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Husqvarna 2009 TE 310 Workshop Manual

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Table of Contents
Workshop Manual
TE 250-310-450-510/2009-I.E.,
TC 250-450-510/2009,
TXC 250-450-510/2009
,
(only USA)
SMR 450-510 2009-I.E.
Part. N. 8000 H0368 (09-2008)

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Table of Contents
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  Also See for Husqvarna 2009 TE 310

  Summary of Contents for Husqvarna 2009 TE 310

  • Page 1 Workshop Manual TE 250-310-450-510/2009-I.E., TC 250-450-510/2009, TXC 250-450-510/2009 (only USA) SMR 450-510 2009-I.E. Part. N. 8000 H0368 (09-2008)
  • Page 2 To the best knowledge of HUSQVARNA MOTORCYCLES S.R.L. - Varese, Inc. the material contained herein is accurate as of the date this pubblication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for demonstration purposes and could not exactly match the detail described.No part of this manual can de reproduced without permission...
  • Page 3: Workshop Manual

    Workshop Manual TE 250-310-450-510/2009-I.E., TC 250-450-510/2009, TXC 250-450-510/2009 (only USA) SMR 450-510/2009-I.E. Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Servizio Assistenza Tecnica Via Nino Bixio, 8 21024 Biandronno (Varese) - Italy tel. ++39 0332 75.61.11 fax ++39 0332 756 558 www.husqvarna-motorcycles.com...
  • Page 4 Additional information concerning the operation under way. Useful suggestions HUSQVARNA suggests, in order to prevent troubles and in order to have an excellent final result, to generically comply with the following instructions: – in case of repair work, weigh the impressions of the Customer who complains about the improper operation of the motorcycle, and formulate proper clearing questions about the symptoms of the trouble.
  • Page 5: Table Of Contents

    FOREWORD, SUMMARY Summary Chapter Section Foreword, summary ............Important notices ............General ................. Maintenance ..............Troubles and remedies ..........Settings and adjustments ..........General operations ............Engine disassembly ............Engine overhauling ............Engine re-assembly ............Front suspension ............Rear suspension ............Brakes ................
  • Page 6 FOREWORD, SUMMARY Part. N. 8000 H0368 (09-2008)
  • Page 7: Important Notices

    IMPORTANT NOTICES Section Part. N. 8000 H0368 (09-2008)
  • Page 8 IMPORTANT NOTICES 1) The TC and TXC models are guaranteed COMPETITION motorcycles exempt from functional defects, the suggested maintenance table for competition use is shown on chapter B. 2) TE and SMR are STREET LEGAL motorcycles (with LIMITED POWER ENGINE); they are guaranteed exempt from functional defects and covered with legal guarantee, if the STANDARD CONFIGURATION is maintained and the suggested maintenance table, shown on chapter B, is observed.
  • Page 9 B by carrying out maintenance checks at authorized HUSQVARNA dealers. The cost for substituting parts and for the labour necessary in order to respect the maintenance plan, is charged to the client. The guarantee is EXTINGUISHED in the case where the motorcycle is rented.
  • Page 10 IMPORTANT NOTICES Part. N. 8000 H0368 (09-2008)
  • Page 11: General

    GENERAL Section Part. N. 8000 H0368 (09-2008)
  • Page 12 GENERAL Engine ................Timing system ..............Fuel feeding ..............Lubrication ..............Cooling ................Ignition ................Starting ................Transmission ............A.4-A.5 Frame ................Suspensions ..............Brakes ................Wheels ................Tires ................Ignition system- electric system ........Weights ................Overall dimensions ............Capacities ...............
  • Page 13: Timing System

    GENERAL ENGINE 4-stroke, single cylinder Bore (250) ..................2.99 in. Bore (310) ..................3.27 in. Bore (450- 510) ................3.81 in. Stroke (250-310) ................2.17 in. Stroke (450) ..................2.39 in. Stroke (510) ..................2.67 in. Displacement (250) ..............15.22 cu. in. Displacement (310) ..............
  • Page 14: Transmission

    GENERAL TRANSMISSION Multi-plate clutch in oil bath, hydraulic control 5-speed (TC) or 6-speed (TE-SMR-TXC) gearbox, constant mesh gear type Drive between engine and gearbox main shaft by straight toothed Primary drive Drive pinion gear (TC 250) ..........z 20 Drive pinion gear (TE-TXC 250, TE 310) ....... z 24 Drive pinion gear (450-510) ...........
  • Page 15 GENERAL Total drive ratios 4th gear (TE-TXC 250, TE 310) ........ 15.329 1st gear (TE-TXC 250, TE 310) ........ 28.205 4th gear (TE-TXC 450-510) ........10.764 1st gear (TE-TXC 450-510) ........19.806 4th gear (TC 250) ............. 15.172 1st gear (TC 250) ............26.055 4th gear (TC 450) ............
  • Page 16: Frame

    GENERAL FRAME Steel single tube cradle (round, rectangular and ellipsoidal tubes, branching off into two parts approximately at the exhaust level), rear frame in light alloy Forward travel (in.) .............. 4.17 (TE-TXC); 4.10 (TC); 3.27 (SMR) SUSPENSIONS Front “MARZOCCHI” Overturned forkrod telehydraulic fork with advanced pin; forkrods 1.97 in. diameter; hydraulic brake adjustment both in compression and extension Axle travel on leg axis (in.) ..........
  • Page 17 GENERAL ELECTRICAL COMPONENTS LOCATION (TE-SMR) The ignition system includes the following elements: - Generator, in oil bath, on the inner side of L.H. crankcase cover; - Electronic ignition coil under the fuel tank; - Electronic power unit C.D.I. under the fuel tank; - Voltage regulator under the fuel tank;...
  • Page 18 GENERAL DIMENSIONS mm- WEIGHTS (§) TE 250-310 ....kg 107/ lb 235.89 TC 250 .....kg 100 /lb 220.46 TE 450 .....kg 112/ lb 246.92 TC 450 .....kg 104,5 / lb 230.38 TE 510 .....kg 112/ lb 246.92 TC 510 .....kg 105 / lb 231.49 TXC 250 .....kg 104,7 / lb 230.82 SMR 450 ....kg 120,5 / lb 265.66 TXC 450 .....kg 110 / lb 242.51...
  • Page 19: Capacities

    GENERAL CAPACITIES TYPE QUANTITY Fuel tank (reserve included) Unleaded gasoline (98 R.O.N.) 1.58 Imp. Gall./ 1.9 U.S. Gall. Fuel reserve 1.58 Imp. Qt./ 1.9 U.S. Qt. Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.5 Imp. Qt./ 1.8 U.S. Qt. (oil and oil filter replacement) Change gear and main transmission oil AGIP RACING 4T (SAE 10W60)
  • Page 20 GENERAL A.10 Part. N. 8000 H0368 (09-2008)
  • Page 21: Maintenance

    MAINTENANCE Section Part. N. 8000 H0368 (09-2008)
  • Page 22 MAINTENANCE PRE -DELIVERY INSPECTION Description Operation Pre-delivery Engine oil Check level Coolant Check / Restore level Cooling system Check for leakage Elettroventole (TE-SMR) Controllo funzionamento Spark plugs Check / Replace Throttle body / Carburettor Check and adjust Brakes / Clutch fluid Check level Brakes / Clutch Check operation...
  • Page 23 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE TC 450, 510; TE-TXC 250, 450, 510-2009; (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TE 310-2009 COMPETITION MOTORCYCLE, RACING USE: COUPON COUPON COUPON COUPON COUPON with FULL POWER ENGINE AFTER FIRST EVERY EVERY EVERY EVERY EVERY...
  • Page 24 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TC 450, 510; TE-TXC 250, 450, 510-2009; TE 310-2009 COMPETITION MOTORCYCLE, RACING USE: COUPON COUPON COUPON COUPON COUPON with FULL POWER ENGINE AFTER FIRST EVERY EVERY EVERY EVERY EVERY...
  • Page 25 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE TC 450, 510; TE-TXC 250, 450, 510-2009; (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) TE 310-2009 COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ENGINE COUPON COUPON COUPON COUPON COUPON AFTER FIRST EVERY EVERY EVERY EVERY EVERY...
  • Page 26 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2009; TE 310-2009 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM...
  • Page 27 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2009; TE 310-2009 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM...
  • Page 28 MAINTENANCE PERIODIC MAINTENANCE SCHEDULE (SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES) SMR 450, 510 - TE 250, 450, 510 / 2009; TE 310-2009 AFTER FIRST EVERY EVERY - STANDARD MOTORCYCLE, STREET LEGAL (with LIMITED 1000 KM 5000 KM 10000 KM...
  • Page 29: Troubles And Remedies

    TROUBLES AND REMEDIES Section Part. N. 8000 H0368 (09-2008)
  • Page 30 TROUBLES AND REMEDIES ENGINE Trouble Cause Remedy Engine don’t start or starts Inadequate compression with difficulty 1. Piston seizure Replace 2. Con-rod small or big end seized Replace 3. Piston rings worn Replace 4. Cylinder worn Replace 5. Low torque cylinder head nuts Tighten 6.
  • Page 31 TROUBLES AND REMEDIES Trouble Cause Remedy Clutch noise 1. Discs worn Replace 2. Excesive free play between clutch drum and driving discs Replace Gearbox noise 1. Gears worn Replace 2. Gear splines worn Replace Rear transmission chain noise 1. Chain stretched or badly adjusted Replace or adjust 2.
  • Page 32 TROUBLES AND REMEDIES FRAME, WHEELS AND SUSPENSION Trouble Cause Remedy Difficult to turn handlebars 1. Low tire pressure Inflate Steering head bearings’ adjustment ring nut or steering stem nut too tight Adjust 3. Bent steering head stem Replace steering bracket 4.
  • Page 33 TROUBLES AND REMEDIES ELECTRICS (see also chapter M) Trouble Cause Remedy Spark plug becomes dirty 1. Mixture too rich Adjust carburettor too frequently 2. Air filter dirty Clean 3. Piston rings worn Replace 4. Piston or cylinder worn Replace Spark plug overheats 1.
  • Page 34 TROUBLES AND REMEDIES Part. N. 8000 H0368 (09-2008)
  • Page 35: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS Section Part. N. 8000 H0368 (09-2008)
  • Page 36 SETTINGS AND ADJUSTMENTS Adjustment of valves play ......... Adjustment of starter decompression device ..... Throttle cable adjustment .......... Carburettor adjustment (TC, TXC) ......Idle adjustment (TC, TXC, SMR 450-R) ....Idle adjustment (TE, SMR) ........Clutch discs replacement (TC, TE, TXC, SMR) ..D.10 Adjustment of the control lever and check of the clutch fluid level ...........
  • Page 37 SETTINGS AND ADJUSTMENTS TC-TXC Part. N. 8000 H0368 (09-2008)
  • Page 38 SETTINGS AND ADJUSTMENTS Adjusting the valve play To check the valve clearance, proceed as follows , WITH COLD ENGINE: First turn counterclockwise fastening rear pin (1) then remove the saddle. HOW TO REMOVE THE TANK (TC, TXC) Close the fuel tap (2) and loosen the strap (3) on the connecting pipe to the carburettor, pull the pipe out of the carburettor.
  • Page 39 SETTINGS AND ADJUSTMENTS HOW TO REMOVE THE TANK (TE-SMR) Remove the screws (1) and the side panels. Remove the locking screw (A) of the tank. Lift the tank, then disconnect the connector of the fuel pump from the main cabling. Disconnect the feeding pump (B) from the outlet coupling (C) on the fuel pump in the lower back section of the tank.
  • Page 40 SETTINGS AND ADJUSTMENTS PROCEDURE APPLYING TO ALL THE MODELS Remove the spark plug (5), the four cylinder head cover fastening screws (6) and the cylinder head cover. Engage second gear and, moving the vehicle forwards and backwards, bring the piston to Top Dead Center (in this condition , the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as illustrated in the figure).
  • Page 41: Adjustment Of Starter Decompression Device

    SETTINGS AND ADJUSTMENTS Adjustment of starter decompression device In order to adjust the lever decompressor free play (approximately 3 mm - 0.12 in.): should the clearance be incorrect, unblock the counter ring-nut and turn the adjusting screw (by unscrewing it, the clearance is reduced, while by screwing screw it is increased);...
  • Page 42: Throttle Cable Adjustment

    SETTINGS AND ADJUSTMENTS Throttle cable adjustment To check the correct adjustment of the throttle operate as follows: - remove the upper rubber cap (1); - by moving cable (2) back and forth check for 2 mm (0.08 in.) clearance; - should the clearance be incorrect, unblock the counter ring-nut (3) and turn the adjusting screw (4) (by unscrewing it, the clearance is reduced, while by screw- ing screw (4) it is increased);...
  • Page 43: Carburettor Adjustment (Tc, Txc)

    SETTINGS AND ADJUSTMENTS Carburettor adjustment (TC, TXC) Adjust the carburettor with warm engine and with the throttle in closed position. Work as follows: - turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).
  • Page 44: Clutch Discs Replacement (Tc-Te-Txc-Smr)

    SETTINGS AND ADJUSTMENTS Clutch discs replacement (TC-TE-TXC-SMR) This operation can be carried out by laying the motorcycle on the left side with- out draining the engine oil. Remove the five fastening screws (1) and the clutch cover (if necessary, lower the rear brake control pedal). Use a 5 mm allen wrench to loosen the six screws (2) that fasten clutch springs.
  • Page 45: Adjustment Of The Control Lever And Check Of The Clutch Fluid Level

    SETTINGS AND ADJUSTMENTS Adjustment of the control lever and check of the clutch fluid level Free play (A) must be at least 3 mm (0.1 in.). The lever position can be adjusted for any driver hand size. To decrease the lever distance from the handle grip, rotate the adjuster (B) CLOCKWISE.
  • Page 46: Adjustment Of Front Brake Control Lever And Fluid Level Control (Te-Tc-Txc- Smr)

    SETTINGS AND ADJUSTMENTS Adjustment of front brake control lever and fluid level control (TE-TC-TXC- SMR) On the SMR model the lever position can be adjusted (4 adjustments) for any driver hand size. To decrease the lever distance from the handle grip, turn the adjuster (B) CLOCKWISE.
  • Page 47: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS Rear brake pedal position adjustment The position of the rear foot brake pedal as to the footrest may be adjusted according to the individual needs. For the adjusting proceed as follows: - loosen the screw (1); - turn the cam (2) in order to adjust the brake pedal idle stroke (A); - the operation done, tighten the screw (1).
  • Page 48: Rear Brake Idle Stroke Adjustment

    SETTINGS AND ADJUSTMENTS Rear brake idle stroke adjustment The rear brake foot pedal should have a (B) 5 mm (0.2 in.) idle stroke before starting the true braking action. Should this not happen proceed as follows: - loosen nut (3); - operate the pump rod (4) to increase or decrease the idle stroke;...
  • Page 49: Checking The Engine Oil Level

    SETTINGS AND ADJUSTMENTS Checking the engine oil level By keeping the motorcycle on a flat surface, in vertical position, remove the control screw (1) and check the oil should just barely escape from the hole on the R.H. cover. To fill up, remove the filler cap (2). : Have this operation made with warmed-up engine.
  • Page 50: Engine Oil Replacement And Bag Filters-Cartridge Filter Cleaning Or Replacement

    SETTINGS AND ADJUSTMENTS Engine oil replacement and bag filters-cartridge filter cleaning or replace- ment Drain the oil with WARM ENGINE; proceed as follows: - remove oil filler cap (2); - even if not necessary, remove the engine guard (A); - place an oil drain pan under the engine block; - remove the oil drain cap (3), drain the used oil completely then clean the mag- net on the cap;...
  • Page 51: 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, on TE and SMR models, it doesn’t exceed the middle of the expansion tank (2) located in front of the rear shock absorber.
  • Page 52: Air Filter Check (Tc-Txc)

    SETTINGS AND ADJUSTMENTS Air filter check (TC-TXC) Turn rear pin (1) counterclockwise, remove it and release the saddle from the front fastening screw. TXC: Take out the battery (A) and place it sideways on the vehicle. To gain access to the air filter, lift a little the electronic power unit (2). Remove screw (3) and the filter (4).
  • Page 53: Air Filter Check (Te-Smr)

    SETTINGS AND ADJUSTMENTS ASSEMBLY To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece (A) is turned upwards and edge (B) is on the left lower side of the filter case. Reassemble the parts previously removed (battery: connect the positive cable first).
  • Page 54 SETTINGS AND ADJUSTMENTS AIR FILTER AND CLEANING Wash filter with a specific detergent (AGIP” Filter clean foam air detergent fluid” or similar) then dry it fully (wash filter with gasoline only in case of necessity). Plunge filter in special oil for filters (AGIP "Foam air filter protection oil" or simi- lar), then wring it to drain superfluous oil.
  • Page 55: Secondary Transmission Chain Adjustment

