TR 650 TERRA 2013 TR 650 STRADA Workshop Manual Ed Rev 00

Transcription

1 TR 650 TERRA 0 TR 650 STRADA 0 Workshop Manual Ed Rev 00

2 Rev. No. Date Page Description Revision Record HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from actual components. No reproduction in full or in part without written authorisation. st edition (09-0) - Rev. 00

3 simbolo FOREWORD, TABLE OF CONTENTS Workshop Manual TR 650 TERRA 0 TR 650 STRADA 0 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 04 (Varese) - Italy tel tel st edition (09-0) - Rev. 00 Printed in Italy MODELS COVERED (from serial number onwards) TR 650 TERRA (4 kw): ZKH0HA#DV00000 TR 650 TERRA (4 kw - ABS): ZKH0HC#DV00000 TR 650 TERRA (5 kw - ABS): ZKH0HD#DV00000 TR 650 STRADA (4 kw - ABS): ZKH0HE#DV00000 TR 650 STRADA (5 kw - ABS): ZKH0HF#DV Chassis serial number H657 Workshop Manual Ed a.

4 FOREWORD, TABLE OF CONTENTS simbolo Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical complement to operator training and operators should become thoroughly familiar with it. This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally omitted as it was considered superfluous. The technicians must adopt special safety procedures that they will deem necessary in order to prevent damages to the motorbike, to its components, and to people. For ease of understanding, diagrams and photographs are provided next to the text. Notes with special significance are identified as follows throughout the manual: Accident-prevention rules for operator and persons working nearby. Damage to vehicle and/or its components may result from incompliance with relevant instructions. Additional information concerning the operation covered in the text. Useful tips To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations: before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify problem symptoms; diagnose the problem and identify the causes clearly. This manual provides basic background information that must be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular periods; plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays; avoid unnecessary disassembly work to get to the part that needs repairing. Always read the relevant instructions and follow the disassembly sequence outlined in this manual. Workshop Manual Ed a.

5 simbolo FOREWORD, TABLE OF CONTENTS Table of Contents Title Section Foreword, table of contents... a Important notices... b General information...a Maintenance...B Troubleshooting... C Settings and adjustments... D General procedures...e Engine settings and adjustments...f General engine procedures...f Cylinder head removal/disassembly...f Crankcase disassembly...f Engine torque figures...f4 Engine parts wear limits...f5 Front suspension... I Rear suspension... J Brakes... L Electrical system... M Engine cooling... N Tightening torque figures...x Chassis and wheels...y NOTES Unless otherwise specified, data and specifications apply to all models. Workshop Manual Ed a.

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7 IMPORTANT NOTICES Section b Workshop Manual Ed b.

8 IMPORTANT NOTICES GENERAL SAFETY WARNINGS Read these general recommendations carefully before using the vehicle. Carbon monoxide Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction system. Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even death if inhaled. Parts of the vehicle that become hot Before working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very hot and remain hot for some time after turning off the engine. Risk of burns - work with caution and wear suitable PPE if necessary. Fuel The fuel used to power internal combustion engines is highly flammable and explosive. Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not smoke and avoid contact between the fuel and naked flames, sparks, etc. that may cause an explosion. Do not dispose of fuel in the environment. Keep out of reach of children. Do not tilt the vehicle excessively since this may cause fuel to leak. Engine In some cases, coolant may become inflammable and if burnt, produce invisible flames which cause burns. Do not spill coolant onto hot components like the engine or exhaust pipe, etc. since it may ignite. During maintenance work, wear latex gloves. Never leave the coolant in open containers in areas accessible to children and animals since it is toxic. DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding. Engine oil Do not dispose of oil in the environment since it is highly polluting. Keep out of reach of children. Wear latex gloves since prolonged contact with the skin can cause serious damage. Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where the vehicle will be used. Brake fluid Brake fluid is highly corrosive and may damage the rubber and painted parts of the vehicle. While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves. In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice immediately. Keep out of reach of children. Workshop Manual Ed b.

9 IMPORTANT NOTICES Battery Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being recharged; do not smoke or use naked flames or sparks. The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water. It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage to the eyes. If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally, drink plenty of water or milk. In all cases, seek medical advice immediately. The battery liquid is corrosive and should not be poured onto the painted or rubber parts. The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery to the special authorised recycling centres in accordance with the legal requirements in force in the country where the vehicle will be used. Keep out of reach of children. TR 650 TERRA and TR 650 STRADA models are STREET LEGAL motorcycles; they are guaranteed exempt from functional defects and covered with legal guarantee, as far as the STANDARD CON- FIGURATION IS MAINTAINED and the suggested maintenance table shown in Section "B" is observed. * In order to maintain the vehicle s Guarantee of Functionality, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client. The warranty becomes NULL AND VOID if the motorcycle is rented. Notes Left and right side is determined when seated on motorcycle. Z: number of teeth H658 Unless otherwise specified, data and instructions apply to all market variants. Workshop Manual Ed b.

10 IMPORTANT NOTICES RECOMMENDED SHOP PRACTICES Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or foreign bodies. - Put the vehicle in a well lit area; - Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts. - Use suitable equipment for lifting/removing heavy parts. - Use appropriate keys (not pliers) to loosen/tighten nuts and screws. - When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the specified torque and follow a cross pattern or a dedicated pattern as outlined in the relevant section. - Always mark any parts or positions that might be confused upon assembly. - Use special tools where specified. - Clean thoroughly the removed components before refitting them - During the reassembly, make sure that the bearings turn freely without obstruction or without getting stuck, otherwise replace them - Always replace the seals, the sealing rings, the split pins, the screws with damaged thread, and the self-locking nuts with new parts. - Use genuine HUSQVARNA parts and the recommended lubricant brands. - At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer. Electrical parts - Disconnect the electrical component connectors by pressing the special safety hooks. - Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products. - Make sure that the cables are correctly seamed to the connector terminals. - When you reconnect the connectors, ensure the correct coupling. Do not disconnect the connectors by pulling the electrical cables. - Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read them. Where not specified, refit the previously removed components following the procedures in the reverse order with respect to the removal. Workshop Manual Ed b.4

11 GENERAL INFORMATION Section A Workshop Manual Ed A.

12 GENERAL INFORMATION Sommario Engine...A. Timing system...a. Lubrication...A. Ignition...A. Fuel system...a. Primary drive...a. Clutch...A. Transmission...A. Transmission ratio...a. Secondary drive...a. Final ratios...a.4 Chassis...A.4 Front suspension...a.4 Rear suspension...a.4 Front brake...a.4 Rear brake...a.4 Wheels...A.4 Tyres...A.4 Table for lubrication, supplies...a.5 Electrical components location...a.5 Dimensions, weight, capacity...a.6 Workshop Manual Ed A.

