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Husqvarna 2011 TE 630 Workshop Manual

Te 630 / 2011 i.e. sms 630 / 2011 i.e.
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Table of Contents
Workshop Manual
TE 630 / 2011 I.E.
SMS 630 / 2011 I.E.
Part. N. 8000 H2051 (02-2010)

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Table of Contents
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  Summary of Contents for Husqvarna 2011 TE 630

  • Page 1 Workshop Manual TE 630 / 2011 I.E. SMS 630 / 2011 I.E. Part. N. 8000 H2051 (02-2010)
  • 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 TE 630 / 2011 I.E. SMS 630 / 2011 I.E. Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com...
  • 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 complement 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 Engine Disassembly ....................F Engine Overhaul ....................G Engine Reassembly....................
  • Page 7: Important Notices

    IMPORTANT NOTICES Section Part. N. 8000 H2051 (02-2010)
  • 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 Part. N. 8000 H2051 (02-2010)
  • 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.5 Electrical components location ..............A.5 Overall dimensions - Weight .................A.6 Capacities .....................A.7 Part.
  • Page 11: Engine

    GENERAL INFORMATION Engine Type ................single cylinder, 4 stroke Cooling ..........Liquid with double radiator and heater fan Bore .......................100 mm Stroke ....................76.4 mm Displacement ..................600 cu.cm Compression ratio ...................12.4:1 Starting ....................electric Timing system Type ......... double overhead camshaft chain operated; 4 valve Valve clearance ( cold with engine) Intake ..................0.10 ÷...
  • Page 12: Chassis

    GENERAL INFORMATION Secondary drive Motion is transmitted from gearbox to rear wheel by 5/8" x 1/4" final drive chain ("D.I.D." 520 DS or "REGINA" 135 RX3) Transmission sprocket ................Z 15 Rear wheel sprocket (TE) ................Z 42 Rear wheel sprocket (SMS)................. Z 38 Transmission ratio (TE) ................
  • Page 13: Tyres

    GENERAL INFORMATION Tyres Front (TE) ..................... 90/90x21” (SMS) ....................120/70x17” Rear (TE) ....................140/80x18” (SMS) ....................150/60x17” Cold tyre pressure (TE) Front Rider only ..................1.2 Kg/cm Rider and passenger ................1.5 Kg/cm Rear Rider only ..................1.5 Kg/cm Rider and passenger ................1.8 Kg/cm Cold tyre pressure (SMS) Front Rider only ..................1.8 Kg/cm...
  • Page 14: Overall Dimensions - Weight

    GENERAL INFORMATION Overall dimensions - Weight Kerb weight, without fuel (TE): ..................150 Kg (330.69 lb) (SMS): ...................158 Kg (348.33 lb) *: max. width Part. N. 8000 H2051 (02-2010)
  • Page 15 GENERAL INFORMATION Part. N. 8000 H2051 (02-2010)
  • Page 16: Capacities

    GENERAL INFORMATION Capacities Type Quantity Fuel tank including reserve 98 octane unleaded fuel 12 litres (3.17 GAL) Reserve fuel (warning light goes on) 2.5 litres (0.66 GAL) Gearbox/engine oil CASTROL POWER 1 RACING 10W-50 2 litres (0.53 GAL) (oil change and oil filter replacement) Gearbox/engine oil CASTROL POWER 1 RACING 10W-50...
  • Page 17: Maintenance

    MAINTENANCE Section Part. N. 8000 H2051 (02-2010)
  • Page 18 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE - SMS REPLACE AFTER FIRST AFTER FIRST AFTER FIRST AFTER FIRST AFTER FIRST - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM 15000 KM...
  • Page 19 MAINTENANCE SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) TE - SMS REPLACE AFTER FIRST AFTER FIRST AFTER FIRST AFTER FIRST AFTER FIRST - STANDARD MOTORCYCLE, FOR ROAD USE 1000 KM 5000 KM 10000 KM 15000 KM...
  • Page 21: Troubleshooting

    TROUBLESHOOTING Section Part. N. 8000 H2051 (02-2010)
  • Page 22 TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression it hardly starts 1. Piston seizure 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 23 TROUBLESHOOTING Trouble Cause Remedy Noise seems to come from the clutch 1. Worn plates Replace 2. Too much clearance between clutch housing and friction plates Replace Noise seems to come from gearbox 1. Worn gears Replace 2. Worn gear grooves Replace The noise seems to come 1.
  • Page 24 TROUBLESHOOTING CHASSIS Trouble Cause Remedy The handlebar is hard to turn 1. Tyre pressure insufficient 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 The handlebar vibrates 1.
  • Page 25 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy The spark plug gets dirty 1. Mixture too rich Adjust carburettor easily 2. Dirty air filter Clean 3. Worn piston rings Replace 4. Worn piston or cylinder liner Replace Spark plug electrodes 1.
  • Page 27: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS Section Part. N. 8000 H2051 (02-2010)
  • Page 28 SETTINGS AND ADJUSTMENTS Saddle removal.....................D.4 Tank removal ....................D.4 Tank removal ....................D.5 Tank disassembly ..................D.8 Valve clearance adjustment ................D.10 Throttle cable adjustment ................D.11 Enrichener lever play adjustment ...............D.11 Idle adjustment ...................D.12 Engine oil level check .................D.12 Engine oil replacement, oil filter replacement ..........D.13 Mesh filters cleaning ...................D.14 Coolant level check ..................D.16 Coolant replacement ..................D.17...
  • Page 29 SETTINGS AND ADJUSTMENTS Part. N. 8000 H2051 (02-2010)
  • Page 30: Tank Removal

    SETTINGS AND ADJUSTMENTS Tank removal Remove the saddle as described in the relevant paragraph. Close both fuel cocks (1). Use a 6 mm Allen wrench to loosen the screw (2) and remove the screw with its spacer. Place a vessel under the R.H. cock to collect fuel. Loosen clamp (3) and disconnect tube (4) from the fuel cock.
  • Page 31 SETTINGS AND ADJUSTMENTS Remove the covers (5) located on the R.H. and L.H. side of the tank. Loosen the screws (6) using an 8 mm wrench. Move to the left side of the tank, slacken clamp (9) and disconnect the breather hose (10).
  • Page 32 SETTINGS AND ADJUSTMENTS Raise the tank from the front end and disconnect the fuel pump (12) connector (11). Disconnect the hose (13) connecting tank to throttle body; press down the ring (14) and disconnect hose (13) from pump (12). Raise the tank (15) and remove it together with the scoops. Reassemble all parts in the reverse order compared to disassembly and tighten screws to the specified torque (see Section X).
  • Page 33: Valve Clearance Adjustment

    SETTINGS AND ADJUSTMENTS Valve clearance adjustment Remove spark plug (1), the four head cover screws (2) and head cover. Engage the 2nd gear and push and pull the motorcycle back and forth to bring the piston to Top Dead Centre. In this condition, the notch on the head will be lined up with the two dots on the camshaft drive gear as shown in the figure.
  • Page 34: Throttle Cable Adjustment

    SETTINGS AND ADJUSTMENTS Throttle cable adjustment To check the correct adjustment of the throttle cable, operate as follows: Remove the fuel tank as described in the relevant paragraph. Loosen screw (1) and remove the protection cover (2); Turn throttle twistgrip (3) and make sure it has about 2 mm free play; if it is not so, loosen the lock nuts (4) and suitably turn the adjuster screws (5) (loosen to decrease play or tighten to increase it);...
  • Page 35: Idle Adjustment

    SETTINGS AND ADJUSTMENTS Idle adjustment Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: turn the idle speed adjustment screw (1) on the throttle body, located on the right-hand side of the vehicle, until the idle speed of 1650 RPM is reached (turn clockwise to increase the speed and anticlockwise to reduce the spe- ed).
  • Page 36: Engine Oil Replacement, Oil Filter Replacement

    SETTINGS AND ADJUSTMENTS Engine oil replacement, oil filter replacement Be careful not to touch hot engine oil. To change engine oil, warm up engine and proceed as follows: Keep the motorcycle upright and place an oil drain pan under the engine. Remove filler cap (1) and drain plugs (2) and (3).
  • Page 37: Mesh Filters Cleaning

    SETTINGS AND ADJUSTMENTS Pull out spring (7) and cartridge (8); reassemble in reverse order as for re- moval and change the O-ring (screws 5: 9.3 Nm/ 0.95 Kgm/ 6.9 ft-lb). Mesh filters cleaning Drain engine oil as described in the relevant paragraph. Filter on right side of engine.
  • Page 38 SETTINGS AND ADJUSTMENTS Filters on left side of engine. Loosen the screws (7) using an 8 mm wrench and remove the cover (8). Remove filters (9) (10) and their gaskets. Wash filters with petrol and blow them with compressed air; refit filters exactly in their original positions using new gaskets (11) which you will have greased properly.
  • Page 39: Coolant Level Check

    SETTINGS AND ADJUSTMENTS Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 10 mm above cells and besides, it shall not exceed the middle of the expansion tank (2) located in front of the rear shock absorber.
  • Page 40: Coolant Replacement

    SETTINGS AND ADJUSTMENTS Coolant replacement Coolant shall be replaced with cold engine and coolant. Standard procedure Place a vessel on the R.H. side of the cylinder, under the coolant drain screw (1). FIRST remove the screw (1) using a ... mm wrench, then SLOWLY open the R.H.
  • Page 41: Clutch Plate Replacement

    SETTINGS AND ADJUSTMENTS Clutch plate replacement Drain engine oil as described in the relevant paragraph. Remove the rear brake lever (1) as follows: disengage the return spring and use a 6 mm wrench to loosen the Allen screw (2). Loosen the eleven M6-L30 screws (3) and the two M6-L40 screws (4) using an 8 mm ring wrench and then remove the clutch cover (5) complete with filter and oil pump.
  • Page 42: Hydraulic Clutch Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS Hydraulic clutch lever adjustment and fluid level check Free play (A) must be at least 3 mm. 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 43: Front Brake Lever Adjustment And Fluid Level Check

    SETTINGS AND ADJUSTMENTS Front brake lever adjustment and fluid level check On the SMS model the lever position can be adjusted (4 settings available) to suit the rider hand size. To decrease the lever distance from the handgrip, turn the adjuster (B) CLOCKWI- SE.
  • Page 44: Rear Brake Pedal 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 (3) within the range available (A);...
  • Page 45: Rear Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS Rear brake fluid level check Master cylinder fluid level shall never drop below the minimum notch shown on the clear reservoir (1). A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.
  • Page 46: Air Filter Cleaning

    SETTINGS AND ADJUSTMENTS Loosen the seven screws (3) and remove the filter cover (4). The screws have a different length, it is recommended to mark them in order to favour correct reassembly. Remove the filter (5) together with support frame. Slide out the filtering element (6) from the support frame (7).
  • 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

    SETTINGS AND ADJUSTMENTS Suspension Standard suspensions setting derives from several extensive demanding tests in various usage conditions of the TE and SMS vehicles. If you intend to use them on more specific ground, following are a few guidelines for setup. Always start from the suspensions standard setting before making any change.
  • Page 50 After changing the standard suspension setting, ride with care. We advise measuring the reference distance “A” before making any change. Never disassemble the shock absorber, which contains compressed gas. Contact your Husqvarna Dealer for any major service. D.24 Part. N. 8000 H2051 (02-2010)
  • Page 51: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment Proceed as follows: 1. Insert the key in latch (1) then turn clockwise to release the saddle lock; remove the saddle. 2- Disengage rear left-hand side panel (2) then slide it toward vehicle front. 3.
  • Page 52 SETTINGS AND ADJUSTMENTS Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stro- A) COMPRESSION - Standard setting: 1) Low damping speed: fully open (adjuster 1) 2) High damping speed: fully open (adjuster 2) To reset the standard setting, turn upper adjuster screws (1) and (2) clockwise until reaching fully closed position.
  • Page 53: Marzocchi Front Fork Adjustment

    SETTINGS AND ADJUSTMENTS MARZOCCHI front fork adjustment a) REBOUND (TOP ADJUSTER) Standard setting: -12 clicks. To reset standard setting, turn adjuster (C) 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 screw counter clockwise.
  • Page 54: Fork Oil Level