    SETTINGS AND ADJUSTMENTS Fig. B Secondary transmission chain adjustment Chain should be checked, adjusted and lubricated as shown on the Mainte- nance Chart (page B.5-B.8) to ensure security and prevent excessive wear. If the chains becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taught), it could escape from sprocket or break.
  • Page 56: Lubricating The Transmission Chain

    SETTINGS AND ADJUSTMENTS Lubricating the chain 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 hepl to rapidly wear out the chain, the sprocket, and the crown.
  • Page 57: Adjusting The Suspensions According To Particular Track Conditions

    SETTINGS AND ADJUSTMENTS Adjusting the suspensions according to particular track conditions The following information is a useful guide for setting up the suspensions according to the road conditions. Always start from the standard calibration before making any change on the suspensions.
  • Page 58: Adjusting The Shock Absorber

    SETTINGS AND ADJUSTMENTS Adjusting the shock absorber The rear shock absorber must be adjusted according to the rider weight and track conditions. Proceed as follows: 1. With motorcycle on the stand, measure distance (A). 2. Take the normal riding position on the motorcycle with all your riding apparel. 3.
  • Page 59: Adjusting The Shock Absorber Spring Preload

    SETTINGS AND ADJUSTMENTS Adjusting the shock absorber spring preload Follow the instructions below to perform the operation: 1. First turn the fastening rear pin (1) anticlockwise, then remove the saddle, loosen the screws (2) and remove the right side panel (3). 2.
  • Page 60: Shock Absorber Hydraulic Brake Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber hydraulic brake adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard calibration: 1) Low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) High damping speed: -15 clicks (± 2 clicks) (adjuster 3) To reset the standard calibration, turn upper adjusters (1) and (3) clockwise TC-TE-TXC-SMR...
  • Page 61: Adjusting The Front Fork

    SETTINGS AND ADJUSTMENTS Adjusting the front fork a) COMPRESSION (LOWER REGISTER) Standard calibration: -12 clicks (TE-SMR); -15 clicks (TC-TXC). Remove plug (B) and turn register (A) clockwise until the position of fully closed is reached then, turn back by the mentioned clicks.To obtain a smoother braking action, turn the register anticlockwise.
  • Page 62: Front Fork Springs

    SETTINGS AND ADJUSTMENTS Front fork springs STANDARD K=4.5 N/mm (TE; A: spring + spacer code 8000 B1713) K=4.8 N/mm (TXC 250; A: spring + spacer code 8000 B1690) K=5.0 N/mm (TC-TXC 450/510; A: spring + spacer code 8000 B1716) K=5.0 N/mm (SMR; A: spring + spacer code 8000 A7608) TC-TXC TE-SMR D.28...
  • Page 63: Steering Bearings Play Adjustment

    SETTINGS AND ADJUSTMENTS Steering bearings play adjustment To ensure maximum safety, the steering should always be adjusted so that the handlebars rotate freely without play. To check steering adjustment, place kick stand or other support under the engine so that the front wheel is raised from ground.
  • Page 64: Handlebar Position And Height Change (Te-Tc-Txc-Smr)

    SETTINGS AND ADJUSTMENTS Handlebar position and height change (TE-TC-TXC-SMR) The handlebar position (a) and height (b) can be changed for better suiting Your driving requirements. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). a) Handlebar position change Turn the lower clamp (2) 180°...
  • Page 65: Checking The Fuel Hose

    SETTINGS AND ADJUSTMENTS Checking the fuel hose Check the hose (1) for leaks and replace it, if necessary. Remove the fuel hose as shown on page E.23. Part. N. 8000 H0368 (09-2008) D.31...
  • Page 66: Replacing The Muffler Deadening Material (Tc-Te-Txc)

    SETTINGS AND ADJUSTMENTS Replacing the muffler deadening material (TC-TE-TXC) First turn counterclockwise fastening rear pin (1) then remove saddle, screws (2) and L.H. side panel (3). Using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (4) of the muffler.
  • Page 67: Replacing The Muffler Deadening Material (Smr)

    SETTINGS AND ADJUSTMENTS Replacing the muffler deadening material (SMR) Remove the saddle after turning the locking back pin (1) anticlockwise, loosen the screws (2) with an 8-mm T-shaped spanner and remove the side panel (3) (do the same on the right side). Using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (4) of the muffler.
  • Page 68: Checking The Exhaust System

    SETTINGS AND ADJUSTMENTS Checking the exhaust system Remove the exhaust system components as shown on page E.20. Check the exhaust pipe (1), (2), (3), (4) and silencer (5) for wear or damages. Replace the component, if necessary. D.34 Part. N. 8000 H0368 (09-2008)
  • Page 69: General Operations

    GENERAL OPERATIONS Section Part. N. 8000 H0364 (09-2008)
  • Page 70 GENERAL OPERATIONS FOREWORD ............E. 3 REMOVAL OF ENGINE FROM MOTORCYCLE ..E. 4 PARTIAL DISMALTEMENTS Removal of saddle and battery ........E. 15 Removal of side panels ..........E. 16 Removal of rear frame with fender (TE- SMR: with tail light) and air filter box assy ..E.
  • Page 71: Foreword

    GENERAL OPERATIONS FOREWORD The operations described in this section are referred to the removal of the engine from the motorcycle. Nevertheless, in the case is had to effect operations on some parts of the motorcycle (as the access to the rear shock absorber, to the electric parts, to the wiring harness etc.), it can be necessary to effect some partial dismantlements.
  • Page 72: Removal Of Engine From Motorcycle

    GENERAL OPERATIONS Removal of engine from motorcycle 1) Pages E.4-E.5: turn counterclockwise the rear fastening pin (1) and remove the saddle. Loosen the screws (2) and remove the side panels (3) and (4). TE-SMR-TXC: first remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);...
  • Page 73 GENERAL OPERATIONS TC-TXC 2) Remove the breather hose (1) from the steering axle. Turn the ring nut of the fuel tap (2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the carburettor fuel pipe; remove this pipe from the carburettor and pour the remain- ing fuel into a container.
  • Page 74 GENERAL OPERATIONS TE-SMR 2) Remove the vent pipe (1) from the steering pin. Remove the fastening screw (2) from the fuel tank by slightly pressing upward in the front area of conveyors and release the conveyors from spoilers on radiators. Disconnect the fuel pump connector from the main cable.
  • Page 75 GENERAL OPERATIONS 3) TE, TC, TXC: using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw (1) of the muffler (4). Remove the spring (2) and with an 8 mm T-shaped spanner remove the screw (3);...
  • Page 76 GENERAL OPERATIONS 3) SMR: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4). Remove the springs (5) that retain front pipes (6) and (7) to intermediate pipe (8).
  • Page 77 GENERAL OPERATIONS 4) TC-TXC: Loosen the clamps (3) and (4) that fasten the carburetor to the intake manifold and air filter box manifold. Pull back the carburetor to free it from the intake manifold and extract the carburetor from the right side of the motorcy- cle.
  • Page 78 GENERAL OPERATIONS 5) Place a vessel on the right side of the motorcycle, under the coolant draining screw (1). Using a 8 mm wrench, FIRST remove the screw (1) then SLOWLY open the R.H. radiator cap (2); slope the motorcycle on the right side to drain the coolant easily in the vessel.
  • Page 79 GENERAL OPERATIONS 6) Even if not essential, it is advisable to remove the engine lower guard (A) then place a vessel under the engine and remove the oil filler cap (1); using a 8 mm Allen wrench, remove the oil draining plug (2) and eliminate the used oil; on the L.H.
  • Page 80 GENERAL OPERATIONS 7) Remove the cap (1) from the spark plug. Remove the clamp (2) and detach the hose (3) from the cylinder head cover. On the L.H. side, using a 6 mm wrench, remove the rear transmission sprocket cover screws (4) and, using a 6 mm Allen wrench, remove the screws (5) that fasten guide-chain plate.
  • Page 81 GENERAL OPERATIONS 8) TE-SMR: disconnect the cooling fan (1) from the main wiring harness. Detach the thermoswitch (2) from the main wiring harness. Remove the two screws (3) and the coolant expansion tank (4). Part. N. 8000 H0364 (09-2008) E.13...
  • Page 82 GENERAL OPERATIONS 9) For the rear chain disassembling (both of the chain type without O-Rings that with rings O-Rings), remove the clip (1), the master link (2) then the chain. Using a 12 mm wrench on the L.H. side and a 10 mm wrench on the R.H. side, remove the side protections (A) and (B) and then unscrew the fastening bolts (3) (engine-frame).
  • Page 83: Removal Of Saddle And Battery

    GENERAL OPERATIONS Removal of saddle and battery Turn counterclockwise the rear fastening pin (1) and remove the saddle. TE-SMR-TXC: First remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable and then the BLACK negative cable);...
  • Page 84: Removal Of Side Panels

    GENERAL OPERATIONS Removal of side panels Turn rear pin (A) counterclockwise and remove the saddle from the front fasten- ing screw. Loosen the screws (2) and remove the side panels (3) and (4). E.16 Part. N. 8000 H0364 (09-2008)
  • Page 85: Removal Of Rear Frame With Fender

    GENERAL OPERATIONS Removal of rear frame with fender (TE- SMR: with tail light) and air filter box assy. Remove the saddle and disconnect the battery (A) from the electric system as shown on page E.14. Remove the side panels as shown on page E.15. Remove the fuel tank as shown on page E.23.
  • Page 86 GENERAL OPERATIONS SMR: use an 8 mm T-wrench and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4). On the left side disconnect the electric connections from the starting motor [use an 8 mm wrench to remove the earth cable (5) and a 10 mm wrench for the nut under the rubber cap (6)], remove the clamps (A) that hold the clutch pipe and the alternator cable.
  • Page 87 GENERAL OPERATIONS On the right side, remove the clamp (B) from the vent pipe from the filter box; remove the pipe (C) from the cylinder head cover. Disconnect the start remote control switch (7) and the connector of the rear light from the cabling system (TE-SMR).
  • Page 88: Removal Of Exhaust System

    GENERAL OPERATIONS Removal of exhaust system Remove the saddle as shown on page E.15. Remove the R.H. side panel (TE-TC-TXC) or both the side panels (SMR) as shown on page E.16. TE-TC-TXC E.20 Part. N. 8000 H0364 (09-2008)
  • Page 89 GENERAL OPERATIONS TE, TC, TXC: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencer (4). Remove the spring (2) and use an 8 mm T-wrench to remove also the screw (3); then extract the silencer (4). Part.
  • Page 90 GENERAL OPERATIONS 3) SMR: use an 8 mm T-wrench outside and a 10 mm T-wrench inside to remove the fastening screw (1) of silencers (3) and (4). Remove the spring (2) and extract silencers (3) and (4). Remove the clamps (A) that the hold front pipes (6) and (7) to the intermediate pipe (8).
  • Page 91: Removal Of Fuel Tank, Conveyors And Spoiler

    GENERAL OPERATIONS Removal of fuel tank, conveyors and spoiler Remove the saddle as described on page E.15. TC-TXC Remove the vent pipe (1) from the steering pin. Turn the ring nut of the fuel tap (2) anticlockwise to stop fuel flowing and loosen the clamp (3) on the carburettor fuel pipe;...
  • Page 92 GENERAL OPERATIONS TE-SMR Remove the vent pipe (1) from the fuel tank cap. Unscrew the fastening screw (6) of the fuel tank. Remove the screws (4) holding the conveyors to the tank; remove the conveyors (7), the screws (5) holding spoilers (8) to radiators. Re- move the spoilers.
  • Page 93: Removal Of Cooling Fan (Te-Smr), Radiators And Coolant Expansion Tank (Te-Smr)

    GENERAL OPERATIONS Removal of cooling fan (TE-SMR), radiators and coolant expansion tank (TE-SMR) TE-SMR: disconnect the cooling fan (1) from the main wiring harness; remove the fan from its holding plate. Detach the thermoswitch (2) from the main wiring harness. Remove the grid (3), detach the breather hose (4), the other hoses (A) from the radiators, remove the three screws (5) and the R.H.
  • Page 94: Removal Of Electronic Power Unit C.d.i., Electronic Coil, Voltage Regulator And Clutch Hose

    GENERAL OPERATIONS Removal of electronic power unit CDI, ignition coil, voltage regulator and clutch hose Remove: saddle, battery, side panels and fuel tank as shown on pages E.15, E.16, E.23. Remove the connector from electronic power unit CDI (1) and the electronic power unit complete with elastic holder from the frame.
  • Page 95: Engine Disassembly

    ENGINE DISASSEMBLY Section Part. N. 8000 H0368 (09-2008)
  • Page 96 ENGINE DISASSEMBLY Cylinder head cover disassembly ......Camshaft disassembly ..........Water pump body disassembly ......... Cylinder head disassembly ........Valve disassembly ............ Cylinder disassembly ..........F.10 Piston disassembly ........... F.10 Flywheel disassembly ..........F.11 Kick start pedal disassembly (TC, TE, TXC) ....F.12 Transmission cover disassembly ......
  • Page 97 ENGINE DISASSEMBLY Part. N. 8000 H0368 (09-2008)
  • Page 98: Cylinder Head Cover Disassembly

    ENGINE DISASSEMBLY Cylinder head cover disassembly Remove the four fastening screws (8 mm wrench) and the cylinder head cover together with the relative gasket. Camshaft disassembly Remove the six fastening screws (8 mm wrench) and the alternator cover. Using a 17mm wrench, position the piston at T.D.C. at the end of the compression stroke (in this condition, the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as shown in the figure on page F.7).
  • Page 99 ENGINE DISASSEMBLY Loosen the cam-chain tensioner (10 mm wrench) then remove the two fastening screws (8 mm wrench) and the cam-chain tensioner assembly. Remove the eight fastening screws of the camshaft clamps (5 mm wrench) and the clamps themselves using these same screws. Remove the lubricating tube.
  • Page 100: Water Pump Body Disassembly

    ENGINE DISASSEMBLY Remove the retaining pin and the valve lifter. Water pump body disassembly Loosen the hose water pump-cylinder head clamp and remove the hose from cylinder head. Remove the two fastening screws (8 mm wrench) and the water pump body from the cylinder head. Remove the timing driven gear (Water pump rotor fastening nut: 4,9 Nm/ 0,5 Kgm/ 3.6 ft/lb+LOCTITE 243).
  • Page 101: Cylinder Head Disassembly

    ENGINE DISASSEMBLY Cylinder head disassembly TE-SMR: remove the coolant fluid temperature sensor with its O-ring. Remove the two screws on the L.H.S (8 mm wrench) then the front nut under the cylinder head (13 mm wrench). Remove the four inner screws on the cylinder head (10 mm wrench) whilst following a cross-over pattern.
  • Page 102: Valve Disassembly

    ENGINE DISASSEMBLY Valve disassembly Using a hook, remove the rocker-arm spacer clip. Remove the fastening screw (5 mm wrench) and the chain slider. Remove the fastening screws (6 mm wrench) then the rocker-arm axles and the rocker-arms themselves. Part. N. 8000 H0368 (09-2008)
  • Page 103 ENGINE DISASSEMBLY Using a tweezer, remove the valve adjusting pads. Use a valve spring compressor tool to remove the valves. Be careful not to damage the gasket surfaces or the combustion chamber. Make sure that the valve spring compressor is always straight, otherwise the valve stem can bend.
  • Page 104: Cylinder Disassembly

    ENGINE DISASSEMBLY Cylinder disassembly After having removed the cylinder head gasket, remove the two dowel bushings and the cylinder itself. Piston disassembly Remove the piston pin clips then the piston pin and the piston. F.10 Part. N. 8000 H0368 (09-2008)
  • Page 105: Flywheel Disassembly

    ENGINE DISASSEMBLY Flywheel disassembly Maintain the rotor immobilized and remove the rotor nut (17 mm wrench). Remove the rotor using the puller (code no. 8000 A1559 for TC-TXC and 8000 B0144 for TE-SMR). Remove the timing system chain. If the chain slider is worn, remove the fastening screw then the chain slider in order to replace it (Chain slider fastening screw 3 Nm/ 0,3 Kgm/ 2.1 ft/lb).
  • Page 106: Kick Start Pedal Disassembly (Tc-Te-Txc)

    ENGINE DISASSEMBLY Kick start pedal disassembly (TC-TE-TXC) Remove kick start pedal fastening screw (4 mm wrench), washer and kick start pedal. F.12 Part. N. 8000 H0368 (09-2008)
  • Page 107: Transmission Cover Disassembly