13 GENERAL INFORMATION Engine Single cylinder, 4 stroke engine with four valves Cooling...liquid and electric fan Bore...,97 in (00 mm) Stroke...,68 in (8 mm) Displacement... 9,787 in (65 cm ) Compression ratio...,: Starting... electric Type of fuel... unleaded fuel 95ROZ/RON Timing system Double overhead camshaft chain operated; 4 valves Valve clearance (with engine cold) Intake...0,009 0,0 in (0, 0,8 mm) Exhaust... 0,05 0,07 in (0,8 0,4 mm) Lubrication Dry sump with tank integrated in the chassis and cartridge oil filter. Ignition Electronic with adjustable advance (digital control) Spark plug type... NGK MAR9A-J-G06 Spark plug electrode gap...0,04 in (± 0,004 in) 0,6 mm (± 0, mm) Fuel system Electronic injection feed Primary drive Drive gear on crankshaft... Z 7 Driven gear on clutch housing... Z 7 Transmission ratio Clutch Multidisc in oil bath with mechanical control Transmission With front couplings always engaged Transmission ratio st gear (/) nd gear (8/6) rd gear.... (/6) 4th gear (/) 5th gear (/4) Secondary drive Transmission sprocket... Z 6 Rear wheel sprocket... Z 47 Transmission ratio...98 Drive chain dimensions...50kr0 links Workshop Manual Ed A.

14 GENERAL INFORMATION Final ratios st gear nd gear rd gear th gear th gear Chassis Single frame, in round, rectangular and ellipsoidal steel pipes; rear steel chassis Front suspension Upside down type hydraulic fork...ø.8 in (46 mm) fork legs Wheel travel in (90 mm) Rear suspension Hydraulic monoshock (adjustment of spring preload and rebound hydraulic damping) Wheel travel in (90 mm) Front brake Ø,8 in (00 mm) fixed disc with hydraulic control and floating calliper Rear brake Ø 9,449 in (40 mm) floating wave disc with hydraulic control and floating calliper Wheels TR 650 STRADA Front...in light alloy:.5 x9 Rear...in light alloy: x7 TR 650 TERRA Front... with spokes and aluminium rim:.85 x Rear...with spokes and aluminium rim: x8 (no ABS) with spokes and aluminium rim: x7 ( ABS) Tyres TR 650 STRADA Front... 0/80 R9 M/C 59 V Rear...40/80 R7 M/C 59 V Cold tyre pressure (Rider only) Front... kg/cm (.9 psi) Rear...0 kg/cm (8.45 psi) Cold tyre pressure (Rider and passenger) Front... kg/cm (.9 psi) Rear...,5 kg/cm (5.56 psi) TR 650 TERRA Front...90/90 M/C 54 H TL (ABS) 90/90 M/C 54 S (no ABS) Rear...40/80 7 M/C 59 H (ABS) 40/80 8 M/C 70 S (no ABS) Cold tyre pressure (Rider only) Front...0 kg/cm (8.45 psi) Rear...5 kg/cm (5.56 psi) Cold tyre pressure (Rider and passenger) Front...,0 kg/cm (8.45 psi) Rear...,8 kg/cm (9.8 psi) Workshop Manual Ed A.4

15 GENERAL INFORMATION Table for lubrication, supplies Engine, gearbox and primary drive lubricating oil... CASTROL POWER RACING SAE 0W-50 Engine coolant... CASTROL MOTORCYCLE COOLANT Brake fluid...castrol RESPONSE SUPER DOT 4 Grease lubrication...castrol LM GREASE Secondary drive chain lubrication... CASTROL CHAIN LUBE RACING Electric contact protection...castrol METAL PARTS CLEANER Electrical components location The ignition system includes the following elements: - Generator on the inner side of R.H. crankcase half cover; - Electronic ignition coil with integrated spark plug cap positioned on cylinder head; - Electronic control unit on rear chassis under saddle; - Spark plug on cylinder head; - Starter motor in front of cylinder block; - Solenoid starter on rear chassis under saddle; - Potentiometer on throttle body; - Voltage regulator on right-hand side of engine; - Neutral position sensor on right-hand side of engine. The electrical system includes the following elements: - V - 0Ah battery in the central part; - Turning indicator flasher integrated in the digital instrument; - Fuel pump relay, main relay and fan on rear chassis under saddle; - Electric fan; - Auxiliary fuses on rear chassis under saddle; two 0A main fuses on solenoid starter; - Coolant temperature sensor on cylinder head; - Lambda sensor; - Headlamp with H4-V-55/60W HD halogen bulb and V-5W parking light bulb; - LED tail light with stop light bulb; - V-RY0W turning indicator bulbs; - Fuel pump inside the tank. - Multifunction digital instrument. Workshop Manual Ed A.5

16 GENERAL INFORMATION Dimensions, weight, capacity Wheelbase...55,055 in (500 mm) Total length (STRADA)... 88,504 in (48 mm) Total length (TERRA)... 89,5 in (67 mm) Overall width...4,84 in (885 mm) Max. height (STRADA)... 47,44 in (05 mm) Max. height (TERRA)... 48,5 in ( mm) Saddle height (STRADA)...,858 in (860 mm) Saddle height (TERRA)...4,449 in (875 mm) (no ABS - 8 ) / 4,055 in (865 mm) (ABS - 7 ) Minimum height off ground (STRADA)...9,84 in (50 mm) Minimum height off ground (TERRA)... 0,47 in (mm 66) (no ABS 8 ) / 0,8 in (57 mm) (ABS 7 ) Weight, without fuel (STRADA)...90,8 lb (77 kg) Weight without fuel. (TERRA)...8,604 (74 kg) Fuel tank capacity including reserve...,08 Imp. Gall. /,698 U.S. Gall. / l 4 Fuel reserve... approx. 0,55 Imp. Gall. / 0,66 U.S. Gall. /.5 l Coolant tank capacity... 0,55 Imp. Gall. / 0,06 U.S. Gall. /.6 l Oil and oil filter replacement... 0,44 Imp. Gall. / 0,58 U.S. Gall. /.0 l Topping up oil between minimum and max. level... 0,055 Imp. Gall. / 0,066 U.S. Gall. / l mm A 885 mm C D B H659 Workshop Manual Ed A.6

17 MAINTENANCE Section B Workshop Manual Ed B.

18 MAINTENANCE TR 650 STRADA TR 650 TERRA Check engine oil level Replace engine oil together with oil filter, clean magnetic plug SERVICE COUPON AFTER THE FIRST.000 Km SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) ENGINE SERVICE COUPON EVERY Km SERVICE COUPON EVERY Km SERVICE COUPON EVERY Km SERVICE COUPON EVERY Km C S S S S S S S S S Check / adjust valve play C/R C/R C/R C/R Replace spark plugs S S Oil filter (on oil return pipe from chassis) P/S P/S Replace coolant EVERY YEARS Check / adjust clutch play C/R C/R C/R C/R C/R EVERY.000 Km EVERY Km or ONCE A YEAR EVERY Km C: Check S: Change R: Reset Workshop Manual Ed B.

