC. • Reference marks (arrows) parallel with cylinder head. H01727 Securing crankshaft at TDC • Remove screw (1) with sealing ring. H01712 • Lock crankshaft at TDC using special tool (8000H5009). 8000H5009 H01713 edition (08-2010) _Rev.

  • Page 122: Camshaft Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Camshaft removal Bearing mount disassembly • Remove screws (1, 2). • Disassemble bearing mount (3). • Remove guide sleeves (4). H01747 • Take special care to camshaft position: both shaft gears reference marks (ar- rows) shall be aligned with sealing surface. •...

  • Page 123: Bearing Mount Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Bearing mount assembly • Assemble guide sleeves (4). • Lubricate mount (3) at camshaft sliding surfaces, then assemble it. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling H01747 • Fit long (1) and short (2) screws, tightening them by hand. Bearing mount securing •...

  • Page 124: Engine Left Crankcase

    ENGINE DISASSEMBLY/REASSEMBLY Engine left crankcase Engine left crankcase cover disassembly • Disassemble the following parts: - Screws (1) and (2) with sealing rings (3) - Cover (4) - Gasket (5) - Guide sleeves (6) - Oil spraying nozzle (7) H01717 Engine left crankcase cover assembly •...

  • Page 125: Alternator Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Alternator replacement Preliminary operations Engine oil drainage Engine positioning at ignition TDC Securing crankshaft at TDC Engine left crankcase cover disassembly Flywheel disassembly • Remove nut (1). H01744 • Heat flywheel (1). 8000H5011 Technical specifications Release/connection 80 °C temperature 8000H5013 •...

  • Page 126: Stator Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Stator disassembly • Disassemble the following parts: - Screws (1) and (2) - Cable retaining plate (3) - Rubber sheath (4) - Stator (5) H01919 Freewheel disassembly • Disassemble the following parts: - Screws (1) - Flywheel (2) - Freewheel (3) H01956 Freewheel assembly...

  • Page 127: Stator Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Stator assembly • Clean screw (1) and (5) threaded holes. • Position stator (6). • Tighten screws (5). Tightening torque figures Stator onto engine left crankcase cover M5 x 20, Microincapsulated 6 Nm screw replacement • Apply a layer of sealant onto rubber sheath (2) sealing surfaces. H01921 Consumables 3 - Bond 1209...

  • Page 128: Crankcase Left Cover Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Crankcase left cover replacement Preliminary operations Engine oil drainage Engine left crankcase cover disassembly Stator disassembly • Disassemble the following parts: - Screws (1) and (2) - Cable retaining plate (3) - Rubber sheath (4) - Stator (5) H01919 •...
  • Page 129 ENGINE DISASSEMBLY/REASSEMBLY • Apply a layer of sealant onto rubber sheath (2) sealing surfaces. Consumables 3 - Bond 1209 Surface sealer • Position retaining plate (4), and pulse transducer (3). • Insert rubber sleeve (2) • Tighten screws (1). Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 - 10.9, Microincapsulated 6 Nm...

  • Page 130: Crankshaft Sensor Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft sensor replacement Preliminary operations Engine oil drainage Engine left crankcase cover disassembly Crankshaft sensor disassembly • Remove screws (1). • Remove crankcase sensor (2). H01960 Crankshaft sensor assembly • Assemble crankcase sensor (2). • Fit new screws (1). Tightening torque figures Pulse transducer onto engine left crankcase cover...

  • Page 131: Freewheel Gear Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Freewheel gear replacement Freewheel gear disassembly • Disassemble the following parts: - Screws (1) - Guide (2) - Gear (3) - Needle roller bearing (4) H01743 Freewheel gear assembly • Lubricate needle roller bearing (4) and gear (3), then fit them. Consumables Molykote D Paste Clear solid lubricant for...

  • Page 132: Clutch Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Clutch disassembly and reassembly or replacement H01987 Preliminary operations Engine oil drainage Securing crankshaft at TDC Brake pedal release Clutch actuator disassembly Clutch cover disassembly • Remove screws (1). • Remove clutch cover (2) with gasket (3). H01988 Removing clutch pressure plate •...

  • Page 133: Removing Clutch Plates

    ENGINE DISASSEMBLY/REASSEMBLY Removing clutch plates • Remove clutch plates pack (1). Technical specifications Clutch plates number 6 steel plates 6 lined plates H01734 Clutch hub disassembly • Remove nut (1). • Remove hub (2). H01735 Clutch housing disassembly • Disassemble the following parts: •...

  • Page 134: Clutch Crankcase Clearance Check

    ENGINE DISASSEMBLY/REASSEMBLY Clutch housing clearance check • Fit clutch housing (1) with needle roller bearing cage and hub (2). • Fit nut (3). Tightening torque figures Clutch hub on crankshaft Collar nut, M20 x 1.5 - 10.9, 120 Nm Replace microincapsulated screw nut Check H01986...
  • Page 135 ENGINE DISASSEMBLY/REASSEMBLY Action: • Replace clutch thrust washer. If needed, repeat the procedure. Technical specifications Space washers 2.200 mm thickness for clutch 2.250 mm cage distance 2.300 mm adjustment 2.350 mm 2.400 mm 2.450 mm 2.500 mm 2.550 mm 2.600 mm •...

  • Page 136: Clutch Housing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Clutch housing assembly • Lubricate bearing (3), and assemble it. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Assemble clutch housing (2). H01858 • Fit thrust washer (1). Clutch hub assembly • Lubricate hub (2) inner toothing, and fit it. Consumables MP 3 paste High-performance...

  • Page 137: Pressure Plate Assembly

    ENGINE DISASSEMBLY/REASSEMBLY • Make sure that the relief on the last steel washer is pointing outwards. • Fit greased clutch plate pack (1). Technical specifications Clutch plates number 6 steel plates 6 lined plates Consumables H01861 Castrol GPS SAE 10W-40 Engine oil Pressure plate assembly •...

  • Page 138: Replacing Clutch Disengagement Bearing

    ENGINE DISASSEMBLY/REASSEMBLY Replacing clutch disengagement bearing Preliminary operations Engine oil drainage Clutch cover disassembly Mushroom-type disengagement element disassembly Clutch disengagement bearing disassembly • Remove disengagement bearing (1). H01989 Clutch disengagement bearing assembly • Lubricate disengagement bearing (1), and assemble it. Consumables Castrol GPS SAE 10W-40 Engine oil...

  • Page 139: Engine Right Crankcase

    ENGINE DISASSEMBLY/REASSEMBLY Engine right crankcase Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly • Disassemble the following parts: - Screws (1, 2, 3) - Washer (4) H01918...
  • Page 140 ENGINE DISASSEMBLY/REASSEMBLY • Fit screw (2). Tightening torque figures Engine and crankcase fairing, screw connections M6 x 30 11 Nm • Fit screws (1) working crossways. H01918 Tightening torque figures Engine and crankcase fairing, screw connections M6 x 25 11 Nm •...

  • Page 141: Clutch Thrust Washer

    ENGINE DISASSEMBLY/REASSEMBLY Clutch thrust washer Clutch thrust washer disassembly • Remove washer (1). H01742 Clutch thrust washer assembly • Fit washer (1). H01869 edition (08-2010) _Rev. 11-2010 F1.35...

  • Page 142: Clutch Housing Axial Bearing

    ENGINE DISASSEMBLY/REASSEMBLY Clutch housing axial bearing Clutch housing axial bearing disassembly • Remove bearing (1). H01720 Clutch housing axial bearing assembly • Lubricate bearing (1), and assemble it. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling H01854 F1.36 edition (08-2010) _Rev.

  • Page 143: Coolant Pump Disassembly And Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Coolant pump disassembly and assembly H01941 Coolant pump cover disassembly • Disassemble the following parts: - Screws (1, 2, 3) - Cover (5) - Seal (6) H01740 Coolant pump rotor disassembly • Disassemble the following parts: - screw (1) - Rotor (2) H01741 edition (08-2010) _Rev.

  • Page 144: Coolant Pump Rotor Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Coolant pump rotor assembly • Fit rotor (2). • Fit screw (1). Tightening torque figures Coolant pump gear on pump shaft M5 x 10 - 10.9, Microincapsulated 6 Nm screw replacement H01741 Coolant pump cover assembly • Clean seal groove and bearing surface, check seal (6) and, if needed, re- place it.

  • Page 145: Coolant Pump Inside Crankcase Oil Seal Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Coolant pump inside crankcase oil seal replacement (crankcase cover removed) H01942 Coolant pump control rear oil seal disassembly • Remove oil seal (1). Coolant pump control shaft check Check Result: Damaged or worn shaft Action: Replace coolant pump drive (crankcase cover removed) H01943 Coolant pump control rear oil seal assembly •...

  • Page 146: Coolant Pump Drive Replacement (Crankcase Cover Removed)

    ENGINE DISASSEMBLY/REASSEMBLY Coolant pump drive replacement (crankcase cover removed) H01945 Slider loosening in the lower area • Remove screw with O-Ring (1). H01944 Coolant pump shaft disassembly • Disassemble the following parts: - Oil seal (1) - Stop ring (2) •...