    ENGINE DISASSEMBLY Transmission cover disassembly Remove the twelve cover fastening screws (8 mm wrench) then the transmission cover. Remove gasket, dowel bushings and O-Rings. Clutch disassembly (TE-TXC-TC; SMR 450-510) Remove the six screws (12) that fasten the springs (11) (5 mm wrench, whilst following a cross-over pattern and in steps).
  • Page 108 ENGINE DISASSEMBLY Remove the clutch control rod (13). Bend back tabs of the hub washer (6) and holding the clutch hub nut (27 mm wrench), remove the nut (7) using the clutch disassembly tool (A) (code no. 8000 79015). Remove the washer (6), the clutch hub (5), the grooved washer (4), the clutch housing (3), the bushing (2) and the washer (1).
  • Page 109: Kick Start Components Disassembly (Tc-Te-Txc)

    ENGINE DISASSEMBLY Kick start components disassembly (TC-TE-TXC) Release spring (1) from seat on crankcase (A) and remove kick starter shaft assy (2). Remove circlip (3), washer (4) and starting idle gear (5). Part. N. 8000 H0368 (09-2008) F.15...
  • Page 110: Electric Starting System Disassembly (Te, Txc; Smr 450-510)

    ENGINE DISASSEMBLY Electric starting system disassembly (TE, TXC; SMR 450-510) Remove the four fastening screws (8 mm wrench) and starting gears retaining plate. Extract the starting gear and starting idle gear. F.16 Part. N. 8000 H0368 (09-2008)
  • Page 111: Oil Pump Disassembly

    ENGINE DISASSEMBLY Remove the two fastening screws (8 mm wrench) and extract the starting motor. Oil pump disassembly Using pointed pliers, remove the oil pump idle gear circlip, then the idle gear. Remove the three fastening screws (8 mm wrench) and extract: the oil pump body, the gasket, the two bushes and the oil pump.
  • Page 112: Gear Control Pedal And Gear Shifter Disassembly

    ENGINE DISASSEMBLY Gear control pedal and gear shifter disassembly Make a mark on the shaft showing the position of the gear control pedal to make the reassembly easier. Remove the fastening screw (8 mm wrench) and the gear control pedal from the gear shifter shaft. Extract, from the R.H.S., the gear shifter shaft and the bushing from the ratchet wheel.
  • Page 113 ENGINE DISASSEMBLY Remove the gear shifter drum fastening bolt (5 mm wrench). Remove the fastening screw and the gears pawl together with its spring. Pay attention for not to lose the roller. Part. N. 8000 H0368 (09-2008) F.19...
  • Page 114: Primary Transmission Driving Gear Disassembly

    ENGINE DISASSEMBLY Primary trasmission driving gear disassembly Place an aluminium shim between the teeth of the free-wheel gear (in order to prevent its rotation) and loosen the fastening nut (27 mm wrench, left side thread nut). Remove the driving gear and the free-wheel (mark the reassembly direction), the free-wheel gear, the needle bearing, the washer and the spacer.
  • Page 115: Crankcase Disassembly

    ENGINE DISASSEMBLY Crankcase disassembly Remove the circlip from the secondary shaft (R.H.S.). Remove the drive sprocket circlip and the drive sprocket from the secondary shaft. Extract the drive sprocket spacer. Remove the twelve screws from the L.H. crankcase side (8 mm wrench). Part.
  • Page 116: Gearbox Disassembly

    ENGINE DISASSEMBLY Fix the crankcase puller (code no. 1517 94702) in the holes of the flywheel cover and pull off the L.H. crankcase side. During this operation, lightly strike the secondary shaft at intervals using a rubber hammer to avoid the crankcase from getting stuck. Gearbox disassembly Remove the fork pins, the forks and the selector drum so they do not interfere with each other: the following pictures show the correct disassembling sequence.
  • Page 117 ENGINE DISASSEMBLY (Primary shaft fork pin). (Selector drum). (Primary shaft fork). Extract the primary and secondary shaft assemblies. Part. N. 8000 H0368 (09-2008) F.23...
  • Page 118: Crankshaft And Counter Balancing Shaft Disassembly (Smr 450-510)

    ENGINE DISASSEMBLY Crankshaft and counter balancing shaft disassembly (SMR 450-510) Place the puller bushing on the R.H.S. of the crankshaft. Fix the puller on the crankcase half and push out th crankshaft (strike lightly the layshaft with a rubber hammer in order to avoid it from getting stuck). F.24 Part.
  • Page 119 ENGINE DISASSEMBLY Place the layshaft idle gear disassembly tool and extract the idle gear. Place the crankshaft in a suitable position and press the crankpin out of one of the crankshaft flywheels. Remove the connecting rod with the needle bearing from the flywheel then turn the flywheel over half and press out the crankpin.
  • Page 120 ENGINE DISASSEMBLY F.26 Part. N. 8000 H0368 (09-2008)
  • Page 121: Engine Overhauling

    ENGINE OVERHAULING Cleaning of components ........... Assemblies ............... Cylinder head ............Recutting the valve seats .......... Valve guides ............. Replacement of valve guides ........Valve ................ Valve spring .............. Installation of valves ..........Inspection of rocker arm ..........Starter decompressor ..........Camshaft ..............
  • Page 122: Cleaning Of Components

    ENGINE OVERHAULING Cleaning of components All component must be cleaned with petrol and dried with compressed air. During this operation inflammable vapours burst out and metal particles may be violently ejected. Consequently, it is recommended to work in a room free from bare flames or sparks and that the operator wears goggles. Assemblies For a good and efficient engine operation, it is essential that all assemblies are within the tolerances prescribed.
  • Page 123: Recutting The Valve Seats

    ENGINE OVERHAULING Recutting the valve seats Clean carbon and deposits from the valves. Apply some “Prussian blue” to the valve face and lap it against the seat with a suitable lapping tool. Remove the valve and measure the width “X” of the contact surface. If the width exceeds 0.06 in.
  • Page 124 ENGINE OVERHAULING Check the valve seat, if there are any low spots or other damage, the seat must be recut. It is important that the contact surface on the valve is in the right place on the valve. Use marking colour to determine where is the contact surface. The contact surface should be 0.02 in.
  • Page 125: Valve Guides

    ENGINE OVERHAULING Valve guides Carry out a careful visual check of the valve guides. The valve guides should be checked for wear by measuring the clearance be- tween the valve stem and valve guide; use a dial gauge and measure the clear- ances on the “x”...
  • Page 126: Valve

    ENGINE OVERHAULING Use a suitable reamer and cutting oil when the valve guide is reamed. Turn the reamer when it is removed, so that no longitudinal scratches occur. When a valve guide is replaced, the valve seat must be refaced Valve Check that the valve stem and contact surfaces are in good condition.
  • Page 127: Installation Of Valves

    ENGINE OVERHAULING Installation of valves Lubricate the valve guides and valve stem with oil when the valve is installed. Install the seal ring, the springs and the cup. Use tool code 8000 39521 to compress the valve springs and can install halves cones.
  • Page 128: Inspection Of Rocker Arm

    ENGINE OVERHAULING Tap gently on the valve stem with a plastic hammer to make the cotters seat. Hit straight on the top of the valve stem so that the valve stem doesn’t get out of true. Inspection of rocker arm Check the clearance between the rockerarm and the rocker arm shaft.
  • Page 129: Camshaft

    ENGINE OVERHAULING Camshaft Check that cam surfaces are scored, stepped, grooved etc. Insert the camshaft between two references and then check deviation using two comparators. Wear limit: 0.0039 in. Check that the cams are in good conditions, without wear or deformation. Cam height “H”...
  • Page 130: Camshaft Chain And Gearing

    ENGINE OVERHAULING Camshaft chain and gearing At every engine overhaul the wear of the camshaft gear teeth and the chain rollers should be checked. If the teeth are badly worn then replace the three components. Hold the chain taut and check the length of 20 links (21 pins). If any one of three cam drive components is found to be worn then all three components should be replaced.
  • Page 131: Cylinder

    ENGINE OVERHAULING Cylinder The cylinder liner bore should be completely smooth, without grooving or scor- ing. To obtain the taper and the ovality of the cylinder liner bore take measure- ments at three different heights and in two positions at 90° to each other. Max taper (wear limit): 0.0019 in.
  • Page 132: Cylinder-Piston Fitting

    ENGINE OVERHAULING Cylinder piston fitting Cylinder bore Use an internal micrometer (Dc) and take the reading at “A” distance from the top 0.80 in. (250-310 cc) or 0.39 in. (450-510 cc). Piston diameter Take the piston diameter (Dp) at “B” distance of 6 mm/0.24 in. (TE-TC-TXC 250), 8 mm/0.31 in.
  • Page 133: Gudgeon Pin

    ENGINE OVERHAULING Gudgeon pin The gudgeon pin should be perfectly smooth without scoring, grooving or bluish discoloration caused by overheating. Part. N. 8000 H0368 (09-2008) G.13...
  • Page 134: Piston Rings

    ENGINE OVERHAULING Piston rings The piston rings should not show signs of excessive wear or scoring. Spacer pistons are supplied complete with rings and gudgeon pins. Piston rings/cylinder clearance Introduce the ring into the lower part of the cylinder. (i.e. where there is least wear), ensure that the ring is squared up and then check the ring end gap.
  • Page 135: Piston Ring/Piston Rings Groove Clearance

    ENGINE OVERHAULING Piston ring/Piston rings groove clearance Use a feeler gauge to check the axial play (H) of the rings in the groove. The manufacturer mark, if it is present on the piston ring, must be turned upwards. PISTON RING CUT SETTING PISTON RING CUT SETTING Gudgeon pin/conrod small end clearance (A): 0.00047÷0.00106 in.
  • Page 136: Connecting Rod Big End Side Clearance

    ENGINE OVERHAULING Connetting rod big end side clearance STANDARD LIMITE DI SERVIZIO 0,300÷0,677 mm 0,75 mm (0.012÷0.027 in) (0.03 in) Crankshaft Main joiurnals must not present any scores, or grooves; their threads, key seats and slots have to be in good conditions. Crankshaft run-out STANDARD WEAR LIMIT...
  • Page 137: Connecting Rod Small End Bush Replacement

    ENGINE OVERHAULING Connecting rod small end bush replacement The bush should be replaced using a correct size punch and drift. Before the assembly, smear the bush outside surface with molybdenum disulfide grease. Insert the bush from the side marked with the elephant and check that the bush holes coincide with the ones of the rod.
  • Page 138: Clutch Unit

    ENGINE OVERHAULING Clutch unit Check that all clutch unit components are in good condition. The clutch discs should not be burnt or scored. Check the thickness of the clutch lining discs. Thickness of new plate: 0.118 in. Wear limit: 0.114 in. Check the distortion of each plate (both lined and unlined) by resting on a flat surface;...
  • Page 139 ENGINE OVERHAULING Clutch checking 1- Clutch disc pressure plate, 2- Clutch plate, 3- Clutch disengagement rod, 4- Clutch slave cylinder: Check that these parts are not worn or broken. lf not, replace the part. 5- Clutch disc hub: check the housing grooves of discs without friction material for wear or failure. If worn or breaked, replace the part. 6- Clutch disc housing: Check the housing grooves of discs with friction material for wear or failure.
  • Page 140: Oil Pump

    ENGINE OVERHAULING Oil pump If they were not previously removed, remove from pump: screw (1), cover (2), shaft (3), and rotors (4) and (5). Clean the rotors and ressemble the above mentioned elements. Check that the pump mounting surface is not scored, grooved or pitted.
  • Page 141: Selector Drum

    ENGINE OVERHAULING Selector drum Check grooves "A" for wear or dents: if grooves are worn or dented, replace drum selector. Check drum selector for bent or damage: if bent, worn or damaged, replace Carburettor overhauling (TC 450-510; TXC 250-450-510) Thoroughly wash with petrol and dry with compressed air all carburetor componets. Thoroughly clean all jets and ducts with com- pressed air only.
  • Page 142 ENGINE OVERHAULING "Keihin" carburettor adjustment (TC 450-510; TXC 250-450-510) Adjust the carburettor with warm engine and with the throttle in closed position. Work as follows: - Turn slow running adjusting screw (1) on the left side of the bike, , until the engine is turning over at fairly high rpm (turn the screw clockwise to increase the rpm, and anticlockwise to descrease the rpm).
  • Page 143 ENGINE OVERHAULING Carburettor checking 1. Inspect: - Carburetor body Contamination: Clean NOTE: - Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. - Never use a wire. 2. Inspect: - Main jet (1) - Pilot jet (2) - Needle jet (9) - Pilot screw (7)
  • Page 144 ENGINE OVERHAULING NEEDLE VALVE Inspect needle valve (9) and valve seat (c) Grooved wear (a): Replace. Dust (b): Clean. THROTTLE VALVE Check for free movement. Stick: Repair or replace. Insert the throttle valve (5) into the carburetor body, and check for free movement. JET NEEDLE Inspect jet needle (6).
  • Page 145 ENGINE OVERHAULING FLOAT HEIGHT Measure: - Float height (a). Out of specification: Adjust. Float height: 8 mm (0.31 in.) Measurement and adjustment steps: - Hold the carburetor in an upside down position. NOTE: - Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
  • Page 146 ENGINE OVERHAULING Fuel draining (TC 450-510; TXC 250-450-510) As the fuel has to be drained from the float chamber, close the fuel tap by tightening the ring nut (A). Place the hose (3) in a vessel, loosen the drain screw (4) on the float chamber lower side, then tighten the screw again after the fuel drain.
  • Page 147: Engine Reassembly

    ENGINE REASSEMBLY Section Part. N. H0368 (09-2008)
  • Page 148 ENGINE REASSEMBLY General directions ............. Instructions for assembly and lubrication ....H.4÷H.13 Reassembly of crankshaft ......... H.14 Reassembly of counter balancing shaft driving gear (SMR 450-510) ............H.16 Reassembly of transmission (TE-TXC-SMR) .... H.17 Reassembly of transmission (TC) ......H.18 Reassembly of crankcase .........
  • Page 149: General Directions

    ENGINE REASSEMBLY General directions For a correct re-assembly follow in the adverse sense what shown for dismantling, however paying a special attention to every operation we specifically mention. We remind you that gaskets, oil rings, clamps and sealing washer in deformable material (as copper, aluminium, fibers, etc.) and self-locking nuts havealways to be renewed.
  • Page 150: Instructions For Assembly And Lubrication