19 MAINTENANCE TR 650 STRADA TR 650 TERRA Check and lubricate secondary chain SERVICE COUPON AFTER THE FIRST.000 Km SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) CHASSIS SERVICE COUPON EVERY Km SERVICE COUPON EVERY Km SERVICE COUPON EVERY Km Lubricate the secondary drive chain at least once every,000 km. If used on dusty or wet roads, do this more frequently SERVICE COUPON EVERY Km Second.Drive chain: check tension and wear C/L/S C/L/S C/L/S C/L/S Check front/rear sprockets for wear: if necessary, replace along with the secondary C/L/S C/L/S C/L/S C/L/S drive chain Air filter S S If the vehicle is used in very dusty conditions/on very dusty roads, reduce this service to 0,000 km Transmission cables and controls C/R/L C/R/L C/R/L C/R/L C/R/L Steering bearings and steering clearance C/R C/R C/R C/R Emptying the intake silencer hose C/P C/P C/P C/P Brake discs C/S C/S C/S C/S Brake pad wear C/S C/S C/S C/S Front fork (oil change) S S General vehicle operation C C C C C Braking systems (check pipes) C/R C/R C/R C/R C/R Cooling system (check level) C/S C/S Lights / warnings C/R C/R C/R C/R C/R Safety switches C/R C/R C/R C/R Brake fluid () C/R C/R C/R C/R C/R Coolant () C/R C/R C/R C/R C/R Checking battery charge level C/R C/R C/R C/R Tyres: Pressure / Wear C/R C/R C/R C/R Wheels (checking spoke tension - terra version) C/R C/R C/R C/R Control unit diagnosis C/R C/R C/R C/R C/R Side stand C/R/L C/R/L C/R/L C/R/L Checking function and clearance of accelerator cable C/R C/R C/R C/R Fuel hoses () C/S Check cooling-water tubes and water pump for condition and leakage / replace if necessary C C C C S: Change L: Lubricate P: Clean R: Reset C: Check (): Replace every years (): Replace every 4 years (): Replace every year Workshop Manual Ed B.

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21 TROUBLESHOOTING Section C Manuale d'officina Ed C.

22 TROUBLESHOOTING ENGINE Trouble Possible causes Remedy Ignition switch not in ON position Switch ignition switch to position ON Engine-stop-switch on OFF position Switch to position ON Starter motor does not operate or does not turn engine over Engine turns over but does not start engine or starts hard Engine runs irregularly at idle Flat battery, loose or rusty connections Ignition circuit in short-circuit Starter motor defect Spark plugs loose Spark plugs not according to specifications or defective Spark plugs fouled or wet Battery nearly discharged, starting rpm too low Fuel supply inadequate Valve clearance below specification Valve timing incorrect Ignition coil or ignition cable defective Ignition unit defective, ignition timing incorrect Cylinder gasket defective Valves and valve guides worn or imperfect valve seat Piston rings and/or cylinder bore worn Engine oil too heavy (winter operation) Excessive spark plug electrode gap Valve clearance below specification Intake coupling not tightened or damaged Ignition unit defective, ignition timing incorrect Valves leaking For other possible causes see also "Engine starts over but does not start engine or starts hard" Check/replace battery and check connections, check charging system Check ignition circuit Replace starter motor Tighten spark plugs Replace spark plug Clean or exchange Check/replace battery and check connections, check if battery is charged by generator Check fuel tank if empty Check / replace fuel supply pipes, fuel pump, fuel pressure sensor and injectors Adjust valve clearance according to specification Adjust position of camshaft gears Check / replace Check / replace crank position trigger and ECU Exchange cylinder head gasket Exchange valves, rework valve seats or exchange cylinder head Exchange piston rings and/or cylinder Exchange engine oil Exchange spark plug Adjust valve clearance according to specification Tighten intake socket or exchange if necessary Check / replace crank position trigger and ECU Rework valve seats Manuale d'officina Ed C.

23 TROUBLESHOOTING Trouble Possible causes Remedy Engine runs irregularly at higher speed Engine has no or insufficient performance Engine knocks or pings Fuel pressure too low Check fuel pressure sensor, fuel pump and fuel supply Leak air Check / replace intake socket Camshafts worn Check and replace if necessary For other possible causes see also "Engine starts over but does not start engine or starts hard" Leak air, intake system leaking Check / replace intake socket Spark plugs not according to specifications or defective Replace spark plug Valve clearance not according specification Adjust valve clearance according to specification Valve timing incorrect Adjust position of camshaft gears Ignition coil supplies insufficient ignition voltage Check / replace ignition coil Ignition unit defective, ignition timing incorrect Valves leaking Clutch slipping Fuel pressure too low Air filter dirty Exhaust system defective Excessive Blow-by gases, Piston rings and/ or cylinder bore worn Engine oil not according to specifications Fuel of too low octane number Spark plugs not according to specifications or defective Leak air, intake system leaking Ignition unit defective, ignition timing incorrect Check / replace crank position trigger and ECU Exchange valves, rework valve seats See remedies "clutch is slipping". Check fuel pressure sensor, fuel pump and fuel supply Exchange Exchange Exchange piston rings and/or cylinder Exchange engine oil Use fuel of specified octane number (min. ROZ 95) Replace spark plug Check / replace intake socket and intake system Check / replace crank position trigger and ECU Manuale d'officina Ed C.

24 TROUBLESHOOTING Trouble Possible causes Remedy Engine overheats Not enough coolant in cooling system, cooling system leaking, air in cooling system Cooling fan motor defective Not enough engine oil in the engine Radiator dirty Faulty thermostatic valve Ignition unit defective, ignition timing incorrect Water pump, water pump drive defective Oil pump or oil pump drive defective, oil circuit blocked Cylinder head gasket defective Leak air Refill coolant, check system under pressure Replace cooling fan motor Refill oil Clean radiator Replace Check / replace crank position trigger, ECU and sensors Repair water pump, check and renew water pump drive Exchange oil pump or oil pump gears, clean oil circuit Exchange cylinder head gasket Check / replace intake socket Engine temperature is too low Faulty thermostatic valve Replace Too much oil in the engine (oil in the airbox) Drain engine oil Cylinder head gasket leaking Exchange cylinder head gasket Engine produces excessive blue smoke or Valve stem seals leaking Exchange valve stem seals engine uses too much oil Oil diluted with fuel / Piston rings and/or Exchange piston rings and/or cylinder cylinder bore worn Oil diluted with fuel / motocycle is only used in short distances (cold engine) Use motorcycle at long distances in between Engine vibrates Engine oil quantity increases Low or no engine oil pressure Engine fixation into frame loose Bearing or bearing seat worn Oil diluted with fuel / motocycle is only used in short distances Oil diluted with fuel / Piston rings and/or cylinder bore worn Not enough engine oil in the engine Pressure regulating piston blocked (bypass valve stuck in opened position) Oil pump and/or oil pump drive defective Oil pump worn Oil diluted with fuel / Piston rings and/or cylinder bore worn Oil diluted with fuel / motocycle is only used in short distances Oil sieve / oil filter dirty/blocked Tighten engine fixation Replace bearing or worn component Use motorcycle at long distances in between Exchange piston rings and/or cylinder Refill oil Check/replace pressure regulating piston Check / replace oil pump and/or oil pump drive Replace oil pump Exchange piston rings and/or cylinder Use motorcycle at long distances in between Clean / replace oil sieve and replace oil filter Manuale d'officina Ed C.4

25 TROUBLESHOOTING Trouble Possible causes Remedy High engine oil pressure Pressure regulating piston blocked (bypass valve stuck in closed position) Oil circuit blocked Check/replace pressure regulating piston Clean oil ducts Manuale d'officina Ed C.5