  • Page 147: Coolant Pump Shaft Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Coolant pump shaft assembly • Lubricate bearing (5), and shaft (3). Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Assemble bearing (5) and stop ring (4) onto shaft (3). H01946 • When fitting the shaft, take special care to the timing chain. •...

  • Page 148: Chain Front Sprocket

    ENGINE DISASSEMBLY/REASSEMBLY Chain sprocket Chain sprocket removal • Remove screws (1), and stop washer (2). • Remove chain sprocket (3). H01739 Sprocket assembly • Assemble chain sprocket (3). • Fit stop washer (2), and new screws (1). Tightening torque figures Sprocket on gearbox output shaft M5 x 8 - 10.9, Microincapsulated 6 Nm...

  • Page 149: Chain Tensioner Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Chain tensioner disassembly and reassembly or replacement H01933 Chain tensioner disassembly • Disassemble the following parts: - screw (1) - Chain tensioner (2) - O-Rings (3, 4) H01871 Chain tensioner assembly • Assemble the following parts: - O-Rings (4, 3) - Chain tensioner (2) •...

  • Page 150: Cylinder Head Disassembly And Reassembly/Head Gasket Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Cylinder head disassembly and reassembly/head gasket replacement Preliminary operations Spark plug recess ignition coil disassembly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly Chain tensioner disassembly Camshaft removal Slider disassembly Cylinder head disassembly Disassemble the following parts: Nuts (1) Screws (2) Nuts (3)

  • Page 151: Cylinder Head Replacement (Cylinder Head Removed)

    ENGINE DISASSEMBLY/REASSEMBLY Cylinder head replacement (cylinder head removed) H01910 Valve removal • Mark bucket type tappets (1), and remove them with a suitable tool. • Check tappet (1) for wear. Replace it, if necessary. • Remove valve bearing plate, and lay it onto the relevant bucket type tappet (1).

  • Page 152: Removing Valve Spring

    ENGINE DISASSEMBLY/REASSEMBLY • Assemble cylinder head onto support plate (N. 8000H5015). • Fit supporting bracket (N. 8000H5017), spindle with handle (N.8000H5016), connector (N. 8000H5018), and compression plate (N.8000H5019). 8000H5016 8000H5017 • Precharge springs using the compression plate (N. 8000H5019). 8000H5019 8000H5018 8000H5015 H01764...

  • Page 153: Rocker Arm Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Rocker arm disassembly • Remove stop rings (1) and rocker arms (2). H01912 Rocker arm shaft disassembly • Remove the screw (1) with the O-ring (2). H06520 • Remove left rocker arm shaft (1) with a suitable tool (2). H01914 •...

  • Page 154: Valve Seat Width Check

    ENGINE DISASSEMBLY/REASSEMBLY Valve seat width check • Check that valve seat contact surface is neither damaged nor worn. Check • Measure valve seat width (A) (contact surface without soot deposits). Technical specifications Intake valve seat width 1.3 mm Wear limit Max.

  • Page 155: Rocker Arm Shaft Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Rocker arms shaft assembly • Lubricate rocker arm shafts. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Assemble right rocker arm shaft (1) with a suitable tool (2). H01916 • Assemble left rocker arm shaft (1) with a suitable tool. H01915 •...

  • Page 156: Rocker Arm Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Rocker arm assembly • Lubricate rocker arm shafts. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Fit tappet roller (2). H01912 Caution Rocker arm correct operation will be impaired if clips are reused. Always change safety clips.

  • Page 157: Valves Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Valve assembly • Assemble cylinder head onto support plate (N. 8000H5015). 8000H5016 • Fit supporting bracket (N. 8000H5017), spindle with handle (N.8000H5016), 8000H5017 connector (N. 8000H5018), and compression plate (N.8000H5019). • Precharge springs using the compression plate (N. 8000H5019). 8000H5019 8000H5018 8000H5015...

  • Page 158: Chain Slider

    ENGINE DISASSEMBLY/REASSEMBLY Chain slider Chain tensioning slider disassembly • Remove screw (1). • Remove chain tensioning slider (2). H01749 Slider disassembly • Disassemble the following parts: - screw (1) - Washer (2) - Screw with O-Ring (3) - Slider (4) H01750 Chain sliding and tensioning sliders check Check...

  • Page 159: Slider Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Slider assembly • Assemble the following parts: - Slider (4) - Washer (2) • Fit screw (1). Tightening torque figures Slider onto cylinder head Calibrated screw, M8 15 Nm H01839 • Fit screw with O-Ring (3). Tightening torque figures Front slider at crankcase lower part 15 Nm Chain tensioner assembly...

  • Page 160: Cylinders Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Cylinder disassembly and reassembly or replacement H01908 Preliminary operations Spark plug recess ignition coil disassembly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly Bearing mount disassembly Camshaft removal Slider disassembly Cylinder head disassembly Cylinder disassembly •...

  • Page 161: Piston Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Piston disassembly • Watch stop rings correct position: ring opening shall be pointing up (arrow). • Disassemble the following parts: - Left and right stop rings (1). - Piston pin (2) - Piston (3) H01754 Cylinder check Check •...

  • Page 162: Piston Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Piston diameter check Check • Measure piston diameter (A) crosswise to piston pin axis. • Size (B) defines the reading beyond piston pin lower edge. Technical specifications Piston diameter New, transverse Tolerance group 1 to piston pin axis, +0.005 97.925 - 0.005...

  • Page 163: Piston Ring Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Piston ring assembly • Fit piston ring and scraper ring inside annular grooves, offset by 180°. Warning Offset garter spring port by approx. 180° compared to scraper ring port. The "TOP" wording shall be pointing up. Technical specifications Piston ring assembly "Top"...

  • Page 164: Subsequent Actions

    ENGINE DISASSEMBLY/REASSEMBLY • Remove the gasket protruding out of the flange used for cylinder connec- tion. • Apply reference pins (3), and a new gasket (2). • Insert timing chain inside recess, fit cylinders (1) with piston until connecting rod small end. H01836 •...

  • Page 165: Timing Chain Disassembly And Reassembly Or Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Timing chain disassembly and reassembly or replacement H01932 Preliminary operations Clutch cover disassembly Spark plug recess ignition coil disassembly Removing cylinder head cover Spark plug recess disassembly Engine positioning at ignition TDC Securing crankshaft at TDC Chain tensioner disassembly Bearing mount disassembly Camshaft removal Clutch disassembly...

  • Page 166: Timing Chain Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Timing chain assembly • Lubricate timing chain (1), and fit it onto countershaft gear (2) working through crankcase from top. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling H01890 Subsequent actions Valve clearance check Chain, chain sprocket check Check •...

  • Page 167: Replacing Oil Pump Gears (Crankcase Cover Removed)

    ENGINE DISASSEMBLY/REASSEMBLY Replacing oil pump gears (crankcase cover removed) Preliminary operations H01937 Idler gear disassembly Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly • Disassemble the following parts: - Stop ring (1) - Washer (2) - Gear (3) - Bearing (4) H01724...

  • Page 168: Disassembly Of Crankshaft Gear Pointing Oil Pump Idler Gear

    ENGINE DISASSEMBLY/REASSEMBLY Disassembly of crankshaft gear pointing to oil pump idler gear 8000H5014 • Fit presser (N. 8000H5014) onto crankshaft. Remove gear using puller (N.8000H5011), and jaws (N. 8000H5012) 8000H5011 8000H5012 8000H5012 Assembly of crankshaft gear pointing oil pump idler gear H01894 •...

  • Page 169: Oil Pump Idler Gear Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Oil pump idler gear assembly • Lubricate bearing (4), and gear (3). Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Assemble the following parts: H01724 - Bearing (4) - Gear (3) - Washer (2) - Stop ring (1) edition (08-2010) _Rev.

  • Page 170: Oil Intake Pump Replacement (Crankcase Cover Removed)

    ENGINE DISASSEMBLY/REASSEMBLY Oil intake pump replacement (crankcase cover removed) Preliminary operations Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly Oil pump control gear disassembly H01940 Oil intake pump disassembly • Disassemble the following parts: - Screws (1) - Cover (2) - Inner rotor (3)

  • Page 171: Removing And Assembling Or Replacing Pressure Oil Pump

    ENGINE DISASSEMBLY/REASSEMBLY Removing and assembling or replacing pressure oil pump Preliminary operations Engine oil drainage Gear lever disassembly Engine left crankcase cover disassembly H01939 Oil force pump disassembly • Disassemble the following parts: - Stop ring (1) - Cover (3) with seal (2) - Inner rotor (4) - Outer rotor (5) - Needle roller (6)

  • Page 172: Oil Pump Shaft

    ENGINE DISASSEMBLY/REASSEMBLY Oil pumps shaft Oil pumps shaft disassembly • Remove shaft (1) from crankcase. H01886 Oil pumps shaft assembly • Lubricate shaft (1), and assemble it inside crankcase. Shaft side with two holes shall be positioned on engine right side. Consumables Molykote D Paste Clear solid lubricant for...

  • Page 173: Replacing Gearbox Control Shaft Radial Sealing Ring

    ENGINE DISASSEMBLY/REASSEMBLY Replace gearbox control shaft radial sealing ring Preliminary operations Gear lever disassembly Removing oil seal from gearbox shaft • Using a suitable tool, remove oil seal (1) with the utmost care. H01997 Fitting gearbox shaft oil seal • Fit oil seal (1) using a suitable tool. H01997 edition (08-2010) _Rev.

