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

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

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Summary of Contents for Husqvarna SM 610 2006

  • Page 1 W orkshop M an u al S M 6 10, T E 61 0/ 2 0 06 P a rt. N . 8 0 0 0 A 4 6 4 0 (0 4 -2 00 5 )
  • Page 2 T o th e b e st kn o w le d g e o f M V A g u sta M o to rc ycle s S .p .A . - V a re se , In c. th e m a te ria l co n ta in e d h e re in is a ccu ra te a s o f th e d a te th is p u b lica tio n w a s a p p ro ve d fo r p rin tin g .
  • Page 3 F o rew o rd T h is p u b lica tio n in te n d e d fo r H U S Q V A R N A W o rks h o p s h a s b e e n p re p a re d fo r th e p u rp o se o f h e lp in g th e a u th o rize d p e rso n n e l in th e m a in te n a n ce a n d re p a ir w o rk o f th e m o to rc ycle s h e re w ith d e a lt w ith .
  • Page 4 T E 6 1 0 S M 6 1 0 - W h e re n o t o th e rw ise sp e cifie d , d a ta a n d in stru ctio n s re fe r to a ll m o d e ls.
  • Page 5 S u m m a ry S ectio n C h a p te r G e n e ra l M ain ten an ce T ro u b les an d rem ed ies S ettin g s an d ad ju stm en ts G en eral o p era tio n s E n g in e d isass em b ly E n g in e o ve rh au lin g...
  • Page 7 G E N E R A L S e ctio n...

  • Page 8: Table Of Contents

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

  • Page 9: E N G In E A

    G E N E R A L E N G IN E 4 -stro ke , sin g le cylin d e r B o re 3 .8 5 in . S tro ke 3 .0 1 in . D isp la ce m e n t 3 5 .1 5 cu .

  • Page 10: T Ra N S M Is S Io N

    G E N E R A L T R A N S M IS S IO N M u lti-p la te clu tch in o il b a th 6 -sp e e d g e a rb o x, co n s ta n t m e sh g e a r typ e D rive b e tw e e n e n g in e a n d g e a rb o x m a in sh a ft b y stra ig h t to o th e d g e a rs...

  • Page 11: * F R A M E

    G E N E R A L * F R A M E W H E E L S S in g le -b e a m in ste e l tu b e s o f circu la r se ctio n sp littin g a p p ro x. R im s o n lin e w ith th e e xh a u st;...

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

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

  • Page 13: W E Ig H Ts

    G E N E R A L W E IG H T S (§ )/ D IM E N S IO N S m m S M 610 T E 610 (§): C u rb w eig h t, w ith o u t fu el S M 6 1 0 .....kg 1 4 2 (3 1 3 lb s) T E 6 1 0 .....

  • Page 14: C A P Ac Itie S

    G E N E R A L C A PA C IT IE S F u e l ta n k (re se rve in clu d e d ) U n le a d e d g a so lin e (9 8 R .O .N .) 2 .6 4 Im p .
  • Page 15 M A IN T E N A N C E S e ctio n...
  • Page 16 M A IN T E N A N C E P R E -D E L IV E R Y IN S P E C T IO N D e s c rip tio n O p e ra tio n P re -d e live ry E n g in e o il C o o la n t...
  • Page 17 M A IN T E N A N C E P E R IO D IC M A IN T E N A N C E S C H E D U L E C O U P O N A - C O U P O N B - C O U P O N C - C O U P O N D -...
  • Page 18 M A IN T E N A N C E P E R IO D IC M A IN T E N A N C E S C H E D U L E C O U P O N A - C O U P O N B - C O U P O N C - C O U P O N D -...
  • Page 19 T R O U B L E S H O O T IN G S e ctio n...
  • Page 20 T R O U B L E S H O O T IN G E N G IN E T ro u b le C a u s e R e m e d y E n g in e d o n t s ta rt o r s ta rts w ith d iffic u lty In a d e q u a te c o m p re s s io n 1 .
  • Page 21 T R O U B L E S H O O T IN G T ro u b le C a u s e R e m e d y E n g in e c u ts o u t e a s ily 1 .
  • Page 22 T R O U B L E S H O O T IN G T ro u b le C a u s e R e m e d y C lu tc h d ra g 1 . E xce ssive clu tch a d ju ste r fre e p la y A d ju st 2 .
  • Page 23 T R O U B L E S H O O T IN G F R A M E W H E E L S A N D S U S P E N - S IO N T ro u b le C a u s e R e m e d y D iffic u lt to tu rn h a n d le b a rs...
  • Page 24 T R O U B L E S H O O T IN G T ro u b le C a u s e R e m e d y P o o r (fro n t a n d re a r) b ra k in g 1 .
  • Page 25 S E T T IN G S A N D A D JU S T M E N T S S e ctio n...
  • Page 26 S E T T IN G S A N D A D JU S T M E N T S T a b le o f C o n te n ts D .3 A d ju stm e n t o f va lve s p la y C o m p res sio n ch eck D .3 C arb u reto r ad ju stm en t...

  • Page 27: C O M P Res Sio N Ch Eck

    S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f va lve s p la y R e m o ve se a t, sp o ile rs, fu e l ta n k, co o le rs a n d e xp a n sio n ta n k a s sh o w n a t ch a p te r G e n e ra l O p e ra tio n s .

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

    S E T T IN G S A N D A D JU S T M E N T S C a rb u re to r a d ju s tm e n t A d ju st th e ca rb u re to r w ith w a rm e n g in e a n d w ith th e th ro ttle co n tro l in clo se d p o sitio n .

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

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

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

    S E T T IN G S A N D A D JU S T M E N T S C le a n in g th e b a g filte rs T h e filte rs (1 ) e t (2 ) a re se t o n th e rig h t sid e b e tw e e n th e co ve r a n d th e su m p (tra n sm issio n to th e sca ve n g e p u m p ), a n d o n th e le ft su m p (tw in -filte r, tra n sm issio n to th e p re ssu re p u m p ).

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

    S E T T IN G S A N D A D JU S T M E N T S R e p la c e m e n t o f c o o la n t S e t a ve sse l u n d e r th e e n g in e a n d w o rk a s fo llo w s : - re m o ve th e rig h t ra d ia to r ca p a n d th e co o lin g flu id d ra in scre w (A ) se t o n th e rig h t o f th e c ylin d e r.

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

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

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

    S E T T IN G S A N D A D JU S T M E N T S T h ro ttle c a b le a d ju s tm en t T o ch e ck th e co rre ct a d ju stm e n t o f th e th ro ttle o p e ra te a s fo llo w s: - re m o ve th e u p p e r ru b b e r ca p (1 );...

  • Page 34: C Lu Tch Ad Ju Stm En T

    S E T T IN G S A N D A D JU S T M E N T S C lu tc h a d ju s tm e n t T h e co n tro l Ie ve r m u st h a ve a 0 .1 2 ÷ 0 .2 0 in . id le stro ke b e fo re b e g in n in g to d ise n g a g e th e clu tch .
  • Page 35 S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f fro n t b ra k e c o n tro l le ve r a n d flu id le ve l c h e c k O n th e S M 6 1 0 m o d e l th e le ve r p o sitio n ca n b e a d ju ste d (4 a d ju stm e n ts) fo r a n y d rive r h a n d size .