26 TROUBLESHOOTING Trouble Possible causes Remedy Engine excessively noisy Noise is heard when the engine is started: Sprag clutch, sprag clutch housing or freewheel gear worn Teeth of starter motor and/or starter drive gears worn Chain tensioner does not work Noise seems to come from the valve train: Excessive valve clearance Chain tensioner does not work Camshaft or brackets of camshaft worn Camshaft drive worn or loose Camshaft chain, chain guide or chain tension guide worn Noise seems to come from the piston: Piston or cylinder worn Piston pin bore or piston pin worn Piston rings broken or ring grooves worn The noise seems to come from the crankshaft, countershaft or crankcase: Bearings of crankshaft or conrods worn Worn needle bushing and/or balancer shaft bearings and/or balancing connecting rod Noise seem to come from the clutch or clutch side: Friction plates (hammer heads) and/or clutch drum worn Excessive or insufficient backlash of the teeth of the primary drive gears Clutch drum, clutch hub or pressure plate worn Bearing of clutch gear worn Disk springs of primary drive assy. worn Springs and spring retainers of primary drive assy. Worn Noise with clutch engaged - ball bearing of the pressure plate worn Noise seem to come from the gearbox: Tooth flanks of the gearbox gears worn Ball bearing of gearbox shafts and/or needle bearings of gears worn Replace Sprag clutch, sprag clutch housing or freewheel gear Replace starter motor and/or starter drive gears Noise disappears after the engine is started when oil pressure is available Adjust valve clearance according to specification Replace chain tensioner Replace camshafts and/or cylinder head Tighten or replace camshaft gears Replace camshaft chain, chain guide or chain tension guide Replace piston or cylinder Replace piston pin bore or piston pin Replace piston rings broken or ring grooves Replace the crankshaft Replace the balancer shaft Replace friction plates and /or clutch drum Replace primary drive assy. Replace clutch drum, clutch hub or pressure plate Replace primary drive assy. Replace primary drive assy. Replace springs and spring retainers Replace ball bearing Check gears and gear shafts, replace if necessary Replace bearings Manuale d'officina Ed C.6

27 TROUBLESHOOTING Trouble Possible causes Remedy Clutch slips Clutch disengages unsatisfactorily The clutch drags Gears do not engage or gears jump out at start or at abrupt acceleration Fatigue of clutch springs Clutch plates worn or warped Engine oil not according to specifications Engine oil not according to specifications Clutch plates warped Clutch plates stuck together Clutch plates worn or warped Guide slots for friction plates in clutch drum are worn Guide slots for steel plates in clutch hub are worn Gearshifting action incomplete Gearshift lever incorrectly adjusted Fastener of gearshift lever loose Gearshift lever bent Function of index lever or index spring imperfect Adjustment of gearshift pawl incorrect Engagement teeth and/or windows of gearbox gears badly worn Gearshift forks are worn or bent Gearbox gears are worn or damaged The clutch does not disengage Replace clutch springs Replace clutch plates Exchange engine oil Exchange engine oil Exchange clutch plates Clean or exchange Replace clutch plates Replace clutch drum Replace clutch hub Always actuate gearshift lever till stop Correct position of gearshift lever Tighten fastener Replace gearshift lever Check index lever and index spring and exchange if necessary Check and adjust pawl wich spring, exchange if necessary Exchange gears Exchange gearshift forks Exchange gearshift gearbox gears See "Clutch disengages unsatisfactorily" Gears can be shifted only noisily Clutch does not disengage See "Clutch disengages unsatisfactorily" Spark plugs overheated, burnt or dirty The generator does not charge the battery Spark plugs not according to specifications Spark plugs loose Intake socket not tight or leaking Fuel supply system defective Battery faulty, loose or corroded connections Rectifier regluator defective Break in current, short circuit or earthing of stator windings Break in cables or short circuit, connections loose Replace spark plug Tighten spark plugs Tighten intake socket or exchange if necessary Check and replace if necessary Check/replace battery and check connections Replace rectifier regluator Replace stator Check and replace if necessary Manuale d'officina Ed C.7

28 TROUBLESHOOTING CHASSIS Trouble Cause Remedy Handlebar turns hard Handlebar vibration Damping is too hard Damping is too soft (Front / rear) wheel shakes Rear suspension is noisy Poor braking (front and rear) Insufficient tyre pressure Bearing adjuster ring nut or steering stem nut overtightened Bent steering stem Worn or seized steering bearings Bent fork legs Bent front wheel axle Warped chassis Bent front wheel rim Worn front wheel bearings Improperly balanced wheel Too much oil in fork legs Fork oil viscosity too high Overinflated tyres Improperly set rear shock absorber Insufficient oil in fork legs Fork oil viscosity too low Weak fork springs Weak rear shock absorber spring Improperly set rear shock absorber Bent wheel rim Worn wheel hub bearings Wheel axle nut loose Worn rear swinging arm bearings Improperly balanced wheel Worn shock absorber joints Shock absorber faulty Air in brake system Insufficient fluid in tank Worn brake pad and/or disc Damaged disc Inflate Adjust Replace bottom yoke Replace Replace Replace Replace Replace Replace Balance Remove excess oil Change Deflate Adjust Top up Change Replace Replace Adjust Replace Replace Tighten Replace Balance Replace Replace Bleed Top up Replace Replace Manuale d'officina Ed C.8

29 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls easily Dirty air filter Worn piston rings Worn piston or cylinder liner Clean Replace Replace Spark plug electrodes overheat Spark plug electrode gap too close Adjust Wrong heat rating Replace with recommended spark plug Cables running to voltage regulator improperly connected or shorted Generator does not charge or is not Connect correctly or replace providing enough charge Voltage regulator faulty Replace Faulty generator Replace Generator overcharges battery Voltage regulator faulty Replace Battery terminals dirty Clean Battery does not hold charge Faulty generator Replace Faulty battery Replace Battery is flat Charge Control on R.H. switch faulty Replace Starter relay faulty Replace Starter motor does not start or slips Starter motor faulty Repair or replace Worn starter gears Replace Worn or damaged freewheel rollers Replace freewheel Ignition key not recognised Check control unit key immobiliser Manuale d'officina Ed C.9

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31 SETTINGS AND ADJUSTMENTS Section D Workshop Manual Ed D.

32 SETTINGS AND ADJUSTMENTS Sommario Saddle removal...d. Removal of central upper cover...d.4 Side panel removal...d.4 Throttle cable adjustment...d.5 Throttle control...d.5 Throttle position adjustment...d.5 Front brake control...d.5 Position adjustment...d.5 Front brake lever adjustment and fluid level check...d.6 Clutch control...d.6 Position adjustment...d.6 Clutch control lever distance adjustment...d.7 Clutch free play adjustment...d.7 Rear brake pedal free play adjustment...d.8 Rear brake fluid level check...d.8 Oil level check...d.9 Engine oil replacement and cartridge filter replacement...d.9 Replacement of cartridge filter...d.0 Filling...D. Coolant level check...d. Coolant replacement...d. Air filter check...d. Chain tension adjustment...d.4 Lubricating the chain...d.4 Suspension...D.5 Shock absorber spring preload adjustment...d.5 Rebound shock absorber hydraulic damping adjustment...d.6 Fork adjustment...d.6 Fuel supply hose inspection and replacement...d.6 Exhaust system check...d.7 Idle speed adjustment...d.8 Checking and adjustment of valve clearance...d.8 Workshop Manual Ed D.

33 SETTINGS AND ADJUSTMENTS Saddle removal To remove the saddle proceed as follows: - Insert the key in the lock () positioned in the rear part of the motorcycle; - turn the key clockwise to release the saddle (), and then lift it and pull it out towards the rear, releasing it from the front fastener. To fit the saddle back on, fasten it at the front and then press the rear until the fastening "Click" is heard. H660 H66 Workshop Manual Ed D.

