Piaggio Typhoon 125 4T MY 2010 (en)

MANUALE STAZIONE DI SERVIZIO 677205(IT)-677206(EN)-677207(FR)-677208 (DE)-677209(ES)-677210(NL)-677211(PT)-677212 (EL)

Typhoon 125 4T (MY 2010)

MANUALE STAZIONE DI SERVIZIO


The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official Piaggio sales network. "© Copyright 2010 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com

MANUALE STAZIONE DI SERVIZIO Typhoon 125 4T (MY 2010) Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS

CHAR

TOOLING

TOOL

MAINTENANCE

MAIN

TROUBLESHOOTING

TROUBL

ELECTRICAL SYSTEM

ELE SYS

ENGINE FROM VEHICLE

ENG VE

ENGINE

ENG

SUSPENSIONS

SUSP

BRAKING SYSTEM CHASSIS PRE-DELIVERY TIME

BRAK SYS CHAS PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR


Characteristics

Rules This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.

CHAR - 7


Characteristics

Vehicle identification Chassis prefix LBMM701 Engine prefix M701M

Dimensions and mass

WEIGHTS AND DIMENSIONS Specification Maximum length Overall width Max. height to the windshield Wheelbase Kerb weight

Desc./Quantity 1947 730 1130 mm 1355 117 kg

Engine ENGINE Specification Engine

CHAR - 8

Desc./Quantity Single cylinder 4-stroke


Characteristics

Specification Timing system Valve clearance

Desc./Quantity Single overhead camshaft (SOHC) with 2 valves intake 0.10 exhaust 0.15 57 x 48.6 mm 124 cm³ (10.6+/-0.5):1 KEIHIN CVEK26 approx. 1.600 ÷ 1.800 rpm starter 10.5 CV at 8000 rpm Forced-circulation air cooling.

Bore x stroke Engine capacity Compression ratio carburettor Engine idle speed Starter Max power to the shaft Cooling

Transmission TRANSMISSION

Specification Transmission

Desc./Quantity With continuously variable expandable pulley transmission with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling.

Capacities CAPACITY Specification Engine oil Rear hub oil Fuel tank capacity Fork stem (oil level height without spring, compressed fork)

Desc./Quantity 1.10 l approx. 250 cc ~ 7.0 litres (2.0 l of which is reserve) 85 mm

Electrical system ELECTRICAL SYSTEM Specification Starter Spark plug Ignition advance Battery Fuses Ignition type Alternator

Desc./Quantity starter Champion NGK CR7EB - RG6YC 15° ± 1° at 2,000 rpm 12 V / 10 Ah No. 1 20A, No. 1 15A, No. 1 7.5A Electronic capacitive discharge ignition (CDI) and variable advance, with separate HV coil. alternating current

Frame and suspensions CHASSIS AND SUSPENSION Specification Chassis Front suspension Rear suspension

Desc./Quantity Tubular steel frame Ø 35 Hydraulic telescopic fork - travel: 90 mm Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 80 mm.

CHAR - 9


Characteristics

Brakes BRAKES Specification Front brake

Desc./Quantity Disc brake (Ø 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Ø 110mm drum brake

Rear brake

Wheels and tyres WHEELS AND TYRES Specification Front wheel rim Front tyre Rear wheel rim Rear tyre Front tyre pressure Rear tyre pressure Rear wheel pressure (rider and passenger):

Secondary air In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the silencer. To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS). This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter. The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise. To ensure the best functioning of the SAS system, every 12,000 km the vehicle should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section).

CHAR - 10

Desc./Quantity Die-cast aluminium alloy; 3.50 x 10" Tubeless 120/80 -10" Die-cast aluminium alloy: 3.50"x10" Tubeless 120/80 - 10" 1.5 bar 1.8 bar 2.0 bar


Characteristics

The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air. CAUTION

CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CARRY OUT THESE OPERATIONS.

Carburettor 125cc Version Kehin CARBURETTOR SETTING Specification Type Throttle valve diameter Diffuser diameter Setting stamping Maximum jet Maximum air jet (on the body) Tapered pin stamping Throttle valve spring Minimum jet Idle air jet (on the body) Idle mixture adjustment screw initial opening Starter nozzle Starter air jet (on the body) Starter pin travel Starter resistance

Desc./Quantity CVEK26 Ø 26.5 Ø 26.4 262A 82 85 NELA 130 ÷ 180 gr. 35 150 1¾ 42 Ø 1.5 10 mm (at 24°) 20 Ohm (at 24°)

Tightening Torques HEAD AND CYLINDER Name Ignition spark plug Head cover screws Nuts fixing head to cylinder (*) Head fixing screws (external) Starter ground screw Flywheel air duct screw Pressure reducer counterweight retainer Camshaft pulley screw Timing chain tensioner slider screw Starter counterweight support screw Tightener screw: Timing chain tensioner central screw Camshaft retention plate screw Nut fixing silencer to cylinder head Head intake manifold screw

Torque in Nm 18 Nm 11 to 13 28 to 30 11 to 13 7 to 8.5 3 to 4 7 to 8.5 12 to 14 10 to 14 11 to 15 5 to 6 5 to 6 5 to 6 16 to 18 11 to 13

(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.

CHAR - 11


Characteristics

TRANSMISSION Name Drive pulley nut (°) Transmission cover screw Driven pulley shaft nut Rear hub cap screws Clutch unit nut on driven pulley

Torque in Nm 75 - 83 11 to 13 54 to 60 24 to 27 55 to 60

(°) Apply LOCTITE 243 threadlock

FLYWHEEL Name Flywheel fan screws Stator assembly screws (°) Flywheel nut Pick-up screw

Torque in Nm 3 to 4 3 to 4 52 to 58 3 to 4

(°) Apply LOCTITE 243 threadlock

CRANKCASE AND CRANKSHAFT Name Internal engine crankcase bulkhead (transmission-side half shaft) screws Oil filter on crankcase fitting Rear brake cam tightening screw Engine-crankcase coupling screws Pre-filter cap Starter screws Silencer to crankcase fixing screws Engine oil drainage cap Oil sump screws Oil pump central screw Oil pump cover screws Minimum oil pressure switch

Torque in Nm 4 to 6 27 to 33 11 to 13 11 to 13 24 to 30 11 to 13 24 to 27 24 to 30 11 to 13 12 to 14 0.7 - 0.9 12 to 14

STEERING ASSEMBLY Name Upper steering ring nut Lower steering ring nut Handlebar fixing screw Mirror fastening spacer

Torque in Nm 30 to 36 10 - 13 (loosen by 90°) 45 to 50 25

CHASSIS ASSEMBLY Name Engine arm pin - chassis arm Centre stand pivot on engine Silent block-swinging arm retaining bolts

Torque in Nm 45.5 42.5 42.5

FRONT SUSPENSION Name Piston tightening fork lower screw Front wheel axle nut Fork clamp screw Fork stanchion upper cap Safety screw on fork leg

Torque in Nm 25 - 35 45 - 50 20 to 25 15 ÷ 30 6-7

FRONT BRAKE Name Brake fluid hose-pump fitting Brake fluid pipe-calliper fitting Calliper to fork tightening screw Disc tightening screw Oil bleed screw

CHAR - 12

Torque in Nm 20 to 25 20 to 25 20 to 25 8 to 12 8 to 12


Characteristics

Name Pump U bolt screw Brake pad fastening screw

Torque in Nm 8 15 to 20

REAR SUSPENSION Name Rear wheel axle Shock absorber nut

Torque in Nm 115 22.5

FUEL TANK UNIT Name Fuel tank to chassis fixing screw

Torque in Nm 10

SADDLE UNIT Name Saddle plate fixing nut

Torque in Nm 10

BODYWORK UNIT Name Helmet compartment fixing screw Rear grab handle fixing screw Battery cover fixing screw Front wheel housing to chassis fixing screw Front wheel housing to leg shield back plate fixing screw Front mudguard fixing screw Footrest fixing screw Screw fixing leg shield back plate to chassis Leg shield back plate to leg shield fixing screw Footrest spoiler fixing screw Passenger footrest protection fixing screw Passenger footrest to side body panel fixing screw Rear mudguard fixing screw Rear brake adjustment nut

Torque in Nm 3 20.5 6 6 3 6 6 6 3 6 3 6 6 5

Overhaul data Assembly clearances Cylinder - piston assy. 125 version

PISTON TO CAST IRON CYLINDER COUPLING (125) Name Coupling Coupling Coupling Coupling Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 3rd oversize

Initials M N O P M1 N1 O1 P1 M2 N2 O2 P2 M3

Cylinder 56.997 to 57.004 57.004 to 57.011 57.011 to 57.018 57.018 to 57.025 57.197 to 57.204 57.204 to 57.211 57.211 to 57.218 57.218 to 57.225 57.397 to 57.404 57.404 to 57.411 57.411 to 57.418 57.418 to 57.425 57.597 to 57.604

Piston 56.944 to 56.951 56.951 to 56.958 56.958 to 56.965 56.965 to 56.972 57.144 to 57.151 57.151 to 57.158 57.158 to 57.165 57.165 to 57.172 57.344 to 57.351 57.351 to 57.358 57.358 to 57.365 57.365 to 57.372 57.544 to 57.551

Play on fitting 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060

CHAR - 13


Characteristics

Name Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize

Initials N3 O3 P3

Cylinder 57.604 to 57.611 57.611 to 57.618 57.618 to 57.625

Piston 57.551 to 57.558 57.558 to 57.565 57.565 to 57.572

Play on fitting 0.046 to 0.060 0.046 to 0.060 0.046 to 0.060

Dimensions 57 x 1 57x1 57x2.5 57.2 x 1

Initials A A A A

Quantity 0.15 to 0.30 0.10 to 0.30 0.10 to 0.35 0.15 to 0.30

57.2x1

A

0.10 to 0.30

57.2x2.5

A

0.10 to 0.35

57.4x1

A

0.15 to 0.30

57.4x1

A

0.10 to 0.30

57.4x2.5

A

0.10 to 0.35

57.6x1

A

0.15 to 0.30

57.6x1

A

0.10 to 0.30

57.6x2.5

A

0.10 to 0.35

Piston rings SEALING RINGS (125) Name Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Description

Maximum clearance after use: 1 mm

Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Transmissionside halfshaft Flywheel-side halfshaft Connecting rod with PP Crank pin width

Description

Dimensions 16.6 +0-0.05

Initials A

Quantity D = 0.20 to 0.50

16.6 +0-0.05 18 -0.10 -0.15 51.400

B C E

D = 0.20 to 0.50 0.20 to 0.50

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS Name Crankshaft Crankshaft

CHAR - 14

Description

Dimensions

Initials Category 1 Category 2

Quantity 28.998 to 29.004 29.004 to 29.010


Name Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2

Description

Characteristics

Dimensions

Initials Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E

Quantity 32.953 to 32.959 32.959 to 32.965 1.973 to 1.976 1.976 to 1.979 1.979 to 1.982

C-C C-C B-B

Crankshaft/crankcase axial clearance: 0.15 to 0.40

Slot packing system - Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure. - Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation) - Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio. - Remove the special tool and the cylinder.

Characteristic Compression ratio 10.6: 1

CHAR - 15


Characteristics

SHIMMING SYSTEM Specification Value measured Thickness Value measured Thickness Value measured Thickness

Desc./Quantity 0 to 0.1 0.8 ± 0.05 0.1 to 0.3 0.6 ± 0.05 0.3 - 0.4 0.4 ± 0.05

Products RECOMMENDED PRODUCTS TABLE Product AGIP ROTRA 80W-90

Description rear hub oil

AGIP CITY HI TEC 4T

Oil to lubricate flexible transmissions (brakes, throttle control and odometer) Oil for air filter sponge

AGIP FILTER OIL AGIP CITY HI TEC 4T AGIP GREASE MU3 AGIP BRAKE 4 AGIP GREASE PV2

AGIP GP 330 AGIP FORK 7.5 W

CHAR - 16

Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil for 4-stroke engines

Mineral oil with specific additives for increased adhesiveness Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil Grease for odometer transmission gear Soap-based lithium grease with NLGI 3; case ISO-L-XBCHA3, DIN K3K-20 Brake fluid FMVSS DOT 4 Synthetic fluid Grease for steering bearings, bolt seatSoap-based lithium and zinc oxide ings for swinging arms and faying surface grease containing NLGI 2; ISO-Lof driven pulley spring (only pulley side) XBCIB2 Grease for brake lever, gas White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 Fork oil Grade 7.5 W

INDEX OF TOPICS

TOOLING

TOOL


Tooling

SPECIFIC TOOLS

TOOL - 18

Stores code 001330Y

Description Tool for fitting steering seats

001467Y009

Driver for OD 42-mm bearings

001467Y013

Calliper to extract ø 15-mm bearings

002465Y

Calliper for circlips

005095Y

Engine support

006029Y

Punch for fitting fifth steering bearing on steering tube

008564Y

Flywheel extractor


Tooling

Stores code 020004Y

Description Punch for removing steering bearings from headstock

020055Y

Wrench for steering tube ring nut

020074Y

Support base for checking crankshaft alignment

020150Y

Air heater mounting

020151Y

Air heater

020193Y

Oil pressure check gauge

020201Y

Spacer bushing driving tube

TOOL - 19


Tooling

TOOL - 20

Stores code 020262Y

Description Crankcase splitting plate

020263Y

Driven pulley assembly sheath

020271Y

Tool for removing-fitting silent bloc

020306Y

Punch for assembling valve seal rings

020329Y

Mity-Vac vacuum-operated pump

020330Y

Stroboscopic light to check timing


Tooling

Stores code 020331Y

Description Digital multimeter

020332Y

Digital rpm indicator

020334Y

Multiple battery charger

020335Y

Magnetic mounting for dial gauge

020357Y 020359Y

32x35-mm Adaptor 42x47-mm Adaptor

TOOL - 21


Tooling

TOOL - 22

Stores code 020360Y

Description 52x55-mm Adaptor

020363Y

20-mm guide

020364Y

25-mm guide

020368Y

driving pulley lock wrench

020375Y

28 x 30 mm adaptor

020376Y

Adaptor handle


Tooling

Stores code 020382Y

Description Valve cotters equipped with part 012 removal tool

020382Y011

adapter for valve removal tool

020409Y

Multimeter adaptor - Peak voltage detection

020412Y

15-mm guide

020423Y

Driven pulley lock wrench

TOOL - 23


Tooling

TOOL - 24

Stores code 020424Y

Description Driven pulley roller casing fitting punch

020425Y

Punch for flywheel-side oil seal

020426Y

Piston fitting fork

020427Y

Piston assembly band

020428Y

Piston position check mounting

020430Y

Pin lock fitting tool


Tooling

Stores code 020431Y

Description Valve oil seal extractor

020434Y

Oil pressure check fitting

020439Y

17-mm guide

020444Y

Tool for fitting/ removing the driven pulley clutch

020456Y 020565Y

Ø 24 mm adaptor Flywheel lock calliper spanner

020622Y

Transmission-side oil seal punch

TOOL - 25

Tooling

TOOL - 26


INDEX OF TOPICS

MAINTENANCE

MAIN


Maintenance

Maintenance chart Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it. It is indispensable to have your vehicle serviced to the prescribed intervals of time, even if you have not reached the predicted mileage. Punctual vehicle servicing is necessary for the correct use of the guarantee. For all further information regarding the Guarantee application modes and the execution of the "Programmed Maintenance" refer to the "Guarantee Booklet".

SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check level every 3000 km ** Replace every 2 years *** Replace every 4 years Km x 1,000 Safety fasteners Spark plug Transmission cables and controls Driven pulley roller casing Drive belt Air filter Rear brake shoes Electrical system and battery Braking systems Light circuit Brake fluid ** Exhaust muffler/ silencer Engine oil filter Valve clearance Hub oil Engine oil* Rear brake cam pin Headlight Vehicle test and brake test - Road test Brake pads Electric starter gear pins Wheels/tyres CVT rollers / Sliding shoes Idle speed Suspension Steering Braking system pipes*** Transmission Fuel pipes ***

1 I

6 I

A

I I I I R R R R

I C I I I I I R R I R L

A I I

I I

I

I

A I I

I I

12 I R A L R C I I I I I I R R I R L I I L I R A I I I L I

18 I

I C I I I I I R R I R L A I I I

I I

24 I R A L R C I I I I I I R R R R L

30

I I L I R A I I I L I

I I

I

I C I I I I I R R I R L

I

I I

36 I R A L R C I I I I I I R R I R L A I I L I R A I I I L I

42 I

I C I I I I I R R I R L I I I

I I

48 I R A L R C I I I I I I R R R R L I I L I R A I I I L I

54 I

I C I I I I I R R I R L A I I I

I I

60 I R A L R C I I I I I I R R I R L I I L I R A I I I L I

Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. MAIN - 28


Maintenance

- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug). - Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines). - Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm). - If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire). - Operating on the flash bulb phase difference calibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified.

Characteristic Ignition advance check 15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm

Spark advance variation ADVANCE VARIATION Specification Operation threshold Reactivation threshold

Desc./Quantity First threshold: 9000±50 Second threshold: 9300±50 First threshold: 8900±50 Second threshold: 9200±50

MAIN - 29


Maintenance

Specification Spark elimination

Spark plug Place the vehicle on its central stand - Remove the central cover; - Detach the coil from the chassis, leaving it connected to the system, and disconnect the spark plug H.V. cable cap - Unscrew the spark plug using the socket wrench supplied. -Examine the condition of the spark plug, check that the insulating material is whole and measure the distance between the electrodes using a feeler gauge. -Adjust the distance if necessary by bending the side electrode very carefully. In the case of defects, replace the spark plug with one of the specified type. MAIN - 30

Desc./Quantity First threshold: 1 spark on 7 Second threshold: 2 sparks on 3


Maintenance

- Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque. - Fit the cap on the spark plug as far as it will go. - Refit the coil and the central cover. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5,000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.

Electric characteristic Recommended spark plug NGK CR7EB Alternative spark plug CHAMPION RG6YC Electrode gap 0.6 to 0.7 mm.

Locking torques (N*m) Ignition spark plug 18 Nm

See also Chassis

Hub oil

MAIN - 31

Maintenance

Check Do the following to check the correct level: - Ride a few kilometres until the regular working temperature is reached, then stop the engine. - Park the vehicle on level ground and rest it on the centre stand. - Unscrew the oil filler dipstick, dry it with a clean cloth and reinsert it. - Remove the dipstick and make sure that the oil level reaches the indicated reference notch. - Screw up the oil dipstick back in and make sure it is locked properly in place.

Recommended products AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Replacement - Ride a few kilometres until the regular working temperature is reached, then stop the engine. - Park the vehicle on level ground and rest it on the centre stand. - Remove the oil filler dipstick and drain out the oil completely. - Screw in the drainage cap again and fill the hub with the prescribed oil. - Check the level. - Screw the oil filler dipstick back into place, being sure it is completely blocked.

Characteristic Rear hub oil Quantity: approx. 250 cc

MAIN - 32



Maintenance

Air filter - Remove the cap of the air cleaner, unscrewing the five screws and the fixing knob. - Take out the filtering element. Cleaning: - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of compressed air. -Saturate with a 50% mixture of gasoline and oil. - Drip dry the filtering element and then squeeze it with your hands without wringing. -Let it dry and refit it again. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness

FILTER BOX REMOVAL - Undo the two screws indicated.

- Loosen the indicated clamps and slide off the filter box.

MAIN - 33

Maintenance


Engine oil Replacement Change oil as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore to facilitate oil drainage, loosen the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. Since a certain quantity of oil still remains in the circuit, fill adding approx. 600 - 650 cm³ of oil through the cap. Then start up the vehicle, leave it running for a few minutes and switch it off: After about five minutes, check the level and, if necessary, top-up but never exceeding the MAX level reference mark. N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Locking torques (N*m) Engine oil drainage cap 24 to 30

See also Engine oil filter

Check In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption can particularly reflect the conditions of use (i.e. when driving at 'full acceleration' all the time, oil consumption increases). MAIN - 34


Maintenance

This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely. 3) Remove the cap/dipstick again and check that the level is between the max. and min levels; topup, if required. The MAX level reference mark indicates the amount of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Characteristic Engine oil 1.10 l The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level between the MIN and MAX reference marks requires ~ 400 cm³ of oil.

Engine oil filter The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has started.

MAIN - 35

Maintenance


If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

transmissions Put the vehicle in gear and regulate the idling by turning the adjustment screw on the left-hand side of the carburettor. Adjust the control cables as follows. Handlebar control: - remove the front handlebar cover leaving it connected to the system; - remove the rubber hoods and regulate the cable adjustments in such a way that they cause a minimum clearance on the throttle. Carburettor control: - remove the inspection cover of the helmet compartment; - remove the rubber hoods and regulate the cable adjustments in such a way that the sheaths have a minimum clearance.

MAIN - 36


Maintenance

Checking the ignition timing -Remove the flywheel fan. -Rotate the flywheel until the reference (arrow) matches the crankcase operation end as shown in the figure (TDC). Make sure that the 2V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction of rotation using a compass spanner applied to the camshaft drive sprocket housing. N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.

Checking the valve clearance -To check valve clearance, centre the reference marks of the timing system - Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with a screwdriver. Intake: 0.10 mm (when cold) Exhauste: 0.15 mm (when cold)

Braking system

MAIN - 37

Maintenance

Level check Proceed as follows: - Rest the vehicle on its centre stand with the handlebars perfectly horizontal; - Check the fluid level through the corresponding sight glass. A certain lowering of the level is caused by wear on the brake pads.

Top-up Proceed as follows: - Undo the two screws and remove the cover with the seal. - Top-up using only the fluid specified, without exceeding the maximum level. CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS. N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

MAIN - 38



Maintenance

Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the borderline of the projected light beam on the screen is no higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of the vehicle's headlamp; 3. Otherwise, adjust the headlight by turning the knobs of the body inside the wheel housing. - Tighten the screw (clockwise) to raise the light beam; - undo the screw (anticlockwise) to lower the light beam. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

CO check - Remove the inspection cover of the SAS valve, by undoing the three indicated screws. - Remove the clamp and the secondary air valve as shown in the photograph. - Connect the exhaust fumes outlet tube with the secondary air tube rubber sleeve. This connection should guarantee the system tightness to avoid distorting the CO value reading N.B. IN CASE OF 1000 PPM UNBURNED HYDROCARBONS (HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS. N.B.

MAIN - 39

Maintenance

IN CASE OF UNSTABLE CO, CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY N.B. OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT. N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION.

Specific tooling 020332Y Digital rpm indicator

Characteristic CO Check 3.8±0.7 to 1650±50 RPM

SAS filters inspection and cleaning - Remove the screw fixing the SAS valve to the flywheel cover, indicated in the photograph.

- Remove the 4 flywheel cover screws indicated in the photograph and remove the flywheel cover.

MAIN - 40



Maintenance

- Remove the filter indicated in the photograph. - Check the condition of the fan cover gasket and its correct positioning. - Check the SAS filter housing for dents or deformations - Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in reverse order. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER

MAIN - 41

INDEX OF TOPICS

TROUBLESHOOTING

TROUBL


Troubleshooting

Engine Poor performance POOR PERFORMANCE Possible Cause Air filter blocked or dirty.

Fuel nozzles or cock clogged or dirty Dirty or faulty vacuum-operated cock Failing automatic starter on the carburettor Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess of scales in the combustion chamber Incorrect timing or worn timing system elements Silencer obstructed Inefficient automatic transmission

Wrong valve adjustment Overheated valves Valve seat distorted Worn cylinder, Worn or broken piston rings

Operation Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (AGIP Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble. Dismantle, wash with solvent and dry with compressed air Check the filter on the cock, remove the petrol and wash the tank, if necessary. Replace the cock as a last resource. Check the electrical wiring and mechanical movement, replace if necessary. Check it and replace, if necessary Replace the worn parts Check for causes and fill to reach the correct level Descale the cylinder, the piston, the head and the valves Time the system again or replace the worn parts Replace Check the rollers and the pulley movement, replace the damaged parts and lubricate the driven pulley moveable guide with Montblanc Molybdenum Grease Adjust the valve clearance properly Remove the head and the valves, grind or replace the valves Replace the head unit Replace the piston cylinder assembly or just the piston rings

Rear wheel spins at idle REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Idling rpm too high Clutch fault

Operation Adjust the engine idle speed and the CO%, if necessary. Check the springs / clutch masses

Starting difficulties START-UP PROBLEMS Possible Cause Flat battery

Faulty spark plug or incorrect ignition advance Engine flooded

Incorrect valve sealing or valve adjustment Rpm too low at start-up or engine and start-up system damaged Altered fuel characteristics Vacuum operated cock failure

Operation Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Replace the spark plug or check the ignition circuit components Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to expel the fuel excess taking care to connect the cap to the spark plug, and this in turn to the ground. If the fuel tank is empty, refuel and start up. Inspect the head and/or restore the correct clearance Check starter motor Drain off the fuel no longer up to standard; then, refill Check that fuel is adequately supplied through the pipe by applying a vacuum to the vacuum pipe

TROUBL - 43


Troubleshooting

Possible Cause Failing automatic starter on the carburettor Start-up enabling buttons failure Carburettor nozzles clogged or dirty Air filter blocked or dirty.

Operation Check the electrical wiring and mechanical movement, replace if necessary. Check continuity using an Ohm meter, with the switch pressed; replace if necessary Dismantle, wash with solvent and dry with compressed air Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (AGIP Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.

Excessive oil consumption/Exhaust smoke EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST Possible Cause Worn valve guides Worn valve oil seal Oil leaks from the couplings or from the gaskets Worn or broken piston rings or piston rings that have not been fitted properly

Operation Check and replace the head unit if required Replace the valve oil seal Check and replace the gaskets or restore the coupling seal Replace the piston cylinder unit or just the piston rings

Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause By-Pass remains open Oil pump with excessive clearance Oil filter too dirty Oil level too low

Operation Check the By-Pass and replace if required. Carefully clean the By-Pass area. Perform the dimensional checks on the oil pump components Replace the cartridge filter Restore the level by adding the recommended oil type.

Engine tends to cut-off at full throttle THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLE Possible Cause Maximum jet clogged Water or condensation in the carburettor chamber Level in chamber too low

Operation Remove the carburettor, wash with solvent and dry with compressed air Remove the tank, wash with solvent and dry with compressed air Restore the level in the chamber by bending on the float the thrusting reed of the petrol intake rod so as to have the float parallel to the chamber level with the carburettor inverted.

Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause Incorrect idle adjustment Incorrect timing The starter remains on Faulty spark plug or incorrect ignition advance Pressure too low at the end of compression Minimum nozzle dirty

TROUBL - 44

Operation Adjust using the rpm indicator Time the system and check the timing system components Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if necessary Replace the spark plug or check the ignition circuit components Check the thermal group seals and replace worn components Wash the nozzle with solvent and dry with compressed air


Troubleshooting

High fuel consumption EXCESSIVE FUEL CONSUMPTION Possible Cause Air filter blocked or dirty. Inefficient Starter

Operation Clean according to the procedure Check: electric wiring, circuit continuity, mechanical sliding and power supply Check the maximum and minimum nozzles are adequately fixed in their fittings Restore the level in the chamber by bending on the float the thrusting reed of the petrol intake rod so as to have the float parallel to the chamber level with the carburettor inverted.

Loose nozzles Incorrect float level

Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Slippage or irregular functioning

Operation Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch housing is mainly in the middle and with equivalent specifications on the three masses. Check that the clutch housing is not scored or worn abnormally Never run the engine without the clutch housing

Insufficient braking INEFFICIENT OR NOISY BRAKING Possible Cause Worn brake pads or shoes Front brake disk loose or deformed

Air bubbles inside the hydraulic braking system Fluid leakage in hydraulic braking system Excessive clearance in the rear brake control cable

Operation Replace the brake pads or shoes and check for brake disk or drum wear conditions. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Failing elastic fittings, plunger or brake pump seals, replace Adjust the clearance with the appropriate adjuster located on the back part of the crankcase.