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

    S E T T IN G S A N D A D JU S T M E N T S A d ju s tm e n t o f re a r c o n tro l p e d a l T h e p o sitio n o f th e re a r b ra ke p e d a l a s re g a rd s th e fo o tre st ca n b e a d - ju ste d a cco rd in g to th e p e rso n a l re q u ire m e n ts.

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

    S E T T IN G S A N D A D JU S T M E N T S S te e rin g b e a rin g s p la y a d ju s tm e n t T o e n su re m a xim u m sa fe ty, th e ste e rin g sh o u ld a lw a ys b e a d ju ste d so th a t th e h a n d le b a rs ro ta te fre e ly w ith o u t p la y.
  • Page 38 S E T T IN G S A N D A D JU S T M E N T S A d ju s tin g th e fo rk a ) C O M P R E S S IO N (L O W E R R E G IS T E R ) S ta n d a rd ca lib ra tio n : -1 2 clicks.

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

    S E T T IN G S A N D A D JU S T M E N T S A d ju stin g th e sh o ck ab so rb er sag T h e re a r sh o ck a b so rb e r m u st b e a d ju ste d a cco rd in g to th e rid e r w e ig h t a n d tra ck co n d itio n s.
  • Page 40 S E T T IN G S A N D A D JU S T M E N T S D rive ch ain a d ju stm en t C a rry o u t th e cle a n in g o p e ra tio n s a s d e scrib e d in th e p e rio d ica l m a in te n a n ce ca rd .
  • Page 41 G E N E R A L O P E R AT IO N S S e ctio n...
  • Page 42 G E N E R A L O P E R AT IO N S T a b le o f C o n te n ts E . 3 F O R E W O R D R em o val o f sa d d le E .
  • Page 43 G E N E R A L O P E R AT IO N S F o rew o rd T h e o p e ra tio n s d e scrib e d in th is se ctio n a re re fe rre d to th e re m o va l o f th e e n g in e fro m th e m o to rc ycle ; fu rth e r o p e ra tio n s n o t d i- re ctly co n n e cte d to th is sco p e a re lo ca te d a t th e e n d o f th e ch a p te r.

  • Page 44: R Em O Val O F Sa D D Le

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

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

    G E N E R A L O P E R AT IO N S R e m o va l o f a ir filte r b o x a n d c a rb u re to r L o o se n o n th e L .H .

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

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

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

    G E N E R A L O P E R AT IO N S R e m o va l o f e x h a u s t s ys te m R e m o ve th e scre w s (1 ), (2 ) a n d th e tw o g u a rd s (3 ) a n d (4 ) fro m th e fro n t e xh a u st p ip e s a n d fro m th e ce n tra l e xh a u st p ip e (N O T E : re a sse m b le th e scre w s (1 ) a n d (2 ) w ith "L O C T IT E 2 4 3 ").

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

    G E N E R A L O P E R AT IO N S R e m o va l o f e le c tric a l c o n n e c tio n s a n d s p a rk p lu g c a p D e ta ch th e e le ctrica l co n n e ctio n s fro m th e e n g in e to th e m a in w irin g h a rn e ss (sta rtin g m o to r ca b le , g ro u n d ca b le b a tte ry-e n g in e , g e n e ra to r ca b le s, n e u tra l sw itch ca b le ) a n d th e sp a rk p lu g ca p .
  • Page 49 G E N E R A L O P E R AT IO N S O n the L.H . of the en gine, rem ove the bre ath er hose (1), the clutch cable (2), the pin io n guard (3), the m aster link a nd the rear cha in (4).
  • Page 50 G E N E R A L O P E R AT IO N S C o o lin g fa n , ra d ia to rs a n d c o o la n t e x p a n s io n ta n k re m o va l D isco n n e ct th e co o lin g fa n (1 ) fro m th e m a in w irin g h a rn e ss;...
  • Page 51 G E N E R A L O P E R AT IO N S E n g in e re m o va l fro m th e fra m e R e m o ve th e u p p e r e n g in e fa ste n in g scre w (1 ) th e n th e p la te (2 ) fro m th e e n g in e .

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

    G E N E R A L O P E R AT IO N S R e m o va l o f re a r fra m e w ith fe n d e r T h is o p e ra tio n d o e sn t co n ce rn th e e n g in e re m o va l fro m th e m o to rc ycle . R e m o ve th e sa d d le , th e sid e p a n e ls, th e a ir filte r b o x, th e fu e l ta n k, th e e x- h a u st sile n ce r a n d th e re a r b ra ke p u m p g u a rd a s sh o w n o n p a g e s E .4 , E .5 , E .7 , E .9 , E .1 3 .
  • Page 53 E N G IN E D IS A S S E M B LY S e ctio n...
  • Page 54 E N G IN E D IS A S S E M B LY T a b le o f C o n te n ts F .4 D is a ss e m b ly o f g e a r le ve r D isas sem b ly o f altern ato r sid e co ve r F .5 D isas sem b ly o f altern ato r...
  • Page 55 E N G IN E D IS A S S E M B LY S P E C IF IC T O O L S 800 0 89 743 C ran k cas e p u ller 800 0 39 523 F lyw h eel p u ller 800 0 90 662 E n g in e h o ld er...

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

    E N G IN E D IS A S S E M B LY T o fa cilita te th e jo b , d ra in th e o il fro m th e e n g in e (a s d e scrib e d in th e ch a p te r S e ttin g s a n d A d ju stm e n ts , p a g e D .5 ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f a lte rn a to r s id e c o ve r R e m o ve th e co ve r (1 ) w ith th e sta to r (8 m m w re n ch ) a n d w ith th e g a ske t. E xtra ct th e g e a r w ith clu tch (2 ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f a lte rn a to r a ) K e e p th e fly w h e e l (1 ) ste a d y u sin g th e to o l (2 ) c o d e 8 0 0 0 3 9 5 2 2 , re m o ve th e 2 4 m m n u t a n d its w a sh e r.

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f th e w a te r p u m p b o d y R e m o ve five scre w s (1 ) (8 m m w re n ch ) re ta in in g th e p u m p h o u sin g (2 ). R e m o ve th e b u sh e s (6 ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c ylin d e r - h e a d c o ve r R e m o ve th e u n io n p ip e (1 ) a n d th e ca rb u re to r. R e m o ve th e va lve re g iste r co ve rs (2 ) (8 m m w re n ch ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c ylin d e r h e a d R e m o ve th e tw o ca m sh a ft g e a r scre w s (1 ) (5 m m w re n ch ). R o ta te th e g e a r (1 );...

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f va lve s U se va lve sp rin g co m p re sso r 8 0 0 0 3 9 5 2 1 to re m o ve th e va lve s. B e ca re fu l n o t to d a m a g e th e g a ske t su rfa ce s o r th e co m b u stio n ch a m b e r o f th e c ylin - d e r h e a d .

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f p is to n H o ld th e p isto n a n d co ve r th e cra n kca se w ith a cle a n ra g . T h e p isto n (1 ) is m a rke d w ith a n a rro w o n th e e xh a u st sid e , in o rd e r to co rre ctly re a sse m b le it.

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly c lu tc h c o ve r R e m o ve a ll scre w s (1 3 p cs.) h o ld in g th e clu tch co ve r (1 ). R e m o ve th e clu tch co ve r (in o rd e r to re m o ve th e co ve r, u se a scre w d rive r).