    SETTINGS AND ADJUSTMENTS Fork oil level For regular fork operation, both legs must be provided with the necessary oil quan- tity. Remove the fork legs from the fork to check the oil level. Work as follows: remove the damper rod caps; remove springs from the legs letting the oil drain into the legs;...
  • Page 55: Marzocchi Front Fork Springs

    SETTINGS AND ADJUSTMENTS MARZOCCHI front fork springs STANDARD K=4.8 N/mm (spring + spacer part no. 8000 H1994) H006002 Part. N. 8000 H2051 (02-2010) D.29...
  • 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: Supply Hose Check

    SETTINGS AND ADJUSTMENTS Supply hose check Remove saddle and tank as outlined in the relevant paragraphs. Check the hose (1) running from pump to throttle body (2). To replace the hose, squeeze the two retainer tabs (3) on throttle body fitting. Part.
  • Page 58: Exhaust System Check

    SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section "E". Check pipes (1), (2) and (3) and silencers (4) for cracks or damage: replace if cracked or damaged. D.32 Part. N. 8000 H2051 (02-2010)
  • Page 59: General Procedures

    GENERAL PROCEDURES Section Part. N. 8000 H2051 (02-2010)
  • Page 60 GENERAL PROCEDURES Foreword ......................E.3 Saddle removal.....................E.4 Side panel removal ..................E.4 Battery removal ....................E.5 Exhaust system removal ................E.6 Air box removal...................E.10 Throttle body removal .................E.12 Removing the rear chassis complete with mudguard .........E.14 Fuel tank removal ..................E.17 Fuel tank disassembly (scoops and fuel pump) .........E.20 Expansion tank removal.
  • Page 61: Foreword

    GENERAL PROCEDURES Foreword This section describes the operations preliminary to engine removal. Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts. RIGHT-HAND SIDE LEFT-HAND SIDE Part.
  • Page 62: Saddle Removal

    GENERAL PROCEDURES Saddle removal Insert the key in latch (1) then turn clockwise to release the saddle lock; remove the saddle. Side panel removal Remove the saddle as described in the relevant paragraph. Disengage rear side panels (2) and (3) then slide them toward vehicle front.
  • Page 63: Battery Removal

    GENERAL PROCEDURES Battery removal Remove the saddle as described in the relevant paragraph. Release the elastic strap (3) holding the battery. First remove the BLACK negative cable (8 mm Allen wrench), then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...
  • Page 64: Exhaust System Removal

    GENERAL PROCEDURES Exhaust system removal H006005 Part. N. 8000 H2051 (02-2010)
  • Page 65 GENERAL PROCEDURES Remove R.H. guard (1) and L.H. guards (2) loosening the screws (3) with a 4 mm Allen wrench. Remove saddle and side panels as described in the relevant paragraph. H006006 Loosen the screws (4) securing silencers to rear chassis using an 8 mm ring wrench on the outside and a 10 mm ring wrench on the inside.
  • Page 66 GENERAL PROCEDURES Loosen metal clip (5) using a 13 mm wrench and remove the silencers (6). H006007 Disconnect the Lambda sensor connector (7). H006008 Part. N. 8000 H2051 (02-2010)
  • Page 67 GENERAL PROCEDURES Loosen the two clamps (8) using a 13 mm ring wrench and remove the central pipe (9). Loosen the four screws (10) of the exhaust manifolds (11) using a 4 mm Allen wrench and remove the manifolds with their rings. H006009 Part.
  • Page 68: Air Box Removal

    GENERAL PROCEDURES Air box removal Remove saddle, right-hand side panel and tank as outlined in the relevant paragraphs. Loosen the upper locking nut (1) using a 12 mm ring wrench. Loosen the lower screw (2) securing air box to chassis using an 8 mm ring wrench.
  • Page 69 GENERAL PROCEDURES Remove the complete air box (5) easing it off in rear to front motion. Part. N. 8000 H2051 (02-2010) E.11...
  • Page 70: Throttle Body Removal

    GENERAL PROCEDURES Throttle body removal Remove tank, saddle and left-hand side panel as outlined in the relevant paragraphs. Loosen the clamps (1) securing throttle body (2) to air box hose coupling and head. Disconnect the M.A.Q.S. sensor connector (3) from the throttle body. Disconnect the wiring harness connector (4) from the throttle body.
  • Page 71 GENERAL PROCEDURES Slacken adjusters (7) and disconnect the throttle cables (8). Remove the starter cable (9). Remove the throttle body (2); on assembly, adjust the throttle cable as outlined in “Section D”. Part. N. 8000 H2051 (02-2010) E.13...
  • Page 72: Removing The Rear Chassis Complete With Mudguard

    GENERAL PROCEDURES Removing the rear chassis complete with mudguard Remove fuel tank, saddle, side panels, battery, air box, silencers and central exhaust pipe as outlined in the relevant paragraphs. Shear the plastic clips securing main wiring harness. Use a 3 mm Allen wrench to loosen the screw (1) and remove the cover (2) of the utilities holder plate (3).
  • Page 73 GENERAL PROCEDURES Loosen the four screws (7) of the internal mudguard (8) using an 8 mm Allen wrench. Push down the internal mudguard (8) and then slide the utilities holder plate (3) toward vehicle front to remove it. Loosen the two screws (9) and remove the rear brake master cylinder cover (10).
  • Page 74 GENERAL PROCEDURES Loosen the two nuts (12) of the voltage regulator (13) and remove it. Unscrew the top locking nut (14), extract the pin (15) and remove the rear chassis sliding it toward the rear end of the vehicle. H006010 E.16 Part.
  • Page 75: Fuel Tank Removal

    GENERAL PROCEDURES Fuel tank removal Remove the saddle as described in the relevant paragraph. Close both fuel cocks (1) Use a 6 mm Allen wrench to loosen the screw (2) and remove the screw with its spacer. Place a vessel under the R.H. cock to collect fuel. Loosen clamp (3) and disconnect tube (4) from the fuel cock.
  • Page 76 GENERAL PROCEDURES Remove the covers (5) located on the R.H. and L.H. side of the tank. Loosen the screws (6) using an 8 mm wrench. Move to the left side of the tank, slacken clamp (9) and disconnect the bre- ather hose (10).
  • Page 77 GENERAL PROCEDURES Raise the tank from the front end and disconnect the fuel pump (12) connector (11). Disconnect the hose (13) connecting tank to throttle body; press down the ring (14) and disconnect hose (13) from pump (12). Raise the tank (15) and remove it together with the scoops. Reassemble all parts in the reverse order compared to disassembly and tighten screws to the specified torque (see Section X) Part.
  • Page 78: Fuel Tank Disassembly (Scoops And Fuel Pump)

    GENERAL PROCEDURES Fuel tank disassembly (scoops and fuel pump) Before disassembling the tank, open both fuel cocks and drain it completely. Remove the fuel tank as described in the relevant paragraph. Raise the cover (1), insert the key, turn it and remove the cap (2). H01160 Use a 3 mm Allen wrench to loosen the M5 screws (3) and a 4 mm Allen wrench to loosen the M6 screw (4);...
  • Page 79 GENERAL PROCEDURES H01162 Part. N. 8000 H2051 (02-2010) E.21...
  • Page 80: Expansion Tank Removal

    GENERAL PROCEDURES Expansion tank removal Remove fuel tank, saddle, right-hand side panel and air box as outlined in the relevant paragraphs. Loosen the two upper retaining screws (1) of the expansion tank (2) on the left side of the motorcycle. Disconnect breather hose from radiator cap.
  • Page 81: Removing Utilities (Solenoid Starter, Relays, Fuses, Flasher)

    GENERAL PROCEDURES Removing utilities (solenoid starter, relays, fuses, flasher) Remove the saddle as described in the relevant paragraph. Loosen screw (1) and remove the cover (2). The utilities holder plate (3) holds: 4) Solenoid starter; disconnect connector (5) and remove solenoid starter from plate with its flexible mount.
  • Page 82: Electronic Control Unit Removal

    GENERAL PROCEDURES Electronic control unit removal Remove the saddle as described in the relevant paragraph. Raise the electronic control unit (1) with its flexible mount and detach it from the rear chassis. Disconnect the connector (2). Voltage regulator removal. Remove saddle, right-hand side panel and air box cover as outlined in the relevant paragraphs.
  • Page 83: Electric Cooling Fan Removal

    GENERAL PROCEDURES Remove the retaining screws (3) and then the coil (4). Electric cooling fan removal Remove saddle and tank as outlined in the relevant paragraphs. Loosen screw (1) and remove the connector (2). Remove the electric fan (3) together with its bracket (4). Loosen the three screws (5) using a 7 mm wrench and take the electric fan (3) off the bracket (4).
  • Page 84 GENERAL PROCEDURES Headlamp removal Proceed as follows to reach the headlamp bulbs: pull out the front fairing (1) to remove it; loosen the three screws (2) and remove the headlamp (3); E.26 Part. N. 8000 H2051 (02-2010)
  • Page 85 GENERAL PROCEDURES On assembly, make sure the midline of side screw heads (2) lines up with the notch (C) on the support. H01177 Part. N. 8000 H2051 (02-2010) E.27...
  • Page 86: Digital Dashboard Removal

    GENERAL PROCEDURES Digital dashboard removal. Remove the headlamp as described in the relevant paragraph. Loosen the three screws (1) using an 8 mm ring wrench; be sure to collect the spacers. Raise the dashboard (2) and disconnect the connector (3). E.28 Part.
  • Page 87: Headlamp Fairing Removal

    GENERAL PROCEDURES Headlamp fairing removal. Remove headlamp, front mudguard and digital dashboard as outlined in the relevant paragraphs. Disconnect the diagnostic connector (1). Loosen the three screws (2) using an 8 mm ring wrench, open the clamp (3), slip off brake and trip meter cables and remove headlamp fairing (4). On assembly, make sure to position bushing (5) and rubbers (6) correctly.
  • Page 88: Ignition Switch Removal

    GENERAL PROCEDURES Ignition switch removal. Remove headlamp fairing, saddle and tank as outlined in the relevant para- graphs. Loosen the two screws (1) using a 6 mm Allen wrench. Release the clamp (2) and slip off the cable (3). Disconnect the connector (4). E.30 Part.
  • Page 89: Thermal Expansion Valve Removal

    GENERAL PROCEDURES Thermal expansion valve removal. Remove saddle and tank as outlined in the relevant paragraphs. Drain coolant from the radiators as described in "Section D". Disconnect the three clamps (1), disconnect the hoses (2) from the thermal expansion valve (3) and remove the valve. H01196 NOTE: After refitting the thermal expansion valve, fill with coolant as outlined in “Section D”.
  • Page 90: Secondary Drive Chain Removal

    GENERAL PROCEDURES Secondary drive chain removal The following procedure applies to both O-ring chains and chains without O- rings: Remove: screws (1), sprocket guard (2), clip (3), master link (4) and chain (5). NOTE: On assembly, follow the instructions given on the paragraph covering the chain in Section "D".
  • Page 91 GENERAL PROCEDURES Loosen the two screws (1) and screw (1a) of the clutch actuator (2) using an 8 mm ring wrench and remove the actuator. Make sure to refit screw (1a) in the original position on assem- bly. Make sure no one pulls the clutch lever with the actuator remo- ved.
  • Page 92 GENERAL PROCEDURES Take off the spark plug cap (9). Loosen the clamp (10) using a 7 mm ring wrench and disconnect the hose (11) from the left-hand radiator to make room for the ignition connectors (3). Loosen the clamps (12) using a 7 mm ring wrench and detach the hoses (13) from the engine.
  • Page 93 GENERAL PROCEDURES Loosen the two screws (14) using an 8 mm ring wrench and remove the rear brake master cylinder guard (15) Disengage the rear brake pedal return spring (16). Loosen the nut (17) of the rear engine mounting bolt using a 22 mm socket wrench.
  • Page 94 GENERAL PROCEDURES Loosen the nut of the front bolts (18) using a 10 mm ring wrench on the left- hand side and a 12 mm wrench on the right-hand side, but do not remove the bolts. Loosen the bolts (19) of the engine front mounting brackets using two 12 mm ring wrenches.
  • Page 95: Radiator Removal