34 SETTINGS AND ADJUSTMENTS Removal of central upper cover - Unscrew the four screws () that fasten the cover () and remove it. H66 Side panel removal - Remove the saddle as described in the relevant paragraph. - Remove the upper cover as described in the relevant paragraph. - Unscrew the five screws () and remove the left-hand side panel () from its fittings. - Repeat to remove the right-hand side panel. When refitting, first insert the rear and then the front fittings. H664 H66 Workshop Manual Ed H665 H666 D.4

35 SETTINGS AND ADJUSTMENTS 4 mm (0,8 in.) Throttle cable adjustment To check the correct adjustment of the throttle control cable, operate as follows: - remove the reservoir and the filter box as outlined in the relevant sections; - turn throttle twistgrip () and make sure that there is a clearance of approx. mm (0.08 in); - if this does not work, unlock the check nut (); - work on the nut () until you have about mm clearance (0.08 in.); - tighten check nut (). - reassemble all parts, in the reverse order compared to disassembly. mm (0,8 in.) H667 Operation with damaged throttle cable could result in an unsafe riding condition. When throttle control cables (4) are replaced, adjust new cables as previously explained. 4 H668 Throttle control The throttle twistgrip () is located on the right-hand side of the handlebar: Throttle position adjustment The position of the control on the handlebar can be adjusted by loosening the two retaining screws (). Do not forget to tighten the screws () after adjusting. H669 Front brake control The brake control lever () is located on the right-hand side of the handlebar. Position adjustment The position of the control on the handlebar can be adjusted by loosening the two retaining screws (). H670 After adjustment, turn the handlebar as far as possible to the right and make sure that the lever does not touch the bodywork A stop switch, during the braking action, causes the stop light on the tail light to come on. Do not forget to tighten the screws () after adjusting. Workshop Manual Ed D.5

36 SETTINGS AND ADJUSTMENTS Front brake lever adjustment and fluid level check The level of the fluid in the master cylinder reservoir must never be below the minimum level visible through the inspection sight glass () on the side of the master cylinder () body. A decrease of the fuel level will let air into the sustem, hence an extension of the level stroke. MIN If the brake lever feels mushy when pulled, there may be air in the brake line or the brake may be defective: CHECK THE BRAKING SYSTEM (see Section "L"). H67 Too much brake lever free play may reduce braking action: CHECK BRAKE PAD THICKNESS (see Section "L"). Do not spill brake fluid onto any painted surface or lens (for example lights lens). Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand. Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. Clutch control The clutch control lever () is located on the left-hand side of the handlebar. Position adjustment The position of the clutch control on the handlebar can be adjusted by loosening the retaining screws (). H67 After adjustment, turn the handlebar as far as possible to the left and make sure that the lever does not touch the bodywork. Do not forget to tighten the screws () after adjusting. A "STOP" switch on the clutch lever support allows you to start the engine when the motorcycle is in gear or the clutch lever is pulled (the stand must be off the ground). Workshop Manual Ed D.6

37 SETTINGS AND ADJUSTMENTS Clutch control lever distance adjustment The lever () can be adjusted ( settings available) to suit the rider's hand size To regulate the position of the lever () push it outwards and then select the required position by means of the adjuster screw (). H67 Clutch free play adjustment Free play (A) must be 5-0 mm ( in). A - Move the rubber gaiter (); - regulate the adjuster screws () and the counter adjuster screw () to obtain the indicated free play. - after completing the operation, make sure the counter adjuster screw () is properly tightened and then replace the rubber gaiter (). H674 Workshop Manual Ed D.7

38 SETTINGS AND ADJUSTMENTS B H675 Rear brake pedal free play adjustment Before staring the braking action, rear brake pedal () shall have a free play (B) of 5-0 mm (0,96 0,9 in.). Should this not happen, operate as follows: - Loosen the nut (); - Operate the master cylinder linkage () to increase or decrease free play; - Tighten the nut () at the end of the operation. When the free play requirement is not met, the brake pads will be subjected to an early wear that may lead to TOTAL BRAKE INEF- FECTIVENESS. If the brake pedal feels mushy when pulled, there may be air in the brake line or the brake may be defective. CHECK THE BRAKING SYSTEM (see Section L). C: to increase clearance D: to decrease clearance D C H676 MAX Rear brake fluid level check The fluid level in the master cylinder tank shall never be below the minimum level () shown on the transparent reservoir (). A decrease in the fluid level will let air into the system and increase the lever stroke. MIN If the brake pedal feels mushy when pulled, there may be air in the brake lines or the brake may be defective. Do not spill brake fluid onto any painted surface or light lens. H677 Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand. Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. Workshop Manual Ed D.8

39 SETTINGS AND ADJUSTMENTS MAX MAX MIN MIN H678 Oil level check The oil level must be checked with the vehicle in vertical position on a flat surface. - Start the motorcycle and heat the engine until the cooling fan starts; wait for another minutes and switch off the engine. - Check the level as follows: - Undo the cap () with the dipstick () and remove it from the frame. - Clean the dipstick () with a cloth. - Place the dipstick () in the hole () without screwing the cap on. - Remove the dipstick () from the hole () and check that the level is between the two MIN and MAX marks. - To top up, pour oil into the hole (); for the type of oil, see the section Technical data. Never exceed max. level. Engine oil replacement and cartridge filter replacement Be careful not to touch hot engine oil. Drain the oil with WARM ENGINE; proceed as follows: - Place the motorcycle on its side stand - Remove the cap () with the dipstick Oil change must be performed in two stages: Draining oil from tank; Draining oil from engine H679 Draining oil from tank: - Place a litre container under the coupling () and then unscrew the screw () and let the oil in the tank drain out completely. - Once it has drained out, tighten the screw () with its corresponding washer. Draining oil from engine: - Place a container to collect the oil under the engine. - Unscrew the screw (4) and let all the oil in the engine drain out completely. - Once it has drained out, clean the magnetic screw (4), replace the gasket and refit it on the engine by tightening it to torque. H680 Fill with oil as described in the relevant paragraph. 4 H68 Workshop Manual Ed D.9

40 SETTINGS AND ADJUSTMENTS 6 Replacement of cartridge filter - Unscrew the screws (5) and remove the sprocket casing (6). - Unscrew the screws (7) and remove the oil filter cover (8). - Replace the filter (9) with a new one, then refit the cover (8) making sure that the O-ring (0) is not damaged and positioned correctly on the cover. - Refit the sprocket casing (6) making sure that the cable () of the rear stop switch is positioned correctly as in the figure and that the cable guide () is fastened externally onto the bottom screw. 5 H H68 9 H684 H Workshop Manual Ed H685 H687 D.0

41 SETTINGS AND ADJUSTMENTS Filling - Remove the cap () with the dipstick. - Pour.5 litres of oil into the chassis tank. - Run the engine for 0 seconds and then switch it off. - Pour another 0.5 litres of oil into the chassis tank. - Check the oil level as described in the relevant paragraph. Check the condition of the gasket () of the cap () with the dipstick and if it is damaged, replace it. For the type of oil to use, refer to the Technical data paragraph. H74 Coolant level check When the engine is cold, check that the level of the coolant is between the MIN and MAX marks on the expansion tank () on the left-hand side of the motorcycle. If topping up is necessary, do the following: Do not remove the radiator cap () since all the liquid in the expansion tank () will flow out. MAX MIN - Remove the cap () and add the fluid needed to restore the level to the expansion tank (). (for the type of liquid to use, see the section Technical data ). Difficulties may arise in eliminating coolant from painted surfaces. If this occurs, wash off with water. Never exceed max. level. H689 H690 Workshop Manual Ed D.