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

    E N G IN E D IS A S S E M B LY R e m o va l o f th e s ta rtin g m o to r a n d h o ld in g fla n g e R e m o ve th e tw o fa ste n in g scre w s (8 m m w re n ch ) a n d th e sta rtin g m o to r (1 ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c lu tc h S e t a n a lu m in u m sh im a m o n g p rim a ry tra n sm issio n te e th (in o rd e r to p re ve n t its ro ta tio n ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly if th e g e a rb o x c o n tro l s h a ft W ith d ra w th e ra ck a n d th e co n n e c te d sh a ft (1 ) R e m o ve th e tw o 4 m m A lle n scre w s (2 ) a n d re m o ve th e p la te (3 ) s p ro cke t o f th e g e a r se cto r (4 ).
  • Page 68 E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c ra n k c a s e , c ra n k s h a ft a n d la y s h a ft P e rfo rm th e fo llo w in g o n th e R .H .
  • Page 69 E N G IN E D IS A S S E M B LY R e m o ve th e se e g e r rin g (7 ) a n d w ith d ra w th e p in io n , o p e ra tin g o n th e L .H . cra n kca se .
  • Page 70 E N G IN E D IS A S S E M B LY R e m o ve th e scre w s lo ckin g th e L .H . to th e R .H . cra n kca se . In sta ll th e sp e cia l to o l (A ) n °...

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f th e g e a rb o x U sin g p lie rs re m o ve th e ro d s (1 ) o n w h ich th e fo rk s a re h in g e d . R e m o ve th e fo rk s.

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f th e o il p u m p F ro m th e p re vio u sly re m o ve d clu tch co ve r, re m o ve th e fo u r o il p u m p fa ste n - in g scre w s (1 ) (8 m m w re n ch ) th a t se cu re th e co ve r, th e n re m o ve a ll th e p a rts u p to th e o il p u m p d rive sh a ft (2 ).

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

    E N G IN E D IS A S S E M B LY D is a s s e m b ly o f c ra n k s h a ft c o m p o n e n ts In se rt a p la te (1 ) b e tw e e n th e tw o flyw h e e l h a lve s.
  • Page 75 E N G IN E O V E R H A U L IN G S e ctio n...
  • Page 76 E N G IN E O V E R H A U L IN G T a b le o f C o n te n ts G .4 C le a n in g o f c o m p o n e n ts A s s e m b lies G .4 C ylin d er h ead...
  • Page 77 E N G IN E O V E R H A U L IN G T a b le o f C o n te n ts C ran k sh aft G .15 C ran k sh aft ru n -o u t G .15 R ep lacin g th e sm all en d b u sh G .16...
  • Page 78 E N G IN E O V E R H A U L IN G C le a n in g o f c o m p o n e n ts A ll co m p o n e n ts m u st b e cle a n e d w ith g a so lin e a n d d rie d w ith co m p re sse d a ir. D u rin g th is o p eratio n in flam m ab le vap o rs b u rst an d m etal p articles m a y b e vio len tly ejected .
  • Page 79 E N G IN E O V E R H A U L IN G C ylin d e r h e a d R e m o ve ca rb o n d e p o sits fro m th e co m b u stio n ch a m b e r u sin g a ro u n d e d scra p e r.
  • Page 80 E N G IN E O V E R H A U L IN G R e p la c in g o ve rs ize va lve s R e m o ve th e se a ts b y m illin g th e rin g s. T a ke g re a t ca re n o t to d a m a g e th e se a t lo ca tio n s in th e h e a d .
  • Page 81 E N G IN E O V E R H A U L IN G R e p la c in g th e va lve g u id e C h a n g e th e va lv e g u id e a s fo llo w s: - P u t th e h e a d in a n o ve n h e a te d a t a te m p e ra tu re a f 2 0 0 °C (3 9 2 °...
  • Page 82 E N G IN E O V E R H A U L IN G V a lve s p rin g C h e ck th e fre e le n g th "L ". If th is d o e s n o t co rre sp o n d to th e p re scrib e d lim its th e n su b stitu te th e sp rin g s.
  • Page 83 E N G IN E O V E R H A U L IN G In s p e c tio n o f ro c k e r a rm C h e ck th e cle a ra n ce b e tw e e n th e ro cke r a rm a n d th e ro cke r a rm sh a ft.
  • Page 84 E N G IN E O V E R H A U L IN G C a m ro lle r re p la c e m e n t R e p la c e th e c a m ro lle r if, in c o n s e q u e n c e o f th e ra d ia l p la y im - p ro ve m e n t (th e n e e d le b e a rin g p in is w o rn ), th e va lve p la y e x c e e d 0 .0 0 6 -0 .0 0 8 in ., b o th fo r th e in ta k e a n d e x h a u s t s id e s .
  • Page 85 E N G IN E O V E R H A U L IN G T im in g c h a in a n d g e a rs R e p la ce th e ch a in in p re se n ce o f n o isin e ss a n d if th e ch a in te n sio n e r o n th e cylin d e r is a t 1 0 clicks o f its stro ke (A ).
  • Page 86 E N G IN E O V E R H A U L IN G C ylin d e r T h e c ylin d e r lin e r b o re sh o u ld b e c o m p le te ly sm o o th , w ith o u t g ro o vin g o r sco rin g .
  • Page 87 E N G IN E O V E R H A U L IN G G u d g e o n p in -c o n n e c tin g ro d s m a ll e n d c le a ra n c e C le a ra n ce a t a sse m b ly sh o u ld b e : 0 .0 0 0 4 7 ÷0 .0 0 1 0 6 in .
  • Page 88 E N G IN E O V E R H A U L IN G P is to n rin g s -c ylin d e r c le a ra n c e In tro d u ce th e rin g in to th e lo w er p a rt o f th e c ylin d e r (i.e . w h e re th e re is le a s t w e a r);...

  • Page 89: C Ran K Sh Aft

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

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

    E N G IN E O V E R H A U L IN G R e p la c in g th e s m a ll e n d b u s h T h e b u sh sh o u ld b e re p la ce d u sin g a co rre ct size p u n ch a n d d rift. B e fo re th e re a sse m b ly a p p ly o n th e b u sh M O L Y B D E N U M B IS U L P H ID E G R E A S E .