    GENERAL PROCEDURES Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs. Remove the electric cooling fan and its bracket as described in the relevant paragraph. Drain all coolant as described in the relevant paragraph (see Section "D"). Release the grids (1) and remove them.
  • Page 96 GENERAL PROCEDURES Use a 7 mm ring wrench to loosen the two screws (11) and a 5 mm Allen wrench to loosen the central screw (12). Remove the left-hand radiator (13). Loosen the two screws (14) using a 7 mm ring wrench and remove the right- hand radiator (15).
  • Page 97: Engine Disassembly

    ENGINE DISASSEMBLY Section Part. N. 8000 H2051 (02-2010)
  • Page 98 ENGINE DISASSEMBLY Layout of engine components ..............F.3 Cylinder head cover removal ................ F.4 Camshaft removal ..................F.4 Water pump body removal ................F.8 Water pump disassembly ................F.8 Cylinder head removal.................. F.9 Valve removal ..................... F.12 Cylinder removal..................F.14 Piston removal ...................
  • Page 99: Layout Of Engine Components

    ENGINE DISASSEMBLY Layout of engine components Cylinder head cover Cylinder head Chain tensioner Cylinder Starter motor Head lubrication pipe Oil pump Clutch cover Oil filter Water pump Ignition cover H006022 H006023 Part. N. 8000 H2051 (02-2010)
  • Page 100: Cylinder Head Cover Removal

    ENGINE DISASSEMBLY Cylinder head cover removal Remove the four retaining screws (1) (8 mm wrench) and remove the head cover (2) with its gasket. H006024 Camshaft removal Remove the head cover as described in the relevant paragraph. Remove the eight screws (1) securing the ignition cover (2) (8 mm wrench) and remove the cover together with stator (3), timing drive gears (4) and gasket.
  • Page 101 ENGINE DISASSEMBLY Using a 24 mm wrench, bring the piston to T.D.C. at the end of the compres- sion stroke. In this condition, the mark (8) on the head will be lined with the mark (9) on camshaft drive gear (10). H006028 H006029 Part.
  • Page 102 ENGINE DISASSEMBLY Remove the chain tensioner (11) as follows: • Loosen the screw (12) with an 8 mm wrench. H006030 • Use a flat head screwdriver to release spring tension turning screw (13) fully clockwise. • Loosen the two screws (14) using an 8 mm wrench and remove the chain tensioner H006031 (11).
  • Page 103 ENGINE DISASSEMBLY Remove the eight screws (15) securing the camshaft (17) caps (16) (5 mm Allen wrench) and remove the camshafts tightening one of the screws you have removed into the threaded holes (18). H006032 Remove the oil pipe (19) and the camshafts (17). H006035 H006033 H006034...
  • Page 104: Water Pump Body Removal

    ENGINE DISASSEMBLY Water pump body removal Remove head cover, camshafts and chain tensioner as described in the relevant paragraph. Loosen the clamp (1) securing the water pump to cylinder head tube (2) and take the tube out of the head. Remove the two screws (3) securing pump body (4) to head (8 mm wrench) and remove pump body and timing drive gear (5).
  • Page 105: Cylinder Head Removal

    ENGINE DISASSEMBLY Cylinder head removal Remove head cover, camshafts, chain tensioner and water pump as described in the relevant paragraph. Remove the two screws (1) on the left side (8 mm wrench) and the nuts (2) located up front and at the rear under the head (13 mm wrench). H006038 H006039 H006040...
  • Page 106 ENGINE DISASSEMBLY Use a 5 mm Allen wrench to loosen the screw (3) and remove the chain slider (4). H006044 H006045 F.10 Part. N. 8000 H2051 (02-2010)
  • Page 107 ENGINE DISASSEMBLY Remove the four stud bolts (5) inside cylinder head (6) (10 mm Allen wrench) in a cross pattern. Remove the cylinder head and its gasket (7). H006041 H006042 H006043 Part. N. 8000 H2051 (02-2010) F.11...
  • Page 108: Valve Removal

    ENGINE DISASSEMBLY Valve removal Remove the cylinder head as described in the relevant paragraph. Remove the rocker arm spring spacers (1) using a hook. Remove the rocker arm shaft screws (2) (6 mm Allen wrench) and then remove rocker arm shafts (3) and rocker arms (4). Mark the valves and their components so as to refit in their original posi- H006046 tions on assembly.
  • Page 109 ENGINE DISASSEMBLY Use a valve spring compressor (6) to compress the valve springs. Be careful not too damage the mating surfaces that contact the gasket or those of the combustion chamber. Make sure the valve spring compressor is aligned straight on the spring, or you might bend the valve stem. Do not compress the springs too much or they will weaken.
  • Page 110: Cylinder Removal

    ENGINE DISASSEMBLY Cylinder removal Remove the head as described in the relevant paragraph. Remove the centring bushings (1). H006054 H006009 Loosen the cylinder retaining screw (2) using an 8 mm wrench. H006055 Remove the cylinder (3) with its gasket (4). H006056 F.14 Part.
  • Page 111: Piston Removal

    ENGINE DISASSEMBLY Piston removal Remove the piston pin retaining rings (1), slide out the piston pin (2) and remove the piston (3). H006057 Flywheel removal Remove the ignition cover as described in the relevant paragraph. Loosen the nut (1) and washer (2) securing the rotor (3) (24 mm wrench). H006058 H006059 Fit guard (4) to the crankshaft.
  • Page 112 ENGINE DISASSEMBLY Remove the rotor (3) using the puller (5) (part no. 8000 39523). H006061 Remove the flywheel (3) together with freewheel and idler gear (6). H01703 Remove the roller cage (7) and the washer (8); H01704 F.16 Part. N. 8000 H2051 (02-2010)
  • Page 113 ENGINE DISASSEMBLY Remove the screws (9) (5 mm Allen wrench) and inspect the freewheel; roller races should show no signs of wear or damage. Ensure that all gears are in good condition. H01705 H006065 Part. N. 8000 H2051 (02-2010) F.17...
  • Page 114: Clutch Cover Removal

    ENGINE DISASSEMBLY Clutch cover removal Before removing the clutch cover, drain engine oil as described in the relevant Section. Remove the thirteen screws (1) securing the cover (2) (8 mm wrench) and remove cover (2) and gasket (3). H006066 The screws are not all the same length; mark them with their positions to ensure correct reassembly.
  • Page 115: Oil Filters Removal

    ENGINE DISASSEMBLY Oil filters removal Mesh filter Remove the clutch cover as described in the relevant paragraph. Extract mesh filter (1) from its seat using long nose pliers. Wash filter with petrol and blow with compressed air; refit filter with the short pin facing outside.
  • Page 116: Clutch Disassembly

    ENGINE DISASSEMBLY Mesh filters on flywheel side Loosen the screws (8) (8 mm wrench) and remove cover (9). Extract the two mesh filters (10), wash them with petrol and blow with com- pressed air. Reassemble all parts, in the reverse order compared to disassembly. Check cover seal for damage.
  • Page 117 ENGINE DISASSEMBLY Extract the plates (5). H006078 Straighten the tab of the lock washer (6). H006079 Remove the nut (7) with its lock washer (27 mm wrench) using the clutch removal tool (A) (part no. 8000 39524). Remove the hub (8). H006080 Part.
  • Page 118 ENGINE DISASSEMBLY Remove the splined spacer (9). H006081 Remove clutch housing (10) and clutch pushrod (11). Clutch housing and drive gear (12) must always be replaced as a set. H006082 Remove the bushing (13) and its washer (14). H006083 F.22 Part.
  • Page 119: Clutch Actuator Removal

    ENGINE DISASSEMBLY Clutch actuator removal Loosen the two screws (1) and screw (1a) of the clutch actuator (2) using an 8 mm ring wrench; remove the actuator. Make sure to refit screw (1a) in the original position on assembly. H006084 Loosen screw (3) and remove the actuator flange (4).
  • Page 120: Starter Motor Flange Removal

    ENGINE DISASSEMBLY Starter motor flange removal Remove the ignition cover together with starter drive gear as described in the relevant paragraph. Remove the flywheel with its drive gear; Remove the flange (1) (tapping gently on the projections with a rubber ham- mer) with its gasket (2), the second drive gear (3) and the centring bushings (4).
  • Page 121: Gearbox Drive Shaft Removal

    ENGINE DISASSEMBLY Gearbox drive shaft removal Pull out the selector shaft (1). H006090 Loosen the two 4 mm socket head screws (2) and remove plate (3) and selector sector gear (4). Be careful not to lose sector gear assembly components. H006091 H006092 Part.
  • Page 122 ENGINE DISASSEMBLY Remove the drum (5) loosening the central shaft (6) with a 12 mm Allen wrench. H006093 H006094 Use a 13 mm socket wrench to loosen the retaining screw (7) of the ratchet (8) and remove ratchet and spring (9). H006095 F.26 Part.
  • Page 123: Gear Sensor Removal

    ENGINE DISASSEMBLY Gear sensor removal Loosen the screws (1) using an 8 mm Allen wrench and remove the sensor (2). H006096 Remove pushrod (3) and spring (4). H006097 Part. N. 8000 H2051 (02-2010) F.27...
  • Page 124: Crankcase, Crankshaft And Countershaft Disassembly

    ENGINE DISASSEMBLY Crankcase, crankshaft and countershaft disassembly Remove head, cylinder, piston, right and left crankcase, starter motor flange with starter motor, filters on flywheel side and gear sensor, as described in the relevant paragraphs. Remove bushing (1) on the sprocket shaft and extract the O-ring (2) using a small screwdriver.
  • Page 125 ENGINE DISASSEMBLY Turn the engine over and lift the tab of lock washer (6) using a chisel. Loosen the countershaft nut (7) using an impact screwdriver (24 mm key) and remove gear (8) and washer (6). Lift the tab of the lock washer (9) using a chisel. Hold the connecting rod with one hand and loosen the crankshaft gear nut (10) using an impact screwdriver (38 mm key).
  • Page 126 ENGINE DISASSEMBLY Remove clutch housing drive gear (11) and countershaft drive gear (12). Turn the engine over. Loosen the crankcase screws (12) using an 8 mm socket wrench; WARNING: The screws are not all the same length, mark them so as to refit them in their original positions on assembly;...
  • Page 127: Left Crankcase Seal Replacement

    ENGINE DISASSEMBLY Left crankcase seal replacement Remove the sprocket seal (1) with a screwdriver. WARNING: On assembly, position the seal flush with the crankcase. Loosen the screws (2) using an 8 mm wrench and remove the plate (3) re- taining the crankshaft seal (4). Remove the seal (4) with a screwdriver.
  • Page 128: Countershaft Removal

    ENGINE DISASSEMBLY Countershaft removal Tap the countershaft (1) with a rubber hammer and remove it from the cran- kcase. Gearbox disassembly Remove the shaft (1) of the output shaft shifter forks. Release the forks (2 ) and (3) from the drum (4) and remove them. Remove the input shaft fork shaft (5) and remove the drum (4).
  • Page 129: Crankshaft Removal

    ENGINE DISASSEMBLY Remove the input shaft fork (6). Remove input shaft (7) and output shaft (8) being careful not to lose any shims (if fitted). Crankshaft removal Slide the puller (1) (part no. 8000 89743) over the right end of the cran- kshaft.
  • Page 130: Crankshaft Components Removal

    ENGINE DISASSEMBLY Crankshaft components removal Insert a plate (1) between the two flywheel halves. Remove the crank pin from one of the flywheel halves using a press. Remove connecting rod and needle roller bearing. Turn the shaft and remove the crank pin (2). Remove the threaded cap and clean the crank pin.
  • Page 131: Right Crankcase Crankshaft Seal Removal

    ENGINE DISASSEMBLY Right crankcase crankshaft seal removal Loosen the screw (1) with an 8 mm wrench and remove the plate (2). Remove the seal (3) with a screwdriver. Crankcase bearings removal Remove the retaining plates (1) and (2) from the crankcase halves. Heat up the crankcase halves to around 125 °C in a furnace and extract the bearings using a suitable driver tool.
  • Page 132: Oil Pump Disassembly