    ENGINE REASSEMBLY Instructions for assembly and lubrication CRANKSHAFT, COUNTER BALANCING SHAFT- ALTERNATOR- LUBRICATION- L.H. CRANKCASE Part. N. 8000 H0368 (09-2008)
  • Page 151 ENGINE REASSEMBLY Tightening torques M14x1 (+LOCTITE 243) 20 Nm- 2 Kgm- 14.5 ft/lb M6x1 11 Nm- 1,1 Kgm- 7.9 ft/lb M16x1,5 25 Nm- 2,55 Kgm- 18.4 ft/lb M14x1,5 25 Nm- 2,55 Kgm- 18.4 ft/lb M12x1 75 Nm- 7,65 Kgm- 55.3 ft/lb M6x1 (+LOCTITE 272) - TC, TXC 8 Nm- 0,8 Kgm- 5.8 ft/lb M5x0,8 (+LOCTITE 272) - TE, SMR...
  • Page 152 ENGINE REASSEMBLY Instructions for assembly and lubrication TRANSMISSION, GEARSHIFT MECHANISM Part. N. 8000 H0368 (09-2008)
  • Page 153 ENGINE REASSEMBLY Tightening torques 22- M8x1,25 (+LOCTITE 270) 20 Nm- 2 Kgm- 14.5 ft/lb 23- M6x1 (+LOCTITE 243) 8 Nm- 0,8 Kgm- 5.8 ft/lb 24- M5x0,8 6 Nm- 0,6 Kgm- 4.3 ft/lb STANDARD ft/lb M5x0,8 6 Nm- 0,6 Kgm- 4.3 ft/l M6x1 8 Nm-0,8 Kgm- 5.8...
  • Page 154 ENGINE REASSEMBLY Instructions for assembly and lubrication CLUTCH- STARTING SYSTEM- LUBRICATION- R.H. CRANKCASE Part. N. 8000 H0368 (09-2008)
  • Page 155 ENGINE REASSEMBLY Tightening torques M18x1,25 180 Nm- 18 Kgm- 130 ft/lb M6x1 (+LOCTITE 272) 11 Nm- 1,1 Kgm- 7.9 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M18x1 75 Nm- 7,6 Kgm- 55 ft/lb M6x1 (+LOCTITE 243) 11 Nm- 1,1 Kgm- 7.9 ft/lb M10x1,25 (+LOCTITE 601) 15 Nm- 1,5 Kgm- 10.8 ft/lb STANDARD...
  • Page 156 ENGINE REASSEMBLY Instructions for assembly and lubrication CLUTCH- STARTING SYSTEM- LUBRICATION- R.H. CRANKCASE H.10 Part. N. 8000 H0368 (09-2008)
  • Page 157 ENGINE REASSEMBLY Tightening torques M18x1,25 180 Nm- 18 Kgm- 130 ft/lb M6x1 (+LOCTITE 272) 11 Nm- 1,1 Kgm- 7.9 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M18x1 75 Nm- 7,6 Kgm- 55 ft/lb M6x1 (+LOCTITE 243) 8 Nm- 0,8 Kgm- 5.8 ft/lb STANDARD ft/lb M5x0,8...
  • Page 158 ENGINE REASSEMBLY Instructions for assembly and lubrication CYLINDER HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG H.12 Part. N. 8000 H0368 (09-2008)
  • Page 159 ENGINE REASSEMBLY Tightening torques M8x1,25 15 Nm- 1,5 Kgm- 10.8 ft/lb M10x1,5 (+MOLIKOTE HSC) 37 Nm+90°- 3.8 Nm+90°- 27.5 ft/lb+90° M6x1 12 Nm- 1,2 Kgm- 8.7 ft/lb M14x1,5 (+LOCTITE 243) 25 Nm- 2,55 Kgm- 18.4 ft/lb M6x1 8 Nm- 0,8 Kgm- 5.8 ft/lb M10x1 15 Nm- 1,5 Kgm- 10.8 ft/lb M6x1 (+LOCTITE 243)
  • Page 160 ENGINE REASSEMBLY Reassembly of crankshaft Carefully clean the lubrication ducts. Lubricate the crankpin with motor oil and place it in the flywheel. Fit the roller bearing and lubricate with engine oil. Fit the connecting rod and the second half-flywheel. See that the half-flywheels are aligned using a triangle. Join all the elements using a press.
  • Page 161 ENGINE REASSEMBLY Check the connecting rod side float into the flywheels. It must be 0,4÷0,5 mm A = 0,4 ÷ 0,5 mm (0.0157÷0.0197 in). (0,0157÷0,0197 in.) Check the alignment of the crankshaft between centers. Runout may not exceed 0.02 mm (0.0008 in) at the bearing positions. Make an initial alignment of the flywheel using a copper hammer.
  • Page 162: Reassembly Of Counter Balancing Shaft Driving Gear (Smr 450-510)

    ENGINE REASSEMBLY Reassembly of counter balancing shaft driving gear (SMR 450-510) Put the flywheel on the press as shown in picture (with the left half-flywheel surface on the press plane) and assemble the layshaft driving gear (2) on the flywheel (use a 4 mm - 0.16 in.
  • Page 163: Reassembly Of Transmission (Te-Txc-Smr)

    ENGINE REASSEMBLY Reassembly of transmission If the gear shafts have been disassembled, the following paragraphs show the reassembly sequence. 6 Speed transmission (TE, TXC, SMR) Main shaft Auxiliary shaft Main shaft complete Main shaft Mount the bushing, the 5th gear on the bushing and after that the washer and the circlip.
  • Page 164 ENGINE REASSEMBLY Auxiliary shaft Mount the plug and the bush. Mount 2nd gear, the washer and the circlip. Mount the 6th gear and the circlip. Mount the washer. Fit the washer into the 3rd gear. Mount the 3rd gear, the washer and the circlip. Apply “MOLYKOTE G-n plus” under 3rd gear. Mount the washer.
  • Page 165 ENGINE REASSEMBLY Auxiliary shaft Main shaft complete Main shaft Mount the bushing, the 5th gear on the bushing and after that the washer and the circlip. The washer should be between the gear and the circlip. Mount the 3rd gear, the circlip and the washer. Mount the 4th gear. Mount the spacer (only for 400-450-510 cc).
  • Page 166: Reassembly Of Crankcase

    ENGINE REASSEMBLY Reassembly of crankcase Clean the faces between the half-cases then support the half-case using a suitable tool code no. 8A00 90662. Warm up at approx. 125°C (257°F), and fit the ball bearings into the two half-cases with a suitable tool (crankcase bearings plates screws: 11Nm/ 1,1 Kgm/ 7.9 ft-lb + LOCTITE 272).
  • Page 167 ENGINE REASSEMBLY Make sure that the mounting of the bushes is correct (apply grease on the bushes). Lubricate with motor oil the surfaces that fit in the gear wheels. Put the selector drum in its place. Part. N. H0368 (09-2008) H.21...
  • Page 168 ENGINE REASSEMBLY Install the gear striker shafts. Make sure that the gear strikers move easily on the shafts. Check gearbox operation by turning the gear selector drum. Lubricate with motor oil the crankshaft journal with grease and assemble the shaft in the right half-crankcase.
  • Page 169 ENGINE REASSEMBLY Mount contemporarily the crankshaft and the counter balancing shaft aligning the chasings on the gears (the contemporary assembling of the crankshaft and the counter balancing shaft is obligatory on 400-450-510models). Mount the distance washer on the crankshaft. Smear the union surface of the left half case with “LOCTITE 510”; warm the crankshaft bearing seat and fit the half case.
  • Page 170: Reassembly Of Gearshift Mechanism, Electric Starting System And Oil Pump

    ENGINE REASSEMBLY Reassembly of gearshift mechanism, electric starting system and oil pump Assembly of the gearshift mechanism should be done in reverse order to disassembly. Tighten the driving gear on the crankshaft to the required torque (180 Nm-18 Kgm- 130 ft/lb + LOCTITE 243). Mount the starting driven gear.
  • Page 171 ENGINE REASSEMBLY Mount the oil pump (8 Nm-0,8 Kgm-5.8 ft/lb). Mount the oil pump driven gear and the circlip. Mount the circlip on the auxiliary shaft. Reassembly of gear shaft Check the shaft for wear in the gear shift mechanism groove. Mount the spring and lubricate the shaft with motor oil.
  • Page 172: Reassembly Of Kick Start Components (Te-Tc-Txc)

    ENGINE REASSEMBLY Reassembly of kick start components (TE-TC-TXC) Assemble the shaft assy. (2) in the seat (B) on crankcase (A) then place the hook return spring (1) in the crankcase hole (D). Assemble idling gear (5), washer (4) and circlip (3). H.26 Part.
  • Page 173: Reassembly Of Clutch (Te-Txc-Tc; Smr 450-510)

    ENGINE REASSEMBLY Reassembly of clutch (TE-TXC-TC; SMR 450-510) Mount the washer (1), the bush (2) and the clutch housing (3). Mount the toothed washer (4), the hub (5), the tab washer (6) and the nut (7). Tighten the nut to the required torque (75 Nm-7,6 Kgm- 55 ft/lb; place an aluminium shim between the teeth of the primary drive gears, in order to prevent its rotation).
  • Page 174 ENGINE REASSEMBLY Reassemble the pinion spacer with the O-ring housing turned inwards. : Be careful not to damage O-Ring on the spline shaft. Mount the pinion and the circlip. H.28 Part. N. 8000 H0368 (09-2008)
  • Page 175: Reassembly Of Timing System Drive Gear And Chain

    ENGINE REASSEMBLY Reassembly of timing system drive gear and chain The key for the cam chain sprocket must be installed with the cut end out towards the drive gear. Lubricate the cam-chain sprocket and install it on the crankshaft using a drift. Reassemble the cam drive chain.
  • Page 176: Reassembly Of Flywheel

    ENGINE REASSEMBLY Reassembly of flywheel Clean the flywheel rotor removing any debris gathered in centrifugated oil and attracted to the magnets. Reassembly the Woodruff key and the rotor on the crankshaft. Holding the rotor (on the R.H. side place an aluminium shim between the teeth of the primary drive gears, in order to prevent its rotation), mount the nut and tighten it to 75 Nm-7,65 Kgm- 55.3 ft/lb.
  • Page 177: Reassembly Of Transmission Cover

    ENGINE REASSEMBLY Reassembly of transmission cover If the centering bushes have been removed, reassemble them in the crankcase. Mount the gasket and the O-rings. : Check that the engine oil hole is not obstructed. Mount the transmission cover and tighten the twelve screws (8 Nm-0,8 Kgm- 5.8 ft/ lb).
  • Page 178 ENGINE REASSEMBLY Fit the piston rings as shown in the picture. The manufacturer mark, if it is present on the piston ring, must be turned upwards. PISTON RING CUT SETTING PISTON RING CUT SETTING PISTON RING CUT SETTING *: "d" cut posistion Assembly of piston and cylinder Install a new base gasket.
  • Page 179 ENGINE REASSEMBLY Assembly of cylinder head For valves reassembly see page G.15. If the rocker arm pivots have been disassembled, tighten the pivots fastening screws to 25 Nm-2,55 Kgm-18.4 ft/lb (+LOCTITE 243), when reassembling. Always use a new gasket head when assembling: see “Cylinder head gasket selection chart”...
  • Page 180 ENGINE REASSEMBLY Tighten the two L.h. external screws (8 Nm-0,8 Kgm- 5.8 ft/lb) and the lower nuts (15 Nm-1,5 Kgm- 10.8 ft/lb). Reassemble the lubrication hose on the transmission cover (15 Nm-1,5 Kgm-10.8 ft/lb). If the intake manifold (A) of the cylinder head has been dismantled, tighten the two screws to 3 Nm-0,3 Kgm-2.2 ft/lb+LOCTITE 272.
  • Page 181 ENGINE REASSEMBLY Position the piston at TDC at the end of the compression stroke. Put the timing gear in seat without rotating the crankshaft and mount the chain. Mount the water pump (8 Nm-0,8 Kgm-5.8 ft/lb+LOCTITE 542), without rotating the crankshaft, in order to obtain the perfect alignement of the twin chasing on the gear to the spline on head face (see picture) (tighten water pump fastening screws to 8 Nm-0,8 Kgm- 5.8 ft/lb+LOCTITE 542).
  • Page 182 ENGINE REASSEMBLY Assembly of cam-chain tensioner (TE-TC-TXC-SMR) TE-TC-TXC-SMR Back the pin for tightening the chain, reassemble the cam-chain tensioner with its two screws (8 Nm-0,8 Kgm-5.8 ft/lb). Insert the spring, the washer and the rear bolt (5 Nm-0,5 Kgm-3.6 ft/lb). TE-TC-TXC-SMR TE-TC-TXC-SMR Mount the intake camshaft aligning the reference on the gear with the left reference...
  • Page 183 ENGINE REASSEMBLY Assembly of valve lifter Mount the valve lifter in the head and, turning it in lift position, insert the retaining pin. Reassemble the lubrication tube. Lubricate the cammes abundantly with motor oil. Reassemble the four U-bolts for fixing the camshaft and tight the screws to 12 Nm- 1,2 Kgm-8.7 ft/lb.
  • Page 184 ENGINE REASSEMBLY Turn the crankshaft a few times in order to set the timing elements, bring the piston to Top Dead Center (in this condition, the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts, as shown in the figure). Check, by means of a feeler gauge, that the valve clearance is 0,10-0,15 mm (0.004-0.006 in.) for INTAKE and 0,15-0,20 mm (0.006-0.008 in.) for EXHAUST.
  • Page 185: Reassembly Of Cylinder Head Cover, Spark Plug, Lubrication Hose

    ENGINE REASSEMBLY Reassembly of cylinder head cover, spark plug, lubrication hose Mount the cylinder head cover and its gasket on the cylinder head. Tight the screws whilst following a cross-over pattern and in steps (8 Nm-0,8 Kgm-5.8 ft/lb). Assemble the spark plug (10÷12 Nm-1÷1,23 Kgm-7.2÷8.9 ft/lb) and the lubrication hose (15 Nm-1,5 Kgm-10.8 ft/lb).
  • Page 186: Reassembly Of Flywhel Cover

    ENGINE REASSEMBLY Fit a new O-ring and remount the neutral indicator locking the two fastening screws (6 Nm-0,6 Kgm-4.3 ft/lb+LOCTITE 243). Reassembly of flywheel cover Mount the stator plate so its mark and stator cover mark are aligned and tighten the two stator fastening screws (8 Nm-0,8 Kgm- 5.8 ft/lb+LOCTITE 272) for TC-TXC and (6 Nm-0,6 Kgm- 4.3 ft/lb+LOCTITE 272) for TE-SMR.
  • Page 187: Reassembly Of The Engine Oil Filters And Drain Plug

    ENGINE REASSEMBLY Reassembly of gearshift pedal and the kick start pedal Mount the gearshift pedal (tighten fastening screw to 8 Nm-0,8 Kgm- 5.8 ft/lb). Check that the control pedal is not damaged. Reassemble kick start pedal (TE-TC- TXC) (8 Nm-0,8 Kgm-5.8 ft/lb +LOCTITE 272); verify that the start pedal does not touch the crankcase cover.
  • Page 188: Engine And Motorcycle Reassembly

    ENGINE REASSEMBLY ENGINE AND MOTORCYCLE REASSEMBLY Reassemble the engine and the motorcycle components previously removed, according to the following order. Place the engine on the motorcycle. Insert the rear swing arm axle on the L.H. side then screw the respective nut using a 22 mm wrench (122,5 Nm-12,5 Kgm-90.3 ft/lb).
  • Page 189 ENGINE REASSEMBLY Part. N. H0368 (09-2008) H.43...
  • Page 190: Cylinder Head Gasket Selection Chart

    ENGINE REASSEMBLY CYLINDER HEAD GASKET SELECTION CHART Position the piston to T.D.C. at the end of the compression stroke, measure the distance "A" between piston crown and cylinder head face then choose the gasket as shown in the table below. 250-310 CONDITION (see picture) “A”...
  • Page 191: Front Suspension

    FRONT SUSPENSION Section Part. N. 8000 H0368 (09-2008)
  • Page 192 FRONT SUSPENSION Front suspension (TE-SMR) ........Instructions for use of Ø45USD fork (TE-SMR) ..............Components of the fork ..........General rules for a proper overhauling ...... Instructions for clamping in the vice ......Problems - Possible causes - Solutions ....General maintenance operations ......
  • Page 193 FRONT SUSPENSION TC-TXC Part. N. 8000 H0368 (09-2008)
  • Page 194: Front Suspension (Te-Smr)

    FRONT SUSPENSION Front suspension (TE-SMR) The front suspension unit is a MARZOCCHI “U.S.D.” telescopic hydraulic fork with advanced axle; the diameter of the stem is 50 mm . The thermal excursion of the wheel on the legs axis is 300 mm (TE) e 250 mm (SMR). Part.
  • Page 195 FRONT SUSPENSION INSTRUCTIONS FOR USE OF Ø50USD FORK (TE-SMR) GENERAL Telehydraulic upside down fork, with advanced axle. This fork is based on a multivalve damping system and spring for static load. The compression hydraulic damping is made through a special valve located in each fork’s leg lower area, whereas the rebound hydraulic damping is made through a cartridge located inside each stanchion.
  • Page 196: Components Of The Fork

    FRONT SUSPENSION COMPONENTS OF THE FORK The fork is based on a multivalve damping system that is exactly the same on both fork’s legs. Each fork’s leg is therefore a complete suspension system which you must refer to when adjusting any part of the fork. 5) Stanchi on tube 8) Lower sliding bushing 9) Spri ng cup...
  • Page 197: General Rules For A Proper Overhauling

    FRONT SUSPENSION GENERAL RULES FOR A PROPER OVERHAULING • After a complete breakdown, always use new, original Marzocchi seals when reassembling. • To tighten two bolts or nuts that are near each other, always follow the sequence 1- 2- 1 using a torque wrench; respect the indicated tightening torques (see Table 1 - Tightening Torques).
  • Page 198: Problems - Possible Causes - Solutions

    FRONT SUSPENSION Problems - Possible causes - Solutions This paragraph indicates some of the problems which may arise during the working life of the fork, as well as the possible causes of these problems and any solutions to the same. Always consult this Table before working on the fork. PROBLEM CAUSE SOLUTION...
  • Page 199: Bleeding The Air

    FRONT SUSPENSION You can find the reference numbers of this chapter about the explored FIG. 5 view of the fork on pag. 6. CLEANING THE DUST SEAL (FIG. 5) This operation can be carried out with the fork installed on the motorcycle. Dismantling •...
  • Page 200: Draining The Oil

    FRONT SUSPENSION Draining the oil WARNING This operation cannot be carried out with the fork installed on the motorcycle. We recommend loosening the fork cap a little before removing the fork leg from the fork yokes. • Remove the fork leg from the fork yokes according to the procedure in the motorcycle owner’s manual.
  • Page 201: Braking Down The Pumping Element And The Bottom Valve