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

    E N G IN E O V E R H A U L IN G C lu tc h h o u s in g -fric tio n d is c c le a ra n c e S T A N D A R D W E A R L IM IT 0 ,5 5 -0 ,7 5 m m 0 ,0 9 m m...
  • Page 92 E N G IN E O V E R H A U L IN G F o rk c o n tro l d ru m - fo rk p in s c o u p lin g C h e ck th e cle a ra n ce b e tw e e n th e se le cto r p in a n d th e se le cto r d ru m g ro o ve b y m e a su rin g th e tw o cle a ra n ce s w ith a g a u g e .
  • Page 93 E N G IN E O V E R H A U L IN G O il p u m p T h e re a re th re e c le a ra n ce s w h ich h a ve to b e ch e cke d to e sta b lish w h e th e r th e o il p u m p n e e d s ch a n g in g o r n o t;...
  • Page 94 E N G IN E O V E R H A U L IN G "K E IH IN " c a rb u re to r o ve rh a u lin g T h o ro u g h ly w a sh w ith p e tro l a n d d ry w ith co m p re sse d a ir a ll ca rb u re to r co m p o n e ts. T h o ro u g h ly cle a n a ll je ts a n d d u cts w ith co m p re sse d a ir o n ly.
  • Page 95 E N G IN E O V E R H A U L IN G C a rb u re to r a d ju s tm e n t A d ju st th e ca rb u re to r w ith w a rm e n g in e a n d w ith th e th ro ttle in clo se d p o si- tio n .
  • Page 96 E N G IN E O V E R H A U L IN G N E E D L E V A L V E In sp e ct n e e d le va lve (9 ) a n d va lve se a t (c) G ro o ve d w e a r (a ): R e p la ce .
  • Page 97 E N G IN E O V E R H A U L IN G J E T N E E D L E In sp e ct je t n e e d le (6 ). B e n d s/W e a r: R e p la ce . S ta n d a rd clip p o sitio n : 4 th G ro o v e .
  • Page 98 E N G IN E O V E R H A U L IN G F L O A T E R In sp e ct: - F lo a t (1 0 ). D a m a g e : R e p la ce . A C C E L E R A T O R P U M P In sp e ct: - D ia p h ra g m (a cce le ra to r p u m p 1 1 ) (a ).
  • Page 99 E N G IN E O V E R H A U L IN G F u e l d ra in in g T o d ra in th e fu e l fro m th e ca rb u re to r flo a t ch a m b e r, clo se th e L .H . sid e fu e l co ck (1 , fig .
  • Page 101 E N G IN E R E A S S E M B LY S e ctio n...
  • Page 102 E N G IN E R E A S S E M B LY T a b le o f C o n te n ts H .4 G e n e ra l d ire c tio n s R e a ss e m b ly o f c ra n k s h a ft H .5 R e a ss e m b ly o f tra n s m is s io n...
  • Page 103 E N G IN E R E A S S E M B LY N O T E : If n o t o th e rw ise sp e cifie d , sta n d a rd tig h te n in g to rq u e s fo r th e fo llo w in g th re a d - M 5 x0 ,8 : 5 ,9 N m - 0 ,6 K g m - 4 .3 ft/lb - M 6 x1 : 9 ,3 N m - 0 ,9 5 K g m - 6 .8 ft/lb - M 8 x1 ,2 5 : 2 2 N m - 2 ,3 K g m - 1 6 .6 ft/lb...
  • Page 104 E N G IN E R E A S S E M B LY G e n e ra l d ire c tio n s F o r a co rre ct re -a sse m b ly fo llo w in th e a d ve rse se n se w h a t sh o w n fo r d ism a n tlin g , h o w e ve r p a yin g a sp e cia l a tte n tio n to e ve ry o p e ra tio n w e sp e cifically m e n tio n .
  • Page 105 E N G IN E R E A S S E M B LY R e a s s e m b ly o f c ra n k s h a ft L u b rica te th e cra n kp in w ith m o to r o il a n d p la ce it in th e flyw h e e l. A lig n th e flo w tro u g h h o le s o f th e e n g in e o il.
  • Page 106 E N G IN E R E A S S E M B LY...
  • Page 107 E N G IN E R E A S S E M B LY R e a s s e m b ly o f tra n s m is s io n If th e g e a r sh a fts h a ve b e e n d isa sse m b le d , th e fo llo w in g p a ra g ra p h s sh o w th e re a sse m b ly se q u e n ce .
  • Page 108 E N G IN E R E A S S E M B LY ¤ A u xilia ry sh a ft In sta ll 2 n d sp e e d g e a r b u sh in g a n d lu b rica te w ith e n g in e o il. M o u n t: 2 n d g e a r a n d p u t g ra p h ite g re a se o n it (th e sid e w ith slo ts sh o u ld fa ce 3 rd sp e e d g e a r), w a s h e r a n d circlip .
  • Page 109 E N G IN E R E A S S E M B LY R e a ss e m b ly o f c ra n k c a s e P o sitio n th e L .H . cra n kca se o n th e h o ldin g pla te (se rvice to o l cod e 8 0 0 0 9 0 6 6 2 );...
  • Page 110 E N G IN E R E A S S E M B LY A = 2 8 m m / 1 .1 in . M A IN S H A F T B = 2 5 m m /0 .9 8 in . A U X IL IA R Y S H A F T...
  • Page 111 E N G IN E R E A S S E M B LY A s s e m b ly o f g e a r fix in g c lip a n d g e a rb o x c o n tro l s h a ft R e a sse m b le th e d ru m (1 ) w ith th e scre w (2 ) (2 8 N m -2 ,8 5 K g m -2 0 .6 ft/ L b + L O C T IT E 2 4 2 ).

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

    E N G IN E R E A S S E M B LY A s s e m b ly o f c o u n te rw e ig h t a n d la ys h a ft g e a r In sta ll th e co u n te rw e ig h t (1 ) o n th e la y sh a ft u sin g th e re la te d ke y (th e fla t su rfa ce m u st b e fa ce d o u tw a rd );...

  • Page 113: R E A Ss E M B Ly O F Flyw H E E L

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f flyw h e e l In sta ll th e tim in g syste m ch a in (1 ) o n th e cra n ksh a ft; - d e g re a se w ith so lve n t th e cra n kca se co n e a n d th e co rre sp o n d in g fittin g su rfa ce o n th e flyw h e e l;...

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

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f s ta to r a n d p ic k -u p M o u n t th e sta to r so th a t th e ca b le h o ld in g p la te is in fro n t o f th e p ick-u p lo ca tio n ;...

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

    E N G IN E R E A S S E M B LY A s s e m b ly o f s ta rtin g m o to r a n d s ta rtin g in te rm e d ia te g e a r In sta ll o n th e cra n kca se th e ce n te rin g b u sh in g s a n d th e fla n g e (1 );...

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

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

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

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f c ylin d e r h e a d A lw a ys u se a n e w h e a d g a ske t (1 ) w h e n a sse m b lin g . A sse m b le th e cylin d e r h e a d ;...

  • Page 118: R E A Ss E M B Ly O F C A M S H A Ft

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f c a m s h a ft F it th e ch a in in to th e g e a r (1 ) w h ile re stin g th e g e a r o n th e in sid e w a ll o f th e h e a d a n d w ith th e n o tc h o n th e o u tsid e a n d a lig n e d w ith th e h e a d co ve r m a tin g su rfa ce ;...

  • Page 119: R E A Ss E M B Ly O F C A M -C H A In Te N S Io N E R

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f c a m -c h a in te n s io n e r B a ck th e ca m ch a in te n sio n e r p in ; - re a sse m b le th e ca m ch a in te n sio n e r w ith th e scre w s (1 ) (4 ,5 N m -0 .4 6 K g m - 3 .2 ft/lb );...

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

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f w ate r p u m p im p e lle r M o u n t th e im p e lle r (1 ) o n ca m sh a ft (3 ) w ith n u t (2 ) (5 N m -0 ,5 K g m -3 .7 ft/lb ). R e a s s e m b ly o f c ylin d e r h e a d c o ve r M o u n t th e ro cke r a rm a n d p u sh in th e ro cke r a rm sh a ft ;...
  • Page 121 E N G IN E R E A S S E M B LY C le a n th e g a ske t su rfa ce s o n b o th th e c ylin d e r h e a d a n d th e c ylin d e r h e a d co ve r w ith so lve n t.

  • Page 122: R E A Ss E M B Ly O F P U M P H O U S In G

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f p u m p h o u s in g G re a se a n d a sse m b le tw o n e w O -R in g s (1 ) o n th e sp a ce r (2 ) h o u sin g . M o u n t th e sp a ce r th e n a sse m b le a n e w e xte rn a l O -R in g (3 ) o n th e sp a ce r e n d .