    ENGINE DISASSEMBLY Oil pump disassembly Take the clutch cover (which you have removed previously) and remove the four screws (1) (8 mm wrench) securing the small cover; remove all compo- nents until getting to the oil pump drive shaft (2). Stator removal Take the ignition cover (which you have removed previously) and remove the five Allen screws [three 6 mm screws (1) and two 4 mm screws (2)];...
  • Page 133: Engine Overhaul

    ENGINE OVERHAUL Cleaning parts ..................... G.2 Clearances ....................G.2 Cylinder head ....................G.2 Valve seat refacing ..................G.3 Valve guide ....................G.5 Valve guide replacement ................G.5 Valve ......................G.6 Valve spring ....................G.6 Valve installation ..................G.7 Rocker arm inspection ................. G.8 Camshaft .....................
  • Page 134: Cleaning Parts

    ENGINE OVERHAUL Cleaning parts All parts must be cleaned with gasoline and dried with compressed air. Flammable vapours develop during this procedure and metal filings blown by compressed air may get into your eyes. Perform this procedure away from open flames or sources of ignition and wear an eye protection. Clearances To ensure the best operating conditions and maximum performance, all clearances must be within the specified tolerance.
  • Page 135: Valve Seat Refacing

    ENGINE OVERHAUL Valve seat refacing Clean off any fouling deposits from the valve. Apply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool. Remove the valve and measure the width “X” of the seating face. If width is greater than 1.5 mm, the seat needs to be refaced.
  • Page 136 ENGINE OVERHAUL Inspect valve seat and reface it if you find any signs of damages. Correct valve seating position is very important. Use a dye to check seat contact surface po- sition, it should be 0.5 mm from valve edge. If seat contact surface is too low on valve face, reface the seat with 73°...
  • Page 137: Valve Guide

    ENGINE OVERHAUL Valve guide Perform a careful visual inspection of the valve guide. To determine wear, measure valve to valve guide clearance in the “x” and “y” di- rections (at right angles to each other) using a suitably positioned dial gauge. Intake valve: normal clearance: 0.008 - 0.035 mm Service limit: 0.05 mm Exhaust valve: normal clearance: 0.018 - 0.045 mm...
  • Page 138: Valve

    ENGINE OVERHAUL Ream the valve guide using a suitable reamer and lubricate with cutting fluid. Rotate the reamer when extracting it to avoid scoring the valve guide. When a valve guide is changed, the valve seat must be refaced. Valve Inspect valve stem and valve seating face to make sure they are in good condition.
  • Page 139: Valve Installation

    ENGINE OVERHAUL Valve installation Smear valve guides and stems with oil before installation. Fit sealing ring (1), springs (2) and valve spring retainer (3). Use tool no. 8000 39521 to compress the valve springs and install the valve collets (4). Do not compress the springs too much and avoid damage to the cylinder head.
  • Page 140: Rocker Arm Inspection

    ENGINE OVERHAUL Lightly tap valve stem with a plastic hammer to help the valve collets become fully seated. Tap the valve stem tip to avoid pushing the valve off centre. Rocker arm inspection Check rocker arm to shaft clearance. Measure rocker arm inside diameter and shaft diameter and calculate clearance.
  • Page 141: Camshaft

    ENGINE OVERHAUL Camshaft Check the contact faces of the lobes for streaks, scoring, dents and waviness. Clamp the camshaft between centres and check deviation using two dial gauges. Service limit: 0.1 mm. Check that the lobes are in pristine conditions, without signs of scoring or distortion.
  • Page 142: Timing Chain And Gears

    ENGINE OVERHAUL Timing chain and gears Check the chain for wear at each engine overhaul. Replace chain is too noisy or worn. Timing chain tensioners Chain tensioners must be replaced when the lower area of the wear indicators is worn down to the metal. G.10 Part.
  • Page 143: Cylinder

    ENGINE OVERHAUL Cylinder Check the walls for dents or scuffing. Measure cylinder bore diameter at three different positions. Measure each diameter in two directions at right angles to each other to determine taper and out-of-round. Max. taper (wear limit): 0.05 mm. Max.
  • Page 144: Cylinder To Piston Clearance

    ENGINE OVERHAUL Cylinder to piston clearance Cylinder diameter Measure inside diameter (Dc) with an internal bore micrometer 10 mm below the edge (distance “A”). Piston diameter Measure piston diameter (Dp) 8-9 mm above skirt edge (distance “B”). Clearance is calculated as follows = Dc-Dp. CLEARANCE (Dc-Dp) SERVICE LIMIT 0.025-0.055 mm...
  • Page 145: Piston Pin

    ENGINE OVERHAUL Piston pin The piston pin must be perfectly smooth, with no signs of scoring, dents or bluing due to overheating. Part. N. 8000 H2051 (02-2010) G.13...
  • Page 146: Piston Rings

    ENGINE OVERHAUL Piston rings They should show no signs of forcing or scoring. Replacement pistons come with piston rings and piston pin. Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore (where minimum wear occurs) taking care to position it squarely and measure end gap.
  • Page 147: Piston Ring To Groove Clearance

    ENGINE OVERHAUL Piston ring to groove clearance Use a feeler gauge to measure the axial clearance (H) of piston rings. If the piston ring is marked on one side, that side must be facing up. PISTON RING END GAP ALIGNMENT Piston pin to small end clearance (A): 0.012-0.027 mm.
  • Page 148: Big End Radial Clearance

    ENGINE OVERHAUL Big end radial clearance STANDARD WEAR LIMIT 0.02-0.028 mm 0.04 mm (0.0008-0.00112 in.) (0.0016 in) Big end radial clearance STANDARD WEAR LIMIT 0.50-0.70 mm 0.080 mm (0.0197-0.0275 in.) (0.00315 in) Balancing countershaft Clamp the countershaft between centres and check that journals run concentric using a dial gauge (maximum runout allowed 0.02 mm).
  • Page 149: Crankshaft

    ENGINE OVERHAUL Crankshaft Main journals and crank pins should show no scoring or scuffing. Threads, keyways and splines must be in good condition. Clamp the shaft between centres and check that crank pins run concentric using a dial gauge (maximum runout allowed 0.02 mm). Crankshaft straightness STANDARD MAX WEAR LIMIT...
  • Page 150: Clutch

    ENGINE OVERHAUL Clutch Inspect all clutch components to make sure they are in the best conditions. Clutch plates should show no signs of bluing, scoring or distortion. Measure the thickness of friction plates. Plate thickness when new: 2.92-3.08 mm (0.1149-0.1212 in.) Service limit: 2.65 mm (0.106 in.).
  • Page 151: Friction Plate To Clutch Housing Clearance

    ENGINE OVERHAUL Friction plate to clutch housing clearance Measure clearance "A" between clutch housing (2) and plate (1) with a feeler gauge and compare measured clearance with the table below. STANDARD SERVICE LIMIT 0.30-0.50 mm 0.6 mm (0.012-0.020 in.) (0.024 in.) If measured clearance exceeds the service limit, replace clutch plates or housing and repeat measurement.
  • Page 152 ENGINE OVERHAUL 1- Pressure plate, 2- Clutch actuator plate, 3- Pushrod, 4- Piston assembly: Check these parts for signs of wear or failure. If any are found, replace the part. 5- Clutch hub: Check the steel plate slots for signs of wear or failure. If any are found, replace the part. 6- Clutch housing: Check the friction plate slots for signs of wear or failure.
  • Page 153: Shifter Forks And Gears

    ENGINE OVERHAUL Shifter forks and gears Visually inspect the shifter forks (1) and replace any bent forks. A bent fork will make gears hard to engage or let the transmission jump out of gear unexpec- tedly under loading. Check the clearance of the each shifter fork in its gear groove using a feeler gauge.
  • Page 154: Selector Drum To Shifter Fork Pins Clearance

    ENGINE OVERHAUL Selector drum to shifter fork pins clearance Determine clearance between shifter fork pin and drum groove taking the ne- cessary measurements with a calliper. If service limit is exceeded, compare the components with new parts to determine which one needs to be removed. Shifter fork to drum groove clearance (from new): 0.15-0.35 mm (0.006-0.014 in.) Service limit: 0.5 mm (0.02 in.)
  • Page 155: Oil Pump Disassembly

    ENGINE OVERHAUL Oil pump disassembly Remove the oil pump from the right crankcase as described in the Section "F". Check side clearance to determine whether the pump needs replacing; use a feeler gauge and a straight-edge. If pump rotors (1) and (2) have been separated from pump body, make sure to line up the dots on inner and outer rotors on assembly.
  • Page 157: Engine Reassembly

    ENGINE REASSEMBLY Section Part. N. 8000 H2051 (02-2010)
  • Page 158 ENGINE REASSEMBLY General ......................H.3 Assembly and lubrication instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF) ......H.4 Tightening torque figures ................H.5 Assembly and lubrication instructions ............H.6 GEARBOX - GEAR SHIFT CONTROL ............H.6 Tightening torque figures ................H.7 Assembly and lubrication instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF) ..........H.8 Tightening torque figures ................H.9 Assembly and lubrication instructions (HEAD - CYLINDER -...
  • Page 159: General

    ENGINE REASSEMBLY General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly are expressly highlighted in the text. Always replace gaskets, oil seals, metal retainers, sealing washers made from deformable material (copper, aluminium, fibre, etc.) and self-locking nuts after removal. Bearing specifications and dimensions have been calculated for a certain life.
  • Page 160: Assembly And Lubrication Instructions (Crank- Alternator- Lubrication- Left Crankcase Half)

    ENGINE REASSEMBLY Assembly and lubrication instructions CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF Part. N. 8000 H2051 (02-2010)
  • Page 161: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M18 x 1.25 70 Nm- 7.2 Kgm- 51.63 ft/lb M16 x 1.25 70 Nm- 7.2 Kgm- 51.63 ft/lb M4 x 4.07 (+Loctite 243) 3 Nm- 0.3 Kgm- 2.21 ft/lb M5 x 0.8 8 Nm- 0.8 Kgm- 5.90 ft/lb M5 x 0.8 (+Loctite 243) 8 Nm- 0.8 Kgm- 5.90 ft/lb M16 x 1.25...
  • Page 162: Gearbox - Gear Shift Control

    ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX - GEAR SHIFT CONTROL Part. N. 8000 H2051 (02-2010)
  • Page 163: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M6x1 10 Nm- 1.02 Kgm- 7.38 ft/lb M8 x 1.25 (+LOCTITE 243) 28 Nm- 2.85 Kgm- 20.65 ft/lb M6 x 1 (+LOCTITE 243) 9 Nm- 0.92 Kgm- 6.64 ft/lb M5 x 0.8 (+LOCTITE 243) 8 Nm- 0.8 Kgm- 5.90 ft/lb LUBRICATION POINTS-NOTES LUBRICANT-INSTALLATION INSTRUCTIONS Install with open end pointing to engine centre...
  • Page 164: Assembly And Lubrication Instructions (Head - Cylinder - Piston - Timing System - Water Pump - Spark Plug)

    ENGINE REASSEMBLY Assembly and lubrication instructions CLUTCH- KICK START- LUBRICATION- RIGHT CRANKCASE HALF Part. N. 8000 H2051 (02-2010)
  • Page 165 ENGINE REASSEMBLY Tightening torque figures M24 x 1.25 (+LOCTITE 243) 100 Nm- 10.2 Kgm- 73.76 ft/lb M18 x 1 61.7 Nm- 6.3 Kgm- 45.73 ft/lb M6 x 1 (+LOCTITE 243) 9 Nm- 0.92 Kgm- 6.64 ft/lb M6 x 1 (+LOCTITE 243) 9 Nm- 0.92 Kgm- 6.64 ft/lb M10 x 1 15 Nm- 1.5 Kgm- 3.69 ft/lb...
  • Page 166 ENGINE REASSEMBLY Assembly and lubrication instructions HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H.10 Part. N. 8000 H2051 (02-2010)
  • Page 167: Tightening Torque Figures