    FRONT SUSPENSION BRAKING DOWN THE PUMPING ELEMENT AND THE BOTTOM VALVE WARNING This operation must be done only after having drained all of the oil out of the fork leg. • Clamp the wheel axle clamp in the vice. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...
  • Page 202 FRONT SUSPENSION • In order to be able to act on the pumping element you will need to remove the foot buffer components: hold the foot buffer nut ( 26 ) using a 18 mm spanner and unscrew the push rod ( 29 ) with a 17 mm hexagonal spanner. •...
  • Page 203: Braking Down The Fork Leg - Slider And Removing The Oil Seals

    FRONT SUSPENSION BRAKING DOWN THE FORK LEG – SLIDER AND REMOVING THE OIL SEALS • Remove the dust seal ( 12 ) from its seat, using a small flat- tip screwdriver. • With the same screwdriver remove the metal stop ring ( 11 ). •...
  • Page 204: Overhauling And Modifying The Cartridge And Bottom Valve Setting

    FRONT SUSPENSION OVERHAULING AND MODIFYING THE CARTRIDGE AND BOTTOM VALVE SETTING CARTRIDGE OVERHAULING (REBOUND BRAKING) Dismantling • CLAMP IN THE VICE THE ROD ( 32 ) MILLED AREA. • Unscrew the nut ( 38 ) using a 12 or 13 mm spanner, according to the mounted nut. •...
  • Page 205: Bottom Valve Overhauling (Compression Braking)

    FRONT SUSPENSION WARNING The piston must be oriented in a way that the holes having smaller diameter are placed towards the setting washers (37). • Tighten the nut ( 38 ) manually. • Clamp in the vice the damping rod ( 32 ) milled area. •...
  • Page 206: Re- Assembling The Fork Leg - Slider And Oil Seals

    FRONT SUSPENSION Assembling: The washers (46) and the piston (45) are the ones causing the compression braking. It is possible, if needed, to modify the fork’s behaviour during the compression phase, by replacing the washers (46) and the piston (45) with other components having different characteristics.
  • Page 207 FRONT SUSPENSION • Insert the following components in the stanchion tube in this order: dust seal ( 12), stop ring ( 11 ), oil seal ( 10 ), spring cup ( 9 ) and bottom guide bushing ( 8 ). WARNING Make sure the oil seal (10) is correctly oriented in a way that the hollow side is turned towards the spring cup (9).
  • Page 208: Re- Assembling The Pumping Element Unit And The Bottom Valve

    FRONT SUSPENSION • Mount the stop ring ( 11 ) using a small flat- tip screwdriver, checking it fits perfectly into its groove and being very careful not to scratch the stanchion tube. • Re- assemble the dust seal ( 12 ) in its seat, pressing it home with your hands. RE- ASSEMBLING THE PUMPING ELEMENT UNIT AND THE BOTTOM VALVE •...
  • Page 209 FRONT SUSPENSION • Insert the foot buffer push rod ( 29 ) into the rod ( 32 ); this must be done in a way that the spanner seizing side is oriented towards the body ( 30 ) and the metal ring seat ( F ) is exceeded.
  • Page 210 FRONT SUSPENSION • Push the pre- assembled pumping element ( 23 ) until it is in contact with the stanchion tube ( 5 ). • Tighten the bottom valve by hand. • Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation;...
  • Page 211: Filling With Oil

    FRONT SUSPENSION FILLING WITH OIL The R5051AC is available as spare part: if you tighten it on the rod’s edge, you can make the rod extraction from the inner part of the slide easier. • Lift the slider completely on the stanchion tube. •...
  • Page 212: Fitting The Fork Back On Themotorcycle

    FRONT SUSPENSION FITTING THE FORK BACK ON THEMOTORCYCLE WARNING Fit the fork back onto the frame following the instructions in the motorcycle manufacturer’s manual, as for the steering elements, brakes and wheel. The incorrect assembly of these elements can be dangerous for the rider. For the fork to work correctly, the wheel must be installed on the fork as follows: •...
  • Page 213: Adjustments

    FRONT SUSPENSION ADJUSTMENTS REBOUND ADJUSTMENT The extension (or rebound) damping adjustment can be made by acting on the adjustment screw ( R ) you can see on the upper cap of both legs. To modify the rebound braking adjustment, always start from the “fully closed”...
  • Page 214: Removing The Front Fork

    FRONT SUSPENSION Removing the front fork Take note of measure “A” which must be restored when reassembling. Set a support under the engine to lift the front wheel from the ground, working as follows: -remove,on the L.H. side, the screws (1) , the brake hose and the instrument cable clamp (TE-SMR) on the fork tube guard;...
  • Page 215 FRONT SUSPENSION - remove the fork legs. Assemble the front wheel following the instructions on page Y.8 and check the distance “B” between magnet (6) on the brake disc and sensor (7) on the brake caliper. Restore the starting measure “A”. B=2÷4 mm (0.08÷0.16 in.) I.25...
  • Page 216: Front Suspension (Tc-Txc)

    FRONT SUSPENSION Front suspension (TC-TXC) The front suspension unit is a MARZOCCHI “U.S.D.” telescopic hydraulic fork with advanced axle;the diameter of the stem is 50 mm . The thermal excursion of the wheel on the legs axis is 300 mm. I.26 Part.
  • Page 217 FRONT SUSPENSION INSTRUCTIONS FOR USE OF Ø45USD FORK (TC-TXC) GENERAL The telehydraulic upside down fork,with advanced axle. The fork multivalve damping system allows rebound and compression to be controlled and adjusted,it also has a spring for static load. The compression hydraulic damping is made through a special valve located in each fork’s leg upper area,whereas the rebound hydraulic damping is made through a sealed cartridge located inside each stanchion.
  • Page 218: Components Of The Fork

    FRONT SUSPENSION COMPONENTS OF THE FORK The SHIVER 50 Factory Works fork is based on a multivalve damping system that is exactly the same on both fork legs. Each fork leg is therefore a complete suspension system which you must refer to when adjusting any part of the fork. 3)Compression adjustment screw 11)Outer spider 12)Lower sliding bushing...
  • Page 219: General Rules For A Proper Overhauling

    FRONT SUSPENSION GENERAL RULES FOR A PROPER OVERHAULING • After a complete breakdown,always use new,original Marzocchi seals when reassembling. • To tighten two screws,bolts or nuts that are near each other,always follow the sequence 1-2-1 using a torque wrench;strictly follow the indicated tightening torques (see Table 5 -Tightening Torques).
  • Page 220 FRONT SUSPENSION Issues - Possible Causes - Solutions This section describes some of the issues that may arise during the working life of the fork. For each issue listed, a possible cause is identified and a possible solution is given. Always consult this table before working on the fork. ISSUE CAUSE SOLUTION...
  • Page 221: Cleaning The Fork Legs

    FRONT SUSPENSION CLEANING THE FORK LEGS This operation can be carried out with the fork installed on the motorcycle. Marzocchi lubricates the dust seals of its forks with grease to help the stanchion tubes slide easier, particularly when the forks have not been used for a long period of time.
  • Page 222: Bleeding The Air

    FRONT SUSPENSION Bleeding the air This operation must be carried out with the fork’s legs fully extended and fork dismantled or with fork installed on the motorcycle and with the front wheel off the ground. The pressure generated by the air that can get into the fork legs while the motorcycle is being used and which, due to the special shape of the sealing rings remains trapped inside, can cause the fork to malfunction.
  • Page 223: Draining The Oil

    FRONT SUSPENSION Draining the oil WARNING This operation cannot be carried out with the fork installed on the motorcycle. We recommend loosening the fork cap a little before removing the fork leg from the fork yokes. • Remove the fork leg from the steering crowns according to the procedure in the motorcycle owner’s manual.
  • Page 224: Valve Setting

    FRONT SUSPENSION REMOVING THE CARTRIDGE UNIT WARNING! This operation must be done only after having drained allof the oil out of the fork leg. • Clamp the wheel axle clamp (70) in the vice. • Unscrew the lower cartridge nut (48) with a 21 mm socket wrench. •...
  • Page 225 FRONT SUSPENSION • Fix the rebound adjuster set (24) with a 17 mm open-ended wrench and unscrew the locknut (27) with another 17 mm open-ended wrench. • Remove the rebound adjustment set (24) and the locknut (27) from the pumping element rod.
  • Page 226: Checking The Rebound Adjusting Unit

    FRONT SUSPENSION CHECKING THE REBOUND ADJUSTING UNIT Dismantling • Push the rebound spring back from the end part of the rod. • Being very careful not to damage the washers, clamp the end of the rod (25) in the vice, exploiting the 17 mm spanner’s grip and without over-tightening. •...
  • Page 227: Compression Valve Overhauling

    FRONT SUSPENSION COMPRESSION VALVE OVERHAULING Dismantling • Being very careful not to damage the washers, clamp the compression valve (43) into the vice, exploiting the parallel surfaces and without over-tightening. • With a 12 mm spanner, unscrew nut (36). • In sequence, remove the nut (36), the spring (37), the by-pass washer (38), the piston (39) with O-ring (40) and the washer or washers’...
  • Page 228: Re-Assembling The Cartridge Unit

    FRONT SUSPENSION RE-ASSEMBLING THE CARTRIDGE UNIT • Insert the spring (23) in its seat on the rod. • Apply some stretched adhesive tape onto the end of the rod (39) in order to cover the rod threading. Do not apply thick adhesive tape. •...
  • Page 229 FRONT SUSPENSION Push the rod for a few times and the cartridge body with some oil up to approx.20 mm from the body top. Screw the oil draining screw (1)in the compression valve unit (43) Seal the cartridge end hermetically by screwing the compression valve (43)and make the rod (25)perform a full stroke;after completing this operation,when the rod is completely extended,you will see that the bladder tends to compress next to the 4 radial holes in the tube sleeve.
  • Page 230 FRONT SUSPENSION Pull the rod (25) to the position of maximum extension and top up oil to the edge Set the compression adjuster to 15 clicks from fully closed position. Unscrew the oil draining screw (1) in the compression valve unit (43) Screw the compression valve unit until the external O-ring seals inside the cap body.
  • Page 231: Breaking Down The Fork Leg - Slider And Removing The Sealing Rings

    FRONT SUSPENSION BREAKING DOWN THE FORK LEG - SLIDER AND REMOVING THE SEALING RINGS Remove the dust seal (16) from its seat, using a small flat-tip screwdriver. With the same screwdriver remove the metal stop ring (15). Pull the stanchion tube (44) out of the slider (11); to separate these two elements you will have to pull hard.
  • Page 232: Re-Assembling The Fork Leg - Slider And Sealing Rings

    FRONT SUSPENSION RE-ASSEMBLING THE FORK LEG - SLIDER AND SEALING RINGS WARNING The old sealing rings and dust seals must not be used again. Before re- assembling, check the conditions of the guide bushings; replace them if they are scratched or grooved. Check the Teflon® coating of the guide bushings which must be in a good condition.
  • Page 233: Re-Assembling The Cartridge

    FRONT SUSPENSION Mount the stop ring (15) using a small flat-tip screwdriver, checking it fits perfectly into its groove and being a careful not to scratch the stanchion tube. Re-assemble the dust seal (16) in its seat, pressing it home with your hands. RE-ASSEMBLING THE CARTRIDGE Insert the pre-load spacer (17) and the spring (19) inside the stanchion tube.
  • Page 234: Filling With Oil

    FRONT SUSPENSION FILLING WITH OIL Because the oil level inside the fork is not known, topping up should be done only after disassembling and removing the fork (see par. 4.8). Clamp the fork leg in the vice in a vertical position. Lift the slider on the stanchion tube up to 50 mm from the cap.
  • Page 235: Adjustments

    FRONT SUSPENSION ADJUSTMENTS Obtaining the maximum performance from your suspension system depends on using the correct settings and making the proper adjustments. This section describes how to properly set and make adjustments to your Marzocchi suspension system. In order to find the best settings for you, you will need to try several times to understand where and how to make adjustments.
  • Page 236: Spring Preload Adjustment

    FRONT SUSPENSION SPRING PRELOAD ADJUSTMENT The spring preload adjustment can be done following the procedure here below described, after disassembly of the cartridge set from the fork’s leg interior (see par. 4.6): Slide the preload adjustment set (7) towards the cartridge lower edge, so that the metal ring seat becomes uncovered.
  • Page 237: Compression Adjustment

    FRONT SUSPENSION COMPRESSION ADJUSTMENT The compression adjustment can be made by by turning on the adjuster (C). WARNING If your fork “bottoms” out, immediately adjust thecompression adjustment or check the oil height of thefork. Incorrect compression adjust can result in forkdamage, an accident, personal injury or death.
  • Page 238: Removing The Front Fork

    FRONT SUSPENSION Removing the front fork Take note of measure “A” which must be restored when reassembling. Set a support under the engine to lift the front wheel from the ground, working as follows: -remove,on the L.H. side, the screws (1) , the brake hose and the instrument cable clamp (TE-SMR) on the fork tube guard;...
  • Page 239 FRONT SUSPENSION - unloose the screws (4) fastening each fork slider to the steering head and steering base; - remove the fork legs. Assemble the front wheel following the instructions on page Y.8 and check the distance “B” between magnet (6) on the brake disc and sensor (7) on the brake caliper.
  • Page 240 FRONT SUSPENSION I.50 Part. N. 8000 H0368 (09-2008)
  • Page 241: Rear Suspension

    REAR SUSPENSION Rear suspension ............Removal of rear shock absorber ....... Disassembly, overhauling and reassembly of the rear shock absorber ........Overhaul the spring ........... Checking the shock absorber ........Removing the reservoir plug and the valve ....Checks on the piston unit .......... Replacing the gasket ..........
  • Page 242: Rear Suspension

    REAR SUSPENSION Rear shock absorber TIGHTENING TORQUES 1, 2: 52.4 Nm/ 5.35 Kgm/ 38.6 ft-lb LUBRICATION POINTS (GREASE) Part. N. 8000 H0368 (09-2008)
  • Page 243 REAR SUSPENSION Rear suspension The suspension of this motorcycle is of the progressive type and consists of a shock absorber, a series of linkages and a swing arm. The pre-load of the shock absorber spring can be adjusted according to the driving and ground conditions. Even the hydraulic damping can be adjusted from outside.
  • Page 244 REAR SUSPENSION Removing the rear shock absorber Remove the saddle, the side panels and the silencer as described in chapter "E’"- General operations (pages E.15-E.16-E.17). Loosen the front clamp (1) of the fitting on the carburettor (TC-TXC-SMR 450 R) or on the throttle body (TE-SMR). Loosen the upper fastening screw (2) of the rear frame (4), remove the lower fastening screw (3) and turn the rear frame forward making sure not to damage electric cables.
  • Page 245: Disassembly, Overhauling And Reassembly Of The Rear Shock Absorber

    REAR SUSPENSION Disassembly, overhauling and reassembly of the rear shock absorber Accurately clean the shock absorber before disassembly. OVERHAULING THE SPRING Measure the spring in its housing before disassembling. Disassembling the spring: when gripping the shock absorber in the vice take care that it gets not warped.
  • Page 246: Removing The Reservoir Plug And The Valve

    REAR SUSPENSION Bleed the gas by pressing on the reservoir valve. To protect his eyes from possible particles, the operator must turn t h e valve away from his eyes. Removing the reservoir plug and the valve Fit a tool on the air chambre cover, then exert a pressure on both the cover and the tool to gain access to the snap ring.
  • Page 247 REAR SUSPENSION Lay the shock absorber on the working table. Loosen or dig ot the cover (according to the model). Once the plug is removed, push and drive the forkrod guide inside the body so as to free snap ring housing. Remove then the snap ring using a screwdriver. Part.
  • Page 248: Checks On The Piston Unit

    REAR SUSPENSION Grip the shock absorber upper side in a vice using aluminium or bronze iaws. Insert a rod or a screwdriver into the connecting hole, and remove tthe piston and forkrod unit from the shock absorber body. Wrap the body in a cloth to prevent spreading the oil on the shock absorber body.
  • Page 249: Checking The Adjustment

    REAR SUSPENSION Checking the adjustment In case of compression adjustment for operating defect, it is necessary to unscrew the knob stopping dowel (before unscrewing, heat with warm air). Proceed as follows: unscrew the ring nut with a suitable wrench, extract the parts paying attention to the dismantling sequence in order to correctly effect then the reassembly.
  • Page 250: Reservoir Replacement