42 SETTINGS AND ADJUSTMENTS Coolant replacement Drainage - Place the motorcycle on its side stand. - Remove the cap () of the expansion tank (). - Place a litre container under the water pump and unscrew the screw (). - Let a small amount of coolant drain out and then turn the radiator cap (4) to the first click and wait for all the coolant to flow out of the water pump drainage hole. 5 Filling - Re-tighten screw () on the water pump. - Remove the radiator cap (4). - Pour the coolant into the radiator (5) until it is full and gradually top up as the level drops until it stays at maximum level. - Put the radiator cap on again and pour the coolant into the expansion tank () until it reaches maximum level. - Put the cap () of the expansion tank on again. - Start the engine, wait for the radiator cooling fan to start up and then wait another minutes. - Switch off the engine and wait for it to cool, then check the level as described in the relevant paragraph. H69 H69 4 Workshop Manual Ed H69 D.

43 SETTINGS AND ADJUSTMENTS Air filter check Note: Clean the filter area before removing the cover. - Unscrew the screws () and remove the cover () together with the filter (); - remove the filter () and check that it is not clogged/dirty; replace if necessary; - when refitting, check that the filter () is correctly placed in its housing (4). Before refitting the filter, check that the contact surfaces between the filter, the filter box and the cover are completely clean. H694 H695 4 H696 H697 Workshop Manual Ed D.

44 SETTINGS AND ADJUSTMENTS A H744 Chain tension adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or too tight), it could jump out of the sprocket or break. - Position the motorcycle on the side stand so the chain is not stressed and loaded; - where the screw () is located, lift the chain () upwards and measure the chain travel. - the correct setting must be 45 mm (.77 in). If this is not the case, proceed as follows: - make sure that the motorcycle is fully upright on the special rear support stand (optional) on the right side, loosen the locking nut () of the wheel axle; - loosen the check nuts (4) on both chain tensioners; - turn the adjuster screws (5) to obtain the correct tension and check on both sides that the wheel centring sliders (6) are in the same position as the markings in the chain tensioner slider seats on the swinging arms; - once adjusted, tighten the check nuts (4) and the wheel axle nut (). After adjusting, always check that distance "A" is 45 mm (.77 in). H H700 Lubricating the chain Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets. Do not wash the chain with high-pressure water jets and do not use harsh or highly flammable solvents. - After washing the chain using special detergent, dry it and lubricate with suitable spray grease. Workshop Manual Ed The chain lubricant must NOT come into contact with the tyres or the rear brake disc. D.4

45 SETTINGS AND ADJUSTMENTS Suspension The vehicle leaves the factory with standard settings for the front and rear suspension that meet most requirements. Before making any change and afterwards, if the adjustment is not satisfactory, always start from the standard suspension setting and increase or decrease the adjusting clicks, one at a time. Shock absorber spring preload adjustment This is easier to do if you lift the motorcycle at the centre so that the rear wheel is released. - Adjust the ring nut () using the spanner provided; by turning left A, the preload increases; by turning right B the preload decreases. Be careful not to touch hot exhaust pipe while adjusting the shock absorber. H70 A: Wheelbase B: Spring in its seat A= 4 ±,5 mm (,45 ± 0,059 in.) TERRA B= 0 ±,5 mm (7,94 ± 0,059 in.) H70 H704 A= 4 ±,5 mm (,45 ± 0,059 in.) STRADA B= 98 ±,5 mm (7,795 ± 0,059 in.) A B H70 H705 Workshop Manual Ed D.5

46 SETTINGS AND ADJUSTMENTS Rebound shock absorber hydraulic damping adjustment It is possible to adjust the rebound travel of the shock absorber. B) REBOUND - Standard setting: - clicks (adjuster ) To reset the standard setting, turn lower adjuster () clockwise until reaching fully closed position. Then turn it back the number of clicks specified above. In order to obtain a smooth braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder braking action. H706 Fork adjustment On the fork installed on this motorbike version, it is not possible to perform any type of adjustment. H707 Fuel supply hose inspection and replacement - Remove the saddle as described in the relevant paragraph. - Check fuel supply hose () conditions; if cracked, swollen, kinked, etc. it is necessary to change it as follows: - Press the ring nut () and unfasten the union (). - Open the clamps (4) and detach the pipe () from the unions () and (5). During this operation, make sure that you do not damage the hose holder coupling on the throttle body. - Replace the pipe () and close the clamps (4) on unions (5) and (). - Refit the union () by pressing it down. H Workshop Manual Ed H709 H70 D.6

47 SETTINGS AND ADJUSTMENTS Exhaust system check Perform a visual inspection of the exhaust system first, in order to identify possible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged. Subsequently, inspect the single components by disassembling the exhaust system. Also check the tightening of the flange nuts () fastening the manifold to the cylinder head and the clamps () fastening the silencers to the manifolds as well as the tightening of the screw () fastening the silencer to its support. The damaged or broken parts must be replaced. H7 H7 H74 H7 Workshop Manual Ed D.7

48 SETTINGS AND ADJUSTMENTS Idle speed adjustment The idle speed is pre-set by the control unit (550 rev/min.) and the stepper motor ensures that this value is preserved. No manual adjustment is possible, nor any adjustment through the diagnostic tool. 4 Checking and adjustment of valve clearance Remove the filter box and the throttle body as described in the relevant paragraphs. Drain the oil from the tank on the chassis as described in the relevant paragraph. - Disconnect the connectors () and () from the coils/tubes () and (4). - Remove the coils/tubes () and (4). - Remove the spark plugs. When refitting, do not invert the coils / tubes; the coil with the white ring nut should be fitted on the outer part of the cylinder head and the connector with the white clamp connected to the cable. H Loosen the clamps (5) and (6) and remove the two pipes (7) and (8). Place them so that they do not drip oil. 5 8 When refitting, do not invert the position of the two pipes; Pipe 7 = oil return pipe to tank must go over the ABS pipes; Pipe 8 = oil delivery pipe must go under the ABS pipes. 6 H Workshop Manual Ed H77 D.8

49 SETTINGS AND ADJUSTMENTS 0 - Loosen the clamp (9) and remove the intake coupling (0) from the cylinder head. 9 When refitting the intake coupling (0) make sure you place the prong (A) on the slot (B) of the intake manifold. - Disconnect the cylinder head from the electrical system. H78 0 A B H79 - Move the two pipes () of the ABS to unscrew the screw (), then unscrew the screws () and remove them. H Remove the head cover (4) at the back of the motorcycle; if this is difficult, remove the intake manifold (5) by unscrewing the corresponding screws without losing the corresponding gaskets. - Adjust valve clearance as described in the relevant paragraph in Section F. 5 H7 Workshop Manual Ed D.9

50

51 ENGINE SETTINGS AND ADJUSTMENTS Section F Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-0 F.

52 ENGINE SETTINGS AND ADJUSTMENTS Sommario VALVE CLEARANCE CHECK... F. Valve clearance check... F. Valve clearance measurement... F. PAD REPLACEMENT... F.4 Locking the crankshaft... F.4 Chain tensioner disassembly... F.5 Chain guide disassembly... F.5 Camshaft removal... F.6 Pad replacement... F.6 Camshaft assembly... F.6 Chain tensioner installation... F.7 Chain guide installation... F.7 Removal of engine block screw... F.7 TIMING CHECK... F.8 ENGINE PHASING... F.9 Workshop Manual Ed.09-0 F.