  • Page 174: Replacing Output Shaft Oil Seal

    ENGINE DISASSEMBLY/REASSEMBLY Replacing output shaft oil seal Gearbox output shaft left oil seal disassembly • Remove oil seal (1). H01998 Gearbox output shaft right oil seal disassembly • Remove oil seal (1). H01999 Gearbox output shaft right oil seal assembly •...

  • Page 175: Disassembling/Assembling Starter Motor

    ENGINE DISASSEMBLY/REASSEMBLY Disassembling/assembling starter motor Removing starter motor • Disconnect positive cable (1). • Remove screws (2). • Remove starter motor (3). H01957 Starter motor assembly • Check sealing ring (1) for damages. Replace it, if necessary. • Lubricate contact surface (arrow). Consumables Molykote D Paste Clear solid lubricant for metal...

  • Page 176: Starter Drive Gear Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Starter idle gear replacement Preliminary operations Engine oil drainage Gear lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Gear disassembly with starter motor protected against overload • Remove gear (1) with shaft (2). H01725 Starter motor idle gear disassembly •...

  • Page 177: Freewheel Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Freewheel gear disassembly • Disassemble the following parts: - Screws (1) - Guide (2) - Gear (3) - Needle roller bearing (4) H01743 Freewheel gear assembly • Lubricate needle roller bearing (4) and gear (3), then fit them. Consumables Molykote D Paste Clear solid lubricant for metal...

  • Page 178: Starter Motor Drive Gear Fitting

    ENGINE DISASSEMBLY/REASSEMBLY Starter motor idle gear fitting • Lubricate bushing (5), and needle roller bearing (4), then assemble them. Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling • Lubricate gear (3), and assemble it with the dowel pointing towards counter- shaft.

  • Page 179: Starter Motor Drive Gear

    ENGINE DISASSEMBLY/REASSEMBLY Starter motor idle gear Starter motor idle gear disengagement • Loosen nut (1). Starter motor idle gear fitting • Tighten nut (1) all the way down. Tightening torque figures Engine and crankcase fairing, screw connections H01721 M12 x 1, Replace 50 Nm microincapsulated screw nut edition (08-2010) _Rev.

  • Page 180: Crankshaft Axial Clearance Check

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft axial clearance check Check • Measure crankshaft axial clearance (G) using a dial gauge. • Read axial clearance moving shaft up and down. Warning To get correct values, exert a greater force. Technical specifications Crankshaft axial 0.30...0.50 mm clearance H01882 Result: Read value outside tolerance values.

  • Page 181: Control Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Control gear disassembly • Lock control gear (1) using tool (N. 8000H5010) to prevent it from moving. • Remove screw. Caution: LH thread (2). • Remove control gear (1). 8000H5010 H01737 Remove crankshaft and countershaft • Move crankshaft (1) and countershaft (2) reference marks (arrows) so as to make them match.

  • Page 182: Crankshaft Right Bearing Bushing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft right bearing bushing disassembly • Remove roller (1). H01789 Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves. • Remove bushing (1) using a suitable pre-heated puller. Technical specifications Pre-heating tempera- 300 °C...

  • Page 183: Crankshaft Left Bearing Bushing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft left bearing bushing disassembly Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves. • Remove bushing (1) using a suitable pre-heated puller. Technical specifications Pre-heating 300 °C H01793 temperature of puller for main bearing inner...

  • Page 184: Crankshaft Wear Check

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft wear check • Check crankshaft support pin (arrows). Result: Support pins are damaged or worn. Action: • Replace crankshaft with connecting rod. H01929 Connecting rod wear check • Check connecting rod for damages and wear • Measure connecting rod bearing clearance. Lock crankshaft in vertical posi- tion and, using a dial gauge, read the max.

  • Page 185: Crankshaft Axial Clearance Adjustment, Left Side

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft axial clearance adjustment, left side • Measure left bearing (C) seat depth using a depth gauge. • Add to this value half of crankcase gasket value. • The value measured on left crankshaft (A1) is deducted from the measured left bearing seat depth (C + half gasket value).

  • Page 186: Crankshaft Left Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft left bearing disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications H01783 Release/connection...

  • Page 187: Crankshaft Right Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications H01784 Release/connection...

  • Page 188: Countershaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Countershaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications Release/connection 180 °C...

  • Page 189: Crankshaft Left Bearing Bushing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft left bearing bushing assembly • If necessary, fit space washer. Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves. • Heat bearing bushing (1). H01798 Technical specifications Pre-heating 300 °C temperature of puller...

  • Page 190: Control Gear Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Crankshaft right bearing bushing assembly Warning Burn hazard in case of contact with hot/heated parts. Should you have to touch hot parts, wear protective gloves. • Heat bearing bushing (2). Technical specifications H01800 Pre-heating 300 °C temperature of puller for main bearing inner rings •...

  • Page 191: Gearbox Unit - Disassembly / Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox unit - disassembly / assembly Preliminary operations Engine oil drainage Head disassembly Gear lever disassembly Engine left crankcase cover disassembly Engine right crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Clutch unit disassembly Crankcase left half disassembly •...

  • Page 192: Disassembly/Reassembly Of The Gearbox (5 Speed) (Tc)

    ENGINE DISASSEMBLY/REASSEMBLY Result: Bearings do not move properly or they have increased clearance. Action: Replace primary shaft (removed shaft) bearings Replace output shaft (removed shaft) bearings • Replace gearbox bearings. Check • Check shaft grooves (2). Result: Damaged or discoloured grooves. Action: •...
  • Page 193 ENGINE DISASSEMBLY/REASSEMBLY Input shaft (6 speed) (TC) Z=14 Z=23 Z=15 Z=23 H06428 Z=16 Output shaft (6 speed) (TC) Z=32 Z=29 Z=23 Z=24 Z=30 H06429 edition (08-2010) _Rev. 11-2010 F1.87...

  • Page 194: Disassembly/Reassembly Of The Gearbox (6 Speed) (Te-Txc-Sms)

    ENGINE DISASSEMBLY/REASSEMBLY Disassembly/Reassembly of the gearbox (6 Speed) (TE-TXC-SMS) Caution During operation, gear wheel sets slide one towards the other. If just one cou- pling gear is replaced, the load bearing capacity on gears may become signifi- cantly worse. Replace gear wheels together with the coupled wheels, only. Caution Reinstall the input shaft and output shaft as indicated in the figure, paying atten- tion not to damage the roller cages, the washers and snap rings.
  • Page 195 ENGINE DISASSEMBLY/REASSEMBLY Input shaft (6 speed) (TE-TXC-SMS) TE - TXC - SMR Z=14 Z=23 Z=15/20 Z=24 H06430 Z=16 Output shaft (6 speed) (TE-TXC-SMS) TE - TXC - SMR Z=32 Z=24 Z=23 Z=25 Z=22 Z=30 H06431 edition (08-2010) _Rev. 11-2010 F1.89...

  • Page 196: Gearbox Oil Pipe Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox oil pipe disassembly • Remove oil pipe (1) Gearbox oil pipe assembly • Fit oil pipe (1) H01816 Gearbox input shaft right bearing disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value.

  • Page 197: Gearbox Output Shaft Right Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox output shaft right bearing disassembly • Remove oil seal (1). Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. •...

  • Page 198: Gearbox Shaft Right Bearing Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox shaft right bearing disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications Release/connection 180 °C...

  • Page 199: Gearbox Input Shaft Idler Gear Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox input shaft idler gear bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. •...

  • Page 200: Gearbox Output Shaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox shaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications Release/connection 180 °C...

  • Page 201: Gearbox Input Shaft Left Bearing Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox input shaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat crankcase. Technical specifications Release/connection 180 °C...
  • Page 202 ENGINE DISASSEMBLY/REASSEMBLY • Remove idler gear (1) using a suitable tool. Technical specifications Release/connection 80 °C temperature H01805 Check • Check bearing (1). H01806 Result: Bearings do not move properly or they have increased clearance. Action: • Replace bearings. Check •...

  • Page 203: Idler Gear Disassembly

    ENGINE DISASSEMBLY/REASSEMBLY Idler gear disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses. Evenly heat casing, making sure not to exceed the recommended value. • Heat gear (1), and remove it using a suitable tool. Technical specifications Release/connection 80 °C...

  • Page 204: Gearbox Shaft Replacement (Crankcase Cover Removed)

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox shaft replacement (crankcase cover removed) H02009 Complete selector shaft disassembly • Remove gearbox shaft (1) with spring (2), and washer (3). H02010 Gearbox shaft check Check • Check gearbox shaft for damages. Result: Damaged gearbox shaft. Action: Replace gearbox shaft (crankcase cover removed) H01813 Gearbox shaft complete assembly...

  • Page 205: Selector Cylinder Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Selector cylinder replacement Selector drum disassembly • Remove gearbox guides (1). • Turn forks (2) from selector cylinder (3). • Remove selector drum (3). H02011 Selector drum check Check • Check drum grooves for wear, at curved sections in particular (arrow). Result: Worn grooves.