    REAR SUSPENSION After having completed the check, insert again the piston, the disk, the spring and the ring with slots. Remove the cone holding shaft from the plug, screw the ring and insert it in the slot applying a light pressure. Lock the assembly with the plug at a torque of 30 Nm (3 kgm;...
  • Page 251: Disassembling The Air/Oil Diaphragm Of The Reservoir

    REAR SUSPENSION Tighten the reservoir usingf Loctite, and see that the O-Ring is undamaged. Use a 40 Nm (4 kgm; 39.2 ft/lb) torque. NOTE: When carriying out these operations see that the place of work and all the elements are well cleaned. Disassembling the air/oil diaphragm of the reservoir Always replace the diaphragm when changing the oil inside the shock absorber.
  • Page 252 REAR SUSPENSION Prepare the diaphragm with assembled OR (we advise using a new one for each replacement). Fill up the reservoir with oil and insert the diaphragm into the reservoir, (see photo). Quickly push the diaphragm downwards at the bottom of the reservoir holding fast the forkdìrod in the topping up position.
  • Page 253 REAR SUSPENSION Reassemble the reservoir plug and the valve, fit it inside the reservoir, then fit the snap ring into the throat. Insert the nitrogen valve - or the air valve if teh nitrogden valve is not an hand - using 10-12 bar pressure. Reassemble the cap on the valve and check to make sure that both air bleeds, or oil leaks, are not present.
  • Page 254: Shock Absorber Damping Adjustment

    REAR SUSPENSION Shock absorber damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION – standard calibration: 1) low damping speed: -15 clicks (± 2 clicks) (adjuster 1) 2) high damping speed: -15 clicks (± 2 clicks) (adjuster 3) To reset the standard calibration, rotate upper adjusters (1) and (3) clockwise to the fully-closed position, then move back for the clicks specified above.
  • Page 255: Disassembly And Overhauling The Rear Swing Arm

    REAR SUSPENSION Disassembling and overhauling the rear swing arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove the chain (1) of the secondary transmission and disengage the rear brake pipe (2) from the fork (A). Remove the two side guards (3) of the frame.
  • Page 256: Overhauling The Rear Swing Arm Axle

    REAR SUSPENSION Overhauling the rear swing arm axle Using a comparator, check the swing arm axle for distortion. Position the axle on two identical contacts. Rotating the axle and moving it horizontally and take the distortion reading with the instrument. Distortion limit: 0,30 mm/ 0.012 in.
  • Page 257: Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner

    REAR SUSPENSION Chain tension rollers, chain driving roller, chain guide, chain runner Check the wear of the above mentioned elements and replace them when necessary. : Check the chain guide alignement, and remember that a bent element can cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket may ensue.
  • Page 258 REAR SUSPENSION Part. N. 8000 H0368 (09-2008) J.18...
  • Page 259: Brakes

    BRAKES Section Part. N. 8000 H0368 (09-2008)
  • Page 260 BRAKES Braking system ............Brake disc ..............Wear check and brake pads replacement ....Front braking system bleeding (TE-TC-TXC) .... Front braking system bleeding (SMR) ....... Rear braking system bleeding ........Fluid replacement ............. Part. N. 8000 H0368 (09-2008)
  • Page 261 BRAKES BRAKING SYSTEM The braking systems is divided into two completely independent circuits.Each system is provided with a caliper connected to a hydraulic control pump with tank for the fluid. 1. Front brake control lever 2. Front brake pump with oil reservoir (TE, TC) 2.
  • Page 262 BRAKES Disc brake A regular check of brake disc condition is most important; the disc should be absolutely clean without any traces of rust, oil, grease or dirt and should not be excessively scored. Front brake disc diameter: 10.24 in. (TE, TC, TXC); 12.6 in. (SMR) Front brake disc thickness (when new): 0.118 in.
  • Page 263 BRAKES Wear check and replacement of brake pads Inspect pads for wear. Service limit “ A” TE, TC, TXC - 3,8 mm-0.15 in. (front and rear pads) If service limit is exceeded, always replace the pads in pairs. a) In front: thickness “A” must never be lower than the one pointed out by the wear control notches.
  • Page 264 BRAKES Front braking system bleeding (TE-TC-TXC) The braking system must be bleed when, due to air in the circuit, the lever stroke is long and spongy. To bleed the system: - Remove the rubber cap on the bleeding valve (1). - Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container (make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation).
  • Page 265 BRAKES Front braking system bleeding (SMR) The braking system must be bleed when, due to air in the circuit, the lever stroke is long and spongy. Regarding the front braking system, first proceed to bleed the upper braking system control (bleeding valve 1), then the brake caliper (bleeding valve 1A). In both cases, proceed as follows: - Remove the rubber cap on the bleeding valve (1) or (1A).
  • Page 266 BRAKES Bleeding the rear breaking system The braking system must be bled when, due to air in the circuit, the pedal stroke is long and spongy. To bleed the system: - Remove the reservoir cover (A) (21 mm wrench) rubber boot and top up with (DOT 4) brake fluid.
  • Page 267 BRAKES Fluid change The brake fluid should be checked and changed in accordance with the Periodic Maintenance Chart (page B.9) or whenever it is contaminated with dirt or water. Don’t change the fluid in the rain or when a strong wind is blowing. Use only brake fluid from a sealed container (DOT 4).
  • Page 268 BRAKES TE-TC-TXC L.10 Part. N. 8000 H0368 (09-2008)
  • Page 269 BRAKES Periodically check the connecting hoses (C) and (D) (see “Periodical maintenance card”, page B.9): if the hoses are worned or cracked, their replacement is advised. Part. N. 8000 H0368 (09-2008) L.11...
  • Page 270 BRAKES L.12 Part. N. 8000 H0368 (09-2008)
  • Page 271 ELECTRIC SYSTEM, DIGITAL INSTRUMENT WIRING DIAGRAM (TE, SMR) .............. KEY TO WIRING DIAGRAM (TE, SMR) ..........Cable colour coding (TE, SMR) ............. WIRING DIAGRAM (TXC 250) .............. KEY TO WIRING DIAGRAM (TXC 250) ..........Cable colour coding (TXC 250) .............. WIRING DIAGRAM (TC, TXC 450-510) ..........
  • Page 272 ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TE-SMR) 1. Electronic power unit 2. Alternator 3. Voltage regulator 4. Rear stop switch 5. Front stop switch 6. Injector 7. Instrument 8. R.H. front turn indicator 9. Front headlamp 10. Electric fan 11.
  • Page 273: Cable Colour Coding (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Cable colour coding (TE-SMR) Blue B/Bk Blue/Black Black Brown Br/B Brown/Blue Br/Bk Brown/Black Br/R Brown/Red Br/W Brown/White Green G/Bk Green/Black Green/Red Green/Yellow Grey Gr/Bk Grey/Black Gr/G Grey/Green Orange O/Bk Orange/Black Pink R/Bk Red/Black Sky blue Violet White W/B White/Blue W/Bk White/Black...
  • Page 274: Cable Colour Coding (Txc 250)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TXC 250) 1. Electronic power unit 2. Alternator 3. Voltage regulator 4. Condenser 5. Battery 6. Electric start remote control switch 7. Starting motor 8. Spark plug 9. Gear shift position sensor 10.
  • Page 275: Cable Colour Coding (Tc, Txc 450-510)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT KEY TO ELECTRIC DIAGRAM (TC-TXC 450-510) 1. Electronic power unit 2. Alternator 3. Voltage regulator (TXC) 4. Condenser (TXC) 5. Battery (TXC) 6. Electric start remote control switch (TXC) 7. Starting motor (TXC) 8. Spark plug 9.
  • Page 276: Electrical Components Location (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRICAL COMPONENTS LOCATION (TE-SMR) The ignition system includes the following elements: - Generator (1), in oil bath, on the inner side of L.H. crankcase cover; - Electronic ignition coil (2) under the fuel tank; - Electronic power unit C.D.I. (3) under the fuel tank; - Voltage regulator (4) under the fuel tank;...
  • Page 277 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 H0368 (09-2008)
  • Page 278: Electrical Components Location (Tc-Txc)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRICAL COMPONENTS LOCATION (TC-TXC) The ignition system includes the following elements: - Generator (1) on the inner side of L.H. crankcase cover; - Electronic coil (2) and condenser (11; TXC) under the fuel tank; - Electronic power unit C.D.I. (3) under the fuel tank; - Voltage regulator (4;...
  • Page 279 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 H0368 (09-2008)
  • Page 280: Charging System (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT CHARGING SYSTEM (TE-SMR) The charging system consists of: - Alternator (2); - Voltage regulator-rectifier (3); - Battery (5). The AC current produced by the alternator is converted by the regulator-rectifier into DC current. The regulator-rectifier prevents overcharging of the battery and changes the AC current to the DC current.
  • Page 281 ELECTRIC SYSTEM, DIGITAL INSTRUMENT For the key to electrical cables see pages M.4÷M.5. Part. N. 8000 H0368 (09-2008) M.11...
  • Page 282: Charging System Checks

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT CHARGING SYSTEM CHECKS Battery current leakage To gain access to the battery (1), remove the saddle (see page E.15). Remove the BLACK negative cable from the battery. Measure the current between the NEGATIVE terminal of the battery and the NEGATIVE cable using a tester.
  • Page 283 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 1) EXCITER - Resistance between BLACK-RED and RED-WHITE cables: 12,7 +/- 15% (TC-TXC) 1) TRIGGER - Resistance between WHITE and GREEN cables: +/- 15% (TE-SMR) 2) CHARGE- Resistance between YELLOW and WHITE cables: 0,16 +/- 15% (TC-TXC) 2) CHARGE- Resistance between then YELLOW cables: 0,65 +/- 15% (TE-SMR)
  • Page 284 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Generator no-load voltage performances 1- Secondary no load voltage 2- Charging current 3- Lighting voltage 4- Rotational frequency TC -TXC : EVERY ENGINE OVERHAUL, CLEAN THE FLYWHEL ROTOR REMOVING ANY DEBRIS GATHERED IN CENTRIFUGATED OIL AND ATTRACTED TO THE MAGNETS.
  • Page 285: Voltage Regulator-Rectifier Check (Te-Smr-Txc)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Voltage regulator-rectifier checking (TE-SMR-TXC) With the ignition definitely functional, whilst the battery is charged (12.5V-13V), start the engine: if the battery tension does not increase (14 V) after about two minutes, substitute the regulator. To access the regulator, remove the seat and fuel tank (pages E.15, E.23).
  • Page 286: Electric Starting System (Txc)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRIC STARTING SYSTEM (TXC) The starter system consists of: - Battery (5); - Electric start remote control switch (6); - Starting motor (7); - Engine stop switch (12); - Engine start switch (13); - Clutch switch (14). Pull the clutch lever until the engine starts.
  • Page 287: Starter System Checks

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT STARTER SYSTEM CHECKS Starter motor disassembly Use a 10 mm wrench to remove the nut (1) under the rubber cap and a 8 mm wrench to remove the starting motor and ground cable screws (2). Remove the starting motor.
  • Page 288: Starter Motor Test Diagram

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Starter motor test diagram 1- Output (W) 2- Torque (TQ) 3- Revolution (N: r.p.m. x 1000) 4- Terminal voltage (V) 5- Load current (A) Starter motor maintenance Maintenance operations on the starter motor involve checking the brushes for wear, that the stator and rotor do not touch, and that they are correctky insu- lated.
  • Page 289: Electronic Ignition System (Tc-Txc)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC IGNITION SYSTEM (TC-TXC) In the C.D.I. system the electrical energy generated by the alternator charges the condenser. The energy is released in a single surge at the specified ignition timing and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting a strong spark between the ignition spark plug gap.
  • Page 290: Electronic Ignition System (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC IGNITION SYSTEM (TE-SMR) The ignition system is controlled by the ECU (1). The system belongs to the category of the integrated systems of digital electronic ignition with advance and static distribution and gasoline electronic injection of intermittent sequential balanced type. This ignition system consists of a sensor of the crankshaft position (Pick-up), an ECU, an ignition coil and an air pressure sensor of the intake manifold.
  • Page 291 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Part. N. 8000 H0368 (09-2008) M.21...
  • Page 292 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Ignition coil resistance check To gain access to the electronic coil (1) remove the saddle and the fuel tank (see pages E.15-E.23). Detach the ignition coil from main wiring harness. Remove the fastening screws, the ignition coil then measure the resistance in the primary and secondary windings using a tester.
  • Page 293 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Electronic unit (ECU) To gain access to the electronic unit (1) remove the saddle and fuel tank (see pages E.15-E.23). This unit consists of a condensor, a pick-up signal rectifier circuit, and ignition advance circuit synchronised with the pick-up signal and a switching circuit for discharging the condensor.
  • Page 294: Electronic Power Unit Wiring Diagram (Ecu) (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT ELECTRONIC POWER UNIT WIRING DIAGRAM (ECU) (TE-SMR) 35 23 33 25 36 - Electronic power unit (1) (ECU); - W.T.S. (33) (Water Temperature Sensor); - Ignition coil (23); - Fuel pump (35); - Clutch switch (27); - Ignition switch (26);...
  • Page 295: Voltage Regulator (Te-Smr-Txc)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Voltage regulator (TE-SMR-TXC) The voltage regulator (1) contains the diodes to rectify the current produced by the generator. It contains also an electronic device operating in relation to the battery tension: if battery has a “low” charge, recharge current will be high; on the contary if battery will be charged the current will be lower.
  • Page 296: Spark Plug

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Spark plug Use "NGK" CR8EB spark plug (1). Check distance "A" (0.7 mm / 0.027 in.) between electrodes. A wider gap may cause difficulties in starting engine and in overloading coil.A gap that is too narrow may cause difficulties when accelerating, when idling the engine or when performing at low speeds.
  • Page 297: Gear Shift Position Sensor Check (Gps)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Gear shift position sensor checking (GPS: Gear Position Sensor) Set the tester on "Ohm" position then detach the 6 ways connector (1) from the main wiring harness (the gear shift position sensor is fastened on the alternator cable with a clamp).
  • Page 298 ELECTRIC SYSTEM, DIGITAL INSTRUMENT Throttle Position Sensor checking (TPS: Throttle Position Sensor) (TC-TXC) Set the tester in “Ohm” position then detach the throttle position sensor cable (1) from the main wiring harness. Set the two tester terminals in corrispondence of YELLOW (A) and BLACK (B) cables and check for the correct values (see table).
  • Page 299: Battery Recharge

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT BATTERY (TE-SMR-TXC) The sealed battery (1) does not require any maintenance work. If the vehicle remains unused for long periods, it is recommended to remove battery from electrical system and store it in a dry place. After an intensive use of the battery, it’s advisable a standard low charge (12V-6Ah battery: 0.6A for 8 hours).
  • Page 300: Headlamp, Tail Lamp (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT HEADLAMP, TAIL-LAMP (TE-SMR) Headlamp adjustment The front headlamp is fitted a dipping bulb for main and dipped beams and a pilot/ side lamp bulb. Particular care should be taken to adjust the headlamp beam; adjust as follows: - position the motorcycle at 33 ft from a flat wall;...
  • Page 301: Rear Tail Light Bulb Replacement

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Rear tail light bulb replacement To gain access to the tail light bulb (12V-5/21W), proceed as follows: - remove the two fastening screws (1) and the rear lens (2); - pull the lamp (3) inside, turn it counterclockwise then remove it from the lamp holder.
  • Page 302: Replacing The Licence Plate Light Lamp

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Replacing the licence plate light lamp Remove the licence plate light support (4) by extracting it from the tail of the motorbike. Extract the lamp holder with the lamp from the support. Turn the lamp (5) to remove it from the lamp holder. After replacing the lamp, reassemble all the parts in the inverse order.
  • Page 303: Handlebar Commutators

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT HANDLEBAR COMMUTATORS Measure the commutators continuity using a tester. In case of anomalies, replace the defective part. 1- Engine start and stop switches TC-TXC 1. Engine ignition button (TXC) 2. Engine stop button (TC-TXC) TE-SMR 2- R.H. Commutator 1.
  • Page 304 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 3- L.H. Commutator TE-SMR High beam flash (self cancelling) Selection control high beam Selection control low beam Left turm signals (automatic return) Right turm signals (automatic return) To deactivate the turn signals, press the control lever after its returning to center.
  • Page 305: Notes

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT NOTES CONNECTORS • When a connector is connected, check that it clicks into position. • Check the connector for corrosion, dirt or a broken cover. COUPLINGS • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.
  • Page 306: Fuses

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT FUSES • When a fuse (1) burns out, always investigate why the fuse has burnt out. Find the cause, repair and then substitute the fuse. • Do not utilise a fuse of a different capacity from the original one. •...
  • Page 307: Digital Instrument, Warning Lights (Te-Smr)