    ENGINE REASSEMBLY Tightening torque figures M14 x 1.5 (+LOCTITE 542) 25 Nm- 2.55 Kgm- 18.44 ft/lb M6 x 1 5 Nm- 0.5 Kgm- 3.69 ft/lb M8 x 1.25 15 Nm- 1.5 Kgm- 11.6 ft/lb M10 x 1.5 (MOLIKOTE HSC -COPPER 37 Nm +90°- 3.8 Kgm +90°- 27.29 ft/lb+90°...
  • Page 168 ENGINE REASSEMBLY Crankshaft assembly Clean the oil galleries thoroughly. Lubricate the crank pin (1) with engine oil and insert it into the flywheel half (2). WARNING: Match the oil passage holes Fig."A". Fit the needle roller bearing (3) and lubricate it the engine oil. Install the connec- ting rod (4) and the second flywheel half (5) and align the two flywheel halves using a square.
  • Page 169 ENGINE REASSEMBLY Finally, join the parts using a press. Make sure the pin does not protrude at either ends as you join the flywheel halves. Observe mounting dimension "A" and set crank pin (1) at distance "B" on the right flywheel half. A = 6.35 - 64.45 mm (2.574-2.578 in.) B = 0.9 - 1.1 mm...
  • Page 170: Input Shaft

    ENGINE REASSEMBLY Input shaft Output shaft H.14 Part. N. 8000 H2051 (02-2010)
  • Page 171 ENGINE REASSEMBLY Input shaft Fit bushing (2) to the input shaft (1). Lubricate inner and outer face with Molikote G-n plus grease before installation. Fit 4th gear (3), washer (4) and retaining ring (5) with the rounded edges of washer and retaining ring facing the gear. Fit 5th/6th sliding gear (6).
  • Page 172 ENGINE REASSEMBLY Output shaft Fit bushing (2) to the output shaft (1). Lubricate inner and outer face with Molikote G-n plus grease before installation. Fit 2nd gear with the splined side facing 3rd gear. Fit washer (4) and retaining ring (5) with the rounded edges of washer and retaining ring facing the gear.
  • Page 173: Crankcase Assembly

    ENGINE REASSEMBLY Crankcase assembly Clean the crankcase half mating faces and place crankcase half on tool no. 8000 90662. Heat up to around 125 °C and drive the ball bearings into each crankcase half using a suitable driver tool. Fit the retaining plates (1) and (2) to the crankcase bearings. (See Section "x"...
  • Page 174 ENGINE REASSEMBLY Install the input and output shaft assembly pushing them fully home into the right crankcase half and make sure input (3) and output shaft (4) gears are flush. Lubricate the shifter forks (5) with engine oil and install them. H.18 Part.
  • Page 175 ENGINE REASSEMBLY Insert the selector drum (6) into its seat. Install the fork shafts (7) and (8) and make sure the forks move freely. Make sure the fork pins (9) are correctly located in the drum grooves (6). Rotate the selector drum to test operation. Part.
  • Page 176 ENGINE REASSEMBLY Heat up the crankshaft bearing (10) and install the crankshaft (11). Fit the countershaft (12) onto its bearing. Make sure both crankcase locating bushings (13) are in place. Apply a layer of “LOCTITE 5205” on the right crankcase mating surface (14). H.20 Part.
  • Page 177 ENGINE REASSEMBLY Heat up the left crankcase bearing locations and install the crankcase. Grease the sprocket bearing bushing (15) and fit it into the bearing; fit the left crankcase half onto the right crankcase half. To join the crankcase halves, tap with a plastic hammer. Tighten the screws (16) using an 8 mm wrench.
  • Page 178 ENGINE REASSEMBLY Install mesh filters (17) and their cover (18) and tighten the screws (19) with an 8 mm wrench (see Section "X" for tightening torque figures). Insert bushing (20) with its O-ring (21); the O-ring groove must be facing into the engine.
  • Page 179: Gear Sensor Installation

    ENGINE REASSEMBLY Gear sensor installation. Insert spring (1) and pushrod (2) into the their seat (3). Fit the sensor (4); make sure to install the gasket. Tighten the screws (5) 8 N/m; 0.8 Kgm; 5.8 ft/lb. Part. N. 8000 H2051 (02-2010) H.23...
  • Page 180: Gear Shift Control Assembly

    ENGINE REASSEMBLY Gear shift control assembly Install the ratchet (1) and tighten the screw (2) (13 mm wrench; 28 N/m; 2.8 Kgm; 20.65 ft/lb). Engage the spring (3) with the suitable pin. Install the selector drum (4) making sure the tab (5) locates in the recess (6) and secure drum with its screw (7).
  • Page 181 ENGINE REASSEMBLY Operate shifter and transmission shaft to test gearbox for proper operation. Refit the ratchet assembly (8) together with the plate, making sure ratchets and springs are in the correct positions. Tighten the screws (9) of plate (10) using a 4 mm Allen wrench (Loctite 243; 9.3 Nm;...
  • Page 182 ENGINE REASSEMBLY Make sure the spring (11) of the gear shift lever shaft is positioned correctly. Lubricate the shaft with engine oil and insert the shaft (12) into the crankcase so that the teeth (13) mesh with sector gear (8) teeth and spring (14) locates to its abutment pin.
  • Page 183: Crankshaft Gears Installation

    ENGINE REASSEMBLY Crankshaft gears installation. Fit the countershaft driving gear (1) to the crankshaft with the timing dot facing out. Fit the input shaft driving gear (2) with the bevelled side facing out. Countershaft weight/gear installation. Fit the countershaft gear (1) line up its dot with that of the crankshaft gear (2) to set timing.
  • Page 184 ENGINE REASSEMBLY Tighten the nut (4) with a 27 mm wrench to 70 N/m; 7 Kgm; 51.58 ft/lb placing an aluminium shim (5) between countershaft gear (1) and crankshaft gear (2). Bend the lock washer (3). Fit the lock washer (6) onto the crankshaft gear making sure the tab locates into the keyway.
  • Page 185 ENGINE REASSEMBLY Turn the engine over. Fit the counterweight (9 ) to the countershaft. Fit the lock washer (10) onto the shaft making sure the tab locates into the keyway. Tighten the nut (11) with a 27 mm wrench to 70 N/m; 7 Kgm; 51.58 ft/lb placing a half gear at the opposite side of the engine between countershaft gear (1) and crankshaft gear (2).
  • Page 186: Clutch Assembly

    ENGINE REASSEMBLY Clutch assembly Slide washer (1) and bushing (2) over the shaft (lubricate with engine oil). Lubricate the shaft with engine oil and fit the clutch housing (3). Fit the splined spacer (4). H.30 Part. N. 8000 H2051 (02-2010)
  • Page 187 ENGINE REASSEMBLY Fit the clutch hub (5) and its lock washer (6). Use the suitable tool (7) to prevent rotation and tighten the nut (8) with a 27 mm wrench to 61.7 Nm; 6.17 Kgm; 45.47 ft/lb. Bend the lock washer (6). Part.
  • Page 188 ENGINE REASSEMBLY Refit the plates (9) (install a friction plate first and then a steel plate and keep alternating between friction and steel plates; the last to go in should be a steel plate). Fit actuator plate (10), thrust bearing (11), thrust washer (12), pressure plate (13) and springs (14).
  • Page 189: Piston Ring Installation

    ENGINE REASSEMBLY Piston ring installation Fit the piston rings as shown in the diagram. If the piston ring is marked on one side, that side must be facing up. *: position of end gap "d" PISTON RING END GAP ALIGNMENT Piston and cylinder installation Remove the cylinder protection (1).
  • Page 190 ENGINE REASSEMBLY Lubricate the cylinder liner (7) with engine oil and slide it over the piston rings. Fit the two locating bushings (8). Secure the cylinder (7) to the crankcase tightening screw (9) with an 8 mm wrench (see Section "X" for tightening torque figures). Install the timing chain (10).
  • Page 191: Cylinder Head Gasket Selection Table

    ENGINE REASSEMBLY Fit screws and spacers (13) to temporarily secure the cylinder liner (7). (2 spacers) Use a 10 mm Allen wrench; 25 Nm; 2.5 Kgm; 18.44 ft/lb. Make sure that the piston is at Top Dead Centre. Measure distance "A" on the two machined faces "B" of the piston and choose the appropriate head gasket according to the table.
  • Page 192: Cylinder Head Installation

    ENGINE REASSEMBLY Cylinder head installation For valve installation instructions, please see Section "G". Always use a new head gasket on assembly: see the "Cylinder head gasket selection table". Install the head (1) while supporting the timing chain (2) with a tool. Tighten the head bolts (3) gradually in a cross pattern to 38 Nm+90°;...
  • Page 193 ENGINE REASSEMBLY Insert the fixed slider (6) and secure it into place tightening the retaining screw (7) with a 5 mm Allen wrench (see Section "X" for tightening torque figures). Refit the four shims (8) on the valves as marked on removal. Fit the shafts (9) of the rocker arms (10) as marked on removal with the slotted end facing outwards.
  • Page 194: Water Pump Installation

    ENGINE REASSEMBLY Water pump installation Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre. Insert the timing drive gear (2) into the head lining up the notch on the camshaft drive gear (3) with the notch on the head mating face.
  • Page 195: Timing Chain Tensioner Installation

    ENGINE REASSEMBLY Timing chain tensioner installation Refit the chain tensioner (1) and its gasket. Tighten the two screws (2) using an 8 mm wrench (10 Nm, 1.0 Kgm, 7.25 ft/lb). Release the chain tensioner (1) using a screwdriver (turn counter clockwise). Refit the screw (3) with its washer (8 mm wrench).
  • Page 196: Camshaft Installation

    ENGINE REASSEMBLY Camshaft installation Secure a dial gauge (1) to the spark plug hole. Turn the crankshaft manually until bringing the piston to Top Dead Centre. Insert the camshaft drive gear (2) into the head lining up the dot on gear (3) with the head mating face.
  • Page 197 ENGINE REASSEMBLY Make sure that the centring bushings are in place in the caps. Refit the camshaft caps (8) and tighten the screws (9) with a 5 mm Allen wrench; 12 Nm; 1.2 Kgm; 8.85 ft/lb as marked on removal. Apply a 38 mm wrench to the clutch side gear and turn the crankshaft manually a few turns to check for free, smooth rotation without any tight points, then bring it back to Top Dead Centre position.
  • Page 198: Cylinder Head Cover And Spark Plug Installation

    ENGINE REASSEMBLY Cylinder head cover and spark plug installation. Smear Arexons 5552 compound on the half-round cutouts (1). Refit head cover (2) and tighten the screws (3) in a cross pattern. 8 mm wrench, 8 Nm; 0.8 Kgm; 5.8 ft/lb. Refit the lubrication pipe to the head (4) and tighten the drilled bolt (5).
  • Page 199: Flywheel And Flywheel Cover Installation

    ENGINE REASSEMBLY Flywheel and flywheel cover installation. Install the stator (1) with its mark lined up with the flywheel cover mark and tighten the three retaining screws (2) (use a 5 mm Allen wrench; 8 Nm; 0.8 Kgm; 5.9 ft/lb + Loctite 272). Insert the cable guide (3) into its seat in the cover and tighten the two retaining screws (4) of the pick-up sensor (5) with its plate using a 3 mm Allen wrench (3 Nm;...
  • Page 200 ENGINE REASSEMBLY Fit the freewheel gear (12) to the flywheel (13) and tighten the screws (14) (5 mm Allen wrench) (see Section "X" for tightening torque figures). Degrease crankshaft taper end and flywheel bore and smear crankshaft taper end with Loctite 270. Install flywheel (13) together with drive gear (14).
  • Page 201 ENGINE REASSEMBLY Fit bushing (17) and starter motor drive gear (18). Install gasket and cover (19) and tighten the screws (20) in a cross pattern with an 8 mm wrench (see Section "X" for tightening torque figures). Screws (20) are not all the same length; make sure to refit them in their original positions.
  • Page 202: Sprocket Installation