  • Page 206: Gear Selector Fork Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Gear selector fork replacement Gear selector fork disassembly • Remove gearbox guides (1). • Remove gear selector forks (2). H02012 Check gear selector forks Check • Check forks (A) bearing surfaces for wear. Technical specifications Gear selector fork rib width on +0.05 - 0.05 contact surfaces...

  • Page 207: Gearbox Assembly

    ENGINE DISASSEMBLY/REASSEMBLY Gearbox assembly • Lubricate shafts, selector drum and forks. Consumables Molykote D Paste Clear solid lubricant for metal parts assembling and settling • Assemble the following parts: - Gearbox output shaft (1) with forks (2) H01818 - Selector drum (3) - Gearbox control shaft (4) with fork (5) - 32-tooth 1st gear (6) - Space washer (7)

  • Page 208: Stop Lever Replacement

    ENGINE DISASSEMBLY/REASSEMBLY Stop lever replacement Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Gear selector lock disassembly •...
  • Page 209 ENGINE DISASSEMBLY/REASSEMBLY Gear selector lock replacement Preliminary operations Clutch cover disassembly Removing clutch pressure plate Removing clutch plates Clutch hub disassembly Clutch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Gear selector disassembly •...
  • Page 211 FRONT SUSPENSION Section edition (08-2010) _Rev. 11-2010...
  • Page 212 FRONT SUSPENSION Front fork removal ..................I.3 Service instructions for Ø48USD Kayaba fork - TC-TXC ......I.5 Front suspension (TC - TXC) ............... I.6 Front fork disassembly (TC - TXC) ............... I.7 Front suspension (TE) ................I.17 Front fork disassembly (TE) ............... I.18 Front suspension (SMR)................

  • Page 213: Front Fork Removal

    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: H006207 H006208 remove the screws (1) and the brake line clamp on the left-hand side;...
  • Page 214 FRONT SUSPENSION remove the six screws (2) and the fork leg guards; TC - TE - TXC 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"; H06387 H06388 loosen the bolts (4) that secure the fork legs to steering head and bottom...

  • Page 215: Service Instructions For Ø48Usd Kayaba Fork - Tc-Txc

    FRONT SUSPENSION Front suspension Mod. TC-TXC Service instructions for Ø48USD Kayaba fork - TC-TXC GENERAL The fork uses a multi-valve damping system with rebound and compression adjustment and spring preload adjustment for static load. Compression damping is controlled by a special valve located at the top of each fork leg.

  • Page 216: Front Suspension (Tc - Txc)

    FRONT SUSPENSION Front suspension (TC - TXC) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. edition (08-2010) _Rev. 11-2010...

  • Page 217: Front Fork Disassembly (Tc - Txc)

    FRONT SUSPENSION Front fork disassembly (TC - TXC) Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). Drain oil from the damper unit. Clamp the wheel axle carrier in a vice and loosen the adjuster screw.
  • Page 218 FRONT SUSPENSION Take the cartridge out of the outer tube. Do not remove the nut at the bottom end of the cartridge. Remove the bottom valve assembly from the cartridge. Hold the cartridge octagonal nut with the suitable tool to prevent rotation. Use a similar tool in the octagonal recess of the bottom valve assembly.
  • Page 219 FRONT SUSPENSION If outer tube and inner tube are still assembled together, place the fork leg upside down and allow at least 20 minutes for oil to drain. Remove the dust seal using a flat head screwdriver. Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube.
  • Page 220 FRONT SUSPENSION Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal. Replace them with new components. Replace damaged sealing rings. Washer and retaining ring may be reused if they are not damaged. Check the rebound adjuster rod for distortion or damage.
  • Page 221 FRONT SUSPENSION Mount sealing rings and metal parts on the inner tube. See the figure below for the installation sequence. Note 1: Grease the edge of the sealing ring. Note 2: Before sliding the sealing ring over the inner tube, cover tube edge with plastic as shown in the figure.
  • Page 222 FRONT SUSPENSION Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube. Refit the cartridge. Tighten the nut all the way onto the rebound adjuster rod. Make sure rebound adjuster rod thread length is at least 15 mm (0.6 in.). Fill the cartridge with the specified oil.
  • Page 223 FRONT SUSPENSION Pull the piston rod until fully extended. Check oil level. It should be about 145 mm (5.7 in.). Push the piston rod all the way down and install the bottom valve assembly. With the bottom valve assembly installed, check that the piston rod is fully extended.
  • Page 224 FRONT SUSPENSION Drain excess oil from the cartridge pushing the damper unit all the way home. Be careful not to distort or damage the piston rod or any other parts. Please note that excess oil may flow out from the hole located before the res- ervoir.
  • Page 225 FRONT SUSPENSION Push down the inner tube. Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw. Be careful not to hurt your fingers. Tighten the adjuster screw all the way in.
  • Page 226 FRONT SUSPENSION Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm (40.5 ft/lb). Fill the outer tube with the specified quantity of oil. Tighten the cylinder onto the outer tube to 29 Nm (21.4 ft/lb). I.16 edition (08-2010) _Rev.

  • Page 227: Front Suspension (Te)

    FRONT SUSPENSION Front suspension Mod. TE /2010 Front suspension (TE) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travelis 300 mm. I.17 edition (08-2010) _Rev. 11-2010...

  • Page 228: Front Fork Disassembly (Te)

    FRONT SUSPENSION Front fork disassembly (TE) Loosen the cap nut at the top of each outer tube. (Note: it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle). Loosen the fork cap nut and the nut with a wrench. Remove top cap nut, spring retainer, spring and rebound adjuster rod.
  • Page 229 FRONT SUSPENSION Remove nut, spring guide, O-ring and collar bushing. Hold the cartridge top end steady. Loosen and remove the bottom valve assembly. I.19 edition (08-2010) _Rev. 11-2010...
  • Page 230 FRONT SUSPENSION Take the cartridge out of the outer tube. Remove the dust seal using a flat head screwdriver. I.20 edition (08-2010) _Rev. 11-2010...
  • Page 231 FRONT SUSPENSION Remove the retaining ring using a flat head screwdriver. Pull the inner tube until separating it from the outer tube. Note: to facilitate removal, quickly (but carefully) pump the tubes back and forth until separating them. Remove the sealing rings and the metal rings mounted on the inner tube. Do not reuse any metal parts after removal.
  • Page 232 FRONT SUSPENSION Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 457 mm (18 in.) or less. Check the inner tube. Replace if distorted. (Never attempt to repair or reuse a distorted fork tube). If the tube shows surface defects, sand the surface.
  • Page 233 FRONT SUSPENSION Fit metal bushing and washer to outer tube using an appropriate installer. Fit the oil seal to the outer tube and push it home using an appropriate in- staller. Make sure that the retaining ring groove inside the outer tube is fully visible. Install the retaining ring.
  • Page 234 FRONT SUSPENSION Insert the cartridge into the outer tube. Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb). I.24 edition (08-2010) _Rev. 11-2010...
  • Page 235 FRONT SUSPENSION Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod. Make sure that at least an 18 mm (0.71 in.) portion of the rebound adjuster rod protrudes from the piston rod. Oil filling.
  • Page 236 FRONT SUSPENSION Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube. Now slowly pump the piston rod up and down to help oil reach all points of the cartridge.

  • Page 237: Front Suspension (Smr)

    FRONT SUSPENSION Front suspension (SMR) Front suspension is handled by a MARZOCCHI “U.S.D.” upside-down telescopic hydraulic fork with advanced axle and 50 mm legs. Wheel travelis 258 mm. I.27 edition (08-2010) _Rev. 11-2010...

  • Page 238: Instructions For Use Of Ø50Usd Fork (Smr)

    FRONT SUSPENSION INSTRUCTIONS FOR USE OF Ø50USD FORK (SMR) GENERAL Telehydraulic upside down fork, with advanced axle. This fork is based on a multivalve damping system and spring for static load. The compression hydraulic damping is made through a special valve located in each fork’s leg lower area, whereas the rebound hydraulic damping is made through a cartridge located inside each stanchion.

  • Page 239: Components Of The Fork

    FRONT SUSPENSION Components of the fork The fork is based on a multivalve damping system that is exactly the same on both fork’s legs. Each fork’s leg is therefore a complete suspension system which you must refer to when adjusting any part of the fork. 5) Stanchi on tube 8) Lower sliding bushing 9) Spri ng cup...

  • Page 240: General Rules For A Proper Overhauling

    FRONT SUSPENSION GENERAL RULES FOR A PROPER OVERHAULING • After a complete breakdown, always use new, original Marzocchi seals when reassembling. • To tighten two bolts or nuts that are near each other, always follow the sequence 1- 2- 1 using a torque wrench; respect the indicated tightening torques (see Table 1 - Tightening Torques).

  • Page 241: Instructions For Clamping In The Vice

    FRONT SUSPENSION Instructions for clamping in the vice For some maintenance procedures you may have to use the vice to clamp some components of the fork. The incorrect use of the vice can cause irreparable damage to the fork. Scrupulously follow the instructions below: •...

  • Page 242: Problems - Possible Causes - Solutions

    FRONT SUSPENSION Problems - Possible causes - Solutions This paragraph indicates some of the problems which may arise during the working life of the fork, as well as the possible causes of these problems and any solutions to the same. Always consult this Table before working on the fork. INCONVENIENTE CAUSA RIMEDIO...