Brakes overheating BRAKE OVERHEAT Possible Cause Rubber gaskets swollen or stuck Compensation holes on the pump clogged Brake disc slack or distorted

Defective piston sliding

Operation Replace gaskets. Clean carefully and blast with compressed air Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Check calliper and replace any damaged part.

TROUBL - 45


Troubleshooting

Electrical system Battery BATTERY Possible Cause Battery

Operation The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 to 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the negative terminal while the red wire is connected to the terminal marked+. Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries.

Turn signal lights malfunction TURN INDICATORS NOT WORKING Possible Cause Electronic ignition device failure

Operation With the ignition switch set to "ON" jump the contacts 1 (BlueBlack) and 5 (Orange) on the control unit connector. If by operating the turn indicators control the lights are not steadily on, replace the control unit; otherwise, check the cable harness and the switch.

Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Steering hardening

Operation Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flattened.

Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Excessive steering clearance

TROUBL - 46

Operation Check the tightening of the top ring nut. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.


Troubleshooting

Noisy suspension NOISY SUSPENSION Possible Cause NOISY SUSPENSION

Operation If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.

Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Oil leakage from suspension

Operation Replace the rear shock absorber or the front fork cartridge.

TROUBL - 47

INDEX OF TOPICS

ELECTRICAL SYSTEM

ELE SYS


Electrical system

Key: 1. Multiple connectors 2. Horn 3. Horn button 4. Fuel level transmitter 5. Diagnostic socket 6. Oil level warning light 7. Instrument panel lighting bulbs 8. High beam warning light 9. Turn indicator warning light 10. Fuel level instrument 11. Instrument panel 12. NTC temperature sensor 13. Low fuel warning light 14. Light switch 15. Key switch 16. Turn indicator switch 17. Starter button 18. Front stop switch 19. Rear stop switch ELE SYS - 49

Electrical system

20. Rear left turn indicator 21. Rear light 22. License plate light 23. Rear right turn indicator 24. Start-up relay 25. Starter motor 26. Battery 27. Main fuse 28. Auxiliary fuses 29. Coil 30. Spark plug 31. Throttle sensor 32. CDI control unit 33. Automatic starter 34. Carburettor PTC heater 35. Regulator 36. Oil pressure sensor 37. Pick-up 38. Generator 39. Front right turn indicator 40. High beam light 41. Front position light 42. Low beam light 43. Front left turn indicator 44. Front headlamp 45. Ground point on chassis Colours of the electrical cables: B = White Bl = Blue G = Yellow Mr = Brown N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Violet ELE SYS - 50



Electrical system

V = Green VN = Green-Black BN = Black-White BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Sky blue GrBl = Grey-Blue GrN = Grey-Black RBl = Red-Blue GR =Yellow-Red BlN = Blue-Black

ELE SYS - 51

Electrical system

Components arrangement

ELE SYS - 52



Electrical system

1. Air temperature sensor - Remove the leg shield, as described in the «BODYWORK» chapter to reach it.

2. Voltage regulator - 3. Coil - Remove the rear central cover to reach it.

4. Battery - 5. Main fuse - Lift the saddle and remove the cover to reach it.

6. Start-up solenoid - Remove the side fairings to reach it.

ELE SYS - 53

Electrical system

7. Secondary fuses - Open the glove-box lid to reach them.

8. Horn - Remove the footrest to reach it.

9. Ignition switch - Remove the leg shield back plate to reach it.

10. Fuel level transmitter - 11. Diagnosis connector - Remove the battery inspection cover to reach them.

ELE SYS - 54



Electrical system

12. Oil pressure sensor - 13. Engine speed sensor - Remove the fan cover cap to reach them, as described in the ENGINE chapter.

14. Starter motor - Remove the helmet compartment to reach it.

15. CDI control unit - Remove the leg shield to reach it.

16. Right brake switch - 17. Left brake switch Remove the front handlebar cover to reach them.

ELE SYS - 55

Electrical system

18. Automatic starter - 19. PTC heater - 20. Throttle position sensor - Remove the helmet compartment to reach them.

21. Horn button - 22. Light switch - 23. Turn indicator switch - They are fixed inside the rear handlebar cover, on the left-hand side.

24. Engine starter button - It is fixed inside the rear handlebar cover, on the right-hand side.

ELE SYS - 56



Electrical system

Ground points - On the vehicle there is a chassis ground point, beneath the rear central cover.

•

On the engine there is a ground point on the starter motor.

Electrical system installation Front side

ELE SYS - 57

Electrical system

1. Upper branch of the main cable harness 2. Front brake stop switch cable 3. Engine starter button cable 4. Front left turn indicator cable 5. Front right turn indicator cable 6. Rear brake stop switch cable 7. Instrument panel connectors 8. Light switch connector

9. Central branch of the main cable harness 10. Air temperature sensor connector 11. Ignition switch connector 12. Front light cable 13. Secondary fuse cable 14. CDI control unit cable

ELE SYS - 58



Electrical system

15. Horn cable 16. Transverse branch of the main cable harness

Back side

17. Ground cable on chassis ELE SYS - 59

Electrical system

18. Regulator cable - chassis ground 19. Coil cable 20. Spark plug cable 21. Branch of devices on engine 22. Rear branch of the main cable harness

23. Start-up solenoid cable 24. Rear lights and fuel level transmitter connecting branch 25. Battery positive and main fuse connecting cable 26. Battery negative connecting cable 27. Diagnosis connector cable 28. Fuel level transmitter cable

ELE SYS - 60



Electrical system

29. Battery positive lead 30. Main fuse connecting cable 31. Battery negative lead 32. Diagnosis connector 33. Rear right turn indicator cable 34. Rear left turn indicator cable 35. Rear light cable 36. License plate lamp cable

37. Ground cable on engine 38. Starter motor positive wire 39. Connector for stator, pick-up and oil pressure sensor 40. Branch connecting devices on carburettor 41. Automatic starter connector ELE SYS - 61

Electrical system

42. PTC resistor connector 43. Throttle position potentiometer connecting cable

Conceptual diagrams Ignition

Key: 1. Multiple connectors 5. Diagnostic socket 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 29. Coil 30. Spark plug 31. Throttle sensor 32. CDI control unit 37. Pick-up

ELE SYS - 62



Electrical system

Battery recharge and starting

Key: 1. Multiple connectors 15. Key switch 17. Starter button 18. Front stop switch 19. Rear stop switch 21. Rear light 24. Start-up relay 25. Starter motor 26. Battery 27. Main fuse 28. Auxiliary fuses 35. Regulator 38. Generator 45. Ground point on chassis

ELE SYS - 63

Electrical system

Level indicators and enable signals section

Key: 1. Multiple connectors 4. Fuel level transmitter 6. Oil level warning light 10. Fuel level instrument 11. Instrument panel 12. NTC temperature sensor 13. Low fuel warning light 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 32. CDI control unit 36. Oil pressure sensor 45. Ground point on chassis

ELE SYS - 64



Electrical system

Instruments and warning lights control board A= High beam warning light; B = Oil pressure warning light; C= Turn indicator warning light; D= Low fuel warning light; E = Odometer; F= Rpm indicator; G= Fuel gauge

LIGHT BULBS TABLE 1

Specification High/low beam light bulb

2

Front side light bulb

3

Instrument panel bulb, indicator warning lights, oil pressure and high beams

4

Front turn indicator light bulb

5

Rear turn indicator light bulb

6

Stop light/rear daylight running light bulb

7

License plate bulb

Desc./Quantity Type: Halogen (H8) Power: 12V - 35W Quantity: 2 Type: All glass Power: 12V 3W Quantity: 2 Type: All glass Power: 12V - 1.2W Quantity: 5 Type: SPHERICAL (amber colour) Power: 12V - 10W Quantity: 1 RHS + 1 LHS Type: SPHERICAL (amber colour) Power: 12V - 10W Quantity: 1 RHS + 1 LHS Type: ALL GLASS (twin-filament) Power: 12V - 21/5W Quantity: 1 Type: All glass Power: 12V - 3W Quantity: 1

ELE SYS - 65

Electrical system

Devices and accessories

Key: 1. Multiple connectors 2. Horn 3. Horn button 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 32. CDI control unit 33. Automatic starter 34. Carburettor PTC heater 45. Ground point on chassis

ELE SYS - 66



Electrical system

Lights and turn indicators

Key: 1. Multiple connectors 7. Instrument panel lighting bulbs 8. High beam warning light 9. Turn indicator warning light 11. Instrument panel 14. Light switch 15. Key switch 16. Turn indicator switch 18. Front stop switch 19. Rear stop switch 20. Rear left turn indicator 21. Rear light 22. License plate light 23. Rear right turn indicator 26. Battery 27. Main fuse 28. Auxiliary fuses

ELE SYS - 67

Electrical system


32. CDI control unit 39. Front right turn indicator 40. High beam light 41. Front position light 42. Low beam light 43. Front left turn indicator 44. Front headlamp

Checks and inspections Ignition circuit All the control operations of the system that entail disconnecting cables (to check connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.

No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Check the Pick-Up. The check includes the Pick-Up and its power line. Disconnect the control unit connector and measure the resistance between terminal No. 10 (Blue/ Yellow) and terminal No. 12 (Blue). If the value measured is incorrect, repeat the check directly on the component. Disconnect the pick-up connector on the engine and measure the resistance between the pin corresponding to the

ELE SYS - 68


Electrical system

Blue-Yellow cable of the wiring and the ground connection on the engine. If correct values are detected, check that the cable is not interrupted.

Electric characteristic Pick-up resistance value ~ 130 Ohm - HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 4 (White/Violet) and terminal No. 12 (Blue) is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If the values are correct, repair the cable harness or reset the connections; otherwise, replace the HV coil

Electric characteristic High voltage coil primary resistance value High voltage coil primary resistance value: ~ 0.5 Ohm - HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.

Specific tooling 020409Y Multimeter adaptor - Peak voltage detection

Electric characteristic High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm

ELE SYS - 69

Electrical system


- H.V. coil With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit. THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.

Electric characteristic High voltage coil voltage value High voltage coil voltage value: > 100 Volt

Battery recharge circuit The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The generator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 20A main protection fuse. This system therefore requires no connection to the ignition switch. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability. For this reason, it is very important that the idle speed is adjusted as prescribed.

Specific tooling 020334Y Multiple battery charger

Switches check To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts. KEY Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red Gre: Green Pr: Purple

ELE SYS - 70


Electrical system

STARTER BUTTON

LIGHT SWITCH

TURN INDICATOR SWITCH

HORN BUTTON

ELE SYS - 71

Electrical system

Stator check Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.

Electric characteristic Ohm value: 1 ± 1 Ohm

Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.

Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 14.5 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.

ELE SYS - 72



Electrical system

Recharge system voltage check Connect the ammeter induction clamp to the voltage regulator positive terminal (Red/Orange), measure the battery voltage and turning on the vehicle lights with the engine off, wait for the voltage to settle at about 12 Volt. Start the engine and measure the current generated by the system with the lights on and a high running engine. In case the generated current value is lower than 8A, repeat the test using a new regulator and/stator alternatively.

Characteristic Distributed current 13A at 6000 rpm

Starter motor WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If it does not work: - Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons. - Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow cables. - Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid. - Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter motor are not interrupted. - Check the start-up solenoid. - Check the contacts of the ignition switch, the starter button and the stop buttons. - Check the efficiency of the fuses. - Check that the starter motor is grounded. - If all the tests are positive, replace the starter motor.

ELE SYS - 73

Electrical system


Horn control

KEY 1. Battery 2. Main fuse (A) 20A 3. Ignition switch contacts 4. Secondary fuse (C) 15A 5. Horn button 6. Horn WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If the horn does not work: - Check the efficiency of the fuses. - Check the ignition switch and the horn button contacts. - If the components are not damaged, check wiring for continuity. - Check the continuity of the Green cable which connects the horn button to 15A fuse (C). - Check the continuity of the Grey cable which connects the switch to the horn. - If all the tests are positive, replace the horn.

ELE SYS - 74


Electrical system

Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative probe to the ground lead and the positive probe to the automatic starter Yellow cable; with the ignition switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the ignition switch. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed and check there is voltage when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one to terminal No. 11 (Green/Black). Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.

Turn signals system check WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. Check that bulb operates properly. Check continuity of the Blue-Black cable between the CDI control unit and the turn indicators switch. Check that the turn indicator switch works properly. Check continuity of the Red and Blue cables which connect the switch to the bulbs.

level indicators WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

ELE SYS - 75

Electrical system

If faults are detected: - With a multimeter, check resistance values between the Grey-Green cable and the Blue cable of the fuel level transmitter by moving the arm with the float. - If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted. - Check continuity of the Green cable which connects the instrument panel to the 15A secondary fuse (C). - Check continuity of the Grey/Green cable which connects the instrument panel to the probe checking fuel level.

Electric characteristic Resistance value when the tank is full ~ 7.4 Ω Resistance value when the tank is empty ~ 101 Ω

Fuses The electrical system is protected by a main fuse (A) connected on the left-hand side of the helmet compartment next to the battery. For access it is necessary to remove the battery cover and the transparent protection over the fuse block. Starter circuit, light circuit, horn and instrument panel are protected by two secondary fuses (B) and (C) located inside the glove-box. CAUTION BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).

ELE SYS - 76



Electrical system

FUSE CHART 1

Specification FUSE A

2

Fuse B

3

Fuse C

Desc./Quantity Capacity:20A Protected circuits: Recharge circuit, oil pressure sensor, oil pressure warning light. Capacity:7.5 A Protected circuits: Start-up circuit, starter motor, stop light bulb, ECU power supply. Capacity:15A Protected circuits: Rear light bulb, license plate light bulb, turn indicator bulb, turn indicator warning light, fuel gauge, instrument panel lighting bulb, horn, low beam bulb, high beam bulb, high beam warning light.