    ENGINE REASSEMBLY Sprocket installation Fit the sprocket (1) and its circlip (2). Oil pump and filter cartridge assembly Assemble oil pump components in the order shown. Secure the cover using the four screws (1) (9 Nm-0.9 Kgm-6.5 ft/lb). Refit the filter cartridge (2) and secure the cover using the two screws (9 Nm-0.9 Kgm-6.5 ft/lb).
  • Page 203: Right Crankcase Assembly

    ENGINE REASSEMBLY Right crankcase assembly Fit the mesh filter (1) with the perforated end facing outwards. Fit the two locating bushings (2) into the crankcase. Refit the gasket (3). Refit the cover (4) making sure to mate pump shaft (5) with the slotted end (6) of the output shaft (gently rock the sprocket to facilitate installation).
  • Page 204: Clutch Actuator Installation

    ENGINE REASSEMBLY Clutch actuator installation Refit the flange (1) and tighten the screw (2). 8 mm wrench (see Section "X" for tightening torque figures). Insert the clutch pushrod (3) thinner end (3a) first. H.48 Part. N. 8000 H2051 (02-2010)
  • Page 205: Front Suspension

    FRONT SUSPENSION Section Part. N. 8000 H2051 (02-2010)
  • Page 206 FRONT SUSPENSION Front fork removal ..................I.4 Marzocchi manual ..................I.5 Part. N. 8000 H2051 (02-2010)
  • Page 207 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: remove the screws (1) and the brake line clamp (2) on the left-hand side;...
  • Page 208 FRONT SUSPENSION Part. N. 8000 H2051 (02-2010)
  • Page 209 FRONT SUSPENSION MARZOCCHI MANUAL Part. N. 8000 H2051 (02-2010)
  • Page 314: Rear Suspension

    REAR SUSPENSION Section Part. N. 8000 H2051 (02-2010)
  • Page 315 REAR SUSPENSION Rear shock absorber ..................J.3 Lubrication points (grease) ................J.3 Rear suspension....................J.4 Rear shock absorber removal ...............J.5 Disassembling, servicing and assembling the rear shock absorber ....J.6 Spring servicing .....................J.6 Shock absorber inspection ................J.7 Reservoir cap with its valve removal .............J.7 Piston assembly inspections ...............J.10 Seal replacement..................J.10 Checking the setting ..................
  • Page 316: Rear Shock Absorber

    REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft/lb Lubrication points (grease) Part. N. 8000 H2051 (02-2010)
  • Page 317 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 318: Rear Shock Absorber Removal

    REAR SUSPENSION Rear shock absorber removal Set a block under the engine and see that the rear wheel is lifted from the ground. Remove saddle, side panels, silencer and rear chassis (see Section "E" - General Procedures). Loosen the front clamp (1) of the intake coupling. Remove the front bolt (2) securing the suspension linkage to the chassis, the bottom (3) and top (4) shock absorber mounting bolts and remove the shock absorber (5).
  • Page 319: Disassembling, Servicing And Assembling The Rear Shock Absorber

    REAR SUSPENSION Disassembling, servicing and assembling the rear shock absorber Clean the shock absorber before disassembly. SPRING SERVICING Measure the spring in place before removal. Spring removal: clamp the shock absorber in a vice taking care to avoid distorting it. Slacken lock ring nut and ring nut, spring retainer and spring. Part.
  • Page 320: Shock Absorber Inspection

    REAR SUSPENSION Measure spring free length. SERVICE LIMIT: 245 +/-1.5 Change the spring if length is outside the service limit. SHOCK ABSORBER INSPECTION Visually inspect the shock absorber and look for oil leaks or other issues. Replace the shock absorber if needed. Push on the reservoir valve to discharge the gas.
  • Page 321 REAR SUSPENSION Prise out the retaining ring using two small screwdrivers. Take care not to da- mage the inner surface. To remove the retaining ring, first prise one end of the ring out of its groove. Then slide out the other end, slip the tip of a screwdriver between ring and reservoir and prise off with the other screwdriver.
  • Page 322 REAR SUSPENSION Place the shock absorber on a bench. Unscrew or knock out the cover (depen- ding on the model). Once the tank cap is removed, push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver. Part.
  • Page 323: Piston Assembly Inspections

    REAR SUSPENSION Clamp the top section of the shock absorber in a vice with aluminium or bronze jaws. Insert a rod or a screwdriver into the mounting hole and extract the rod guide and piston assembly from the shock absorber body. Before extracting the assembly, cover the end of the shock body with a cloth to capture leaking oil.
  • Page 324: Checking The Setting

    REAR SUSPENSION Checking the setting If the suspension is not operating properly and you need to adjust compression damping, loosen the knob dowel (heat with an air gun before loosening). Proceed as follows: loosen the ring nut with the suitable key, slide off all parts noting their positions to ensure correct assembly.
  • Page 325 REAR SUSPENSION Part. N. 8000 H2051 (02-2010) J.12...
  • Page 326 REAR SUSPENSION After the inspection, refit piston, disc, spring and slotted ring. Slide the needle shaft off the cap, tighten the ring, insert into slot pressing lightly and secure in place tightening the cap to 30 Nm (3 kgm; 29.2 ft/lb). It is strictly forbidden to change the compression washers.
  • Page 327: Reservoir Replacement

    REAR SUSPENSION Reservoir replacement In the event the reservoir needs to be replaced, heat the area near the threaded end with an air gun and loosen using suitable equipment. Replace the reservoir O-ring. Grease the O-ring being careful not to smear the thread in the mount.
  • Page 328: Shock Absorber Assembly

    REAR SUSPENSION SHOCK ABSORBER ASSEMBLY Wash the shock absorber body thoroughly with a degreasing product. Make sure it is fully dry. Blow with compressed air if needed. Clamp the shock absorber eye in a vice with aluminium or bronze jaws (or use a shop rag to protect the eye).
  • Page 329 REAR SUSPENSION Fit a new O-ring to the floating piston (always use a new O-ring after removal). Fill the reservoir with oil, then quickly insert the floating piston into the reservoir (see picture). Push the floating piston quickly down to reservoir bottom while holding the rod steady in the appropriate position for top-up.
  • Page 330 REAR SUSPENSION Top up with oil up to nearly 2 cm (0.8 in.) below shock body edge. Pump the rod up and down through 5 - 6 cm (2-2.4 in.) strokes four or five times to expel any air trapped under the piston. Pump slowly or the floating piston might become displaced due to cavita- tion or compression.
  • Page 331 REAR SUSPENSION Refit the reservoir cap with its valve. Fit it into the reservoir and fit the circlip into the groove. Fill nitrogen (or air) through the valve and pressurise to 10-12 bar. Refit the cap to the valve and check for oil or air leaks. Drive the cap onto the body.
  • Page 332: Shock Absorber Damping Adjustment

    REAR SUSPENSION Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stro- A) COMPRESSION - Standard setting: 1) Low damping speed: fully open 2) High damping speed: fully open To reset the standard setting, turn upper adjuster screws clockwise until rea- ching fully closed position.
  • Page 333: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION Disassembling and servicing the swinging arm. Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove the rear wheel as described in "Section Y". Remove the final drive chain (1) as described in "Section E". Detach the rear brake line (3) from the swinging arm (2).
  • Page 334 REAR SUSPENSION Disengage the rear brake pedal return spring (6). TIGHTENING TORQUE FIGURES 8=80 Nm - 8.2 Kgm - 59 ft/lb 11=122.5 Nm - 12.5 Kgm - 90.3 ft/lb (+LOCTITE 243) Loosen the nut (11) using a 22 mm socket wrench and remove the rear engine/ swinging arm mounting bolt (12) from the right-hand side.
  • Page 335: Servicing The Swinging Arm Shaft

    REAR SUSPENSION Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion. Service limit: 0.30 mm. Servicing the rear suspension drop and drag link With drop link (1) and drag link (2) still in place (connected to swinging arm and chassis, respectively), rock them both back and forth in all directions to check for...
  • Page 336: 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. In this case, chain might unwrap from the sprocket.
  • Page 338: Brakes

    BRAKES Section Part. N. 8000 H2051 (02-2010)
  • Page 339 BRAKES Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Pads cleaning ....................L. 5 Bleeding the front braking system (TE) ............L.7 Bleeding the front braking system (SMS) ............. L.8 Bleeding the rear braking system ...............
  • Page 340: Braking System

    BRAKES Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir (TE) 2.
  • Page 341: Brake Disc

    BRAKES Brake disc Checking the brake disc is an important safety procedure; the disc must be spotless, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: 260 mm (TE) - 320 mm (SMS) Front brake disc thickness (when new): 3.0 mm (TE) - 5.0 mm (SMS) Wear limit: 2.5 mm (TE) - 4.5 mm (SMS) Rear brake disc diameter: 220 mm Rear brake disc thickness (when new): 4.0 mm...
  • Page 342: Pads Cleaning

    BRAKES Checking brake pads for wear / replacing the pads TE - FRONT Check brake pad wear. Service limit ”A” 3.8 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs. Pads cleaning 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 343 BRAKES INSTALLATION OF BRAKE PADS TE - FRONT TE front/TE-SMS rear Install new brake pads. Reassemble pin (2) and clips (1). SMS front Install new brake pads. Install clips (3) by pushing them toward the calliper. Install the pins (4). Pull clips (3) out, to make sure they are engaged on pins (4) The above procedure eliminates the need to bleed the braking system after replacing the pads.
  • Page 344: Bleeding The Front Braking System (Te)

    BRAKES BLEEDING THE FRONT BRAKING SYSTEM (TE) 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. Proceed as follows. Take the rubber cover off the bleed valve (1).
  • Page 345: 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 346 BRAKES Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure. Brake fluid is corrosive. In the event of contact with eyes, rinse with abundant water. Motorcycle handlebar must be turned to the left during the bleeding procedure.
  • Page 347: 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 cover (A) (rubber gaiter), and diaphragm and fill with fluid (DOT 4).
  • Page 348 BRAKES SMS - FRONT Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind. Use only fluid taken from a sealed container (DOT 4).
  • Page 349 BRAKES Remove the reservoir cover (3) or (3A) and the rubber gaiter. Loosen the bleed valve (2) or (2A) on the calliper. Pump the brake lever (4) or the brake pedal (4A) until draining all fluid. Tighten the bleed valve and fill the reservoir with fresh fluid. Loosen the bleed valve, operate lever or pedal, tighten the valve keeping lever or pedal pressed and then release quickly.
  • Page 350 BRAKES Brake fluid quickly corrodes painted surfaces, remove any traces of spills immediately. Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses.
  • Page 352: Electrical System

    ELECTRICAL SYSTEM Section Part. N. 8000 H2051 (02-2010)
  • Page 354 ELECTRICAL SYSTEM Wiring diagram .................... M.5 Key to wiring diagram .................. M.5 Colour coding key ..................M.5 LOCATION OF ELECTRICAL COMPONENTS ........... M.6 WIRING DIAGRAM .................. M.10 CHARGING SYSTEM ................M.10 CHARGING SYSTEM INSPECTIONS ............M.11 Current loss at the battery ................. M.11 Regulated voltage..................
  • Page 355 ELECTRICAL SYSTEM TROUBLESHOOTING ................M.42 CHARGING SYSTEM ................M.42 STARTING SYSTEM ................. M.42 ELECTRONIC IGNITION SYSTEM ............M.42 Wiring ......................M.43 Cable routing and electrical parts installation instructions ......M.44 • Coil position and connector connection ..........M.44 • Position of utilities ................... M.44 •...
  • Page 356: Wiring Diagram