  • Page 123: L A Y-S H A Ft Tim In G

    E N G IN E R E A S S E M B LY L a y-s h a ft tim in g In sta ll th e ke y o n th e cra n ksh a ft a n d p la ce th e d rivin g g e a r in p o sitio n . O p e ra te a n a lo g y fo r th e la y-sh a ft.

  • Page 124: R E A Ss E M B Ly O F C Lu Tc H

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f c lu tc h P la ce a n a lu m in u m sh im b e tw e e n th e te e th o f th e p rim a ry d rive g e a rs, in o rd e r to p re ve n t its ro ta tio n .

  • Page 125: R E A Ss E M B Ly O F O Il P U M P A N D O Il Filte R C A Rtrid G E

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f o il p u m p a n d o il filte r c a rtrid g e A sse m b le th e o il p u m p in o rd e r sh o w n in th e p ictu re .

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

    E N G IN E R E A S S E M B LY R e a s s e m b ly o f a lte rn a to r c o ve r R e a sse m b le th e ig n itio n co ve r (2 ), w ith th e sta to r , b y in se rtin g th e c e n te rin g p in (1 ) a n d a n e w g a ske t;...
  • Page 127 E N G IN E R E A S S E M B LY R e a s s e m b ly o f re a r p in io n , n e u tra l s e n s o r a n d g e a r s h ift p e d a l In sta ll th e re a r p in io n (1 ) w ith a n e w re ta in in g rin g .

  • Page 128: In S Tru C Tio N S Fo R Lu B Ric A Tio N

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

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

    F R O N T S U S P E N S IO N F ro n t s u s p e n s io n T h e fro n t su sp e n sio n u n it is a M A R Z O C C H I U .S .D . te le sco p ic h yd ra u lic fo rk w ith a d va n ce d a xle ; 1 .7 7 in . d ia m e te r s ta n ch io n s. W h e e l tra ve l a lo n g th e le g s is 9 .8 4 in .

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

    F R O N T S U S P E N S IO N IN S T R U C T IO N S F O R U S E O F Ø 4 5U S D F O R K G E N E R A L R e m o te h yd ra u lic fo rk w ith re ve rs e d le g s w ith sta tic lo a d sp rin g a n d ca rtrid g e m u lti-va lve d a m p in g syste m .

  • Page 133: F O Rkw O Rkin G

    F R O N T S U S P E N S IO N F O R K W O R K IN G T h e h yd ra u lic s yste m o f th is fo rk re lie s o n m u ltiva lve s; a syste m a lre a d y te ste d in th e p a st M A G N U M b u t w ith d iffe re n t fe a tu re s a s b o th le g s h a ve th e sa m e se ttin g .

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

    F R O N T S U S P E N S IO N L e t s se e w h a t h a p p e n s in e a ch le g d u rin g R E B O U N D . S p rin g re b o u n d a ctio n p u sh e s th e sta n ch io n d o w n w a rd s, th u s ca u sin g a n o il n e e d in to th e ca rtrid g e (se e F IG .

  • Page 135: M Ain Ten An Ce Reco M M En D Atio N S

    F R O N T S U S P E N S IO N M A IN T E N A N C E M a in te n a n ce re c o m m e n d a tio n s T h is fo rk is th e re su lt o f ye a rs o f e xp e rie n ce m a d e o n th e m o st im p o rta n t ra cin g tra cks.
  • Page 136 F R O N T S U S P E N S IO N O IL D R A IN F IG .6 B e fo re re m o vin g th e fo rk le g s fro m th e ste e rin g cro w n a n d th e ste e rin g h e a d , lo o se n th e u p p e r p lu g (4 8 ) o f e a c h slid e r (7 ) w ith th e 1 9 -m m w re n c h .
  • Page 137 F R O N T S U S P E N S IO N O IL F IL L IN G F IG . 1 0 P o sitio n th e slid er (7 ) to its e n d o f stro ke a g a in st th e sta n ch io n tu b e (5 -6 ). P o u r 2 /3 o f th e in d ica te d o il q u a n tity in to th e sta n ch io n .
  • Page 138 F R O N T S U S P E N S IO N D IS A S S E M B L Y F o llo w th e in stru ctio n s fro m F IG .6 to F IG . 9 , a s in d ica te d in th e a b o v e p a ra g ra p h .

  • Page 139: 1 -S Lid E R D Is A S S E M B Ly

    F R O N T S U S P E N S IO N 4 - A ir b le e d in g (F IG .2 3 ) N O T E P e rfo rm th is o p e ra tio n w ith le g s fu lly in re b o u n d (fro n t w h e e l u p fro m th e so il), still fitte d in th e m o to rc ycle .

  • Page 140: 3 - R E B O U N D S E Ttin G C H A N G E

    F R O N T S U S P E N S IO N 2 - S ta n c h io n d is a s s e m b ly F IG . 2 4 F ix th e slid e r o f th e sta n ch io n tu b e (5 -6 ) in to a vice e q u ip p e d w ith p ro te ctio n ja w s.

  • Page 141: 1 - D A M P In G U N It Re A S S E M B Ly

    F R O N T S U S P E N S IO N In se rt th e a d ju stin g scre w (1 9 ) in to th e p lu g se a t (4 8 ); p u sh it d o w n w h ile tu rn in g co u n te r clo ckw ise u n til it lo cks.

  • Page 142: A D Ju Stm En T

    F R O N T S U S P E N S IO N A D J U S T M E N T S T A N D A R D se ttin g fo r C O M P R E S S IO N : w h e n in "co m p le te ly clo se d " p o sitio n , u n scre w b y 1 2 clicks (F IG .3 7 ) S T A N D A R D se ttin g fo r R E B O U N D : w h e n in co m p le te ly clo se d p o sitio n , u n scre w b y 1 2 clicks (F IG .

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

    F R O N T S U S P E N S IO N R e m o vin g th e fro n t fo rk T a ke n o te o f m e a su re A w h ich m u st b e re sto re d w h e n re a sse m b lin g . S e t a su p p o rt u n d e r th e e n g in e to lift th e fro n t w h e e l fro m th e g ro u n d , w o rkin g a s fo llo w s: -re m o ve ,o n th e L .H .
  • Page 145 R E A R S U S P E N S IO N S e ctio n...
  • Page 146 R E A R S U S P E N S IO N T a b le o f C o n te n ts R e a r su s p en s io n R em o val o f re ar sh o ck ab so rb er O ve rh au l o f rear sh o ck ab so rb er O ve rh au l th e sp rin g C h eckin g th e sh o ck ab so rb er...

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

    R E A R S U S P E N S IO N R e a r s u s p e n s io n T h e su sp e n sio n o f th is m o to rc ycle is o f th e p ro g re ssive typ e a n d c o n sists o f a sh o ck a b so rb e r, a se rie s o f lin ka ge s a n d a sw in g a rm .