Sealed battery Commissioning sealed batteries INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode -Constant voltage equal to 14.40÷14.70V -Initial charge voltage equal to 0.3÷0.5 for nominal capacity -Duration of the charge: 10 to 12 h recommended Minimum 6 h ELE SYS - 77

Electrical system


Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

Battery installation VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF) WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN 1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.

2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulfuric acid.

ELE SYS - 78


Electrical system

3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping. 4) Control the flow of electrolyte Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery. 5) Take out the container. Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing. Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery. 7) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle. The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between

ELE SYS - 79

Electrical system

12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.

f - Check the ignition of the green LED indicated with a red arrow in figure.

ELE SYS - 80



Electrical system

g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place

h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

ELE SYS - 81

INDEX OF TOPICS

ENGINE FROM VEHICLE

ENG VE


Engine from vehicle

Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head

- Undo the 2 screws fixing the silencer to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Locking torques (N*m) Nut fixing silencer to cylinder head 16 to 18 Silencer to crankcase fixing screws 24 to 27

Removal of the engine from the vehicle - Remove the side fairings. - Remove the helmet compartment. - Remove the full silencer unit. - Remove the fastening screw of the rear brake transmission shown in the photograph and slide off the cable of the retainer brackets.

ENG VE - 83

Engine from vehicle

- Loosen the throttle control cables by acting on the carburettor set screws and slide them off the pulley.

See also Exhaust assy. Removal - Remove the fuel supply pipe from the carburettor

- Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph

- Remove the flywheel wiring connector, the ground terminal and the starter motor positive cable indicated in the figure

ENG VE - 84



Engine from vehicle

- Remove the clamp retaining the starter wiring and the heater indicated in the figure

- Disconnect the automatic starter and carburettor heater connectors.

- Keep the engine-swinging arm pin nut blocked on the left-hand side of the vehicle and undo the pin from the opposite side.

ENG VE - 85

Engine from vehicle

- Adequately support the vehicle (i.e. with a jack) and remove the engine-swinging arm pin and the shock absorber lower mount. The engine is now free.

ENG VE - 86


INDEX OF TOPICS

ENGINE

ENG

Engine


This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes. Using the clutch housing lock wrench, remove the driven pulley axle locking nut and recover the washer. - Remove the cap/dipstick from the engine oil filling hole. - Remove the ten screws. - Remove the transmission cover. If this operation is performed directly on the vehicle, it is necessary to remove the air filter housing retainers.

Specific tooling 020423Y Driven pulley lock wrench

Air duct - Unscrew the Torx screws fixing the air duct bulkhead and remove the bulkhead. - Remove the 3 screws, then take out the duct as well as the filter.

ENG - 88


Engine

Air duct filter - Unscrew the two fixing screws and slide off the filter. - Clean with water and milid soap.

Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Use the specific tools to remove the bearing from the crankcase. CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.

Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor

ENG - 89

Engine

Refitting the driven pulley shaft bearing - Heat up the crankcase inside with the hot air gun. - Insert the bearing in its housing, refit the Seeger ring. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.

Specific tooling 020151Y Air heater 020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15-mm guide

Removing the driven pulley - Remove the spacer, the clutch housing and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.

Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.

Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø 134 - 134.2 mm

ENG - 90



Engine

Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.

- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell.

Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge

Characteristic clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm

Removing the clutch - Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to «C». - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.

ENG - 91

Engine


- Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. Afterwards make the support screw make contact with a minimum force. - Using the specific wrench, inserted 46 mm from the side, remove the clutch central locking nut.

- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings). CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL.

Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55

Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic Check minimum thickness 1 mm

ENG - 92


Engine

Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.

Removing the driven half-pulley bearing - Remove the retainer ring using two flat blade screwdrivers. - Using a hammer and pin, knock the ball bearing out as shown in the figure. - Remove the roller bearing using the specific extractor. N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.

Specific tooling 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide

ENG - 93

Engine

Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bushing.

Characteristic Minimum diameter permitted Ø 40.96 mm Standard diameter Ø 40.965 mm

Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two Orings. - Measure the inside diameter of the mobile halfpulley bushing.

Characteristic Minimum admissible diameter: Ø 41.08 mm Standard diameter Ø 41.035 mm

Refitting the driven half-pulley bearing - Assemble a new roller bearing using the specific punch, fit the bearing with the label facing outward and insert it completely up to the punch on the halfpulley. N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.

Specific tooling 020424Y Driven pulley roller casing fitting punch

ENG - 94



Engine

- To assemble the new ball bearing insert it completely down in its housing with the specific punch and finally assemble the Seeger ring.

Specific tooling 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide

Refitting the driven pulley - Check that the faying surfaces between the 2 half-pulleys and the belt do not show any signs of wear, scoring and grease. - Insert the new oil seals and O-rings on the movable half-pulley. - Assemble the half-pulley on the ringlet with the appropriate protection sheath. - Make sure the pins and collar are not worn, reassemble the pins and collar. - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

Specific tooling 020263Y Driven pulley assembly sheath

Recommended products MONTBLANC MOLYBDENUM GREASE Grease with molybdenum disulphide

ENG - 95

Engine

Inspecting the clutch spring - Measure the length of the spring when it is relaxed.

Characteristic Standard length: 106 mm Acceptable limit after use 102.5 mm (4.035 in)

Refitting the clutch - Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic Minimum thickness permitted: 1 mm - Support the driven pulley spring compressor specific tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring No. 11 with the chamfering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring that abuts against the torque server closing collar. - Insert the spring with its plastic holder in contact with the clutch. - Insert the drive belt into the pulley unit according to their direction of rotation.

ENG - 96



Engine

- Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis. - Fully preload the spring. - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt according to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool. N.B. DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.

Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55

Locking torques (N*m) Nut locking clutch unit on pulley 55 to 60 Nm

ENG - 97

Engine


Refitting the driven pulley - Reassemble the clutch housing and spacer.

Drive-belt - Make sure the drive belt is not damaged and does not show abnormal wear. - Replace as indicated in the scheduled maintenance table.

Removing the driving pulley - Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the cup washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.

Specific tooling 020368Y driving pulley lock wrench - Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers. - Remove the return rollers plate with the relative guide sliders.

Inspecting the rollers case - Check that the internal bushing is not abnormally worn and measure inner diameter. N.B.

DO NOT LUBRICATE OR CLEAN THE BUSHING. ENG - 98


Engine

BUSHING ROLLER HOUSING Specification Maximum allowable diameter Standard diameter

Desc./Quantity Ø 26.121 mm Ø 26+0 +0.021 mm

BUSH SLIDE PULLEY Specification Minimum diameter permitted Standard diameter

Desc./Quantity Ø 25.950 mm Ø 26-0.020 -0.041 mm

CVT ROLLERS Specification Minimum diameter permitted Standard diameter

Desc./Quantity Ø 18.5 mm Ø 26±0.1 mm

- Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.

- Pre-assemble the movable half-pulley with the roller contrast plate by placing the rollers as shown in the figure, that is, during insertion, the closed side should be on the left side of the pulley thrust. - Mount the complete bushing unit on the crankshaft.

ENG - 99

Engine

Refitting the driving pulley - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread threadlock on the thread and screw the nut to the prescribed torque. -Avoid the half-pulley rotation using a calliper spanner N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT

Specific tooling 020368Y driving pulley lock wrench

Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock

Locking torques (N*m) Drive pulley nut 75 - 83

Refitting the transmission cover - Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the transmission cover is adequately fitted. - Replace the cover and tighten the 10 screws to the specified torque. - Refit the oil loading cap/bar. - Refit the steel washer and the driven pulley nut. - Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools. - Refit the plastic cover.

ENG - 100



Engine

Specific tooling 020423Y Driven pulley lock wrench

Locking torques (N*m) Transmission cover screws 11 to 13 Driven pulley shaft nut 54 to 60

End gear Removing the hub cover - Empty the rear hub through the oil drainage tap located inside the hub cover - Remove the brake shoe and relevant spring - Remove the 7 flanged screws as shown in the figure. - Remove the rubber cover and the brake shoes lever sliding unscrewing the relevant retaining screw to reach the rear of the cover - Take off the hub cover and relevant gaskets

Removing the wheel axle Remove the intermediate gear and the complete hub cover.

ENG - 101

Engine


Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).

Specific tooling 001467Y009 Driver for OD 42-mm bearings 001467Y013 Calliper to extract ø 15-mm bearings

Removing the wheel axle bearings - Take out the clip on the outside of the hub cover. - Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the figure.

Specific tooling 020376Y Adaptor handle 020364Y 25-mm guide With the appropriate tools, remove the oil seal as shown in the figure.

Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm Adaptor

Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley. - Extract the driven pulley shaft from its bearing. - Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to damage the housing, make it come out of the belt transmission side. - Remove the Seeger ring shown in the figure ENG - 102


Engine

With the sectional punch, remove the driven pulley shaft bearing.

Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20-mm guide

See also Removing the driven pulley

Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged components.

Inspecting the hub cover - Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and the brake camshaft. - If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing - Heat up the parts using the specific heat gun

Specific tooling 020150Y Air heater mounting 020151Y Air heater - Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of the hub cover using the adequate tools

Specific tooling 020376Y Adaptor handle

ENG - 103


Engine

- Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil seal flush with the crankcase.

Refitting the wheel axle bearing - Heat up the parts using the specific heat gun

Specific tooling 020151Y Air heater 020150Y Air heater mounting -The wheel axle bearing on the cover, should be assembled with the specific tools

Specific tooling 020364Y 25-mm guide 020360Y 52x55-mm Adaptor 020376Y Adaptor handle •

Assemble the Seeger ring.

•

Assemble the oil seal flush with the internal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub.

Specific tooling 020376Y Adaptor handle 020360Y 52x55-mm Adaptor

Refitting the hub cover bearings - For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the specific heat gun.

Specific tooling 020150Y Air heater mounting 020151Y Air heater ENG - 104


Engine

- The three 15 mm bearings must be fitted using the appropriate tools.

Refitting the hub bearings - Insert the cover prepared in the crankcase taking care of inserting the gear of the pulley shaft on the intermediary gear.

Refitting the ub cover - Fit a new gasket together with the alignment dowels. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Screw the 7 screws to the specified torque, positioning the support plate of the pipe in the position shown in the figure. - Remove the control pin of the shoe taking care so as the long tooth coincides with the groove on the control lever.

Locking torques (N*m) Rear hub cap screws 24 to 27

ENG - 105

Engine

Flywheel cover Cooling hood - Remove the SAS valve and the cylinder head connecting pipe (see SAS valve). - Remove the flywheel duct by undoing the four fixing screws. CAUTION UPON REMOVAL SLIDE THE CONNECTOR OFF ITS FITTING ON THE DUCT.

- Loosen the clamp and remove the carburettor from the manifold. -Remove the complete manifold acting on the 2 retainers as shown in the figure.

- Slide the access flap to the spark plug. - Remove the two self threading screws, left and right and the lateral left fixing screw on the crankcase base. - Take off the two caps from the thermal group. - Remove the gasket seal of the housing on the head.

Locking torques (N*m) Flywheel hood fixing screws 1 ÷ 2

ENG - 106



Engine

Cooling fan - Remove the fan cover cap. - Remove the cooling fan by acting on the three fixings indicated in the figure.

Locking torques (N*m) Flywheel fan screws 3 to 4

Removing the stator - Remove the magneto flywheel. - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure. - Remove the stator and its wiring.

Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque. - Place the cable harness as shown in the figure. N.B. THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE DOWEL AS SHOWN IN THE DETAIL DRAWING.

Locking torques (N*m) Stator screw 3 to 4 Pick-up screw 3 to 4

ENG - 107

Engine


Flywheel and starting Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat.

Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS

Specific tooling 020565Y Flywheel lock calliper spanner

- Extract the flywheel with the extractor.

Specific tooling 008564Y Flywheel extractor

Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.

ENG - 108


Engine

Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 to 0.76 mm. The air gap cannot be modified when assembling the Pick-Up. Different values result from deformations visible on the Pick-Up mounting. N.B. A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED

Locking torques (N*m) Flywheel nut 52 to 58

Refitting the starter motor - Fit a new O-ring on the starter and lubricate it. - Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque. N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.

Locking torques (N*m) Starter screws 11 to 13

Cylinder assy. and timing system

ENG - 109

Engine

Removing the timing system drive - Remove the parts listed below first: transmission cover, belt driving pulley, oil pump pulley cover and pinion separator washer. - Remove the tappet cover.

- Remove the central screw fastener and the automatic valve lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer.

- Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket.

- Remove the inner hexagonal screw and the counterweight - Remove the camshaft control pulley with its washer. ENG - 110



Engine

- Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The tensioner pad must be removed from the transmission side. As regards the lower chain guide slider, it may only be removed after the head has been removed. N.B.

IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.

See also Transmission cover Removing the driving pulley Removal

Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram.

- Remove the cam shaft.

- Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic washer. N.B. MARK THE ROCKERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INTAKE WITH THE EXHAUST.

ENG - 111

Engine

Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two alignment dowels and the gasket. N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the caps and the spring between the valves.

Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool

- Remove the oil seals with the appropriate tool. - Remove the lower spring supports.

Specific tooling 020431Y Valve oil seal extractor

ENG - 112



Engine

Removing the cylinder - piston assy. - Remove the chain guide slider. - Remove the cylinder base gasket. CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.

- Remove the two retainer rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston. N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.

Inspecting the small end - Measure the internal diameter of the connecting rod small end using an internal micrometer. N.B. IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".

Characteristic Connecting rod small end check-up: Maximum diameter 15.030 mm Connecting rod small end check-up: Standard diameter 15+0.015+0.025 mm

ENG - 113

Engine

Inspecting the wrist pin - Check the outer diameter of the gudgeon pin.

Characteristic Standard pin diameter 14.996 to 15 mm Minimum diameter permitted Ø 14.994 mm

- Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.

Characteristic Piston pin bore - standard diameter Ø 15+0.001 +0.006

- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Measure 36.5 mm from the piston crown's shown in the figure. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.

- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Characteristic Maximum allowable run-out: 0.05 mm

ENG - 114



Engine

- The cylinder rectifying operation should be carried out with a surfacing that respects the original angle. - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consumption and guarantees optimum performance. - The pistons are oversized due to cylinder rectification and are subdivided into three categories 1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They are also classified into 4 categories A-A, B-B, CC, D-D.

Inspecting the piston - Carefully clean the sealing ring housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.

STANDARD COUPLING CLEARANCE Name Top piston ring Middle piston ring oil scraper

Description

Dimensions 0.025 to 0.070 0.015 to 0.060 0.015 to 0.060

Initials

Quantity

MAXIMUM ADMITTED CLEARANCE AFTER USE Name Top piston ring Middle piston ring oil scraper

Description

Dimensions 0.080 mm 0.070 mm 0.070 mm

Initials

Quantity

ENG - 115

Engine

Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin retainer ring onto the appropriate tool.

Specific tooling 020430Y Pin lock fitting tool

- With the opening in position indicated on the tool, take retainer ring in the closed position using the punch. - Fit the wrist pin retainer ring using the plug as shown in the figure N.B. THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.

ENG - 116



Engine

Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the piston crown. The tapered side of the middle piston ring should always be facing away from the piston crown. - Fit the middle piston ring with the identification letter facing the piston crown. In any case, the step must be facing opposite the piston crown. - Fit the top piston ring with the word 'top' or the reference mark facing the crown of the piston. - Offset the piston ring gaps on the three rings by 120° to each other as shown in the figure. - Lubricate the components with engine oil. N.B. SO AS TO OBTAIN THE BEST CONFIGURATION THE 2 SEALING RINGS ARE MADE WITH A CONTACT CONICAL CYLINDER SECTION.

Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.

Specific tooling 020426Y Piston fitting fork ENG - 117


Engine

020427Y Piston assembly band

Inspecting the cylinder head - Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.

Characteristic Maximum admitted unevenness: Cylinder head check 0.05 mm

STANDARD DIAMETER Specification Standard diameter Standard diameter Standard diameter

Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft drive pulley, the chain assembly and the sprocket wheel are not worn. - If sings of wear are found, replace the parts. if the chain, pinion or pulley are worn, replace the whole assembly.

ENG - 118

Desc./Quantity A Ø 32.5 to 32.525 B Ø 20 to 20.021 C Ø 12 to 12.018


Engine

- Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.

Inspecting the valve sealings - Measure the width of the sealing surface on the valve seats.

VALVE SEAL SURFACE Specification Intake valve - seal surface Exhaust valve - seal surface

Desc./Quantity 2.4 to 2.8 mm 2.2 to 2.6 mm

Inspecting the valve housings - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide. - Take the measurement at three different heights in the rocker arm push direction.

Characteristic Standard drainage guide diameter 5.012 mm Standard intake guide diameter 5.012 mm

ENG - 119

Engine

- If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head. - Check width of the impression on the valve seat «V»

Characteristic Wear limits: Max. 1.6 mm.

Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide.

Characteristic Minimum diameter admitted - Intake: 4.96 mm Minimum diameter admitted - Exhaust: 4.95 mm Standard clearance - Intake: 0.013 to 0.040 mm Standard clearance - Exhaust: 0.025 to 0.052 mm Maximum clearance admitted- Intake: 0.062 mm Maximum clearance admitted - Exhaust: 0.072 mm - Check that there are no signs of wear on the contact surface with the articulated register terminal. - If the sealing surface on the valves is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.

Characteristic Standard valve length - Intake: 80.6 mm Valve standard length: Exhaust ENG - 120



Engine

79.6 mm - If no faults are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem/guide coupling. CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.

- Insert the valves into the cylinder head. - Test the 2 valves alternatively. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.

Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. - Check the unloaded springs length.

Characteristic Valve spring length 33.9 to 34.4 mm

ENG - 121

Engine

Refitting the valves - Lubricate the valve guides with engine oil. - Place the lower caps of the valve spring on the head. - Use the punch to fit the 2 sealing rings one at a time.

Specific tooling 020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the spring retaining caps. Using the appropriate tool with adapter 11, compress the springs and insert the cotters in their seats.

Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool

Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams.

Characteristic Standard diameter Bearing A Ø: 32.5 mm -0.025 -0.050 mm Standard diameter Bearing B 20 -0.020 -0.041 mm Minimum admitted diameter bearing A Ø: 32.440 mm Minimum admitted diameter bearing B Ø: 19.950 mm Intake cam height 27.512 mm Exhaust cam height 27.212 mm

ENG - 122



Engine

- Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.

Characteristic Maximum axial clearance admitted 0.42 mm - Check there are no signs of wear on the automatic valve lifter cam, or the end-of stroke roller, or the rubber buffer on the automatic valve-lifter retaining cover. - Check that the valve lifter spring has not yielded. - Replace any defective or worn components.

- Check there are no signs of scoring or wear on the rocking lever bolt. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. - Measure the internal diameter of each rocking lever. -Check that the elastic washer dedicated to the axle clearance of the rocking levers is not worn. In case of failure, replace the damaged components.

Characteristic Minimum diameter permitted Ø 11.970 mm Maximum diameter allowed Ø 12.030 mm

Refitting the head and timing system components - Fit the timing chain guide slider. - Insert the head and cylinder alignment dowels, fit the head gasket and the head on the cylinder. ENG - 123

Engine


-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.

Locking torques (N*m) Nuts fixing head to cylinder 28 to 30 - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.

Locking torques (N*m) Head fixing screws (external) 11 to 13

- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the tensioner pad by the cylinder head. - Fit the spacer and the screw fastener. - Fit the pin, the exhaust rocking lever, the spring washer and the intake rocking lever. - Lubricate the 2 rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the camshaft in the cylinder head with the cams opposing the rocking levers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed torque.

Locking torques (N*m) Camshaft retention plate screw 5 to 6

ENG - 124


Engine

- Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head. - Fit the pulley onto the camshaft. - Assemble the counterweight with the corresponding fixing screw and tighten to the specified torque.

Locking torques (N*m) Pressure reducer counterweight retainer 7 to 8.5

-Fit the end-stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft. - Fit the automatic valve lifter return spring. - During this operation the spring must be loaded approximately 180°. N.B. GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE.

- Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed torque.

Locking torques (N*m) Camshaft pulley screw 12 to 14

- Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. ENG - 125

Engine


Locking torques (N*m) Tightener fastening screws: 11 to 13 - Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque.

Locking torques (N*m) Timing chain tensioner central screw 5 to 6 - Adjust the valve clearance. - Fit the spark plug

Electric characteristic Recommended spark plug NGK CR7EB Electrode gap 0.6 ÷ 0.7 mm

Locking torques (N*m) Ignition spark plug 18 Nm - Assemble the casing sealing gasket on the head. On the fitting direction, use the supplements on the timing side as reference. - Assemble the screw fixing the housing to the crankcase to the specified torque and the 2 selftapping screws joining the half-shells. - Take care that the gasket is well inserted in its housing during the assembly stage. - Place the spark plug access cap.

Locking torques (N*m) Flywheel air duct screw 3 to 4 - Fit the intake manifold and lock the 2 screws to the specified torque. - Fit the carburettor onto the intake manifold and lock the clamp N.B. FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD.

Locking torques (N*m) Head intake manifold screw 11 to 13

ENG - 126


Engine

- Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque. - Refit the fan and the housing. - Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as described in the lubrication chapter. - Reassemble the driving pulley, the belt and the transmission cover as described in the transmission chapter.

Locking torques (N*m) Head cover screws 11 to 13

Crankcase - crankshaft - Precautionary remove the following units: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals as described in the transmission chapter. - Remove the oil sump, the by-pass, the chain compartment cover and the oil pump as in the lubrication chapter. - Remove the flywheel cover, the fan, the flywheel and the stator as described in the magneto flywheel chapter. - Remove the oil filter and the oil pressure bulb. - Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter. - Remove the 2 retainers indicated in the figure and the starter motor. - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with specific tool dial gauge.

Specific tooling 020262Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge

Characteristic Standard clearance ENG - 127

Engine

0.15 to 0.40 mm

Splitting the crankcase halves Remove the 11 coupling screws to the crankcase. - Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase. Remove the crankshaft. CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.

- Remove the coupling gasket of the crankcase halves. - Remove the two screws and the internal shield shown in the diagram. CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.

- Remove the oil seal on the flywheel side. - Remove the oil filter fitting shown in the diagram

- Check the axial clearance on the connecting rod.

Characteristic Standard clearance 0.20 to 0.50 mm

ENG - 128



Engine

- Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial clearance are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram. CAUTION BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.

Characteristic Standard clearance 0.036 to 0.054 mm - If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase. CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING.

Characteristic Distance between the shoulders 55.67 to 55.85 mm - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.

STANDARD DIAMETER Specification Category 1 Category 2

Desc./Quantity 28.998 to 29.004 28.004 to 29.010

ENG - 129

Engine

Inspecting the crankshaft alignment To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the crankshaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft. The big end bushings cannot be replaced. For the same reason, the connecting rod may not be replaced and, when cleaning the crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted. - A wrong installation of a cap can seriously affect the bushing lubrication pressure. N.B. THE MAIN BEARINGS ARE NOT GRINDABLE

Specific tooling 020074Y Support base for checking crankshaft alignment

Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm

ENG - 130



Engine

Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission side crankcase half, take particular care cleaning the housing and oil ducts for the following components: the oil pump, the oil by-pass valve, the main bushings and the cooling jet on the transmission side (see diagram). - Take particular care, also, that there are no signs wear in the oil by-pass valve housing (see Chapter Lubrication), as this could prevent a good seal in the piston, which regulates the oil pressure. N.B. THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKS CAN CAUSE A CONSIDERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD.

- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil seal. N.B. THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.

- Inspect the mating surfaces on the crankcase halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves. - Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.

ENG - 131

Engine


- Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and dimensions.

Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels. - The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposed the cylinder. - To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the figure. - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface. N.B. TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.

Characteristic Standard driving depth 1.35 to 1.6 - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram. - The standard bushing diameter after driving is variable on the basis of a coupling selection. ENG - 132


Engine

- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft. - The main bushings are subdivided into 3 thickness categories; see the table below: N.B.

DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.

MAIN BEARINGS Specification B C E

Desc./Quantity Blue Yellow Green

Refitting the crankcase halves - Fit the internal shield by locking the two screws to the prescribed torque.

Locking torques (N*m) Internal engine crankcase bulkhead (transmission-side half shaft) screws 4 to 6

- Fit the oil filter joint and tighten it to the prescribed torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, together with the alignment dowels.

Locking torques (N*m) Oil filter on crankcase fitting 27 to 33

ENG - 133

Engine

- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half. - Reassemble both crankcase halves. - Fit the 11 screws and tighten them to the prescribed torque. N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.

Locking torques (N*m) Engine-crankcase coupling screws 11 to 13 - Lubricate the flywheel oil seal. - Use the appropriate tool to assemble the oil seal. - Fit a new O-ring on the pre-filter and lubricate it. - Insert the pre-filter on the engine with its corresponding cover to the specific torque. N.B. REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE BETTER SEALING PERFORMANCE. N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.

Specific tooling 020425Y Punch for flywheel-side oil seal

Locking torques (N*m) Pre-filter cap 24 to 30

Lubrication

ENG - 134



Engine

Conceptual diagrams

ENG - 135

Engine

Oil pressure check - After removing the fan cover duct as described in the "Flywheel Cover" chapter, remove the electric connection of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure is between 0.5 to 1.2 atm. - With the engine idling at 6000 rpm and the oil temperature at ~90°C, check that the oil pressure is between 3.2 to 4.2 atm. - Remove the appropriate tools once the measurement is complete, refit the oil pressure switch and washer, tightening it to the prescribed torque and fit the flywheel cover. - If the oil pressure is not within the specified limits, in the following order, check: the oil filter, the oil by-pass valve, the oil pump and the crankshaft seals. N.B. THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER CONDITION.

Characteristic Minimum pressure admitted 3.2 atm.

Locking torques (N*m) Minimum oil pressure switch 12 to 14

Crankshaft oil seals

ENG - 136



Engine

Removal - Remove the transmission cover and the complete drive pulley beforehand

- Install the base of the appropriate tool on the oil seal using the screws provided.

- Screw the threaded bar onto the base of the tool and extract the oil seal.

Specific tooling 020622Y Transmission-side oil seal punch

Refitting - Prepare the new oil seal, lubricating the sealing lip. Warning: do not lubricate the surface for keying onto the engine crankcase. CAUTION DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE.

ENG - 137

Engine

- Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft

- Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT THE OIL SEAL. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH.

- Orientate the oil seal by inserting the bracket which is part of the specific tool.

- Tighten the threaded bar onto the crankshaft as far as it will go.

ENG - 138



Engine

- Use the nut to move the base of the tool until you can see end of the oil seal driving stroke

- Remove all of the tool components following the procedure in reverse order CAUTION

FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN. Assemble a new oil seal on the flywheel side using the specific tool as shown in the photograph N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.

Specific tooling 020425Y Punch for flywheel-side oil seal

Oil pump Removal - Remove the chain cover acting on the 3 retaining screws as shown in the figure and the relevant copper washers. - Extract the cover using the appropriate appendages. N.B. WITH THE AIM OF AVOIDING DAMAGING THE APPENDAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT.

ENG - 139

Engine

- Remove the cover of the pump control pulley using the two retainers, as shown in the figure. - Block the rotation of the oil pump control pulley using a screwdriver inserted through one of its two holes.

- Remove the central screw with cup washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion.

- Remove the oil pump acting on the 2 retainers as shown in the figure. - Remove the oil pump seal. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.

Inspection - Remove the two screws and the oil pump cover. - Remove the circlip retaining the innermost rotor. - Remove and wash the rotors thoroughly with petrol and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the retainer ring.

ENG - 140



Engine

- Using a feeler gauge, check the distance between the rotors in the position shown in the figure.

Characteristic Maximum clearance admitted 0.12 mm

Measure the distance between the outer rotor and the pump body; see figure.