53 ENGINE SETTINGS AND ADJUSTMENTS VALVE CLEARANCE CHECK Remove the coil / spark plug cap, spark plugs and the head cover as described in chapter "F". Valve clearance check - Remove the screw plug (). - Place an Allen wrench into the hole () and turn the crankshaft in the normal sense of rotation until the ignition TDC. - the marks () placed on the crankshaft gears must be coplanar to the sealing surfaces and the holes (4) must face upwards. - In this position, both cams of the intake and exhaust camshafts must face upwards and be at the same angle relative to the upper face of the head. H48 4 Valve clearance measurement Measure valve clearance using a feeler between the cam and valve bucket both for the intake (4) and exhaust (5) cams. Note down the measurements on a measurement sheet. H H08 H486 Technical specifications Intake valve clearance with cold engine max. 5 C Exhaust valve clearance with cold engine max. 5 C mm in mm in. If the valve clearance does not lie within the correct tolerance, correct clearance must be restored by replacing the pads beneath the valve buckets. - Reassemble the screw plug () and all other parts removed. H484 Workshop Manual Ed.09-0 F.

54 ENGINE SETTINGS AND ADJUSTMENTS PAD REPLACEMENT Bring the to the top dead centre as described in the previous paragraph and lock the crankshaft.. H487 Locking the crankshaft Remove the screw () with the sealing ring. Check that the notch on the crankshaft is visible through the hole. H75 Fully screw down the retaining screw () manually; the screw must perfectly engage in the notch of the crankshaft. H75 Workshop Manual Ed.09-0 F.4

55 ENGINE SETTINGS AND ADJUSTMENTS Chain tensioner disassembly - Remove the screw () with the sealing ring () and chain tensioner (). H49 H490 Chain guide disassembly - Remove the screws () and chain guide (). H49 Workshop Manual Ed.09-0 F.5

56 ENGINE SETTINGS AND ADJUSTMENTS Camshaft removal - Remove the screws () with the washers.(). - Remove the top part of the support (). - Remove the chain (4) from the gears and fix to a point safe to avoid it from falling into the engine. - Remove the camshafts (5) with the chain gears. - Remove the bottom part of the support (6). - Remove the chain slider (7). 7 H49 Pad replacement - Mark the valve bucket () with a marker (e.g. A= intake valve). - Extract the valve bucket () - According to the measurement of the valve clearance, replace the pads with those of a size appropriate to restore the correct valve clearance. - Replace adjustment pad () with one having a thickness adequate to restore the correct value, making sure it is firmly seated in the seat. - Install the corresponding valve buckets as marked. H494 a b Camshaft assembly - Install the chain slider () making sure that the top part of the slider is aligned with the sealing surface. - Mount the bottom part of the support (). - Lubricate all contact surfaces with engine oil. - Fit the camshaft exhaust (a), then the cam shaft intake (b) with the timing chain and positioning them in phase. - Mount the top part of the support (4). - Tighten the screws (5) with the washers (6). H495 Workshop Manual Ed.09-0 F.6

57 ENGINE SETTINGS AND ADJUSTMENTS Chain tensioner installation - Insert the chain tensioner () and tighten the screw () replacing the gaskets (). H496 H497 Chain guide installation - Clean the threading and screws. - Install the chain guide () and tighten the screws (). H498 Removal of engine block screw - Remove the locking screw () and re-tighten the screw () to torque, replacing the gasket. H499 H646 Workshop Manual Ed.09-0 F.7

58 ENGINE SETTINGS AND ADJUSTMENTS TIMING CHECK - Remove the coil / spark plug cap, head cover, spark plugs and chain tensioner and the head cover as described in chapter "F". - Remove the screw () with the sealing ring. - Remove the plug (). H488 H500 - Check the position of the camshaft gears. - The marks (dashes) () located on the camshaft gears must be coplanar with the sealing surface. - Make sure the notch on the crankshaft is visible through the hole (marks () coplanar to the surface and notch (4) visible indicate a correct timing). - If the notch cannot be seen through the hole, carefully turn the engine until it can be seen through the hole, then fully tighten down the retaining screw (5) manually, blocking the engine at TDC; it must perfectly engage in the notch of the crankshaft. H50 If the marks on the camshaft gears are not opposed and parallel to the sealing surface, a collision between pistons and valves is possible. 4 5 Workshop Manual Ed.09-0 H50 H50 F.8

59 ENGINE SETTINGS AND ADJUSTMENTS ENGINE PHASING Proceed as follows to rephase the engine. - Remove the head cover as described in chapter "F". - Lock the crankshaft as previously described. - Remove the chain tensioner and guide as previously described. - Remove the screws () with the washers.(). - Remove the top part of the support (). 4 4 H647 - Lift the camshaft (4) from the opposite side of the distribution gears to facilitate the removal of the chain, then position the camshafts (4) so that the marks (dashes) (5) are coplanar with the sealing surface. - Reassemble all parts, in the reverse order compared to disassembly and tighten the screws to the specified torque H506 Workshop Manual Ed.09-0 F.9

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61 GENERAL ENGINE PROCEDURES Section F Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-0 F.

62 GENERAL ENGINE PROCEDURES Sommario CLUTCH COVER REMOVAL / INSTALLATION...F. Gearbox lever removal/installation...f. Clutch cover removal...f. Remove the left engine crankcase cover...f. Coolant pump cover removal...f.4 Left engine cover removal...f.4 Gearbox selector shaft oil seal removal/installation...f.4 Clutch engagement lever removal/refitting...f.5 Clutch disengagement shaft removal...f.5 Clutch disengagement shaft oil seal removal...f.5 Clutch disengagement shaft bearing removal...f.6 Installation of both clutch disengagement shaft bearings...f.6 Clutch disengagement shaft oil seal installation...f.6 Disengagement shaft installation...f.6 Left engine crankcase cover assembly...f.7 IGNITION COVER REMOVAL/REFITTING...F.7 Crankshaft sensor and stator removal...f.8 Crankshaft sensor and stator installation...f.8 Mounting the ignition cover...f.9 Replacement of the gearbox output shaft oil seal...f.9 Flywheel and starter motor idle gear removal...f.0 Removal/installation of the freewheel from/on the flywheel...f.0 Starter motor idle gear removal/installation... F. Installation of the flywheel with freewheel control gear... F. CHAIN SPROCKET REMOVAL/INSTALLATION...F. Starter motor removal/installation...f. REMOVING THE NEUTRAL POSITION SENSOR...F. REMOVAL/INSTALLATION OF THE COMPLETE CLUTCH...F. Clutch pressure plate disassembly...f.6 PUMPS...F.7 OIL PUMP REMOVAL/INSTALLATION...F.7 REPLACEMENT OF THE OIL PRESSURE VALVE AND UNIDIRECTIONAL VALVE...F.8 COOLANT FLUID PUMP REMOVAL/INSTALLATION...F.9 REMOVAL/INSTALLATION OR REPLACEMENT OF THE TIMING CHAIN...F.0 Workshop Manual Ed.09-0 F.