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Digital instrument, warning lights (TE-SMR) The motorcycle is equipped with a digital instrument; on the instrument are located 3 warning lights too: high beam, blinkers and fuel reserve. 1- BLUE warning light “HIGH BEAM” 2- GREEN warning light “BLINKERS” 3- ORANGE warning light “Fuel reserve”...
  • Page 308 ELECTRIC SYSTEM, DIGITAL INSTRUMENT 2- SPEED / CLOCK (figure 2) - SPEED: motorcycle speedmaximum value: 299 Km/h o 299 mph; - CLOCK: clock- Reading from 0:00 to 23:59:59; To reset the clock, push the knob SCROLL (A) for more than 3 seconds in order to increase the hours;...
  • Page 309 ELECTRIC SYSTEM, DIGITAL INSTRUMENT The instrument display shows even then informations of the “Neutral” condition and of any possible “Malfunction” of the FUEL INJECTION SYSTEM; this last condition is showed with absolute priority with respect to any other information. NEUTRAL: if the speed is under 20 Km/h (12,5 mph), the “Neutral” condition the instrument displays the N character before the value of the speed.
  • Page 310: Instrument Replacement

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT Instrument replacement (TE-SMR) - remove the upper fastening screw of the the headlamp carrier to the instrument panuel support (A); - push forward the headlamp carrier (B) and pull it towards the high (C) in order to uncouple from the two lower supports.
  • Page 311: Wire Harness Tc-Txc

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT WIRE HARNESS TC-TXC-SMR 450R WIRE HARNESS TE-SMR Part. N. 8000 H0368 (09-2008) M.41...
  • Page 312: Cable Runway And Assembling Instructions For The 'Te/Smr' Electric Parts

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT CABLE RUNWAY AND ASSEMBLING INSTRUCTIONS FOR THE "TE/SMR" ELECTRIC PARTS • H.T. coil positioning Connect the H.T. colil as shown in the picture. • Relay positioning (3 parts) R.S. relay. L.S. relay. • Turn indicators flash device positioning Turn indicators flash device.
  • Page 313 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Injection central unit positioning Injection central unit installed with flat side downward. • Remote control switch positioning Install the remote control switch as shown. • Positioning the voltage rectifier Voltage regulator with dissipation plate covered in thermal grease •...
  • Page 314 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Securing of earth cables between motor-frame-battery. Earth cables between motor and frame and between motor and battery are secured to the left screw of the starter motor. • Threading of negative battery cable. Threading of earth cable between motor and negative cable of battery •...
  • Page 315 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connection of cables to voltage regulator. Connect the regulator connector. Be careful with the routes of the radiator vent pipe and the gas pipes! • Connecting relay Connect the "DC" cable to the relay on the right side of the motorbike. •...
  • Page 316 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connecting the injector Connect the injector connector as shown. • Connecting the central unit Connect the central unit connector as shown. • Ignition coil connection Connect the ignition coil connector as shown • Positioning of the fuel pump connector Place the fuel pump connector as shown.
  • Page 317 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connecting the MAQS connector Connect the MAQS connector as shown. • Connecting the engine water temperature connector Connect the engine water temperature connector as shown. • Posiotioning the lambda sensor Screw the lambda sensor as shown. •...
  • Page 318 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connection of starter and speed sensor cables. Connection of starter and speed sensor cables. • Threading of frame cables and back light connector. Thread the back of the cables as shown in the figure. Connect the back light connector.
  • Page 319 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Threading of cables to filter box. Thread the cables as shown, fasten with the clip provided. • Fastening of clip to fuse box. Fit the clips provided to the three fuse boxes. • Fastening of clip to fuse box. Fit the three fuses in the pierced wall on the back fender.
  • Page 320 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Connection of tilt sensor (SM only) Connect the drop sensor as shown in the figure. • Connection of back stop. Connect the stop sensor as shown in the figure. • Threading of steering sleeve cables Secure the cables with the clip provided.
  • Page 321 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Double-map connector plug. Fit the plug into the double-map connector. • Clutch and left handle block connectors. Connect the left block and clutch sensor connectors • Front stop, speed sensor and right handle block connectors. Connect the right block, front stop and speed sensor connectors •...
  • Page 322 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Fastening wiring Fasten the wire harness to the frame with a clamp as shown in the picture. • Fastening wiring Fasten the back stop cable to the frame with a strap as shown in the figure. •...
  • Page 323 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Fastening wiring Make sure the cable node is secured outside the frame. • Fastening wiring Place the GPS and Pick-Up connectors as shown. • Fastening wiring Secure the generator connector as shown. • Fastening wiring Connect the start, speed sensor and lambda sensor cable bundle to the hydraulic clutch pipe.
  • Page 324 ELECTRIC SYSTEM, DIGITAL INSTRUMENT • Fastening wiring Connect the start and speed sensor cable bundle to the hydraulic clutch pipe. • Fastening wiring Fasten the front wire harness with two clamps as shown. • Fastening wiring Fasten the front wire harness with two clamps as shown. M.54 Part.
  • Page 325: Important Recommendation

    ELECTRIC SYSTEM, DIGITAL INSTRUMENT IMPORTANT RECOMMENDATION (pages M.62-M.63) Premised that, before the motorcycle washing, it is necessary to protect opportunely from the water the following parts: a) Rear opening of the muffler; b) Clutch and brake levers, hand grips, handlebar commutators; c) Air cleaner intake;...
  • Page 326 ELECTRIC SYSTEM, DIGITAL INSTRUMENT M.56 Part. N. 8000 H0368 (09-2008)
  • Page 327: Engine Cooling System

    ENGINE COOLING SYSTEM Section Part. N. 8000 H0368 (09-2008)
  • Page 328 ENGINE COOLING SYSTEM Checking the cooling fluid level ......... Cooling system ............Engine cooling system overhauling ......Part. N. 8000 H0368 (09-2008)
  • Page 329 ENGINE COOLING SYSTEM Checking the cooling fluid level Cooling fluid absorbs the heat from the thermic group (piston, cylinder, head) and conveys it to the exterior atmosphere through radiator. For a correct operation of the cooling system it is of utmost importance the periodical check of fluid level. The lack of the heat exchange means (water) between thermic mass and radiant mass could cause overheating of the cylinder-piston assembly with consequent seizure and, the worst, damages to the crankshaft assembly.
  • Page 330 ENGINE COOLING SYSTEM Cooling system The cooling system is of the forced circulation type, with centrifugal pump located on the L.H. side of the cylinder head, and two cooolers with vertical flow. Radiator cap R. H. Radiator L. H. Radiator Union Water pump Water pump cover...
  • Page 331 ENGINE COOLING SYSTEM Engine cooling system overhauling Verifying too high temperatures of cooling fluid, check the radiant mass. Whether on fins are noticed obstructions to the air flux as leaves, bugs, mud etc., carry out removal of these obstructions taking care not to damage radiator. If distortions are noticed, it is advisable to straighten them so restoring the air passage.
  • Page 332 ENGINE COOLING SYSTEM Part. N. 8000 H0368 (09-2008)
  • Page 333 “KIT” ASSEMBLING INSTRUCTIONS Side engine guards (SMR excluded) central engine guard ..........Passenger footrest Kit (SMR) ........Carburetor KEIHIN 37 kit (TXC 250) and KEIHIN 41 kit (TC-TXC 450-510) ......Hand guards kit (TE) ..........Blinkers Kit (SMR) ............ Blinkers Kit (TE) ............O.11 Hook Kit for race starting phase (TC-TXC) ....
  • Page 334: Central Engine Guard

    “KIT” ASSEMBLING INSTRUCTIONS 1- 8000 H0188 (TE, TC, TXC) Side engine guards (page O.3) 2- 8000 B0157 Central engine guard (page O.3) 3- 8000 B0152 (SMR) (*) Passenger footrest Kit (page O.4) 4- 8000 A4295 (TXC 250) Carburetor KEIHIN 37 kit (page O.7) 4- 8000 A4296 (TC-TXC 450-510) Carburetor KEIHIN 37 kit (page O.7) 5- 80A0 A6211 (TE)
  • Page 335 “KIT” ASSEMBLING INSTRUCTIONS 1- Side engine guards (SMR excluded) and central engine guard. 1, 2- Side engine guards (SMR excluded) 3- Central engine guard A- Screw M6x25 mm (no. 4 pieces) B- Bushing Ø6,2xØ8xØ12x9 mm (no. 4 pieces) C- Nut M6 (no. 4 pieces) D- Screw M6x15 mm (no.
  • Page 336 “KIT” ASSEMBLING INSTRUCTIONS 3- Passenger footrest (SMR). To always have the rear frame (a) fastened in two points, assemble the footrests first on to one side of the motorcycle then on the other one. The description refers to the assembly of the left footrest (7), the assembly of the right footrest (8) is symmetrical. Proceed as follow: - Preliminarily mount the foot-rests (A) and (B) on the relevant supports (C) and (D);...
  • Page 337 “KIT” ASSEMBLING INSTRUCTIONS - Insert the plate (2) on the back frame; - Remove the frame lower screw (7); - Provisionally, fasten the foot-rest support in the front side by means of the M8x25 mm (4) screw supplied with the Kit (do not tighten fully); - Insert the spacer (5) into the plate and fasten the rear by means of the M8x40 mm (6) screw also supplied with the Kit;...
  • Page 338 “KIT” ASSEMBLING INSTRUCTIONS - Fully tighten also the front screw (4); -- Assemble back the rear fastening screws (1) of the air filter box; -- Assemble back the saddle and side panels. Part. N. 8000 H0368 (09-2008)
  • Page 339 “KIT” ASSEMBLING INSTRUCTIONS 4- KEIHIN 37 carburetor Kit (TXC 250) and KEIHIN 41 (TXC 450-510) - Remove the carburetor (page E.9). The kit consists of: TXC 250 1- Idle jet: 40, 45 3- Main jet: 170, 180 TXC 450-510 1- Idle jet: 42, 48 3- Main jet: 185 Remove the floater chamber (A).
  • Page 340 “KIT” ASSEMBLING INSTRUCTIONS 5- Hand guards kit (TE) Remove the rubber guards and the fastening screws of the front brake (a) and clutch (b) control levers. Place the right hand guard (A) then fasten it with screw (1), washer (2) and nut (3). Place the left hand guard (B) then fasten it with screw (4), washer (5) and nut (6).
  • Page 341 “KIT” ASSEMBLING INSTRUCTIONS 6- Blinkers Kit (SMR) FRONT TURN SIGNALS Remove the upper fastening screw of the the headlamp carrier to the instrument panuel support (A); - push forward the headlamp carrier (B) and pull it towards the high (C) in order to uncouple from the two lower supports.
  • Page 342 “KIT” ASSEMBLING INSTRUCTIONS REAR TURN SIGNALS Remove the saddle and left side panel as shown on page E.15-E16. Assemble the flash device (8) on the metal tab (E) near the start remote control switch (D). Assemble the turn signal (2) on the hole of the frame tightening the nut (6). Remove the screws (9), the rear tail light then connect the turn signals and the flasher to the main wiring harness.
  • Page 343 “KIT” ASSEMBLING INSTRUCTIONS 6- Turn signals KIT (TE) FRONT TURN SIGNALS Remove the upper fastening screw of the the headlamp carrier to the instrument panuel support (A); - push forward the headlamp carrier (B) and pull it towards the high (C) in order to uncouple from the two lower supports.
  • Page 344 “KIT” ASSEMBLING INSTRUCTIONS REAR TURN SIGNALS Remove the seat and the L.H. side panel as shown on page E.15-E16. Assemble the turn signal flasher (12) on the metal plate (F) near the solenoid starter (G). Assemble the turn signal (3) or (4) on the hole of the frame and tighten the nut (10).
  • Page 345 “KIT” ASSEMBLING INSTRUCTIONS TE-SMR Part. N. 8000 H0368 (09-2008) O.13...
  • Page 346 “KIT” ASSEMBLING INSTRUCTIONS 7- The Kit Hook for race starting phase (TC, TXC: Code 8000 B1530) consists of: Part. No. Description Code Q.ty Ring (8000A6135) Hook (8000B1529) Screw (80B047053) Screw (60N407330) O.14 Part. N. 8000 H0368 (09-2008)
  • Page 347 “KIT” ASSEMBLING INSTRUCTIONS Preliminary operations Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the four screws (1 fig.1) fixing the front wheel axle. Hold the head (3 fig.2) of the wheel axle in place, unscrew the bolt (2 fig. 1) on the opposite side;...
  • Page 348 “KIT” ASSEMBLING INSTRUCTIONS 9- Kick starter kit (34, for SMR) To effect the above mentioned operations, it is not necessary to remove the engine from the motorcycle. 6- Plate(1) 43- Pedal hub (1) 10- Washer(2) 44- Spring (1) 14- Spring(1) 45- O Ring (1) 15- Sliding gear(1) 46- Screw M6x28 mm(1)
  • Page 349 “KIT” ASSEMBLING INSTRUCTIONS Remove oil line bolt on R.H. crankcase cover (13 mm wrench ). Remove 12 cover fastening screws (8 mm wrench ), cover and gasket. Use a punch to remove the brass plug cap (A) and install oil seal (50). Remove the six screws (12) that fasten the springs (11) (5 mm wrench, whilst following a cross-over pattern and in steps).
  • Page 350 “KIT” ASSEMBLING INSTRUCTIONS Remove the circlip (13), the spacer (12) then fasten the plate (6) in the holes (A) on the R.H. crankcase (C) using the two screws (38) M6x14 (+LOCTITE 243). Assemble the shaft assy. (E) in the seat (B) then place the hook return spring (37) in the crankcase hole (D).
  • Page 351 “KIT” ASSEMBLING INSTRUCTIONS Reassemble: clutch disc housing (3), grooved washer (4), hub (5), lock washer (6) and fastening nut (7) (27 mm socket and tool "A" code no. 8000 79015; tighten at 75 Nm-7,5 kgm-55 ft/lb). Remember to bend locking tab over nut when tight.
  • Page 352 “KIT” ASSEMBLING INSTRUCTIONS Reassemble R. H. crankcase cover gasket, reassemble cover and tighten 12 fastening screws at 8 Nm-6 ft/lb (8 mm wrench). Reassemble oil line bolt on crankcase cover (13 mm wrench; tighten at 15 Nm-1,5 kgm-11 ft/lb). Assemble kick start pedal (42) tightening the screw (48) with 4 mm allen wrench; (tighten at 8 Nm-0,8 kgm-6 ft/lb);...
  • Page 353 “KIT” ASSEMBLING INSTRUCTIONS Pour the proper oil amount in the crankcase (1,5 l.-1.3 Imp. Quarts- 1.6 U.S. Quarts of AGIP RACING 4T/ 10W-60). Reassemble the rear brake control pedal (6 mm allen wrench; tighten fastening bolt at 42 Nm-4,2 kgm-31ft/lb+LOCTITE 243).
  • Page 354 “KIT” ASSEMBLING INSTRUCTIONS 9- Assemblling instructions for full power version on TE-SMR models (unless specified, instructions are referred to both the models). Illustrations are merely for demonstration purposes and could not exactly match the detail described. All modifications reported below cause THE REGISTERED VEHICLE TO BE NON COMPLIANT and unsuitable for circulating on public roads: consequently it may be used only in “CLOSED CIRCUITS”...
  • Page 355 “KIT” ASSEMBLING INSTRUCTIONS INTRODUCTION Using the above mentioned parts automatically implies the modification of the central unit mapping, thus operating the vehicle at full power. The vehicle cannot be used without battery under any circumstances: do not remove the battery. If the battery is removed/disconnected while the engine is running, the injection system is damaged seriously;...
  • Page 356 “KIT” ASSEMBLING INSTRUCTIONS Throttle body plate removal Identify the cover of the throttle cable pulley of the throttle body located on the right side of the vehicle. Move away the pedal starting lever from the pulley cover. Loosen the hexagonal socket screw holding the plastic cover. Remove the screw.
  • Page 357 “KIT” ASSEMBLING INSTRUCTIONS Loosen the nuts of the throttle cables. Remove the throttle cables from their housings. Loosen both screws fastening the pulley locking plate. Remove the locking plate. Part. N. 8000 H0368 (09-2008) O.25...
  • Page 358 “KIT” ASSEMBLING INSTRUCTIONS Apply thread locking compound, e.g. “Loctite 243”, to the previously removed plate holding screws. Tighten both screws. Place the throttle cables into their housings. Tighten the throttle cables by means of the relevant nuts. Make sure that the cable has a certain clearance.
  • Page 359 “KIT” ASSEMBLING INSTRUCTIONS Position the pulley cover into its housing. Anchor the pulley cover by means of the previously removed suitable screw. Part. N. 8000 H0368 (09-2008) O.27...
  • Page 360 “KIT” ASSEMBLING INSTRUCTIONS Catalyst removal (TE) Remove the saddle and L.H. side panel. Using an 8 mm T-shaped spanner on the outside and a 10 mm T-shaped spanner on the inside, remove the locking screw of the muffler. Remove the spring between muffler and the central pipe then with an 8 mm T-shaped spanner remove the front fastening screw of the central pipe to the frame.
  • Page 361 “KIT” ASSEMBLING INSTRUCTIONS Intake silencer replacement Remove the battery then place it on the side of the bike. Remove the wing nut bolt and the air filter. Remove the intake silencer from the air filter then replace it with the filter cage 800069549 supplied with the KIT.
  • Page 362 “KIT” ASSEMBLING INSTRUCTIONS Reassemble the new air filter assy. according with the pictures. Reassemble the battery. O.30 Part. N. 8000 H0368 (09-2008)
  • Page 363 “KIT” ASSEMBLING INSTRUCTIONS Full power version components assembling Loosen the lambda probe from the exhaust pipe. DO NOT EXPOSE THE PROBE TO OIL OR SOLVENTS. Assemble the 8000A7724 probe plug with the 8000A7749 gasket. Tighten the lambda probe plug. Detach the lambda probe connector from the main wiring harness then mount in its place the connector 8000 A6750.
  • Page 364 “KIT” ASSEMBLING INSTRUCTIONS “DUAL MODE” BUTTON ASSEMBLING (TE) Dual mode button 8000H0590 The “dual mode” button allows to select the correct map according with the ground conditions (knob in rest position to select dry ground map- SEL 1 on instrument display; push knob to select wet ground map- SEL 2 on instrument display).
  • Page 365 “KIT” ASSEMBLING INSTRUCTIONS Remove the upper fastening screw of the the headlamp carrier to the instrument panuel support; push forward the headlamp carrier and pull it towards the high in order to uncouple from the two lower supports. Remove the headlamp carrier. Remove the plug on the cable located behind the headlamp carrier.
  • Page 366 “KIT” ASSEMBLING INSTRUCTIONS NOTES When turn the ignition key in position IGNITION, for the first 2 seconds, the instrument shows the version of the checking SW; after the check, the instrument shows ALWAYS the map SEL 1. The switching to SEL 2 is possible with ENGINE ON, pushing the “dual mode”...
  • Page 367 “KIT” ASSEMBLING INSTRUCTIONS “RACING” LICENSE PLATE HOLDER ASSEMBLING Remove the rear turn indicators. Licence plate holder kit 8000B1641 Drill one 6.5 mm hole on the rear mudguard as shown in the picture, then two additional holes with the same diameter matching the holes of the Racing light. Use the available screws to anchor.
  • Page 368 “KIT” ASSEMBLING INSTRUCTIONS Pass the licence plate holder cables along the rear frame. Connect the rear light connector. Reassemble the previous removed parts. O.36 Part. N. 8000 H0368 (09-2008)
  • Page 369: Hydraulic Control Clutch