Characteristic Admissible limit clearance: 0.20 mm

Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure.

Characteristic Limit values admitted: 0.09 mm

Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly. - Fit the pulley to the pump, the central screw to the specified torque and the cup washer. -Fit the oil pump cover, by tightening the two screws to the prescribed torque. ENG - 141

Engine

N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.

Locking torques (N*m) Central screw 12 to 14 Nm Cover screws 0.7 to 0.9 Nm

Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmission chapter. - Drain the oil from the sump as described above. - Remove the 7 screws indicated in the figure and the 2 rear brake transmission fixing brackets. - Remove the spring, the by-pass piston and the gasket shown in the second image.

Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defective parts.

Characteristic By-pass check up: Standard length 54.2 mm

ENG - 142



Engine

Refitting the oil sump - Refit the by-pass piston in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump. - Refit the rear brake transmission mounting brackets and the screws in the reverse order from which they were removed. - Tighten the screws to the prescribed torque. - Refit the driving pulley assembly, the drive belt, the sprocket wheel and the transmission cover, as described in the "Transmission" chapter. - When testing the lubrication system, refer to the "Crankcase and Crankshaft" chapter, regarding lubrication of the connecting rod assembly

Locking torques (N*m) Oil sump screws 11 to 13

SAS valve Inspecting the one-way valve - Remove the SAS valve. - Provisionally assemble the rubber sleeve of the SAS valve outlet to ensure tightness. - Connect the MITYVAC vacuum pump to the rubber sleeve as shown in the photograph. - Set the pump to the low-pressure position (VACUUM). - Operate the pump slowly. - Check that the one way valve allows the air to pass through causing a slight vibration. - Switch the pump to pressure mode (PRESSURE).

ENG - 143

Engine

- Operate the pump slowly and check if there is an increase of pressure. A small leakage is considered to be normal. If anomalies are detected, replace the pump. N.B. A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN RUBBER SLEEVE AND FILTER OVERHEATING N.B. ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING

Specific tooling 020329Y Mity-Vac vacuum-operated pump

Inspecting the cut-off - Remove the SAS valve. - Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake. - Apply a vacuum value higher than 0.5 BAR. - Check that this value is kept all the time. - If a worn seal is detected, replace it. - With a "T" bypass and flexible rubber hoses make a parallel connection between the rubber sleeve and the vacuum intake of the CUT-OFF valve. - Connect the bypass to the MITYVAC pump. - Set the pump set to the low-pressure mode (VACUUM). - Using a pair of long flat pliers, choke the rubber hose next to the valve. - Operate the pump until vacuum is higher than 0.5 BAR. - Release the hose and check how the vacuum reacts. - Under normal functioning conditions the vacuum undergoes a slight fall and then readjusts. Then there is a stage of gradual and slow loss of vacuum up to a value of approx. 0.4 BAR. At this point the valve opening and the sudden vacuum resetting is detected.

ENG - 144



Engine

Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it. N.B. LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS IN THE SILENCER). INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTIC CONVERTER MALFUNCTIONING N.B. A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERATION OF THE CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING


Fuel supply - Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - By means of the MITYVAC pump apply 0.1 bar of suction to the tap. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the vacuum pipe to the manifold. - Position the fuel pipe with the outlet at the point of the tap. - Turn the engine by using the starter motor for five seconds with the carburettor at minimum. - Take up the fuel by means of a graded burette. N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-

ENG - 145

Engine

LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.


Characteristic Minimum flow rate 20 cc - Completely empty the fuel tank. - Remove the petrol delivery pipe and the lowpressure pipe. - Loosen the clip and remove the cock. - Clean the tank and the filter of the cock with a specific solvent. - Refit the cock making sure that there is an ORing. - Turn the cock to the direction it had before it was removed and block the clip. N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING.

Removing the carburettor - To detach the carburettor from the engine, it is necessary to move the air filter and remove the throttle control transmission, the automatic starter connection, the clamps anchoring the carburettor to the filter housing and to the intake manifold, the air delivery pipe to the diaphragm, the heater and the intake fitting.

ENG - 146



Engine

With the multimeter, check if the potentiometer is working correctly by placing the probes on both contacts indicated in the photograph. With throttle valve completely closed, the resistance value should be approx. 1.3 kOhm. With throttle valve completely open, the resistance value should be approx. 4.05 kOhm.

- Remove the heater.

- Remove the protection, the bracket and the starter acting on the screw shown in the figure.

- Remove the 2 screws and the starter support with the gasket.

ENG - 147

Engine

- Remove the clamp and cover with the airing filter of the diaphragm chamber.

- Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.

- Remove the vacuum valve together with the diaphragm.

ENG - 148



Engine

- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle

- Remove the 4 screws indicated in the figure.

- Remove the chamber with the accelerating pump, its control and gasket.

- Remove the oil pump seal. - Remove the intake and exhaust valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL. N.B. AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL.

ENG - 149

Engine

Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger. - Remove the maximum nozzle

-Remove the maximum nozzle.

ENG - 150



Engine

-Remove diffuser.

- Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.

-Remove the minimum nozzle.

ENG - 151

Engine

- Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PROGRESSIONS AND INTAKE NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER FITTING AND THEIR REMOVAL DAMAGES THE SHAFT.

Refitting the carburettor - Before refitting, wash the carburettor body accurately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat.

- For maximum circuit, check the air adjustment is correct as shown in the figure.

ENG - 152



Engine

- For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section controlled by flow screw, progression holes near the throttle valve.

- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. N.B.

THE ACCELERATION NOZZLE EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING. - Check that there are 5 closing ball joints for the operating pipes on the carburettor body. - Check that the coupling surfaces, the chamber and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities. - Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching. N.B.

TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS. - Wash and blow the minimum nozzle properly and reassemble it.

ENG - 153

Engine


- Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser. - Assemble the diffuser making sure the sprayer is being adequately inserted and lock it. -Assemble the maximum nozzle.

- Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp. - Replace the rod if worn out.

- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that there are no fuel infiltration. - Replace it in case of failures. - Introduce the float with the rod on the fuel feeding tube side. N.B.

INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY

ENG - 154


Engine

- Remove the drainage screw from the tank, wash and blow it properly and make sure the acceleration pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves following this order: INTAKE VALVE (A) •

Spring

•

Ball

•

Nozzle

IN VALVE (M) •

Ball

•

Spring

•

Nozzle

N.B. THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED.

-Check the screw tightness introducing a small amount of fuel in the tank. - Assemble a new gasket on the tank. - Assemble the tank on the carburettor body fastening the 4 screws. - Check that the control roller is free to rotate in its own seat. N.B. MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED N.B. AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKER.

- Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body.

- The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position.

ENG - 155

Engine


Level check - Place the carburettor inclined as shown in the figure.

- Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.

ENG - 156


Engine

•

Insert a transparent rubber pipe to the bleeding intake of the fuel tank.

•

Keep the pipe up so that the ends are higher than the venturi pipe.

•

Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the diagram.

ENG - 157

Engine

Inspecting the valve and needle - Check that the tapered pin of the vacuum valve does not show wear. - Check that the depression valve does not show threads on the external surfaces. - Check that the vacuum intake hole is not clogged. - Check that the diaphragm is not damaged or has hardened, otherwise replacement the whole valve. - Insert the tapered pin into the vacuum valve housing. - Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is inserted into the sprayer. N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION.

- Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws.

ENG - 158



Engine

- Wash and blow dry the filter sponge of the ambient pressure intake.

- Reassemble the filter with its clamp.

- Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.

ENG - 159

Engine

Inspecting the automatic choke device - Check that the automatic starter piston is not deformed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the piston sealing gasket is not deformed. - The starter must be more or less functional depending on the ambient temperature. - Measure the protrusion of the piston as shown in the figure and check its corresponding value. - Make sure that the starter is adjusted for the ambient temperature. - The starter should disconnect progressively by means of electric heating. - Check the starter resistance when adjusted to the ambient temperature. With a 12V battery power the automatic starter and check that the piston protrudes as much as possible. - The correct warm up time depends on the ambient temperature. - If protrusion, resistance or timing values are different from the ones prescribed, replace the starter. - Assemble the starter to the carburettor being careful to position the O-Ring correctly, insert the plate with the machined side contacting the starter, tighten the fixing screws. - Position the starter as shown in the figure. - Assemble the protection casing. N.B. TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER.

Characteristic Check the Kehin automatic starter: Protrusion value

ENG - 160



Engine

XX ÷ XX mm at approx. 20°C Check max. protrusion of Kehin aut. starter XXX ÷ XXX mm Check aut. Kehin max. time starter 5 min

Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow certain rules when adjusting the idle speed. - Before adjusting the carburettor make sure to respect the lubrication requirements, valve clearance, and complying timing, spark plug should be in optimum conditions, air filter clean and sealed, and the exhaust system tight. - Warm up the engine by running it at least 5 minutes at approximately 50 kph. - Connect the vehicle to the exhaust fumes analyser inserting the probe into a sealed extension pipe placed at the muffler exit end. - Connect a millimetre thermometer (020331y) on the sump, using a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is between 70÷80 °C. - Using the rpm indicator or any other instrument (020332y), adjust the idle screw to obtain 1600 rpm ÷ 1700 rpm. N.B. THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED. CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000

ENG - 161

Engine

ENG - 162


INDEX OF TOPICS

SUSPENSIONS

SUSP

Suspensions

Front Removing the front wheel - Loosen the wheel axle lock nut, by keeping the wheel axle blocked on the opposite side.

- Loosen the two wheel axle safety screws on the fork leg, on the odometer gear side.

- Pull out the wheel axle.

SUSP - 164



Suspensions

- Remove the front wheel. - Slide off the odometer gear from the wheel hub. CAUTION DO NOT ACT ON THE FRONT BRAKE LEVER ONCE THE FRONT WHEEL IS REMOVED. BY DOING SO, THE CALLIPER PISTONS COULD COME OUT FROM THEIR HOUSING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.

Front wheel hub overhaul Check that the wheel bearings do not show signs of wear. If you have to replace the wheel bearings, proceed as follows: - Remove the bearing on the odometer drive side using the pliers 14 and the bell detail 9.

Specific tooling 001467Y013 Calliper to extract ø 15-mm bearings 001467Y009 Driver for OD 42-mm bearings

SUSP - 165

Suspensions

- Remove the internal spacer.

- Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle, 24 mm adaptor and 15 mm guide) from the odometer drive side to permit the removal of the brake disc side bearing and the spacer bushing.

Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020412Y 15-mm guide

SUSP - 166



Suspensions

- Heat the bearing seat on the side the brake disc with the heat gun.

- Grease one side of the new bearing to make it stay together with the adaptor.

- Insert the bearing using the punch consisting of adaptor handle, 42x47 mm adaptor and 15 mm guide, and drive it up to the stop.

- Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop.

Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide 020201Y Spacer bushing driving tube

SUSP - 167

Suspensions


- Turn the wheel upside-down and insert the inner spacer.

- Heat the bearing seat on the odometer drive side with the heat gun. - Grease one side of the new bearing to make it stay together with the adaptor.

- Insert the new bearing on the odometer drive side by using a punch consisting of adaptor handle, 32x35 adaptor and 15 mm guide and drive it fully home.

Specific tooling 020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15-mm guide

SUSP - 168


Suspensions

WHEEL RIM INSPECTION - Make sure that the rim is not deformed or cracked. Replace it if necessary. - Check wheel eccentricity. If tolerance limits are exceeded, check the wheel rim and the bearings. If necessary, replace the wheel.

Characteristic Eccentricity limits: Vertical: 2 mm Horizontal: 2 mm

- Check the wheel balance. - Check wheel on the wheel balancer and turn it several times, paying attention to its position when it stops. If the wheel is steadily balanced, it will not always stop at the same point. If it always stops at the same point, the wheel is not balanced and must be balanced. Place weights on the lightest part of the wheel so that it does not stop any more at a particular point after being turned several times.

SUSP - 169

Suspensions

Refitting the front wheel - First shift by 90° the inner stop of the odometer drive with respect to the one on the wheel.

- Insert the wheel axle after greasing it from the brake disc opposite side, centring the retainer on the fork leg onto the projecting parts of the odometer drive. - Holding the wheel axle, lock the nut on the opposite side to the specified torque.

SUSP - 170



Suspensions

- Make the fork travel to adjust the fork legs on the wheel axle. - Lock the two safety screws located on the fork leg to the specified torque, according to the sequence 1-2-1.

Locking torques (N*m) Front wheel axle nut 45 - 50 Safety screw on fork leg 6 - 7

Handlebar Removal - Remove the front and rear handlebar cover. - Detach the front brake pump from the handlebar. - Disconnect the rear brake, throttle control and odometer control cables. - Remove the screw fixing the handlebar to the steering tube. - Remove the handlebar.

See also Front handlebar cover Rear handlebar cover Front brake pump

Refitting - Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the prescribed torque.

Locking torques (N*m) Handlebar fixing screw (*) 45 to 50

SUSP - 171

Suspensions

(*) Lubricate the nut with engine oil before installation

Front fork Removal

REMOVING THE STANCHIONS - Remove the legshield. - Remove the brake calliper. - Remove the front wheel. - Remove circlip «7», the two screws «8» and slide off the stanchion. - Unscrew the upper cap «6». - Remove the components including the spring. - Drain the oil into a collecting container.

SUSP - 172



Suspensions

- Undo screw «3», remove the stanchion and the piston.

See also Legshield Removal Removing the front wheel

Overhaul STANCHION INSPECTION - Check the sliding surface for scorings and/or scratches. - If the scorings are deep, replace the stanchion. SLEEVE INSPECTION - Check that it is not damaged and/or cracked. - If there are signs of excessive wear or damage, replace the affected component. - Replace the oil seal «4» and the dust gaiter «5» and fit it once you have lubricated their seat. - Replace the O-ring on the inner cap «1» - Replace sealing washer «2».

Refitting - Refit the stanchion and the piston and tighten screw «3» with its washer «2» to the specified torque. - Pour the recommended quantity of specific oil into the stanchion unit. - Insert the spring and the components. - Tighten the upper cap «6» to the specified torque. - Introduce the stanchion in the bottom yoke and install the circlip «7».