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

    R E A R S U S P E N S IO N D is a s s e m b ly, o ve rh a u lin g , a n d re a s s e m b ly o f th e re a r s h o c k a b s o rb e r A ccu ra te ly cle a n th e sh o ck a b so rb e r b e fo re d isa sse m b ly.
  • Page 149 R E A R S U S P E N S IO N B le e d th e g a s b y p re ssin g o n th e re se rvo ir va lve . T o p ro te ct h is e ye s fro m p o ssib le p a rticle s, th e o p e ra to r m u st tu rn th e va lve a w a y fro m h is e ye s.
  • Page 150 R E A R S U S P E N S IO N O n ce th e p lu g is re m o ve d , p u sh a n d d rive th e fo rk ro d g u id e in sid e th e b o d y so a s to fre e sn a p rin g h o u sin g .
  • Page 151 R E A R S U S P E N S IO N G rip th e sh o ck a b so rb e r u p p e r sid e in a vice u sing a lu m in u m o r b ro n ze ja w s. In se rt a ro d o r a scre w d rive r in to th e co n n e ctin g h o le , a n d re m o ve th e p isto n a n d fo rk ro d u n it fro m th e sh o ck a b so rb e r b o d y.
  • Page 152 R E A R S U S P E N S IO N C h e c k in g th e a d ju s tm e n t In ca se o f co m p re ssio n a d ju stm en t fo r o p e ra tin g d e fe ct, it is n e ce ssa ry to u n scre w th e kn o b sto p p in g d o w e l (b e fo re u n scre w in g , h e a t w ith w a rm a ir).
  • Page 153 R E A R S U S P E N S IO N...
  • Page 154 R E A R S U S P E N S IO N A fte r h a vin g co m p le te d th e ch e ck, in se rt a g a in th e p isto n , th e d isk, th e sp rin g a n d th e rin g w ith slo ts.

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

    R E A R S U S P E N S IO N D is a s s e m b lin g th e a ir/o il d ia p h ra g m o f th e re s e rvo ir A lw a ys re p la ce th e d ia p h ra g m w h e n ch a n g in g th e o il in sid e th e sh o ck a b so rb e r.
  • Page 156 R E A R S U S P E N S IO N P re p a re th e d ia p h ra g m w ith a sse m b le d O R (w e a d vise u sin g a n e w o n e fo r e a ch re p la ce m e n t).
  • Page 157 R E A R S U S P E N S IO N R e a sse m b le th e re se rvo ir p lu g a n d th e va lve , fit it in sid e th e re se rvo ir, th e n fit th e sn a p rin g in to th e th ro a t.
  • Page 158 R E A R S U S P E N S IO N L = 2 3 4 ,5 ÷2 3 7 ,5 m m (9 .2 3 ÷9 .3 5 in .)
  • Page 159 R E A R S U S P E N S IO N S h o c k a b s o rb e r d a m p in g a d ju s tm e n t A d ju stm e n t o f th e co m p re ssio n stro ke is in d e p e n d e n t fro m th e re b o u n d stro ke .
  • Page 160 R E A R S U S P E N S IO N D is a s s e m b lin g a n d o ve rh a u lin g th e re a r sw in g a rm (p a g e s J .2 6 -J .2 7 ) S e t a sta n d o r a b lo ck u n d e r th e e n g in e a n d se e th a t th e re a r w h e e l is lifte d fro m th e g ro u n d .