    ELECTRICAL SYSTEM Wiring diagram Key to wiring diagram 29. Front stop switch 30. Rear stop switch 1. Electronic control unit 31. Rear R.H. turning indicator 2. Control unit interface 32. Tail light 3. Coolant temperature sensor 33. Rear L.H. turning indicator 4.
  • Page 357 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS LOCATION The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; Electronic ignition coil (2) under the fuel tank; Electronic control unit (3) under the saddle; - Voltage regulator (4) on the R.H. side of the rear chassis; Part.
  • Page 358 ELECTRICAL SYSTEM Spark plug (5) on the R.H. side of the cylinder head; 12V-700W Starter motor (6) behind the cylinder; Solenoid starter (8) located on the fuse holder plate, under the saddle; M.A.Q.S. sensor (air temperature, pressure, throttle position) (10) on throt- tle body.
  • Page 359 ELECTRICAL SYSTEM The electrical system includes the following elements: - 12V-14Ah Battery (7) under the saddle; H01364 Turning indicators flasher (17) located on the utilities holder plate, under the saddle; Relays located on the utilities holder plate, under the saddle; Electric fan relay (14);...
  • Page 360 ELECTRICAL SYSTEM Lambda sensor (18); Headlamp (20) with twin halogen bulb of 12V-60/55W and parking light bulb of 12V-5W; - The tail light (21) is a LED light; Turning indicators (22) 12V-10W bulb; Fuel pump (19) inside the fuel tank. Part.
  • Page 361: Wiring Diagram

    ELECTRICAL SYSTEM WIRING DIAGRAM For a description of wires, please see page M.5. CHARGING SYSTEM The alternated current produced by the generator is converted into direct current by the voltage regulator/rectifier. The voltage regulator/rectifier serves a dual purpose: it provides overvoltage protection for the battery and converts alternated current into direct current.
  • Page 362: Charging System Inspections

    ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTIONS Current loss at the battery Remove the saddle (as described in the relevant section) to gain access to the battery. Disconnect the BLUE negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using a meter.
  • Page 363: Generator Inspection

    ELECTRICAL SYSTEM Generator inspection A: Set the meter to the "Impedance" scale and take measurement at 2-way connector to check pick-up. Reading should be: 100 Ohm (+/- 20%) at 20°C B: Set the meter to the "Impedance" scale and check battery charging. Any and all combinations of the three wires should give the following reading: 0.21 Ohm (+/- 15%) at 20 °C C: Check that NONE of the three wires has continuity to ground.
  • Page 364: Generator No-Load Performance

    ELECTRICAL SYSTEM Generator no-load performance 1- Battery charging current 2- RPM Voltage regulator/rectifier inspection The voltage regulator/rectifier (18) incorporates the diodes used to rectify the generator current output. It also incorporates an electronic device that adjusts charging voltage to battery charge: if battery charge is low, charging voltage will be lower.
  • Page 365: Starting System

    ELECTRICAL SYSTEM STARTING SYSTEM Pull in the clutch lever and hold it squeezed until the engine starts. When the starter button is pressed, the starter relay is energised and closes the circuit that connects starter motor and battery. - Clutch microswitch (6); - Ignition switch (8);...
  • Page 366: Starting System Inspection

    ELECTRICAL SYSTEM STARTING SYSTEM INSPECTION Starter motor removal Remove the starter motor as described in Section "F". Starter motor inspection 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 367: Starter Motor Test Curves

    ELECTRICAL SYSTEM STARTER MOTOR TEST CuRvES 1- Output power 2- Torque 3- RPM 4- Light voltage 5- Charging current Starter motor test curves Starter motor maintenance Starter motor maintenance consists in inspecting brushes for wear and checking the electrical and mechanical insulation between stator and rotor. Accurately grease starter motor moving parts with "CASTROL LM GREASE 2".
  • Page 368: Solenoid Starter Inspection

    ELECTRICAL SYSTEM Solenoid starter inspection Remove the saddle as described in Section "E". Loosen screw (2) and remove the cover (1). Disconnect the starter relay connector (3). Disconnect the cables (4) at the battery negative terminal to avoid possible short circuits during disassembly. Disconnect the starter motor and battery positive cable wires at relay end.
  • Page 369: Electronic Ignition System

    ELECTRICAL SYSTEM Electronic ignition system The ignition system is controlled by the ECU. The ignition is an integrated digi- tal electronic ignition system with static timing and advance using intermittent sequential phased electronic fuel injection. This ignition system is composed of a crankshaft position (pick-up) sensor, an ECU, an ignition coil and an inta- ke manifold pressure sensor.
  • Page 370 ELECTRICAL SYSTEM Wiring diagram - Electronic control unit (1) (ECU) - Water temperature sensor (3) - Ignition coil (4) - Fuel pump (5) - Clutch microswitch (6) - Ignition switch (8) - Lambda sensor (9) - Battery (15) - Solenoid starter (16) - Starter motor (17) - Voltage regulator/rectifier (18) - Alternator (19)
  • Page 371: Checking Ignition Coil Windings Resistance

    ELECTRICAL SYSTEM Checking ignition coil windings resistance Remove the fuel tank (as described in Section "D") to gain access to the coil (1). Disconnect the coil connector (2) from the wiring, remove retaining screws (3) and coil (1) and measure resistance in the primary and secondary windings with a meter.
  • Page 372: Electronic Control Unit (Ecu)

    ELECTRICAL SYSTEM C: terminal cap resistance: 5 KOhm (+/- 10%) at 20 °C. If resistance is outside the specified limits, replace the cap. NOTE: The area where the coil is secured must be totally free from oxide and paint. A faulty ground contact will damage the coil and cause ignition problems. Electronic control unit (ECu) Remove the saddle as described in Section "E"...
  • Page 373: Spark Plug

    ELECTRICAL SYSTEM Spark plug Check electrode gap "A" (0.7 mm) of spark plug (1). 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 374: Gear Position Sensor Inspection (Gps: Gear Position Sensor)

    ELECTRICAL SYSTEM Gear position sensor inspection (GPS: Gear Position Sensor) Set the meter to the “Ohm” scale and disconnect the alternator six-way connector (1) from the main wiring harness. Touch one meter probe to engine ground and insert the other probe into the connector hole for the WHITE/BLACK gear sensor wire (2).
  • Page 375: Battery

    ELECTRICAL SYSTEM Battery The sealed battery does not require any maintenance. Replace the battery in the event of electrolyte leaks. If the vehicle remains unused for long periods, it is recommended to discon- nect the battery from the electrical system and store it in a dry place. - After an intensive use of the battery, it is advisable to carry out a standard slow charging cycle (12V-14Ah battery: 1.4A for 10 hours).
  • Page 376 ELECTRICAL SYSTEM The battery contains sulphuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. After milk, take ma- gnesia, beaten eggs or vegetable oil. Immediately call a doctor. Eyes: Flush with water for no less than 15 minutes and get prompt medi- cal attention.
  • Page 377: Headlight Adjustment

    ELECTRICAL SYSTEM HEADLIGHT ADJuSTMENT When checking the proper aiming of the headlight beam: inflate tyres at the right pressure, have a person sit astride the motorcycle and set the motor- cycle perpendicular to its longitudinal axis at 10 m from a wall or screen. Then trace a horizontal line at the height of headlight centre and a vertical one, in line with vehicle longitudinal axis.
  • Page 378: Headlamp Bulbs Replacement

    ELECTRICAL SYSTEM Headlamp bulbs replacement Proceed as follows to reach the headlamp bulbs: - pull out the front fairing (1) to remove it; - loosen the three screws (2) and remove the headlamp (3); - detach connector (4) from the bulb; - slide off the rubber gaiter (5);...
  • Page 379 ELECTRICAL SYSTEM To replace the parking light bulb (8) extract it from the inside cover. After replacement, reassemble any removed parts making sure to set the centre of side screws (2) at the notch (C) on the support. H01177 M.28 Part.
  • Page 380: Tail Light Replacement

    ELECTRICAL SYSTEM Tail light replacement Remove the tail light as follows: - Loosen the two screws (1) under the rear mudguard. - Extract the tail light (2) and disconnect the connector (3). Once the tail light has been replaced, reverse the above procedure to reas- semble.
  • Page 381: Turning Indicator Bulb Replacement

    ELECTRICAL SYSTEM Turning indicator bulb replacement Loosen the screw (1) with a Phillips screwdriver. Remove the lens (2) Remove the bayonet-style bulb (3); push in and turn bulb to remove. Once the bulb has been replaced, reverse the removal procedure to reas- semble.
  • Page 382: Front Turning Indicator Removal

    ELECTRICAL SYSTEM Front turning indicator removal Remove headlamp cover and headlamp as described in the relevant para- graph. Disconnect connector (1), left turning indicator, connector (2) and right turning indicator. Loosen the screws (3) using an 8 mm Allen wrench on the outside and a 10 mm wrench on the inside and then remove the turning indicators (4).
  • Page 383: Number Plate Light Removal

    ELECTRICAL SYSTEM Number plate light removal Remove the tail light as described in the relevant paragraph Detach the rubber gaiter (1) and extract the turning indicator and number plate cables. Disconnect the two connectors (2). Use a 4 mm Allen wrench on the outside and an 8 mm ring wrench on the inside to loosen the screw (3), remove the tail light (4) and extract the bulb (5) together with its bulb holder.
  • Page 384: Number Plate Holder Removal

    ELECTRICAL SYSTEM Number plate holder removal Remove the tail light as described in the relevant paragraph Detach the rubber gaiter (1), extract the turning indicator, tail light and number plate light cables (2) and disconnect them. Loosen the two screws (3) using an 8 mm Allen wrench and remove the number plate holder (4) together with the turning indicators.
  • Page 385: Left-Hand Switch

    ELECTRICAL SYSTEM Left-hand switch High beam flasher (self-cancelling) High beam switch Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling) To deactivate the turning indicators, press the control lever after it is returned to the centre. Horn. G-Bk Colour coding key B ....
  • Page 386: Right-Hand Switch

    ELECTRICAL SYSTEM Right-hand switch 1. Engine start button 2. Engine start/stop switch H01040 Bk-Br Y-Sb H01041 Colour coding key B ....Blue Br ....Brown Br-Bk ..... Brown-Black Y-Sb ....Yellow-Sky blue Part. N. 8000 H2051 (02-2010) M.35...
  • Page 387: Fuses

    ELECTRICAL SYSTEM FuSES • When you find a blown fuse (1), always investigate and eliminate the cau- se 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 388: Connectors

    ELECTRICAL SYSTEM CONNECTORS • When connecting a connector, push until you hear a click. • Check connector for signs of corrosion or dirt and inspect its cover for damage. COuPLERS • When working with lock-type couplers, make sure to release the lock befo- re disconnecting and push coupler fully in when connecting it.
  • Page 389 Note: The RPM function seen on the vertical bar indicator is ALWAYS active. Functions of the GREEN warning light (4)“NEuTRAL” in case of FuEL INJECTION SYSTEM malfunction (contact your local HuSQvARNA Dealer) a) With the GEARBOX NOT in NEuTRAL position: the warning light FLASHES INTERMITTENTLY.
  • Page 390 ELECTRICAL SYSTEM 1- SPEED (kmh or mph) / ODO / RPM (figure 1) SPEED: vehicle speed - maximum value: 299 kmh or 299mph; ODO: odometer- maximum value: 99999 km or 62136.5 mi; RPM: engine r.p.m. shown on the vertical bar indicator. To change unit from kilometres to miles or miles to kilometres, proceed as follows: 1) set to figure 1, place the ignition key in the OFF position and push the...
  • Page 391 ELECTRICAL SYSTEM 4- SPEED / TRIP 1 / RPM (figure 4) - SPEED: speed - maximum value: 299 kmh or 299 mph; - TRIP 1: distance - maximum value: 999.9 km or 621,31 mi (data will be lost after disconnecting the battery). Resetting the STP 1 also resets the TRIP 1 and AVS 1 data.
  • Page 392 ELECTRICAL SYSTEM 7- SPEED / V MAX / RPM (figure 7) - SPEED: speed - maximum value: 299 kmh or 299mph; - V MAX: Shows the maximum speed reached by the vehicle, in kmh or mph. Maximum value: 299 kmh or 299 mph. To set to zero V MAX, push the knob SCROLL (A) for more than 3 seconds;...
  • Page 393: 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 "Checking generator stator windings resistance");...
  • Page 394: Wiring

    ELECTRICAL SYSTEM Wiring 1 Horn 2 Voltage regulator 3 Electronic control unit 4 Main wiring harness 5 Rear wiring harness :Turning indicators :Tail light :Number plate light 6 Relay 7 Turning indicator flasher 8 Fuses 9 Solenoid starter 10 Rollover sensor (SMS) Part.
  • Page 395: Cable Routing And Electrical Parts Installation Instructions