SUSP - 173

Suspensions

- Push on the upper cap «6» until the circlip touches the bottom yoke. - Tighten the screws «8» to the prescribed torque.

Characteristic Fork stem (oil level height without spring, compressed fork) 85 mm

Locking torques (N*m) Fork clamp screw 20 to 25 Fork stanchion upper cap 15 ÷ 30 Piston tightening fork lower screw 25 - 35

Steering column Removal

SUSP - 174



Suspensions

- Position the vehicle on centre stand. - Set a support under the vehicle in such a way that the wheel is able to move freely and the vehicle does not fall. - Remove the handlebar. - Remove the legshield. - Remove the front brake calliper. - Release the fork from the odometer cable and from the front brake calliper pipe. - Loosen the upper ring nut «1» and collect the shim washer «2».

Specific tooling 020055Y Wrench for steering tube ring nut

Locking torques (N*m) Upper steering ring nut 30 to 36 - Remove the upper ring (or lower ring nut) «3» of the upper bearing «A». - Slide the fork and collect the cage with the balls «4» of the upper bearing «A».

Locking torques (N*m) Lower steering ring nut 10 - 13 **

When the specified torque of the lower ring nut is reached, loosen by 90°.

See also Removal Legshield Removal - Remove the balls retainer «7» of the lower bearing «B» from the steering tube.

- Wash carefully all the parts removed. - To refit, carry out the removal operations but in reverse order. SUSP - 175

Suspensions


- Appropriately lubricate the bearings with recommended products. BEARING SEAT REPLACEMENT ON CHASSIS - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper bearing «A» seat «5» by putting the special tool into the lower part of the headstock as indicated in the figure. - Remove the lower bearing «B» seat «6» on the headstock by inserting the punch from the top on the headstock.

Specific tooling 020004Y Punch for removing steering bearings from headstock - Using the special tool, refit the upper «A» and lower «B» bearing seats on the headstock.

Specific tooling 001330Y Tool for fitting steering seats

LOWER BEARING SEAT REPLACEMENT ON FORK Check the condition of the lower bearing «B» seat «8» on the fork (steering tube). Replace if there are faults. - Support the fork properly. - Using the special tool, remove the seat «8» on the steering tube as shown in the photograph by applying small mallet blows.

Specific tooling 020004Y Punch for removing steering bearings from headstock

SUSP - 176


Suspensions

Always use a new seat on refitting. - Using the special tool, refit the seat «8» with the aid of a few mallet blows and bring it as far as the stop shown in the photo.

Specific tooling 006029Y Punch for fitting fifth steering bearing on steering tube

Steering bearing CHECKING THE BEARINGS CLEARANCE To check the steering, it is necessary to: - Position the vehicle on centre stand. - Place a support under the motorcycle in such a way that the front wheel is able to move freely and the vehicle does not fall. When carrying out this operation, pay attention not to mistake the centre stand clearance with that of the steering. Repeat this test many times before deciding if the steering clearance must be adjusted. - Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward position. - There should be no clearance forward or backward If there is clearance, the steering must be adjusted. ADJUSTING THE BEARING CLEARANCE - Remove the legshield. - Loosen the upper ring nut «1» using the specific wrench. - Screw in the lower ring nut «3» until the bearing clearance is totally eliminated. CAUTION DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT «3» BECAUSE THE STEERING BEARINGS COULD GET DAMAGED.

- Check clearance as described above. Make sure the front fork can move all long its stroke, from left to right or vice versa, rotating freely and smoothly. SUSP - 177

Suspensions


- Keep the lower ring nut «3» in position, by using a specific wrench and tighten the upper ring nut «1» to the specified torque. Check again the bearings clearance.

Specific tooling 020055Y Wrench for steering tube ring nut

Locking torques (N*m) Lower steering ring nut 10 - 13 ** Upper steering ring nut 30 to 36 When the specified torque of the lower ring nut is reached, loosen by 90°.

See also Legshield

Rear Removing the rear wheel - Position the vehicle on centre stand. - Remove the silencer. - Use a screwdriver to remove the plastic cap.

- Remove the cotter pin. - Remove the cap.

SUSP - 178


Suspensions

See also Exhaust assy. Removal - Pull the rear brake and keep it pulled with a clamp. - Unscrew the wheel fixing nut and collect the washer. - Take out the wheel from its housing.

- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.

Locking torques (N*m) Rear wheel axle 115

Swing-arm Removal - Rest the vehicle on its centre stand. - Support the engine adequately. - Unscrew the nut on the left-hand side of the engine and slide off the bolt from the opposite side.

SUSP - 179

Suspensions

- Loosen the nut on the inside of the frame from the left-hand side and remove the relevant pin.

- Remove the Seeger ring shown in the picture. - Remove the helmet compartment. - Slide off the support spring by using a normal spring puller.

SUSP - 180



Suspensions

- Lower the front end of the engine to free the swinging arm. - Slide off the swinging arm from the right-hand side of the vehicle. - To replace the silent block it is necessary to remove the support bracket, after removing the swinging arm and the side fairings. - Unscrew the two indicated retainers and remove the bracket with silent block from chassis. - To remove the silent block from the bracket, please use the specific tool.

Specific tooling 020271Y Tool for removing-fitting silent bloc

Locking torques (N*m) Engine arm pin - chassis arm 45.5 Silent blockswinging arm retaining bolts 42.5

Overhaul Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed as follows: - Position the vehicle on centre stand. - Hold the rear wheel firmly and try to move it perpendicularly to the travel direction. - If there is any clearance, check all the fastening elements that connect the swinging arm to the engine and chassis as well as the condition of the silent block.

Shock absorbers

SUSP - 181

Suspensions

Removal - Remove the side fairings. - Support the vehicle adequately. - Undo the inner nut and slide off the shock-absorber to chassis upper fixing screw.

- Undo the inner nut and slide off the shock-absorber to engine lower fixing screw. - Remove the shock absorber. - To refit tighten the screws to the prescribed tightening torque.

Locking torques (N*m) Shock absorber nut 22.5

See also Side fairings

Centre-stand - Support the vehicle adequately. - Undo the nut on the left-hand side of the engine.

SUSP - 182



Suspensions

- Remove the stand pin and collect the return springs.

- When refitting lubricate the pin and the springs with the specified grease and tighten the nut to the specified tightening torque.

Locking torques (N*m) Centre stand pivot on engine 42.5

SUSP - 183

INDEX OF TOPICS

BRAKING SYSTEM

BRAK SYS


Braking system

Front brake calliper Removal - Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/or the components of the system, it is necessary to replace them. - Detach the oil brake pipe from the calliper; pour the fluid inside a container. - Remove the two clamps shown in the figure. - Remove the brake calliper from the fork.

Refitting - Refit the calliper on the support and tighten the screws to the specified torque. - Refit the tube complete with fitting with new copper gaskets. - Place the tube joint in the original position and tighten it to the specified torque. - Bleed the air from the system.

Locking torques (N*m) Brake fluid pipe-calliper fitting 20 to 25 Calliper to fork tightening screw 20 to 25 Oil bleed screw 8 to 12

See also Front

Front brake disc

BRAK SYS - 185

Braking system

Removal Proceed as follows: - remove the front wheel. - Undo the five screws fixing the disc. - Remove the brake disc.

Refitting When refitting, position the disc correctly, following the direction indicated on the same disc.

Locking torques (N*m) Disc tightening screw 8 to 12

Disc Inspection - Check the disc thickness.

Characteristic Disc minimum thickness: 3.5 mm

BRAK SYS - 186



•

Braking system

Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm.

•

If a value other than that prescribed is detected, remove the front wheel and check how much the disc protrudes. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and repeat the check.

•

If the problem persists, check and replace the wheel rim if necessary.

Specific tooling 020335Y Magnetic mounting for dial gauge

See also Removing the front wheel

Front brake pads Removal - Remove the brake calliper. - Undo and remove the two screws indicated.

- Remove the pads. - Remove the inner spring. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.

BRAK SYS - 187

Braking system

See also Front brake calliper - Check the thickness of the friction material. If thinner than the minimum value, replace it.

Characteristic Minimum friction material thickness 1.5 mm

- In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.5 mm. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

BRAK SYS - 188



Braking system

Refitting - To refit, carry out the disassembly operations in the inverse order, fitting the inner spring correctly and tightening the fixing screws to the specified torque.

Locking torques (N*m) Brake pad fastening screw 15 to 20

Fill Front N.B.

IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THE POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPER PERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGINESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY. CAUTION

CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REGULAR MAINTENANCE OPERATIONS. - Once the bleed valve is closed, fill the system with brake fluid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system. The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque. N.B. IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS:

BRAK SYS - 189

Braking system

IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. CAUTION - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY. CAUTION WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL ON IT.


Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

Locking torques (N*m) Oil bleed screw 8 to 12

Front brake pump - Remove the front and rear handlebar cover. - Disconnect the tube, collecting the brake oil in a container.

BRAK SYS - 190



Braking system

- Operate on the two U bolt clamps (see figure). - On refitting, perform the operation in reverse. - Tighten the hydraulic line to the prescribed torque and then fill and purge the system.

Locking torques (N*m) Brake fluid hose-pump fitting 20 to 25 Pump U bolt screw 8

See also Front handlebar cover Rear handlebar cover

Rear drum brake Drum brake adjustment Regulate the point where the rear drum brake intervenes, using the adjustment indicated in the figure. With the brake lever at rest, the wheel must turn freely.

Drum brake removal - Remove the rear wheel. - Hold the lower shoe and slide it out with the upper one. For fitting: - First assembly two shoes and the springs then place them on the pin and on the cam.

See also Removing the rear wheel

BRAK SYS - 191

Braking system

Transmission replacement - Remove the front handlebar cover. - Remove the leg shield and the footrest. - Loosen the brake set screw - Release the transmission from its retainers to the engine.

See also Front handlebar cover Legshield Footrest - Release the transmission from the retainers on chassis and from the control lever. - Fit the new transmission, fixing and positioning it like the one replaced. - Adjust the drum brake activation point.

Locking torques (N*m) Rear brake adjustment nut 5

BRAK SYS - 192



Braking system

BRAK SYS - 193

INDEX OF TOPICS

CHASSIS

CHAS


Chassis

Seat - Undo the four nuts indicated in the figure and collect the washers.

Locking torques (N*m) Saddle plate fixing nut 10

Driving mirrors - Lift the rubber cover. - Loosen the indicated nut, keeping the lower spacer blocked. - Undo the mirror from the lower spacer. - Remove the lower spacer, if necessary. N.B. THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCKWISE.

Locking torques (N*m) Mirror fastening spacer 25

Rear handlebar cover - Remove the front handlebar cover. - Undo the four screws indicated.

CHAS - 195

Chassis

- Disconnect the connectors of the instrument panel and the odometer cable. - Remove the handlebar cover together with the instrument panel and controls.

See also Front handlebar cover

Instrument panel - Remove the rear handlebar cover. - Undo the four screws indicated.

See also Rear handlebar cover

CHAS - 196



Chassis

Front handlebar cover - Remove the rear-view mirrors and the lower spacers. - Undo the two screws indicated.

- Undo the front screw. - Lift the upper edge to release and separate it from the rear handlebar cover. - Disconnect the turn indicators connections and remove the front handlebar cover.

See also Driving mirrors

CHAS - 197

Chassis

Headlight assy. - Remove the legshield. - Undo the four screws indicated.

FRONT TURN INDICATORS - Remove the front handlebar cover. - Undo the three screws indicated.

See also Legshield Front handlebar cover

Legshield - Remove the leg shield back plate. - Working from the front wheel housing internal side, undo the two screws from both sides of the vehicle.

CHAS - 198



Chassis

- Undo the indicated screw, beneath the leg shield lug.

- Move the leg shield forward, opening the lower ends and detach the headlight bulb connections.

Knee-guard - Remove the front handlebar cover. - Undo the five side screws on the sides of the leg shield back plate as shown.

CHAS - 199

Chassis

- Undo the screw in the glove-box and the one under the chassis number lid. - Before refitting the leg shield back plate, loosen the footrest fixing screws, so as to fit the two components in the best conditions. N.B. WHILE REFITTING, PLEASE REMEMBER TO ATTACH THE GLOVE-BOX OPENING LEVER TO THE KEY-OPERATED DEVICE.

See also Front handlebar cover

Front wheel housing - Remove the legshield. - Remove the front mudguard - Remove the front wheel. - Undo the three screws indicated.

- Undo the upper screw. - Slide the housing off the fork stanchions.

See also Legshield Front mudguard Removing the front wheel

CHAS - 200



Chassis

Footrest - Remove the leg shield back plate. - Remove the side fairings. - Undo the indicated screws and remove the protections.

- Undo the four screws indicated.

See also Knee-guard Side fairings

Side fairings - Remove the rear handles. - Remove the rear central cover. - Undo the two screws indicated.

CHAS - 201

Chassis

- Undo side screw from both sides of the vehicle.

- Undo the two screws on the helmet compartment.

- Undo the two upper screws.

- Undo from both sides of the vehicle the screw placed under the footrest.

CHAS - 202



Chassis

- Open the front ends of the side fairings to slide off the indicated upper inserts.

- Disconnect the connections of the turn indicators and of the rear light unit.

See also Handles and top side fairings Rear central cover

License plate holder - Remove the side fairings. - Disconnect the connections of the turn indicators and of the license plate light.

CHAS - 203

Chassis

- Undo the rear screw outside the license plate support.

- Undo the two screws indicated. - Remove the license plate support together with the turn indicators.

See also Side fairings

Rear mudguard - Undo the right-hand side screw.

- Undo the rear screw that fixes also the air filter box.

CHAS - 204



Chassis

Helmet bay - Remove the side fairings. - Remove the battery cover and the battery. - Undo the two screws inside the helmet compartment.

- Disconnect the fuse box and free the helmet compartment from the cables.

See also Side fairings Battery

spoiler - Remove the footrest. - Undo the three screws indicated.