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

    R E A R S U S P E N S IO N O ve rh a u lin g th e re a r sw in g a rm a x le U sin g a co m p a ra to r, ch e ck th e sw in g a rm a xle fo r d isto rtio n . P o sitio n th e a xle o n tw o id e n tica l co n ta cts.
  • Page 162 R E A R S U S P E N S IO N C h a in te n s io n ro lle rs , c h a in d rivin g ro lle r, c h a in g u id e , c h a in ru n n e r C h e ck th e w e a r o f th e a b o ve m e n tio n e d e le m e n ts a n d re p la ce th e m w h e n n e ce ssa ry.
  • Page 163 B R A K E S S e ctio n...
  • Page 164 B R A K E S T a b le o f C o n te n ts L .3 B ra k in g s ys te m B ra ke d isc L .4 W ear ch ec k a n d b rake p ad s rep lacem en t L .5 F ro n t b rakin g s ystem b leed in g L .7...
  • Page 165 B R A K E S B R A K IN G S Y S T E M T h e b ra kin g s yste m s is d ivid e d in to tw o co m p le te ly in d e p e n d e n t circu its. E a ch syste m is p ro vid e d w ith a ca lip e r co n n e cte d to a h yd ra u lic co n tro l p u m p w ith ta n k fo r th e flu id .
  • Page 166 B R A K E S D is c b ra k e A re g u la r ch e ck o f b ra ke d isc co n d itio n is m o st im p o rta n t; th e d isc sh o u ld b e a b so lu te ly cle a n w ith o u t a n y tra ce s o f ru st, o il, g re a se o r d irt a n d sh o u ld n o t b e e xce ssive ly sco re d .
  • Page 167 B R A K E S W e a r c h e c k a n d re p la c e m e n t o f b ra k e p a d s In sp e ct p a d s fo r w e a r. S e rvice lim it A a ) T h e fro n t p a d th ickn e ss m u st no t b e lo w e r th a n 3 ,5 m m (S M ) o r 3 .8 m m (T E ).
  • Page 168 B R A K E S F ro n t b ra k in g s ys te m b le e d in g T h e b ra kin g s yste m m u st b e b le e d w h e n , d u e to a ir in th e circu it, th e le ve r stro ke is lo n g a n d sp o n g y.
  • Page 169 B R A K E S B le e d in g th e re a r b re a k in g s ys te m T h e b ra kin g s yste m m u st b e b le d w h e n , d u e to a ir in th e circu it, th e p e d a l stro ke is lo n g a n d sp o n g y.
  • Page 170 B R A K E S F lu id c h a n g e T h e b ra ke flu id s h o u ld b e ch e cke d a n d ch a n g e d in a cco rd a n ce w ith th e P e rio d ic M a in te n a n ce C h a rt (p a g e s B ..) o r w h e n e ve r it is co n ta m in a te d w ith d irt o r w a te r.
  • Page 171 B R A K E S P e rio d ica lly ch e ck th e co n n e ctin g h o se s (A ) a n d (B ): if th e h o se s a re w o rn o r cra cke d , th e ir re p la ce m e n t is a d vise d .
  • Page 173 E L E C T R IC S Y S T E M S e ctio n...
  • Page 174 E L E C T R IC S Y S T E M T a b le o f C o n te n ts M .4 W IR IN G D IA G R A M (T E , S M ) K E Y T O W IR IN G D IA G R A M (T E , S M ) M .5 E L E C T R IC A L C O M P O N E N T S L O C A T IO N ( T E ,...
  • Page 175 E L E C T R IC S Y S T E M T a b le o f C o n te n ts T A IL L A M P M .43 M .43 R e a r ta il lig h t b u lb re p la ce m e n t H A N D L E B A R C O M M U T A T O R S M .44 R .H .
  • Page 176 E L E C T R IC S Y S T E M...
  • Page 177 E L E C T R IC S Y S T E M K E Y T O E L E C T R IC D IA G R A M (T E -S M ) C a b le c o lo r c o d in g 1 .
  • Page 178 E L E C T R IC S Y S T E M E L E C T R IC A L C O M P O N E N T S L O C A T IO N (T E -S M ) - G e n e ra to r (1 ), in o il b a th , o n th e in n e r sid e o f L .H .
  • Page 179 E L E C T R IC S Y S T E M...
  • Page 180 E L E C T R IC S Y S T E M C H A R G IN G S Y S T E M T h e ch a rg in g s ys te m co n sists o f: - A lte rn a to r (2 );...
  • Page 181 E L E C T R IC S Y S T E M C H A R G IN G S Y S T E M C H E C K S B a tte ry c u rre n t le a k a g e T o g a in a cce ss to th e b a tte ry, re m o ve th e sa d d le (se e p a g e E .4 ).
  • Page 182 E L E C T R IC S Y S T E M G e n e ra to r s ta to r c o il c o n tin u ity c h e c k R e m o ve th e sta to r co il-m a in w irin g h a rn e ss co n n e cto r th e n ch e ck th e co n tin u ity u sin g a te ste r.
  • Page 183 E L E C T R IC S Y S T E M V o lta g e re g u la to r-re c tifie r c h e c k in g W ith th e ig n itio n d e fin ite ly fu n ctio n a l, w h ilst th e b a tte ry is ch a rg e d (1 2 .5 V -1 3 V ), sta rt th e e n g in e : if th e b a tte ry te n sio n d o e s n o t in cre a se (1 4 .5 V ) a fte r a b o u t fo u r m in u te s, su b stitute th e re g u la to r.
  • Page 184 E L E C T R IC S Y S T E M S T A R T E R S Y S T E M T h e sta rte r s yste m co n sists o f: - B a tte ry (1 6 );...
  • Page 185 E L E C T R IC S Y S T E M S T A R T E R S Y S T E M C H E C K S S ta rte r m o to r d is a s s e m b ly U se a 1 0 m m w re n ch to re m o ve th e n u t (1 ) u n d e r th e ru b b e r ca p a n d a 8 m m w re n ch to re m o ve th e sta rtin g m o to r a n d g ro u n d ca b le scre w s (2 ).
  • Page 186 E L E C T R IC S Y S T E M S ta rte r m o to r te s t d ia g ra m 1 - O u tp u t 2 - T o rq u e 3 - R e vo lu tio n 4 - te rm in a l vo lta g e 5 - L o a d c u rre n t...
  • Page 187 E L E C T R IC S Y S T E M E le c tric s ta rt re m o te c o n tro l sw itc h c h e c k D isco n n e ct th e sta rte r re la y co u p lin g (A ). D isco n n e ct th e ca b le s fro m th e p o sitive a n d n e g a tive p o le s o f th e b a tte ry to a vo id sh o rt circu its d u rin g a ssem b ly.
  • Page 188 E L E C T R IC S Y S T E M E L E C T R O N IC IG N IT IO N S Y S T E M In th e C .D .I. s yste m th e e le ctrica l e n e rg y g e n e ra te d b y th e a lte rn a to r ch a rg e s th e c o n d e n se r. T h e e n e rg y is re le a se d in a sin g le su rg e a t th e sp e cifie d ig n itio n tim in g a n d th e cu rre n t flo w s th ro u g h th e p rim a ry sid e o f th e ig n i- tio n co il.
  • Page 189 E L E C T R IC S Y S T E M Ig n itio n c o il re s is ta n c e c h e c k T o g a in a cce ss to th e e le ctro n ic co il (1 ) re m o ve th e sa d d le a n d th e fu e l ta n k (se e p a g e E .1 6 -E .2 3 ).
  • Page 190 E L E C T R IC S Y S T E M E le c tro n ic u n it T h e e le ctro n ic u n it (1 ) is fa ste n e d u n d e r th e sa d d le . T h e o p e ra tio n is ch a ra cte rize d b y th e p re se n ce o f a co n d e n se r th a t is lo a d e d b y th e g e n e ra to r a n d th a t th e n re le a se th e ch a rg e to th e co il in a cco rd w ith th e p ick-u p sig n a l a n d th e p ro g ra m m e d tim in g va lu e .
  • Page 191 E L E C T R IC S Y S T E M S p a rk p lu g U se "N G K " C P R 8 E sp a rk p lu g . C h e ck d ista n ce "A " (0 ,6 ÷0 ,7 m m / 0 .0 2 2 ÷0 .0 2 6 in .) b e tw e e n e le ctro d e s.
  • Page 192 E L E C T R IC S Y S T E M T h ro ttle P o s itio n S e n s o r c h e c k in g (T P S ) S e t th e te ste r in O h m p o sitio n th e n d e ta ch th e th ro ttle p o sitio n se n so r ca b le (1 ) fro m th e m a in w irin g h a rn e ss.
  • Page 193 E L E C T R IC S Y S T E M B A T T E R Y T h e se a le d b a tte ry (1 ) d o e s n o t re q u ire a n y m a in te n a n ce w o rk. If th e ve h icle re - m a in s u n u se d fo r lo n g p e rio d s, it is re co m m e n d e d to re m o ve b a tte ry fro m e le ctri- ca l syste m a n d s to re it in a d ry p la ce .
  • Page 194 E L E C T R IC S Y S T E M D IG IT A L IN S T R U M E N T , W A R N IN G L IG H T S 1 - G R E E N w a rn in g lig h t L ig h ts 2 - G R E E N w a rn in g lig h t N e u tra l 3 - B A T T E R Y C H A R G E w a rn in g lig h t (th e w a rn in g lig h t co m e s o n , co n te m p o ra rily w ith th e ve rtica l L E D in d ica to r 1 0 , w h e n th e e n g in e is sto p p e d a n d th e ig n itio n ke y is o n...