  • Page 243: Cleaning The Dust Seal

    FRONT SUSPENSION You can find the reference numbers of this chapter about the explored view of the fork on pag. 6. Cleaning the dust seal (FIG. 5) FUG.5 This operation can be carried out with the fork installed on the motorcy- cle.

  • Page 244: Draining The Oil

    FRONT SUSPENSION DRAINING THE OIL This operation cannot be carried out with the fork installed on the motorcycle. We recommend loosening the fork cap a little before removing the fork leg from the fork yokes. • Remove the fork leg from the fork yokes according to the procedure in the motorcycle owner’s manual.

  • Page 245: Braking Down The Pumping Element And The Bottom Valve

    FRONT SUSPENSION Braking down the pumping element and the bottom valve This operation must be done only after having drained all of the oil out of the fork leg. • Clamp the wheel axle clamp in the vice. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...
  • Page 246 FRONT SUSPENSION • In order to be able to act on the pumping element you will need to remove the foot buffer components: hold the foot buffer nut ( 26 ) using a 18 mm spanner and unscrew the push rod ( 29 ) with a 17 mm hexagonal spanner. •...

  • Page 247: Braking Down The Fork Leg - Slider And Removing The Oil Seals

    FRONT SUSPENSION Braking down the fork leg – slider and removing the oil seals • Remove the dust seal ( 12 ) from its seat, using a small flat- tip screwdriver. • With the same screwdriver remove the metal stop ring ( 11 ). •...

  • Page 248: Overhauling And Modifying The Cartridge And Bottom Valve Setting

    FRONT SUSPENSION Overhauling and modifying the cartridge and bottom valve setting CARTRIDGE OVERHAULING (REBOUND BRAKING) Dismantling • Clamp in the vice the rod ( 32 ) milled area. • Unscrew the nut ( 38 ) using a 12 or 13 mm spanner, according to the mounted nut.

  • Page 249: Bottom Valve Overhauling (Compression Braking)

    FRONT SUSPENSION The piston must be oriented in a way that the holes having smaller diam- eter are placed towards the setting washers (37). • Tighten the nut ( 38 ) manually. • Clamp in the vice the damping rod ( 32 ) milled area. •...

  • Page 250: Re- Assembling The Fork Leg - Slider And Oil Seals

    FRONT SUSPENSION Assembling: The washers (46) and the piston (45) are the ones causing the com- pression braking. It is possible, if needed, to modify the fork’s behaviour during the compression phase, by replacing the washers (46) and the piston (45) with other components having different characteristics.
  • Page 251 FRONT SUSPENSION • Insert the following components in the stanchion tube in this order: dust seal ( 12), stop ring ( 11 ), oil seal ( 10 ), spring cup ( 9 ) and bottom guide bushing ( 8 ). Make sure the oil seal (10) is correctly oriented in a way that the hollow side is turned towards the spring cup (9).

  • Page 252: Re- Assembling The Pumping Element Unit And The Bottom Valve

    FRONT SUSPENSION • Mount the stop ring ( 11 ) using a small flat- tip screwdriver, checking it fits perfectly into its groove and being very careful not to scratch the stanchion tube. • Re- assemble the dust seal ( 12 ) in its seat, pressing it home with your hands.
  • Page 253 FRONT SUSPENSION • Insert the tip (29) of stop buffer onto rod (32); it must be inserted so that the side with the flat is facing the case (30) and that you overcome the housing of the wire (F). • Insert the metal ring ( 27 ) into the proper seat( F ) •...
  • Page 254 FRONT SUSPENSION • Push the pre- assembled pumping element ( 23 ) until it is in contact with the stanchion tube ( 5 ). • Tighten the bottom valve by hand. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...

  • Page 255: Filling With Oil

    FRONT SUSPENSION Filling with oil The R5051AC is available as spare part: if you tighten it on the rod’s edge, you can make the rod extraction from the inner part of the slide easier. • Lift the slider completely on the stanchion tube. •...
  • Page 257 REAR SUSPENSION Section edition (08-2010) _Rev. 11-2010...
  • Page 258 REAR SUSPENSION Rear shock absorber ..................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.5 Disassembling and servicing the swinging arm..........J.6 Linkage disassembly..................J.8 Chain roller, chain guide, chain slider ............J.9 Chain sprocket removal .................J.9 edition (08-2010) _Rev. 11-2010...

  • Page 259: Rear Shock Absorber

    REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1, 2 = 50 Nm/ 5.0 Kgm/ 36.88 ft-lb H006175 H006176 Lubrication points (grease) H006244 H006178 edition (08-2010) _Rev. 11-2010...
  • Page 260 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. Hydraulic damping is also adjustable using outer adjuster screws.

  • Page 261: Rear Shock Absorber Removal

    REAR SUSPENSION Rear shock absorber removal H006179 - Fit a support under the engine so that the rear wheel is raised off the ground. - Remove the saddle, the side panels and control unit as described in the cor- responding chapters. - Remove wiring from the top mounting point.

  • Page 262: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION Disassembling and servicing the swinging arm H006192 - Remove the chain and rear wheel, as described in the relevant chapters. - Remove the two side protections (A) from the chassis. - Disconnect the rear stop connector (1). H006183 - Loosen the two screws (2) and remove the brake master cylinder (3) complete with tube and calliper (4).
  • Page 263 REAR SUSPENSION - Loosen the two screws (5) using an 8 mm wrench, and remove rear brake hose support (6) to slide out the pin (7). H006186 - Using a 17 mm wrench, loosen nut (8) and remove pin (7) on the other side. H006188 H006187 - Using a 10 mm Allen wrench, loosen pins (9) and remove swinging arm (10).

  • Page 264: Linkage Disassembly

    REAR SUSPENSION - Check bearings (11), seals and bushings for wear. H006191 - Upon reassembly, tighten nut (8) to 80 Nm - 8 Kgm - 59.00 ft-lb and pins (9) to 100 Nm - 10 Kgm - 73.76 ft-lb. Grease the inner race of the bearings before refitting them. Linkage disassembly To remove drag link (1) and drop link (2), proceed as follows: - Using a 14 mm wrench, remove the screw (3) retaining shock absorber drop...

  • Page 265: Chain Roller, Chain Guide, Chain Slider

    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. The chain could also drop out of the sprocket. 1 Chain roller 2 Chain guide 3 Chain slider...
  • Page 267 BRAKES Section edition (08-2010) _Rev. 11-2010...
  • Page 268 BRAKES Braking system ..................... L.3 Brake disc ..................... L.5 Checking brake pads for wear / replacing the pads (TC-TE-TXC) ....L.6 Checking brake pads for wear / replacing the pads (TC-TE-TXC) ....L.7 Bleeding the front braking system (TC-TE-TXC) .......... L.8 Bleeding the front braking system (SMS) .............

  • Page 269: Braking System

    BRAKES Braking system TC - TE - TXC 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 2a.Brake master cylinder 2b.Brake fluid reservoir 3.
  • Page 270 BRAKES 6. Rear brake fluid reservoir 7. Rear brake line 8. Rear brake calliper 9. Rear brake disc 10. Rear brake master cylinder 11. Rear brake control pedal H006214 edition (08-2010) _Rev. 11-2010...

  • Page 271: Brake Disc

    BRAKES TC - TE - TXC 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 (10.24 in) (TC-TE-TXC) 320 mm (12.6 in) (SMR) Front brake disc thickness (when new): 3.0 mm (0.12 in) (TC-TE-TXC)

  • Page 272: Checking Brake Pads For Wear / Replacing The Pads (Tc-Te-Txc)

    BRAKES Checking brake pads for wear / replacing the pads (TC-TE-TXC) Check brake pad wear. Service limit ”A” 3.8 mm (0,15 in) (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.
  • Page 273 BRAKES Checking brake pads for wear / replacing the pads (TC-TE-TXC) Check brake pad wear. Service limit ”A” 3.8 mm (0,15 in) (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.

  • Page 274: Bleeding The Front Braking System (Tc-Te-Txc)

    BRAKES Bleeding the front braking system (TC-TE-TXC) 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).

  • Page 275: Bleeding The Front Braking System (Sms)

    BRAKES Bleeding the front braking system (SMS) A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding is also required after changing brake fluid. To bleed the front brake, begin with the control on the handlebar and then bleed the calliper: the procedure is the same.

  • Page 276: Bleeding The Rear Braking System

    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).

  • Page 277: Changing The Fluid

    BRAKES Changing the fluid TC - TE - TXC 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).
  • Page 278 BRAKES Remove the reservoir cap (2) or (2A) 21 mm wrench and the rubber gaiter. TC - TE - TXC Loosen the bleed valve (1) and (1a) 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.
  • Page 279 BRAKES Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance TC - TE - TXC Chart, Section B): replace worn or cracked hoses. H06407 H06408 H006230 edition (08-2010) _Rev. 11-2010 L.13...
  • Page 281 ELECTRICAL SYSTEM Section edition (08-2010)_Rev. 11-2010...