CHAS - 205

Chassis

- Undo from both sides of the vehicle the screw placed under the footrest.

See also Footrest

Fuel tank Remove the side fairings and the helmet compartment. - Detach the pipes from the vacuum-operated cock.

- Undo the indicated screw on both sides of the vehicle.

CHAS - 206



Chassis

- Undo the central screw and loosen the two side screws on the license plate support frame.

- Disconnect the fuel probe connector and detach the breather pipe from the filler.

Locking torques (N*m) Fuel tank to chassis fixing screws 10

See also Side fairings Helmet bay

Rear central cover - Remove the saddle. - Undo the four indicated screws and remove the cover by sliding it upwards so as to detach the locking tabs on the sides.

See also CHAS - 207

Chassis

Seat

Front mudguard - Operating from both sides of the vehicle, undo the three indicated screws.

Handles and top side fairings - Remove the three screws indicated in the figure and collect the washers. - Remove the rear handles.

Locking torques (N*m) Rear grab handle fixing screw 20.5

Battery - Undo the three indicated screws and remove the battery cover.

CHAS - 208



Chassis

- Disconnect the negative and positive cables. - Slide off the breather pipe.

CHAS - 209

INDEX OF TOPICS

PRE-DELIVERY

PRE DE


Pre-delivery

Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt

Tightening torques inspection Lock check - Safety fasteners - Fixing screws Safety fasteners: Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Swinging arm - chassis pin Engine-swinging arm pin Engine arm pin - Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut

Electrical system Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights - Horn - Starter PRE DE - 211

Pre-delivery


CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL FIRST. CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE. WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

Levels check Level check: - Hydraulic braking system fluid level. - Rear hub oil level - Engine oil level

Road test Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise

PRE DE - 212


Pre-delivery

Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection Functional Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the chassis and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories

PRE DE - 213

INDEX OF TOPICS

TIME

TIME


Time

Engine

ENGINE 1

Code 001001

Action Engine from chassis - Removal and refit.

Duration

TIME - 215


Time

Crankcase

CRANKCASE 1 2

Code 001133 001153

3

002031

TIME - 216

Action Engine crankcase - Replacement Crankcase halves gasket - Replacement Rear wheel hub bearings - Replacement

Duration


Time

Crankshaft

CRANKSHAFT 1 2

Code 001117 001099

Action Crankshaft - Replacement Flywheel-side oil seal - Replacement

Duration

TIME - 217


Time

Cylinder assy.

CYLINDER ASSEMBLY 1 2

TIME - 218

Code 001002 001107

Action Cylinder-Piston - Replacement Cylinder / piston - Inspection / cleaning

Duration


Time

Cylinder head assy.

HEAD ASSEMBLY 1 2 3

Code 001045 001056 001126

Action Valves - Replacement Head gasket - change Head - Replacement

Duration

TIME - 219


Time

Rocker arms support assy.

ROCKERS MOUNTING UNIT 1 2 3

TIME - 220

Code 001044 001148 001049

Action Camshaft - Replacement Rockers valves - Replacement Valves - adjust

Duration


Time

Cylinder head cover

HEAD COVER 1 2 3 4 5 6 7

Code 001089 001088 001159 001093 001097 001091 001074

Action Head cover - Replacement Head cover gasket - Replacement Oil vapour recovery tank - Service Spark plug - Replacement Cooling hood - Replacement Head cover sealing ring Oil vapour recovery pipe - Replacement

Duration

TIME - 221


Time

Chain tensioner

CHAIN TENSIONER 1

Code 001129

2

001124

TIME - 222

Action Chain tensioner - Service and Replacement By pass lubrication - Replacement

Duration


Time

Oil filter

OIL FILTER 1 2 3 4

Code 001123 001160 003064 001102

Action Oil filter -Replacement Oil pressure sensor - change Engine oil - change Net oil filter - change / Cleaning

Duration

TIME - 223


Time

Flywheel cover

FLYWHEEL COVER 1 2

Code 001087 001163

3

001161

4 5

001174 001164

TIME - 224

Action Flywheel cover - Replacement Silencer secondary air connection Replacement Secondary air filter - Replacement / Cleaning SAS valve - Replacement Crankcase secondary air connection - Replacement

Duration


Time

Driven pulley

DRIVEN PULLEY 1 2 3 4

Code 001155 001022 001012 001110

Action clutch housing - Replacement Clutch - Replacement Driven pulley - overhaul Driven pulley- Replacement

Duration

TIME - 225


Time

Oil pump

OIL PUMP 1 2 3 4 5 6 7

TIME - 226

Code 001051 001125 001042 001112 001130 001100 001122

Action Belt/Timing chain - Change Chain guide pads - Replacement Oil pump - overhaul Oil pump - change Oil sump - change Clutch-side oil seal - Replacement Oil pump chain - Replacement

Duration


Time

Final gear assy.

FINAL REDUCTION GEAR 1 2

Code 004125 001156

3 4

003065 001010

Action Rear wheel axle - Replacement Gear reduction unit cover - Replacement Gear box oil - Replacement Geared reduction unit - Service

Duration

TIME - 227


Time

Driving pulley

DRIVING PULLEY 1 2 3 4

TIME - 228

Code 001066 001086 001177 001011

Action Driving pulley - Removal and refitting Driving half-pulley - Replacement CVT rollers / sliders - Replacement Drive belt - Replacement

Duration


Time

Transmission cover

TRANSMISSION COVER 1

Code 001096

2

001135

3

001065

Action Transmission crankcase cover - Replacement Transmission cover bearing - Replacement Transmission cover - Removal and Refit

Duration

TIME - 229


Time

Starter motor

STARTER MOTOR 1 2

TIME - 230

Code 001020 001017

Action Starter motor - Replacement Start-up pinion - Replacement

Duration


Time

Flywheel magneto

Belt cooling duct

TIME - 231


Time

BELT COOLING PIPE 1 2

Code 001170 001132

3

001131

Action Air duct - replacement Transmission air intake pipe - Replacement Transmission air intake - Replacement

Duration

Carburettor

CARBURETTOR 1

Code 001082

2 3

001013 004122

4 5 6

001081 001008 001063

TIME - 232

Action Carburettor heating resistor - Replacement Intake manifold - change Air cleaner carburettor fitting - Replacement Automatic choke - Replacement Carburettor - Inspection Carburettor - Replacement

Duration


Time

Exhaust pipe

SILENCER 1 2 3

Code 001009 001136 001095

Action Silencer - Replacement Exhaust emissions - Adjustment Silencer heatshield - Replacement

Duration

TIME - 233


Time

Air cleaner

AIR CLEANER 1 2

TIME - 234

Code 001014 001015

Action Air filter - Replacement/Cleaning Air filter box - Replacement

Duration


Time

Frame

CHASSIS 1 2 3

Code 004001 004004 001053

Action Chassis - Replacement Stand - Replacement Stand pin - Replacement

Duration

TIME - 235


Time

Legshield spoiler

SPOILER LEGSHIELD 1 2 3

Code 004159 004149 004064

4 5

004015 004053

TIME - 236

Action Plates / Stickers - Replacement Shield central cover - Replacement Leg shield, front part - Removal and refitting Footrest - Removal and Refitting Spoiler - Replacement

Duration


Time

Rear cover

REAR SHIELD 1 2

Code 004174 004065

3

004081

Action Trunk levers - Replacement Legshield, rear part - Removal and refitting Top box lid - Replacement

Duration

TIME - 237


Time

Central cover

CENTRAL COVER 1

Code 004059

2

004106

3 4 5

004085 004105 004131

TIME - 238

Action Spark plug inspection flap - Replacement Helmet compartment band - Replacement Fairing (1) - Replacement Right side clamp - Replacement Luggage rack mounting - Replacement

Duration


Time

Underseat compartment

HELMET COMPARTMENT 1 2

Code 005046 004016

3

001027

Action Battery cover - change Helmet compartment - Removal and Refitting Body / air cleaner union - Replacement

Duration

TIME - 239


Time

Plate holder

LICENSE PLATE HOLDER

1

Code 004136

2

005048

TIME - 240

Action License plate holder mounting - Replacement number plate holder - Replacement

Duration


Time

Mudguard

MUDGUARDS 1 2

Code 004002 004009

Action Front mudguard - change Rear mudguard - Replacement

Duration

TIME - 241


Time

Fuel tank

FUEL TANK 1 2 3

Code 004168 005010 004112

4 5 6

004005 004007 004109

TIME - 242

Action Fuel tank cap - Replacement Tank float - Replacement Cock-carburettor hose - Replacement Fuel tank - Replacement Fuel valve - Replacement Fuel tank breather - change

Duration


Time

Rear shock-absorber

REAR SHOCK ABSORBER 1

Code 003007

Action Rear shock absorber - Removal and Refitting

Duration

TIME - 243


Time

Steering column bearings

STEERING BEARING 1 2

TIME - 244

Code 003002 003073

Action Steering bearing - Replacement Steering clearance - Adjustment

Duration


Time

Handlebar covers

HANDLEBAR COVERS 1

Code 004019

2

004018

3 4 5 6

005078 005076 005014 005038

Action Handlebar rear section - Replacement Handlebar front section - Replacement Odometer glass - Replacement Clock / Cell - Replacement Odometer - Replacement Instrument panel warning light bulbs - Replacement

Duration

TIME - 245


Time

Handlebar components

HANDLEBAR COMPONENTS 1 2 3 4 5 6

Code 004066 002037 002071 003001 005017 002024

7 8

003061 002060

9

004162

10 11

002059 002063

TIME - 246

Action Driving mirror - Replacement Brake or clutch lever - Replacement Left hand grip - Replacement Handlebar - Removal and refitting Stop switch - Replacement Front brake pump - Removal and Refitting Accelerator transmission - adjust Complete throttle control - Replacement Mirror mounting and/or brake pump fitting U-bolt - Replacement Right hand grip - Replacement Throttle control transmission - Replacement

Duration


Time

Swing-arm

SWINGING ARM 1

Code 001072

2

003080

Action Engine / frame swinging arm fitting Replacement Swinging arm on chassis - Replacement

Duration

TIME - 247


Time

Brake hoses

BRAKE PIPING 1

Code 002007

2

002039

3

002021

4

002047

TIME - 248

Action Front brake shoes/pads - Remov. and Refitt Front brake calliper - Removal and Refitting Front brake hose - Remov. and Refitt. Front brake fluid and system bleeding plug - Repl.

Duration


Time

Seat

SADDLE 1 2

Code 004003 004068

Action Saddle - Replacement Passenger handgrip - Replacement

Duration

TIME - 249


Time

Turn signal lights

INDICATOR LIGHTS 1 2 3

Code 005002 005012 005067

4 5 6 7

005008 005005 005066 005022

8

005068

9

005131

10

005031

11

005032

TIME - 250

Action Front headlamp - Replacement Front turn indicator - Replacement Front turn indicator bulb - Replacement Headlight bulbs - Replacement Taillight - change Rear light bulbs - Replacement Rear turning indicators - Replacement Rear turning indicator bulb - Replacement number plate light support - Replacement number plate light bulb - Replacement number plate light glass - Replacement

Duration


Time

Front wheel

FRONT WHEEL 1 2 3 4 5

Code 003038 002011 003040 003047 003037

6 7

004123 002041

Action Front wheel axle - Remov. and Refit. Odometer drive - Replacement Front wheel bearings - Replacement Front tyre - Replacement Front wheel rim - Removal and Refitting Front wheel - Replacement Brake disc - Replacement

Duration

Tone wheel or drive greasing Please take note that the code has been introduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide). In the following points, the area to be greased is indicated with an arrow (1 - Drive, 2 - Tone wheel)

TIME - 251


Time

Rear wheel

REAR WHEEL 1 2 3 4

TIME - 252

Code 002002 004126 001016 001071

Action Rear brake pads/shoes - Repl. Rear wheel tyre - Replacement Rear wheel - Replacement Rear wheel rim - Removal and Refitting

Duration


Time

Electric devices

ELECTRICAL DEVICES

1 2 3 4 5 6 7 8 9 10 11

Code 001023 005035 005001 001094 001069 005052 005025 005009 005011 005007 005114

Action Control unit - Replacement Headlight solenoid - Replacement Electrical system - Replacement Spark plug cap - Replacement HV coil - Replacement Fuse - Replacement Battery fuse box - Replacement Voltage regulator - Replacement Start-up solenoid - Replacement Battery - change Electrical system - Service

Duration

Electronic controls ELECTRIC CONTROLS 1 2

Code 005039 005006

3 4 5 6 7 8

005040 005003 005041 005016 004096 005072

Action Lights switch - Replacement Light or turning indicator switch - Replacement Horn button - Replacement Horn - Replacement Starter button - Replacement Key switch - Replacement Lock series - Replacement Immobilizer aerial - Replacement

Duration

TIME - 253


Time

Front suspension

FRONT SUSPENSION 1 2 3 4 5 6

TIME - 254

Code 003010 003048 003076 003079 003051 003069

Action Front suspension - Service Fork oil seal - Replacement Fork sleeve - Replacement Fork stem - Replacement Complete fork - Replacement Front fork oil - Replacing

Duration

A Air filter: 33

B Battery: 46, 63, 70, 77, 78, 205, 208 Brake: 171, 185, 187, 188, 190, 191, 248 Bulbs:

C Carburettor: 11, 146, 152, 232 Checks: 68

E Electric: 253 Engine oil: 34

F Fuel: 45, 145, 206, 242 Fuses: 76

H Headlight: 39, 198 Horn: 74 Hub oil: 31

I Identification: 8 Instrument panel: 196

M Maintenance: 7, 28 Mirrors: 195, 197

O Oil filter: 34, 35, 223

R Recommended products:

S Saddle: Shock absorbers: 181 Spark plug: 30, 68 Start-up: Suspension: 47, 254

T Tank: 206, 242 Transmission: 9, 45, 88, 100, 111, 229 Turn indicators: 67 Tyres: 10

V Vehicle: 8, 83

Piaggio Typhoon 125 4T MY 2010 (en)

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