  • Page 195 E L E C T R IC S Y S T E M In s tru m e n t s e ttin g s T h is o p e ra tio n a llo w s yo u to se t th e p a ra m e te rs o f th e in stru m e n t fo r u se o n m o to rc ycle s w ith d iffe re n t ch a ra cte ristics (S M -T E ).
  • Page 196 E L E C T R IC S Y S T E M A d d in g / R e m o vin g S c re e n s T h is o p e ra tio n a llo w s yo u to a d d a n d re m o ve d iffe re n t scre e n s (fu n c tio n s) to th e u n it. T h e co m p u te r co n ta in s 9 scre e n s in a ll. T h e scre e n s m a y b e sh o w n w ith th e b a r g ra p h a ctin g a s a ta ch o m e te r o r a b a tte ry m e te r.
  • Page 197 E L E C T R IC S Y S T E M F ig .1 F ig .1 F ig .6 F ig .1 1 F ig .2 F ig .7 F ig .1 2 F ig .3 F ig .8 F ig .4 F ig .9 F ig .5...
  • Page 198 E L E C T R IC S Y S T E M In s tru m e n t re p la c e m e n t - M o d e l T E : re m o ve th e fo u r e la stic 1 fig .1 a n d re m o ve th e h e a d la m p h o ld e r 2 ; - M o d e l S M : re m o ve th e scre w 3 fig .
  • Page 199 E L E C T R IC S Y S T E M H E A D L A M P H e a d la m p a d ju s tm e n t (T E - S M ) T h e fro n t h e a d la m p is fitte d a d ip p in g b u lb fo r m a in a n d d ip p e d b e a m s a n d a p ilo t/sid e la m p bu lb .
  • Page 200 E L E C T R IC S Y S T E M R e a r ta il lig h t b u lb re p la c e m e n t (T E -S M ) T o g a in a cce ss to th e ta il lig h t b u lb (1 2 V -5 /2 1 W ), p ro ce e d a s fo llo w s: - re m o ve th e tw o fa ste n in g scre w s (1 ) a n d th e re a r le n s (2 );...
  • Page 201 E L E C T R IC S Y S T E M H A N D L E B A R C O M M U T A T O R S M e a su re th e co m m u ta to rs co n tin u ity u sin g a te ste r. In ca se o f a n o m a lie s, re p la ce th e d e fe c tive p a rt.
  • Page 202 E L E C T R IC S Y S T E M L .H . C O M M U T A T O R T E -S M...
  • Page 203 E L E C T R IC S Y S T E M A R R A N G E M E N T O F W IR IN G H A R N E S S O N T H E F R A M E 1 : in o rd e r to fa cilita te th e ta n k a n d sa d d le a sse m b lin g , h o ld d o w n w a rd th e sh e a th 2 : M a ke a tte n tio n to co rre ctly p o sitio n in g th e co n n e cto r ru b b e r o f th e in stru m e n t A sse m b le th e clam p s a s sh o w n in th e fig u re .
  • Page 204 E L E C T R IC S Y S T E M N O T E S C O N N E C T O R S W h e n a co n n e cto r is co n n e cte d , ch e ck th a t it clicks in to p o sitio n . C h e ck th e co n n e cto r fo r co rro sio n , d irt o r a b ro ke n co ve r.
  • Page 205 E N G IN E C O O L IN G S Y S T E M S e ctio n...
  • Page 206 E N G IN E C O O L IN G S Y S T E M T a b le o f C o n te n ts C h e ck in g th e c o o lin g flu id le ve l N .2 C o o lin g syste m N .4...
  • Page 207 E N G IN E C O O L IN G S Y S T E M 1 . C e n trifu g a l p u m p 2 . R .H . co o le r 3 . L .H . co o le r 4 .
  • Page 209 L U B R IC AT IO N C IR C U IT S e ctio n...
  • Page 210 L U B R IC AT IO N C IR C U IT L u b ric a tio n s ys te m T h e e n g in e lu b rica tio n is o f th e fo rce d typ e , w ith d u a l lo b e p u m p lo ca te d in sid e th e R .H .
  • Page 211 S P E C IF IC TO O L S S e ctio n...
  • Page 212 S P E C IF IC TO O L S S P E C IA L T O O L S 1 - (8 0 0 0 8 9 7 4 3 ) C ra n kca se 2 - (8 0 0 0 3 9 5 2 3 ) F lyw h e e l p u lle r 3 - (8 0 0 0 9 0 6 6 2 ) E n g in e h o ld e r 4 - (1 5 1 4 1 3 4 0 1 ) S w in g a rm p u lle r 5 - (8 0 0 0 3 9 5 2 4 ) C lu tch h u b re ta in in g...
  • Page 213 TO R Q U E W R E N C H S E T T IN G S S e ctio n T ig h te n a ll n u ts a n d b o lts w ith a to rq u e w re n ch a t th e co rre ct se ttin g . In su fficie n t tig h te n in g o f n u ts o r b o lts ca n ca u se th e m to b e co m e d a m a g e d o r lo o se le a d in g to ve h icle d a m a g e o r in ju ry to th e rid e r.
  • Page 214 TO R Q U E W R E N C H S E T T IN G S E N G IN E T IG H T E N IN G T O R Q U E S (+ /- 5 % ) C ylin der h ea d fastening n ut M 8x1,25 25 N m...
  • Page 215 TO R Q U E W R E N C H S E T T IN G S E N G IN E T IG H T E N IN G T O R Q U E S (+ /- 5 % ) E ngine oil dra in plu g M 14 x1,5 24 N m...
  • Page 216 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) R ear fram e lo w er fastenin g scre w M 8x1,25 25,5 N m...
  • Page 217 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) C hain gu id e bracket to rear sw ing arm fastenin g M 8x1,25 25 N m...
  • Page 218 TO R Q U E W R E N C H S E T T IN G S C H A S S IS T IG H T E N IN G T O R Q U E S (+ /- 5 % ) F ront brake disc fastening scre w (S M )/ M 8x1,25 34,7 N m...
  • Page 219 F R A M E A N D W H E E L S S e ctio n...
  • Page 220 F R A M E A N D W H E E L S T a b le o f C o n te n ts Y .3 F ra m e F ro n t w h eel Y .4 R em o vin g th e fro n t w h eel Y .5 R ea sse m b lin g th e fro n t w h eel...
  • Page 221 F R A M E A N D W H E E L S F R A M E T h e fra m e is a sin g le -b e a m w ith d o u b le -cra d le typ e clo se d in ste e l tu b e s. L ig h t a llo y re a r fra m e . F o r a ro u g h ch e ck, p le a se se e th e p ictu re (p a g e Y .
  • Page 222 F R A M E A N D W H E E L S F ro n t w h e e l H u b a n d rim in lig h t a llo y w ith h ig h te n sile ste e l spo ke s. R im m a ke , typ e a n d d im e n sio n (T E ) "T A K A S A G O E xce l in lig h t a llo y: 1 ,6 x2 1 (S M ) "S A N R E M O "...
  • Page 223 F R A M E A N D W H E E L S R e m o vin g th e fro n t w h e e l S e t a sta n d o r a b lo ck u n d e r th e e n g in e a n d se e th a t th e fro n t w h e e l is lifte d fro m th e g ro u n d . L o o se n th e b o lts (1 ) h o ld in g th e w h e e l a xle (2 ) to th e fro n t fo rk sta n ch io n s.
  • Page 224 F R A M E A N D W H E E L S R e a r w h e e l H u b a n d rim in lig h t a llo y w ith h ig h te n sile ste e l spo ke s. R im m a ke , typ e a n d d im e n sio n (T E ) "T A K A S A G O E xce l in lig h t a llo y: 2 ,1 5 x1 8 (T C ) "T A K A S A G O E xce l in lig h t a llo y: 1 ,8 5 x1 9 (2 5 0 );...
  • Page 225 F R A M E A N D W H E E L S R e m o vin g th e re a r w h e e l U n scre w th e n u t (1 ) o f th e w h e e l p in (3 ) a n d e xtra ct it. It is n o t n e ce s- sa ry to u n lo o se th e ch a in a d ju ste rs (2 );...
  • Page 226 F R A M E A N D W H E E L S W h e e ls o ve rh a u lin g C h e ck th e w e a r sta te o f th e h u b b e a rin g s. In ca se o f e xce ssive clea ra n ce (ra d ia l a n d a xia l), o p e ra te a s fo llo w s: - la y th e h u b o n a fla t h o ld e r w ith h o le , a llo w in g fo r th e p a ssa g e o f th e re m o ve d b e a rin g ;...
  • Page 227 F R A M E A N D W H E E L S R im s w a rp a g e T h e ta b le b e lo w sh o w s th e co n tro l va lu e th a t th e w h e e l rim m u st b e ch e cke d . T o o m u ch skid a n d e cce n tricity a re g e n e ra lly ca u se d b y a n y w o rn b e a rin g s.
  • Page 228 F R A M E A N D W H E E L S C H E C K IN G T H E W E A R O F C H A IN , P IN IO N A N D S P R O C K E T P ro ce e d a s fo llo w s: - F u lly stre tch th e ch a in w ith th e a d ju stin g scre w s.
  • Page 229 N O T E S F O R U S A /C D N -A U S M O D E L S S e ctio n...
  • Page 230 N O T E S F O R U S A /C D N -A U S M O D E L S T a m p e rin g w a rn in g T a m p e rin g w ith N o ise C o n tro l S yste m P ro h ib ite d . F e d e ra l la w p ro h ib its th e fo llo w in g a cts o r ca u sin g th e re o f: (1 ) T h e re m o va l o r re n d e rin g in o p e ra tive b y a n y p e rso n o th e r th a n fo r p u rp o se s o f m a in te n a n ce , re p a ir, o r re p la ce m e n t, o f a n y d e vice o r e le m e n t o f d e sig n in co rp o ra te d in to a n y n e w ve h icle fo r th e p u rp o se o f n o ise co n tro l p rio r...

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