  • Page 282: Electrical System

    ELECTRICAL SYSTEM Engine wiring diagram (TC) ................. M.4 Engine wiring diagram (TE-TXC-SMR) ............M.6 Adapter (TXC) ..................... M.8 Electrical components location (TC) ............M.10 Electrical components location (TE - SMR) ..........M.13 Electrical components location (TXC) ............M.18 Generator stator windings resistance (1) inspection ......... M.22 Generator no-load performance ...............
  • Page 283 ELECTRICAL SYSTEM TROUBLESHOOTING ................M.48 CHARGING SYSTEM ................M.48 STARTING SYSTEM ................. M.48 ELECTRONIC IGNITION SYSTEM ............M.48 Connector position (TE - SMR) ..............M.49 Connector position (TC) ................M.53 Connector position (TXC) ................. M.55 IMPORTANT ....................M.58 edition (08-2010)_Rev. 11-2010...

  • Page 284: Engine Wiring Diagram (Tc)

    ELECTRICAL SYSTEM Engine wiring diagram (TC) edition (08-2010)_Rev. 11-2010...
  • Page 285 ELECTRICAL SYSTEM Key to wiring diagram 1. Control unit 2. Neutral 3. Crankshaft pick up 4. Air temperature sensor 5. MAP sensor 6. Injector 7. Throttle valve position 8. Coil ground 9. Ignition coil 10. Coolant temperature sensor 11. Generator 12.

  • Page 286: Engine Wiring Diagram (Te-Txc-Smr)

    ELECTRICAL SYSTEM Engine wiring diagram (TE-TXC-SMR)    edition (08-2010)_Rev. 11-2010...
  • Page 287 ELECTRICAL SYSTEM Colour coding key Key to wiring diagram blge ....Blue/Yellow 1. Control unit blgn ....Blue/Green 2. Neutral blrt....Blue/Red 3. Crankshaft pick up blsw ....Blue/Black 4. Second throttle motor br ....Brown 5. Air temperature sensor brbl....

  • Page 288: Adapter (Txc)

    ELECTRICAL SYSTEM Adapter (TXC) edition (08-2010)_Rev. 11-2010...
  • Page 289 ELECTRICAL SYSTEM Key to wiring diagram 1. Adapter to engine wiring connector 2. Clutch connector 3. RH switch connector 4. Speed sensor connector edition (08-2010)_Rev. 11-2010...

  • Page 290: Electrical Components Location (Tc)

    ELECTRICAL SYSTEM Electrical components location (TC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H06284 Electronic ignition coil (2) with integrated spark plug cap positioned on cylinder head; Spark plug on cylinder head; H06442 Electronic control unit (3) under the saddle;...
  • Page 291 ELECTRICAL SYSTEM Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis; H06443 "MAP. SENSOR" (7) sensor on throttle body; H06276 The electrical system includes the following elements: Fuel pump (8) positioned inside the tank (9); H06271 edition (08-2010)_Rev.
  • Page 292 ELECTRICAL SYSTEM 12V - 4Ah Battery (10) under the saddle; H06277 A 30A fuse (11) positioned on the solenoid starter; H06444 Fuel pump relay (12) positioned on the front left side, under the air box: Main starting relay (13) positioned on the front left side, under the air box: H06278 Coolant temperature sensor (14);...

  • Page 293: Electrical Components Location (Te - Smr)

    ELECTRICAL SYSTEM Condenser (15) positioned on engine rear side. H06280 Electrical components location (TE - SMR) The ignition system includes the following elements: Generator (1) on the inner side of L.H. crankcase half cover; H06284 Electronic ignition coil (2) with integrated spark plug cap positioned on cylinder head;...
  • Page 294 ELECTRICAL SYSTEM Voltage regulator (4) located at the back of the steering tube. H06274 Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis; H06443 Potentiometers (7) and (8) on throttle body; throttle throttle H06281...
  • Page 295 ELECTRICAL SYSTEM The electrical system includes the following elements: 12V - 6Ah Battery (9) under the saddle; H06287 Turning indicator flasher (10) at the front end, below the headlamp fairing; Light relay (11); H06288 Fuel pump relay (12) and main relay (13) positioned on the front left side, under the air box;...
  • Page 296 ELECTRICAL SYSTEM Electric fan (15); H06293 A 10A (lights) fuse (16) positioned below the headlamp fairing and a 30A (main) fuse (17) positioned on the solenoid starter; H06282 H06445 Coolant temperature sensor (18); Lambda sensor (19); H06283 M.16 edition (08-2010)_Rev. 11-2010...
  • Page 297 ELECTRICAL SYSTEM Headlamp (20) with 12V-35W twin halogen bulb and 12V-5W parking light bulb; H06295 LED tail light (21) with stop light bulb; Turning indicators (22), 12V-6W bulbs; H06296 Fuel pump (23) inside the tank (24); H06291 Odometer (25); H06294 edition (08-2010)_Rev.

  • Page 298: Electrical Components Location (Txc)

    ELECTRICAL SYSTEM Condenser (26) positioned on engine rear side. H06292 Electrical components location (TXC) The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H06284 Electronic ignition coil (2) with integrated spark plug cap positioned on cylinder head;...
  • Page 299 ELECTRICAL SYSTEM Voltage regulator (4) located at the back of the steering tube. H06274 Starter motor (5) in front of engine cylinder; H06285 Solenoid starter (6) positioned under saddle, on rear chassis; H06443 Potentiometers (7) and (7A) on throttle body; throttle (7A) = 1 throttle...
  • Page 300 ELECTRICAL SYSTEM The electrical system includes the following elements: Fuel pump (8) positioned inside the tank (9); H06271 12V - 6Ah Battery (10) under the saddle; H06277 A 30A fuse (11) positioned on the solenoid starter; H06444 Fuel pump relay (12) positioned on the front left side, under the air box: Main starting relay (13) positioned on the front left side, under the air box: H06278 M.20...
  • Page 301 ELECTRICAL SYSTEM Electric fan relay (14), on the chassis right side. Lambda sensor (15) H06299 Coolant temperature sensor (16); H06377 Electric fan (17); H06378 Condenser (18) positioned on engine rear side. H06300 edition (08-2010)_Rev. 11-2010 M.21...

  • Page 302: Generator Stator Windings Resistance (1) Inspection

    ELECTRICAL SYSTEM Generator stator windings resistance (1) inspection Disconnect the stator coil connector from the wiring and measure resistance with a meter. H06284 1) Check that across the terminals of the connector (2), the value is about 0.8 . If resistance is outside the specified limits, replace the complete generator. H06449 Generator no-load performance MAX 13A at 14V.

  • Page 303: Condenser Inspection

    ELECTRICAL SYSTEM Condenser inspection The condenser (1) keeps the bike running in case of accidental disconnection of battery (loosening of cable fastening device). - Disconnect the condenser and check that its capacitance is 2,200 Micro- farad. In case the reading is different, it is necessary to replace it. H06459 edition (08-2010)_Rev.

  • Page 304: Ignition System (Tc)

    ELECTRICAL SYSTEM Ignition system (TC) M.24 edition (08-2010)_Rev. 11-2010...
  • Page 305 ELECTRICAL SYSTEM The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed. This ignition system is composed of a crankshaft position (pick-up) sensor (2), an ECU (1), an ignition coil (3) and an intake manifold pressure sensor (5).

  • Page 306: Ignition System (Te - Txc - Smr)

    ELECTRICAL SYSTEM Ignition system (TE - TXC - SMR)    M.26 edition (08-2010)_Rev. 11-2010...
  • Page 307 ELECTRICAL SYSTEM The ignition system is controlled by the ECU (1). The ignition is an integrated digital electronic ignition system with static timing and advance using intermit- tent sequential phased electronic injection feed. This ignition system is com- posed of a crankshaft position (pick-up) sensor (2), an ECU (1), an ignition coil (3) and an intake manifold pressure sensor (5).

  • Page 308: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM The charging system is composed of: - Alternator (1); - Voltage regulator/rectifier (2); - Solenoid starter (3); - Battery (4). - Starter motor (5) The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator/rectifier.

  • Page 309: Charging System Inspections

    ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTIONS Current loss at the battery Remove the saddle (as described 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.
  • Page 310 ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM The starting system is composed of: - Battery (1); - Solenoid starter (2); - Starter motor (3); - R.H. switch (4); - Clutch microswitch (5) (TC - TXC); - Ignition switch (6) (TE - SMR); For a description of wires and components, please see the key to the wiring diagram TE - SMR...

  • Page 311: Starting System Inspection

    ELECTRICAL SYSTEM STARTING SYSTEM INSPECTION Starter motor inspection Remove the starter motor (1) as described in the relevant paragraph. Whenever a starter motor fault is detected, check the starter motor as follows: - connect a meter across ground and starter motor contact. - Check for continuity between the positive pole and motor ground.

  • Page 312: Coil Windings Resistance Inspection

    ELECTRICAL SYSTEM Coil windings resistance inspection Disconnect the connector (1) from the coil (2). Remove the coil (2) as described in the relevant paragraph. Measure primary and secondary winding resistance with a meter. Primary winding resistance: 0.6÷0.7 ±15% at 20°C. Secondary winding resistance: Open circuit.

  • Page 313: Spark Plug

    ELECTRICAL SYSTEM Spark plug Check the gap "A" (0.7 mm) between the electrodes. A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed.