    HYDRAULIC CONTROL CLUTCH Hydraulic clutch system ..........Discharge of hydraulic system fluid ......Overhaul of the control pump for clutch release ..Bleeding of the hydraulic system ....... Section Part. N. 8000 H0368 (09-2008)
  • Page 370 HYDRAULIC CONTROL CLUTCH Part. N. 8000 H0368 (09-2008)
  • Page 371: Hydraulic Clutch System

    HYDRAULIC CONTROL CLUTCH Hydraulic clutch system The hydraulic system consists of a pump with its own tank, placed on handlebar L.H. side, and a small piston, placed in the L.H. engine crankcase. The clutch desengagement is effectued by the slave cylinder (5) that, acting on the push rod, move the pressure disc (6).
  • Page 372: Discharge Of Hydraulic System Fluid

    HYDRAULIC CONTROL CLUTCH Discharge of hydraulic system fluid Connect a small plastic hose to the discharge valve and unscrew it by one or two turns. Remove the reservoir cover and the diaphragm and act release control lever until all fluid is discharged. Overhaul of the control pump for clutch release Drain the system, detach the pump from the L.H.
  • Page 373: Bleeding Of The Hydraulic System

    HYDRAULIC CONTROL CLUTCH Bleeding of the hydraulic system Proceed as follows: - remove screws (1), cap (2) and rubber pump diaphragm (4); - remove the rubber cap (3) and the bleeding nipple (5); - mount a syringe in the bleeding nipple hole, then refill with fresh fluid (see LUBRICATION TABLE on page A.9).
  • Page 374 HYDRAULIC CONTROL CLUTCH Part. N. 8000 H0368 (09-2008)
  • Page 375: Optional Parts List

    OPTIONAL PARTS LIST Section Part. N. 8000 H0368 (09-2008)
  • Page 376 OPTIONAL PARTS LIST OPTIONAL PARTS LIST (TE) Pos. Code Nr. NAME MODELS 8A0096837 REAR SPROCKET Z=47 (1) 250-310 8B0096837 REAR SPROCKET Z=48 (1) 250-310-450-510 8C0096837 REAR SPROCKET Z=49 (1) 250-310-450-510 8D0096837 REAR SPROCKET Z=50 (1) 450-510 800063829 DRIVE SPROCKET Z=14 (1) 250-310-450-510 800063827 DRIVE SPROCKET Z=12 (1)
  • Page 377 OPTIONAL PARTS LIST OPTIONAL PARTS LIST (SMR) Pos. Code Nr. NAME MODELS 8A00A4859 REAR SPROCKET Z=43 450-510 8B00A4859 REAR SPROCKET Z=44 450-510 8G00A4859 REAR SPROCKET Z=45 450-510 800063829 DRIVE SPROCKET Z=14 450-510 8000H0772 LICENCE PLATE HOLDER KIT RACING (1) 450-510 8000A5982 ENGINE GASKET KIT 450-510...
  • Page 378 OPTIONAL PARTS LIST Part. N. 8000 H0368 (09-2008)
  • Page 379: Fuel Injection System

    FUEL INJECTION SYSTEM Fuel injection system .............. S.2 Operating instructions for the "DIAGNOSIS SOFTWARE KIT" on the fuel injection ....S.3 Fuel pump check ..............S.5 Relay check ................S.6 Section Part. N. 8000 H0368 (09-2008)
  • Page 380 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM The fuel injection system consists of: fuel tank (1), electric pump (2), hose (3) and injector (4). The fuel in the tank is pumped by the fuel pump and the pressurized fuel flows into the injector installed in the throttle body (6). The fuel is injected into the throttle body with a conical dispersion when the injector opens according to the injection signal coming from the Electronic power unit (5) located under the fuel tank.
  • Page 381 FUEL INJECTION SYSTEM Operating instructions for the "DIAGNOSIS SOFTWARE KIT" on the fuel injection system Premised that the fuel injection system doesn’t need any programmed maintenance, the Diagnosis Software Kit code no. 8000 A9634 allows to effect the check of the components of the fuel injection system in case of malfunction. In case of malfunction on the right side of the instrument display will be dis- played the warning message “FAIL”, with the ignition key in ON position and the right commutator in RUN position.
  • Page 382 FUEL INJECTION SYSTEM This diagnosis software allows, besides the identification of the malfunctions in progress, also the memorization of those that are already occurred and that have been eliminated: for these last ones it is possible to effect the cancellation, following the instructions of the Operation Manual (page 29).
  • Page 383 FUEL INJECTION SYSTEM Fuel pump check Remove the pump as shown on page S.2. - A: reserve sensor Check that in the reserve sensor has not remained any gasoline therefore set the meter on "Impedance" position and effect the reading on the cables BLUE and WHITE.
  • Page 384 FUEL INJECTION SYSTEM Relay check Remove the saddle and the the fuel tank as shown on pages E.15-E.23. Re- move the relays (1) located on the frame, R.H. side (no. 1) and L.H. side (no. 2). A: set the meter on "Impedance" position and check that the exciter coil func- tions properly;...
  • Page 385: Lubrication System

    LUBRICATION SYSTEM Section Part. N. 8000 H0368 (09-2008)
  • Page 386 LUBRICATION SYSTEM LUBRICATION SYSTEM PARTS NAME Double net filter Main oil pump Easy-change filter Piston - D.C. roller bearing - Conn.-rod - Starter driver wheel Camshaft (Intake) Camshaft (Exhaust) Spark and timing chamber Cranking mechanism chamber Net filter Oil pump for secondary circuit Mainshaft Counter shaft Primary drive driven gear...
  • Page 387 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM Part. N. 8000 H0368 (09-2008)
  • Page 388 LUBRICATION SYSTEM Part. N. 8000 H0368 (09-2008)
  • Page 389: Specific Tools

    SPECIFIC TOOLS Section Part. N. 8000 H0368 (09-2008)
  • Page 390 SPECIFIC TOOLS SPECIAL TOOLS 1- (1517 94702) Crankcase puller 2- (8000 A1580) Crankshaft guard 3- (8000 A1559) Flywheel extractor (TC-TXC) 3- (8000 B0144) Flywheel extractor (TE-SMR) 4- (8000 39521) Valves assembling and removing tool 5- (8A00 90662) Support for assy 6- (8000 A9634) Diagnosys kit (TE-SMR) *6A- (8000 H0237) Control unit - Reprogramming kit (TE-SMR) 8- (8000 A1625) Dial gauge holding tool...
  • Page 391: Torque Wrench Settings

    TORQUE WRENCH SETTINGS Section Tighten all nuts and bolts with a torque wrench at the correct setting. Insufficient tightening of nuts or bolts can cause them to become damaged or loose leading to vehicle damage or injury to the rider. Overtightening a nut or bolt can strip its thread or cause breakage.
  • Page 392 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) ENGINE Application Camshaft cap fastening screw M6x1 12 Nm 1,2 Kgm 8.7 ft/lb Rocker arm axle plug M14x1,5 (+LOCTITE 243) 25 Nm 2,55 Kgm 18.4 ft/lb Cylinder head cover fastening screw M6x1 0,8 Kgm 5.8ft/lb Cylinder head fastening nut M8x1,25...
  • Page 393 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Rear frame lower fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb Engine guard fastening screw M6x1 14,7 Nm 1,5 Kgm 10.8 ft/lb Rear chain roller fastening screw M8x1,25 26,95 Nm 2,75 Kgm 19.9 ft/lb Side stand fastening screw M8x1,25 (+LOCTITE 243) 11,75 Nm 1,2 Kgm 8.7 ft/lb...
  • Page 394 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Frame to tie rod fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb Rocker arm to tie rod lubricator M6x1 2,95 Nm 0,3 Kgm 2,2 ft/lb Rear shock absorber to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb Rocker arm to frame fastening pivot...
  • Page 395 TORQUE WRENCH SETTINGS TIGHTENING TORQUES (+/- 5%) CHASSIS Application Air filter box flange fastening nut M5x0,8 3,45 Nm 0,35 Kgm 2.5 ft/lb Front brake caliper fastening screw (TE- TC) M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb Brake hoses lower fastening screw M10x1 19 Nm 1,95 Kgm 14 ft/lb...
  • Page 396 TORQUE WRENCH SETTINGS NOTE: If not otherwise specified, standard tightening torques for the following thread (+/- 5%) steel screws on plastic with metal spacer 2 Nm 0,2 Kgm 1.45 ft/lb steel screws on brass, copper, aluminium 2 Nm 0,2 Kgm 1.45 ft/lb steel screws on iron, steel 3 Nm...
  • Page 397 FRAME AND WHEELS Frame ............... Front wheel ............... Removing the front wheel ......... Reassembling the front wheel ........Rear wheel ............... Y.10 Removing rear wheel ..........Y.11 Wheels overhauling ..........Y.12 Bending the wheel pin ..........Y.12 Wheel spokes ............Y.13 Rims warpage ............
  • Page 398: Frame

    FRAME AND WHEELS FRAME The single-beam frame splits approximately at the exhaust level and includes round, rectangular and elliptic section steel pipes; light alloy rear frame. For a rough check, please see the picture. The size indicated enable to see if the frame should be realigned or replaced. The frames seriously damaged should be replaced.
  • Page 399 FRAME AND WHEELS STANDARD mm (in.) AXIS “X” “Y” -576.7 +440.5 (22.7) (17.34) -460 +423 (18.11) (16.65) -442 +259 (17.40) (10.19) -394.2 +337.2 (15.52) (13.27) -311 +23.2 (12.24) (0.91) -302.4 +1.8 (11.9) (0.07) -262.5 -81.5 (10.33) (3.2) -240.8 -95.9 (9.48) (3.77) +65.5 +170...
  • Page 400 FRAME AND WHEELS Check the assemblies shown on the picture for wear or failure. If worn or breaked, replace them. A. ENGINE FASTENING BOLTS B. REAR FRAME FASTENING BOLTS C. CHAIN GUIDE ROLLER-BEARING D. FOOTRESTS-PIVOTS-SPRINGS E. SIDE STAND- SPRINGS Part. N. 8000 H0368 (09-2008)
  • Page 401: Front Wheel

    FRAME AND WHEELS TE-TC-TXC Front wheel Hub and rim in light alloy with high tensile steel spokes. Rim make, type and dimension (TE, TC, TXC) "TAKASAGO"" Excel in light alloy: 1.6x21” (SMR) "SANREMO" in light alloy: 3.50x17” Tire make, type and dimension (TE, TXC) "Michelin"...
  • Page 402 FRAME AND WHEELS Removing the front wheel (pages Y.6-Y.7) Set a stand or a block under the engine and see that the front wheel is lifted from the ground. SMR: remove the two screws (A) and the brake caliper. Loosen the screws (1) fastening the wheel axle (2) to the fork rod supports. TE-TC-TXC TE-TC-TXC Lock the wheel pin head and at the same time loosen the screw (3) on the...
  • Page 403 FRAME AND WHEELS Do not operate the front brake lever when the wheel has been removed; this causes the caliper piston to move outwards. After removal, lay down the wheel with brake disc on top. Part. N. 8000 H0368 (09-2008)
  • Page 404 FRAME AND WHEELS Reassembling the front wheel (pages Y.8-Y.9) Fit the L.H. spacer on the wheel hub. TE-TC-TXC TE-TC-TXC: Fit the wheel between the front fork legs so that the brake disc is fitted TE-TC-TXC into the caliper. SMR: Fit the wheel between the front fork legs. Fit the wheel axle (2) from the R.H.
  • Page 405 FRAME AND WHEELS Tighten the screw (3) on the fork L.H. side but DO NOT lock it. Now, pump for a while, TE-TC-TXC pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned. Lock: the screws (1) on the R.H. leg (10,4 Nm/ 1,05 Kgm/ 7.7 ft-lb), the screw (3) on the L.H.
  • Page 406: Rear Wheel

    FRAME AND WHEELS Rear wheel Hub and rim in light alloy with high tensile steel spokes. Rim make, type and dimension (TE, TXC) "TAKASAGO“ Excel in light alloy: 2,15x18” (TC) "TAKASAGO“ Excel” in light alloy: 1,85x19”(250); 2,15x19”(450-510) (SMR) "SANREMO" in light alloy: 4,25x17” Rim make, type and dimension (TE, TXC) “Michelin”...
  • Page 407 FRAME 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 pin (3) and extract it. It is not necessary to unloose the chain adjusters (2);...
  • Page 408: Wheels Overhauling

    FRAME AND WHEELS Wheels overhauling Check the wear state of the hub bearings. In case of excessive clearance (radial and axial), operate as follows: - lay the hub on a flat holder with hole, allowing for the passage of the removed bearing;...
  • Page 409: Wheel Spokes

    FRAME AND WHEELS WHEEL SPOKES Check to make sure that all the nipples are tight (4,4 Nm/ 0,45 Kgm/ 3.2 ft-lb); tighten them if necessary. Remember that an insufficient stretch jeopardizes the motorcycle stability. For an instant check, use a metal point (for instance, a screwdriver) to beat the spokes with.
  • Page 410 FRAME AND WHEELS Rear sprocket, transmission sprocket and drive chain The figure shows the outline of teeth in normal and excessive wear. 1- Normal consumption 2- Excessive consumption Should the sprocket be badly worn out, replace it by loosening the six fastening screws to the hub.
  • Page 411 FRAME AND WHEELS CHECKING THE WEAR OF CHAIN, PINION AND SPROCKET Proceed as follows: - Fully stretch the chain with the adjusting screws. - Mark 20 chain links. - measure the distance “A” between 1st pin center and 21 st pin center. Check the pinion damages or wear and replace it should the wear degree be as the one shown in figure.
  • Page 412 FRAME AND WHEELS Y.16 Part. N. 8000 H0368 (09-2008)