    ELECTRICAL SYSTEM Cable routing and electrical parts installation instructions • Coil position and connector connection Connect the HT coil (1) as shown in the figure Secure the main wiring harness ground to screw (A). Secure the engine ground to screw (B) Connect connector (C) to the main wiring harness.
  • Page 396: Electronic Control Unit Position

    ELECTRICAL SYSTEM • Electronic control unit position (10) Mounted on flexible mount under the saddle H01439 • Voltage regulator position (11) Coat voltage regulator with heat grease. • Securing the starter motor/solenoid starter cable Connect the starter motor/solenoid starter cable (12) as shown in the figure. •...
  • Page 397: Wiring Connection To Voltage Regulator

    ELECTRICAL SYSTEM • Wiring connection to voltage regulator Connect connector (14) to the regulator and tighten the ground cable (15) to the regulator retaining screw. • Electric fan connection Connect the electric fan connector (16). • Injector connection Connect the connector (17) to the throttle body. •...
  • Page 398: Lambda Sensor Position And Connector

    ELECTRICAL SYSTEM • Lambda sensor position and connector Tighten the Lambda sensor (20) into its seat. Connect the Lambda sensor connector (21) as shown. • Ignition switch and left-hand switch connection Connect the ignition switch (22) and left-hand switch (23) connec- tors as shown.
  • Page 399: Ignition And Gear Sensor Cable Connection

    ELECTRICAL SYSTEM • Ignition and gear sensor cable connection Connect the ignition (25) and gear sensor (26) connectors as shown. • Rear stop connection Connect the wiring connector (27) to the rear STOP sensor. • Securing the handlebar wiring harness Strap wiring to handlebar with rubber clips as shown in the figure.
  • Page 400: Securing The Dashboard Bracket Connectors

    ELECTRICAL SYSTEM • Securing the dashboard bracket connectors Secure dashboard connector (35) and diagnostic connector (36) using the suitable clip. Fit the cap to the diagnostic connector (36). • Headlamp, front turning indicators, STOP light connection Connect the headlamp unit to the matching connector. Connect the connectors (39) to the turning indicators.
  • Page 401: Securing The Gear Sensor, Lambda Sensor, Stop Micro Switch Cables

    ELECTRICAL SYSTEM • Securing the wiring harness Strap main wiring harness to chassis with clips (6). • Securing the gear sensor, Lambda sensor, Stop micro switch cables. Strap the gear sensor cable (7) to the clutch hose (8) with clips (9) Strap the Lambda sensor cable (10) to the wiring harness with clip (11).
  • Page 402: 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 404: Engine Cooling

    ENGINE COOLING Section Part. N. 8000 H2051 (02-2010)
  • Page 405 ENGINE COOLING Coolant level check ..................N.3 Cooling circuit ....................N.4 Engine cooling system overhaul ..............N.5 Part. N. 8000 H2051 (02-2010)
  • Page 406 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 407 ENGINE COOLING Cooling circuit To head To cylinder on left-hand side To cylinder on right-hand side The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Fitting Water pump...
  • Page 408 ENGINE COOLING Engine cooling system overhaul (TC) 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. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected.
  • Page 410: Hydraulically Controlled Clutch

    HYDRAULICALLY CONTROLLED CLUTCH Section Part. N. 8000 H2051 (02-2010)
  • Page 411 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 Part. N. 8000 H2051 (02-2010)
  • Page 412: Hydraulic Clutch System

    HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system The hydraulic circuit is composed of a master cylinder (1) with its reservoir located on the left side of the handlebar, and a piston (5) installed on the left crankcase half. The clutch is disengaged by the piston (5) that actuates the pushrod (4) to operate the pressure plate (6).
  • Page 413: Draining Clutch Fluid

    HYDRAULICALLY CONTROLLED CLUTCH Draining clutch fluid - Remove cap "A". - Connect a plastic hose to the bleed valve (1) and 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.
  • Page 414: 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 415: 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: NEVER use brake fluid. Remove screws (1), cover (2) and rubber diaphragm;...
  • Page 416 HYDRAULICALLY CONTROLLED CLUTCH Check that fluid level is not lower than 4 mm below the upper edge (A) of master cylinder body. Refit any parts you have removed. Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure. Hydraulic fluid is corrosive.
  • Page 418: Optional Components

    OPTIONAL COMPONENTS Section Part. N. 8000 H2051 (02-2010)
  • Page 419 OPTIONAL COMPONENTS OPTIONAL COMPONENTS (TE) Pos. Part No. Description 8A00A8006 CENTRE STAND ASSEMBLY (1) 8A0078466 ROTATION BUSHING (1) 800060898 SCREW TTEI M6x1-CH5 L15 (1) 800030319 WASHER D20-D6.4-THK2.5 (1) 800098910 STAND RETURN SPRING (1) 800048802 RUBBER BLOCK (2) 8B0096837 *CHAIN SPROCKET Z=48 (1) 8A0096837 *CHAIN SPROCKET Z=47 (1) 800096837...
  • Page 420 OPTIONAL COMPONENTS Part. N. 8000 H2051 (02-2010)
  • Page 422: Fuel Injection System

    FUEL INJECTION SYSTEM Section Part. N. 8000 H2051 (02-2010)
  • Page 423 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM .................S.3 Operation Manual for "DIAGNOSTIC TOOL SOFTWARE KIT" for fuel injection system ................S.4 Fuel pump test ....................S.6 Relay test .....................S.7 Part. N. 8000 H2051 (02-2010)
  • Page 424 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM The fuel injection system is composed of fuel tank (1), electric pump (2), pipe (3) and injector (4). The fuel in the tank is pumped by the pump. The pressurised fuel flows into the injector installed on the throttle body (6). The electronic control unit (5) located under the saddle signals the injector to open and a fan-shaped spray of fuel is injected into the combustion chamber.
  • Page 425 FUEL INJECTION SYSTEM Operation Manual for "DIAGNOSTIC TOOL SOFTWARE KIT" for fuel in- jection system. The fuel injection system does not require scheduled maintenance. The DIAGNOSTIC TOOL SOFTWARE KIT part no. 8A00 A9634 lets you test system components in the event of a malfunction. A malfunction is indicated by the word "FAIL"...
  • Page 426 FUEL INJECTION SYSTEM If the throttle body (H) has been removed and/or replaced, the TPS will need to be re-initialised using options "TPS idle setting" (see Operation Manual) and "Feedback Correction" (Operation Manual). For "Feedback Correction Value", see fig. 9-3-4 on page S.6. This diagnostic software can check the following injection para- meters: AIR TEMPERATURE (air temperature in the intake manifold);...
  • Page 427 FUEL INJECTION SYSTEM In addition to identifying any current malfunction, the software sto- res past malfunctions that have been resolved: store malfunctions can be deleted following the instructions provided in the Operation Manual. The ECU stores the number of service hours of the engine (tolerance range: + / - 1 hour).
  • Page 428 FUEL INJECTION SYSTEM Fuel pump inspection Remove the pump as described on page S.2. fuel reserve sensor Make sure there is no fuel left in the sensor and then set the meter to the "Impedance" scale and measure across contacts T3 and T4. Correct value is as follows: 1.3 KOhm (+/- 10%) at 20 °C.
  • Page 429 FUEL INJECTION SYSTEM Relay test Remove cover of saddle and utilities as described in "Section E". Remove the relays (1) located on the utilities holder plate. A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.
  • Page 430: Special Tools

    SPECIAL TOOLS Section Part. N. 8000 H2051 (02-2010)
  • Page 431 SPECIAL TOOLS SPECIAL TOOLS (8000 89743) Crankcase puller (8000 39523) Flywheel puller (8000 90662) Engine jig (8000 A8072) Flywheel removal tool (8000 A1625) Dial gauge mount 10 (8A00 H1387) Diagnostic CD 12 (8000 39521) Valve installation / removal tool 13 (1519 84701) Spring hook 14 (8000 39524) Clutch hub tool...
  • Page 432: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent. Part. N. 8000 H2051 (02-2010)
  • Page 433 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) ENGINE (8000 H1759) Engine/Cylinder-Head Motore/Manovellismo Motore/Trasmissione Motore/Distribuzione Motore/Basamento 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 434 TIGHTENING TORQUE FIGURES Engine/Lubrication System Engine/Electrical System Engine/Clutch Engine/Gear shift control Engine/Cooling System 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 435 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) CHASSIS (93909) 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows M5x0.8 5.6-6.2 Nm 0.57-0.63 Kgm 4.1-4.5 ft/lb M6x1 7.6-8.4 Nm 0.80-0.85 Kgm 5.8-6.1 ft/lb M8x1.25 24-26 Nm 2.4-2.6 Kgm 17.3-18.8 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 436 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) HANDLEBAR AND CONTROLS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) FRONT SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 437 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) REAR SUSPENSION (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 438 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FAIRINGS AND MUDGUARDS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) ELECTRICAL SYSTEM (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 439 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) FUEL SYSTEM (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) WHEELS AND BRAKES (99669) 1 Nm = 0.73756 ft/lb Part. N. 8000 H2051 (02-2010)
  • Page 440 TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES (+/- 5%) EXHAUST (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) INSTRUMENTS (99669) 1 Nm = 0.73756 ft/lb TIGHTENING TORQUE FIGURES (+/- 5%) COOLING SYSTEM (99669) 1 Nm = 0.73756 ft/lb Part.
  • Page 441 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 M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb Steel screws on plastic, with metal spacers 4 Nm 0.4 Kgm 3 ft/lb Steel screws on brass, copper, aluminium M5 4 Nm 0.4 Kgm...
  • Page 442: Chassis And Wheels

    CHASSIS AND WHEELS Section Part. N. 8000 H2051 (02-2010)
  • Page 443 CHASSIS AND WHEELS Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Front wheel ....................Y.5 Front wheel removal ..................Y.6 Front wheel installation ................. Y.7 Rear wheel ....................Y.8 Rear wheel removal..................Y.9 Wheel servicing ..................Y.10 Wheel axle warpage ................... Y.10 Axle runout over 100 mm ................
  • Page 444: 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. Part. N. 8000 H2051 (02-2010)
  • Page 445: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS Lubrication points (lubricant) 1 Steering bearings (grease) Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING BOLTS AND BRACKETS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER/BEARING D FOOTPEGS/PINS/SPRINGS E PASSENGER GRAB HANDLES Part.
  • Page 446: Front Wheel

    CHASSIS AND WHEELS Front wheel Light alloy wheel hub and rim with high-strength steel spokes. RIMS Front (TE) ........in light alloy: 1.6”x21” Front (SMS) ....... in light alloy: 3.50”x17” TYRES Front (TE) ..........90/90x21” (SMS) ........120/70x17” COLD TYRE PRESSURE (TE) Front Rider only ........
  • Page 447 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. SMS: Remove the screws (A) and the brake calliper. Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts. Hold the head of the wheel axle in place, and unscrew the bolt (3) on the opposite side;...
  • Page 448 CHASSIS AND WHEELS Reassembling the front wheel Fit the L.H. spacer (D) on the wheel hub. (TE) Fit the wheel between the fork legs so as to set the brake disc into the calliper. FINAL RATIOS (SMS) Fit the wheel between the fork legs. Fit the wheel axle (2) from the R.H.
  • Page 449: Rear Wheel

    CHASSIS AND WHEELS Rear wheel Light alloy wheel hub and rim with high-strength steel spokes. RIMS Rear (TE) ........in light alloy: 2.15”x18” Rear (SMS) ........ in light alloy: 4.25”x17” TYRES Rear (TE) ..........140/80x18” (SMS) ........150/60x17” COLD TYRE PRESSURE (TE) Rear Rider only ........
  • Page 450 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. Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...
  • Page 451: 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 452: 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 453: 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 454: Checking Chain And Sprockets For Wear

    CHASSIS AND WHEELS Checking chain and sprockets for wear Check chain wear as follows: turn the adjuster screws to stretch the chain taut; mark 20 chain links; measure distance “A” (centre distance between 1st and 21st link). Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

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