  • Page 314: Headlamp, Tail Light (Te - Smr)

    ELECTRICAL SYSTEM HEADLAMP, TAIL LIGHT (TE - SMR) 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 (32.8 ft) away from a vertical wall;...
  • Page 315 ELECTRICAL SYSTEM - loosen the two lower screws (2) using a Phillips screwdriver; H06313 - move headlight unit (3) aside; H06314 - release connector (4); H06315 - slide off the rubber gaiter (5); H06316 edition (08-2010)_Rev. 11-2010 M.35...
  • Page 316 ELECTRICAL SYSTEM - release the bulb holder clips (6) and take out bulb (7); NOTE*: Headlamp bulb (7) is of the halogen type; be careful when replacing it since the glass part shall not be touched with bare hands. (12V 35+35 W bulb - HS1) H06317 H06318 To replace the parking light bulb (8) extract it from the inside cover.

  • Page 317: Turning Indicator Bulb Replacement (Te - Smr)

    ELECTRICAL SYSTEM Turning indicator bulb replacement (TE - SMR) - Loosen screw (1) using a Phillips screwdriver; H06320 - remove lens (2) and replace bulb (3) pushing it inside, and turning it to remove Once the bulb has been replaced, reverse the above procedure to reassem- ble.

  • Page 318: Number Plate Bulb Replacement (Te - Smr)

    ELECTRICAL SYSTEM Number plate bulb replacement (TE - SMR) - Loosen screw (1) and remove the number plate bulb (2) from the mud- guard. H06323 - 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.

  • Page 319: Left-Hand Switch (Te - Smr)

    ELECTRICAL SYSTEM Left-hand switch (TE - SMR) 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 to the centre. Horn.

  • Page 320: Right-Hand Switch (Te - Txc - Smr)

    ELECTRICAL SYSTEM Right-hand switch (TE - TXC - SMR) 1. Engine start button 2. Engine start/stop switch B/Bk H06453 Colour coding key B ....Blue Br ....Brown G ....Green Br-Bk ..... Brown-Black M.40 edition (08-2010)_Rev. 11-2010...

  • Page 321: Right-Hand Switch (Tc)

    ELECTRICAL SYSTEM Right-hand switch (TC) 1. Engine start button 2. Double map push-button Bk/G Bk/G B/Bk H06453 Colour coding key Bk ....Black R ....Red B ....Blue G ....Green Br-Bk ..... Brown-Black Bk-G ..... Black-Green B-Bk ....Blue-Black edition (08-2010)_Rev.

  • Page 322: Fuses

    ELECTRICAL SYSTEM FUSES • When you find a blown fuse, 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.

  • Page 323: Relay Test

    ELECTRICAL SYSTEM Relay test Gain access to the relays as indicated in the relevant paragraph; then, remove them. 1) Main starting relay 2) Fuel pump relay H06327 3) Electric fan relay (TE - TXC - SMR) H06328 4) Light relay (TE - SMR) H06329 edition (08-2010)_Rev.
  • Page 324 ELECTRICAL SYSTEM A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation. Reading should be: 80 Ohm (+/- 10%) at 20 °C. B: Set the meter to "Continuity" mode and check the circuit is open. C: Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes.

  • Page 325: Digital Dashboard, Warning Lights (Te)

    IMPORTANT: In the event of a FUEL INJECTION SYSTEM MALFUNCTION, the word FAIL appears on the right side of the dashboard display: When this is the case, contact your HUSQVARNA dealer. 1- SPEED (km/h or mph) / ODO - SPEED: vehicle speed - maximum value: 299 Km/h or 299 mph;...
  • Page 326 ELECTRICAL SYSTEM 3 - SPEED / TRIP 1 - SPEED: speed - maximum value: 299 Km/h or 299 mph - TRIP 1: distance - maximum value: 999.9 km or 621,31 mi (data will be lost after disconnecting the battery). To reset TRIP, push the SCROLL button (A) and hold for more than 3 sec- onds.

  • Page 327: Dashboard Replacement (Te - Smr)

    ELECTRICAL SYSTEM Dashboard replacement (TE - SMR) Remove the headlamp fairing as explained under "Headlamp bulb replace- ment". 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. H06331 H06330 edition (08-2010)_Rev.

  • Page 328: Troubleshooting

    ELECTRICAL SYSTEM 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"); 2) incorrect voltage (see paragraph "Regulated voltage"); 3) no continuity in generator (see paragraph "Generator stator windings resist- ance inspection");...

  • Page 329: Connector Position (Te - Smr)

    ELECTRICAL SYSTEM Connector position (TE - SMR) The following connectors are positioned on the front side, below the headlamp fairing: 1) Headlamp connector 2) Turning indicator flasher connector 3) Light relay connector 4) Dashboard connector 5) Wiring harnesses connector 6) Front brake stop switch connector 7) Speed sensor connector 8) Ignition switch connector H06332...
  • Page 330 ELECTRICAL SYSTEM The following connectors are positioned on the bike right side: 12) Temperature sensor connector 13) Electric fan relay connector 14) Lambda sensor connector H06336 15) Condenser connector H06338 16) 2 throttle connector 17) 1 throttle connector 18) Sensor connector H06455 19) Current generator connector H06456...
  • Page 331 ELECTRICAL SYSTEM 20) Voltage regulator connector H06342 21) Injector connector H06344 22) Pressure sensor connector H06345 23) Rear stop (brake) connector H06340 edition (08-2010)_Rev. 11-2010 M.51...
  • Page 332 ELECTRICAL SYSTEM The following connectors are positioned on the bike rear side: 24) Tail light connector 25) Rear turning indicator connector 26) Number plate light connector H06341 The following connectors are positioned on the bike left side: 27) Main starting relay connector 28) Fuel pump relay connector 29) Air temperature sensor connector 30) Electric fan connector...

  • Page 333: Connector Position (Tc)

    ELECTRICAL SYSTEM 35) Diagnostics connector H06348 Connector position (TC) The following connectors are positioned on the front side, below the number holder: 1) RH switch connector 2) Clutch sensor connector 3) Engine stop connector H06349 The following connectors are positioned on the bike right side: 4) Temperature sensor connector H06350 5) TPS connector...
  • Page 334 ELECTRICAL SYSTEM 10) Voltage regulator connector H06352 The following connectors are positioned on the bike left side: 11) Main starting relay connector 12) Fuel pump relay connector 13) Air temperature sensor connector 14) Coil connector H06353 15) Condenser connector H06354 The following connectors are positioned under the saddle: 16) Electronic control unit connector 17) Solenoid starter connector...

  • Page 335: Connector Position (Txc)

    ELECTRICAL SYSTEM 18) Diagnostics connector H06356 Connector position (TXC) The following connectors are positioned under the number holder: 1) Speed sensor connector 2) Clutch connector 3) RH switch connector 4) Wiring harnesses connector H06357 The following connectors are positioned on the bike right side: 5) Temperature sensor connector 6) Electric fan relay connector 7) Lambda sensor connector...
  • Page 336 ELECTRICAL SYSTEM 11) Current generator connector H06527 12) Voltage regulator connector H06361 13) Pressure sensor connector H06362 The following connectors are positioned on the bike left side: 14) Main starting relay connector 15) Fuel pump relay connector 16) Air temperature sensor connector 17) Electric fan connector 18) Coil connector H06363...
  • Page 337 ELECTRICAL SYSTEM The following connectors are positioned under the saddle: 19) Fuel pump connector H06364 20) Electronic control unit connector 21) Solenoid starter connector H06365 22) Diagnostics connector H06366 edition (08-2010)_Rev. 11-2010 M.57...

  • Page 338: Important

    ELECTRICAL SYSTEM IMPORTANT Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches; c) Air filter intake; d) Steering head, wheel bearings; e) Rear suspension drag drop link.
  • Page 339 ENGINE COOLING Section edition (08-2010) _Rev. 11-2010...
  • Page 340 ENGINE COOLING Coolant level check ..................N.3 Cooling circuit ....................N.4 Engine cooling system overhaul ..............N.5 edition (08-2010) _Rev. 11-2010...
  • Page 341 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.
  • Page 342 ENGINE COOLING Cooling circuit H06390 TE-TXC-SMR 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 Water temperature sensor Water pump Breather hose Cylinder head / radiator connection pipe Water pump / radiator lower pipe Cooling fan (TE - TXC - SMR) edition (08-2010) _Rev.
  • Page 343 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.
  • Page 345 HYDRAULICALLY CONTROLLED CLUTCH Section edition (08-2010) _Rev. 11-2010...
  • Page 346 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system ................P.3 Draining clutch fluid ..................P.4 Clutch master cylinder servicing ..............P.5 Bleeding the clutch system ................P.6 edition (08-2010) _Rev. 11-2010...

  • Page 347: Hydraulic Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH H006204 Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the right crankcase half. Clutch is disengaged through piston (1) that works on clutch pushrod. 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose...

  • Page 348: Draining Clutch Fluid

    HYDRAULICALLY CONTROLLED CLUTCH Draining clutch fluid Connect a plastic hose to the bleed valve (1) and the loosen the valve turning it back 1 or 2 turns. Remove reservoir cap (2) and gasket (3) and operate the control lever (4) until draining all fluid. H006205 edition (08-2010) _Rev.

  • Page 349: Clutch Master Cylinder Servicing

    HYDRAULICALLY CONTROLLED CLUTCH Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart. Replace all seals, reassemble the master cylinder and refit it to the handlebar. Reconnect the hose and fill fresh fluid into the reservoir; bleed the system as described in the relevant paragraph.

  • Page 350: Bleeding The Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH Bleeding the clutch system A long travel and mushy feel of the clutch lever indicate that there is air in the system and the clutch hydraulic system needs bleeding. Bleeding procedure is as follows: Take the rubber cap off the bleed valve (1). Attach a clear plastic hose to the 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).
  • Page 351 FUEL INJECTION SYSTEM Section Edition (08-2010)_Rev. 11-2010...
  • Page 352 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM .................S.3 Instructions for using "HUSQVARNA SERVICE TOOL" for fuel injection system ..................S.4 Fuel pump check ..................S.6 edition (08-2010)_Rev. 11-2010...
  • Page 353 Fuel injection pulse width; Ignition coil; Lambda sensor heater; Rich or lean combustion mixture (LAMBDA sensor); "HUSQVARNA SERVICE TOOL" diagnostic software allows you to test the components listed above in the event of a fuel injection system malfunction. H06266 H06265...
  • Page 354 The fuel injection system does not require any scheduled maintenance. The "HUSQVARNA SERVICE TOOL" part no. 8000 H3898 allows you to test injection system components in the event of a malfunction. TE = A malfunction is indicated by the word "FAIL" appearing in the right-hand portion of the tool display when the ignition key is set to ON.
  • Page 355 FUEL INJECTION SYSTEM In addition to identifying any current malfunction, the software stores past malfunctions that have been resolved: store malfunc- tions can be deleted following the instructions provided in the Operation Manual. For fuel pump and relay inspections, see relevant paragraphs. Edition (08-2010)_Rev.
  • Page 356 FUEL INJECTION SYSTEM Fuel pump inspection Remove the pump as described in Section "E". Connect the power supply unit positive pole (12V) to the red lead pin in the pump connector; Connect the power supply unit negative pole to the negative lead pin in the pump connector.
  • Page 357 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.
  • Page 358 TIGHTENING TORQUE FIGURES Assembly Cycle Operation Description ft/lb BRAKE PEDAL ADJUSTING CAMS TO CHASSIS FASTENING 10,00 1,00 7,38 CHASSIS CHAIN SLIDER TO TRANSVERSAL LOWER TUBE FASTENING 1,00 0,10 0,74 CONDENSER PLATE TO ENGINE FASTENING 10,00 1,00 7,38 ENGINE FRONT PLATE TO ENGINE FASTENING (WITH LOCTITE 270) 25,00 2,50 18,44...
  • Page 359 TIGHTENING TORQUE FIGURES Assembly Cycle Operation Description ft/lb SILENCER TO REAR CHASSIS FASTENING 25,00 2,50 18,44 MANIFOLD FLANGE NUT FASTENING 13,00 1,30 9,59 SILENCER CLAMP FASTENING 20,00 2,00 14,75 HEADLIGHT TO GRILLE FASTENING 10,00 1,00 7,38 RING TO GRILLE/NUMBER HOLDER FASTENING 0,70 0,07 0,52...
  • Page 360 TIGHTENING TORQUE FIGURES Assembly Cycle Operation Description ft/lb LEFT SWITCH FASTENING 2,50 0,25 1,84 CLUTCH MASTER CYLINDER FASTENING 5,00 0,50 3,69 HANDLEBAR CLAMPS FASTENING 45,00 4,50 33,19 INSTRUMENT PANEL PLATE FASTENING 5,00 0,50 3,69 FUEL PUMP FASTENING 7,00 0,70 5,16 COCK FASTENING 1,50 0,15...
  • Page 361 TIGHTENING TORQUE FIGURES NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on brass, copper, aluminium 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on iron, steel...
  • Page 362 TIGHTENING TORQUE FIGURES edition (08-2010) _Rev. 11-2010...
  • Page 363 CHASSIS AND WHEELS Section edition (08-2010) _Rev. 11-2010...

  • Page 364: Chassis And Wheels

    CHASSIS AND WHEELS Chassis ......................3 Lubrication points (lubricant) ................4 Front wheel (TC - TE - TXC) ................5 Front wheel (SMR) ..................6 Removing the front wheel ................7 Reassembling the front wheel ................. 8 Rear wheel (TC - TE - TXC) ................11 Rear wheel (SMR) ..................

  • Page 365: Chassis

    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. edition (08-2010) _Rev. 11-2010...

  • Page 366: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS Lubrication points (lubricant) 1 Steering bearings (grease) H006231 H006232 Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE RETAINING PINS/SCREWS B ENGINE MOUNTING LINKS C REAR CHASSIS MOUNTING BOLTS D CHAIN GUIDE ROLLER/BEARING E FOOTPEGS/PINS/SPRINGS edition (08-2010) _Rev.

  • Page 367: Front Wheel (Tc - Te - Txc)

    CHASSIS AND WHEELS Front wheel (TC - TE - TXC) H006233 Light alloy wheel hub and rim with high-strength steel spokes. Type and size of wheel rims ........light alloy: 1.6x21” (TC - TXC) Type and size of tyre ..........80/100 x 21” (TE) Type and size of tyre ..........90/90 x 21 Cold tyre pressure...

  • Page 368: Front Wheel (Smr)

    CHASSIS AND WHEELS Front wheel (SMR) H06413 Light alloy wheel hub and rim with high-strength steel spokes. Type and size of wheel rims ........light alloy: 3.5x17” Type and size of tyre ..........120/70x17” Cold tyre pressure SMR (*) ..............1.4 Kg/cm SMR (%) ...............1.8 Kg/cm SMR (&) ..............2.0 Kg/cm (*) - In case of racing use (%) - Rider only...

  • Page 369: Removing The Front Wheel

    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. H006234 TC - TE - TXC Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. H06409 H06411 edition (08-2010) _Rev.

  • Page 370: Reassembling The Front Wheel

    CHASSIS AND WHEELS Hold the head of the wheel axle in place, and unscrew the bolt (3) on the op- TC - TE - TXC posite side; draw the wheel axle out. Do not operate the front brake lever when the wheel has been removed;...
  • Page 371 CHASSIS AND WHEELS Fit the wheel between the fork legs so as to set the brake disc into the calliper. TC - TE - TXC Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully home against the L.H.
  • Page 372 CHASSIS AND WHEELS TE - TXC - SMR TE - TXC -SMR Check the gap “B” between magnet (6) on brake disc and sensor (7) on brake calliper. H06389 Set height “A” back to original value. Y.10 edition (08-2010) _Rev. 11-2010...

  • Page 373: Rear Wheel (Tc - Te - Txc)

    CHASSIS AND WHEELS Rear wheel (TC - TE - TXC) H006238 Light alloy wheel hub and rim with high-strength steel spokes. (TC) Type and size of wheel rims ......light alloy: 2,15x19”; (TE - TXC) Type and size of wheel rims ......light alloy: 2.15x18”; (TC) Type and size of tyre ........

  • Page 374: Rear Wheel (Smr)

    CHASSIS AND WHEELS Rear wheel (SMR) H06414 Light alloy wheel hub and rim with high-strength steel spokes. Type and size of wheel rims ......light alloy: 4,25”x17”; Type and size of tyre ........150/60x17” Cold tyre pressure SMR (*) ............1,6 Kg/cm SMR (%) ............

  • Page 375: Removing The Rear Wheel

    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. H006239 Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...

  • Page 376: Wheel Servicing

    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);...

  • Page 377: Wheel Spokes

    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.

  • Page 378: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    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.

  • Page 379: Checking Pinion And Sprockets For Wear

    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.
  • Page 381 NOTES FOR USA/CDN Section edition (08-2010) _Rev. 11-2010 Z.19...
  • Page 382 NOTES FOR USA/CDN SPARK ARRESTER (TE - TXC - SMR) The models are equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance. “SPARK ARRESTER” MAINTENANCE AND CLEANOUT IN- STRUCTIONS Proceed as follows: DISASSEMBLY AND CLEANOUT(EVERY 5000MILES) H06433 Z.20 edition (08-2010) _Rev.
  • Page 383 NOTES FOR USA/CDN - Unscrew the screw on the end cap then pull out the screen. H06434 H06435 H06436 - Inspect the screen and: a) Cleanout the screen blowing air on the outside surface in order to remove any carbon particles. b) Shake the muffler handling it vertically, with S.A.
  • Page 384 NOTES FOR USA/CDN Assembly - Mount the screen matching the 3 holes. - Tighten the screw and washer with a torque of 3Nm. For all screws check the proper torque every 500Km and tighten if necessary. H06434 Final assembly H06438 Muffler-side view H06439 SA Homologation stamp on the opposite face...
  • Page 385 NOTES FOR USA/CDN KIT Canister (TE - TXC - SMR) SERBATOIO FUEL TANK RESERVOIR TANK DEPOSITO MOTORE ENGINE MOTEUR MOTOR MOTOR ARIA LUFT AIRE H06441 Canister Support Clamp Adhesive gum Fitting Seal washer Clamp Clamp Clamp Tube Tube Tube edition (08-2010) _Rev. 11-2010 Z.23...

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