63 GENERAL ENGINE PROCEDURES CLUTCH COVER REMOVAL / INSTALLATION Gearbox lever removal/installation Removal: - Loosen the screw () then remove the lever (). Installation: - Fit the lever () and tighten the screw to torque (). H507 4 Clutch cover removal - Remove the lever () as described in the relevant paragraph. - Remove the screws (), the screws () and cover (4) with relative sealing ring. When refitting mount the screws () on the top part of the cover (4) and screws () on the bottom part. H648 - Check the sealing ring condition and replace as necessary. - Tighten the screws at recommended torque in a crosswise sense and refit the lever (). Remove the left engine crankcase cover - Remove the lever () as described in the relevant paragraph. - Remove the water pump supply pipe (). Loosen the three screws (); - Remove the screw (4) and the washers(5). - Remove the screws (6) paying attention to the gaskets (7). - Release the oil piping (8) and remove the crankcase cover (9). 9 H649 Check gasket condition when refitting and replace if necessary H50 Workshop Manual Ed.09-0 F.

64 GENERAL ENGINE PROCEDURES Coolant pump cover removal - Remove the pipe () from the pump cover (). - Remove the screws (). - Remove the coolant pump cover () and its gasket. H760 Check gasket condition when refitting and replace if necessary. - Reassemble all parts, in the reverse order and tighten screws to recommended torque. H76 Left engine cover removal - Remove the water pump cover, the clutch cover and the left casing as described in the relative chapters. - Remove the water pump () and oil seal () of the gearbox selector shaft as described in the relative section. - Replace the casing () and reassemble everything following steps in inverse order. H5 Gearbox selector shaft oil seal removal/installation - Using an appropriate tool carefully remove the oil seal from the inside diameter (). - Lubricate the seal lip of the new oil seal; then fit it on the cover, using an appropriate tool. - Protect the oil seal lip from possible damage by winding, for example, masking tape around the shaft broaching. Workshop Manual Ed.09-0 H5 F.4

65 GENERAL ENGINE PROCEDURES Clutch engagement lever removal/refitting Removal: - Undo the screws () and slide the lever out upwards (). H54 4 Installation: - Manually turn the shaft () clockwise until reaching the limit. - Keeping the shaft () in place, slide the lever () onto the shaft are release. Check the lever () when at fill stroke to make sure that there is no interference with the cover (4) of the clutch (see arrow). H754 Clutch disengagement shaft removal - Remove the clutch cover as described in the relevant paragraph. - Remove the retaining ring (). - Extract the clutch disengagement shaft () by pulling it out upwards. H56 Clutch disengagement shaft oil seal removal - Protect the housing from damage using adhesive tape. - Lift the oil seal () using a suitable tool. H76 Workshop Manual Ed.09-0 F.5

66 GENERAL ENGINE PROCEDURES Clutch disengagement shaft bearing removal - Remove the two needle roller bearing using an appropriate tool (). H59 Installation of both clutch disengagement shaft bearings - Lightly lubricate both bearings with engine oil. - Install the needle roller bearings () and (). - Secure the needle roller bearings using an appropriate tool. The top bearing () must be aligned with the sealing ring seat. H5 Clutch disengagement shaft oil seal installation - Lubricate the oil seal lip () with engine oil. If the clutch disengagement shaft is installed, cover the notches with adhesive tape and use an appropriate tool so that the oil seal is not damaged. - Install the shaft oil seal () using a suitable tool. - The open side of the sealing ring must face inward of the casing. H50 Disengagement shaft installation - Lubricate the clutch disengagement shaft with engine oil. - Insert the clutch disengagement shaft (), being careful not to damage the sealing ring. - Install the retaining ring (). H5 Workshop Manual Ed.09-0 F.6

67 GENERAL ENGINE PROCEDURES Left engine crankcase cover assembly - Clean the sealing faces and fit a new gasket. - Turn the water pump impeller until the transmission sprocket mates correctly. - Tighten the screws () replacing the sealing ring (). - Check that the broaching of the clutch disengagement shaft mates properly with the clutch centre pin. - Mount the screws () with the washers. H755 Screw in screws () and () to torque in two steps and in a cross pattern. H756 IGNITION COVER REMOVAL/REFITTING - Remove the screws (). - Remove the cover () with its gasket and be careful of the washer () (arrow) and of the bushing (4), because they may stick to the cover. H76 4 H757 Workshop Manual Ed.09-0 F.7

68 GENERAL ENGINE PROCEDURES Crankshaft sensor and stator removal - Unscrew the screws (). - Remove the bracket () with the sensor (4). - Remove the cable ring (). 4 H Unscrew the screws (5). - Remove the cable ring (6) and stator (7). 5 7 H58 Crankshaft sensor and stator installation - Spread sealant on the cable ring () and insert into the cover. - Clean the threads of the screws () with oil. - Tighten the screws () to torque. H59 - Clean and spread sealant on the cable ring () and insert into the cover. - Install the crankshaft sensor (4) with its support (5) and the screws (6) by tightening these last to torque. The new cover has no threading as it is created by the tapping screw. In this case no screw sealant must be used. If reusing the cover, tighten the screws to torque with Loctite H50 Workshop Manual Ed.09-0 F.8

69 GENERAL ENGINE PROCEDURES Mounting the ignition cover - Clean the sealing faces and fit a new gasket. - Install the cover (), being careful with the washer () (arrow) and bushing (4). - Install the screws () of the engine casing cover, right side, tightening to torque in a cross pattern. H764 4 H758 Replacement of the gearbox output shaft oil seal - Remove the sprocket chain as described in the relevant paragraph. - Use an appropriate tool to remove the oil seal () paying attention to avoid damaging the seat. - Lubricate the new oil seal lip. - Cover the shaft toothing () with an appropriate tool or adhesive tape, successively mount the new oil seal () using an appropriate tool. - Refit the sprocket chain as described in the relevant paragraph. H5 H54 Workshop Manual Ed.09-0 F.9

70 GENERAL ENGINE PROCEDURES Flywheel and starter motor idle gear removal - Remove the right crankcase and fix the engine at the top dead centre, as described in the relevant paragraphs. - Heat the flywheel hub () to a temperature of approx. 00 C. - Unscrew the nut () and washer (). - Remove the flywheel together with the freewheel (4) using a suitable puller. H55 4 H56 Removal/installation of the freewheel from/on the flywheel - Heat the freewheel to about 0 C. - Undo the screws (), remove the flange () and freewheel (). Installation: - Check the condition of the freewheel (), and replace it if it is ruined. - Install the freewheel () onto the flywheel with the mark (4) facing the flywheel. - Fit the flange (). - Replace the screws () with pre-lubricated screws and tighten to torque or use Loctite 648. H57 4 Workshop Manual Ed.09-0 H58 F.0

71 GENERAL ENGINE PROCEDURES 4 Starter motor idle gear removal/installation - Remove the washer () and bushing (). - Remove the dual gearbox (4). - Remove the idle gear (). H59 - Remove the freewheel gear (5) - Reassemble all parts, in the reverse order compared to disassembly. 5 H540 Installation of the flywheel with freewheel control gear - Clean the collar and internal bearing of the freewheel gear and lubricate with engine oil. - Clean the cone of the crankshaft and of the flywheel. - Apply a thin layer of Loctite 648 on the crankshaft cone. Pay attention that the freewheel bearing does not come into contact with the Loctite. H54 - Fit the flywheel () onto the crankshaft, making sure that the groove and the key are aligned and that the freewheel is set on the relevant gear - Clean the threading on the crankshaft. - Insert the washer () and replace the nut () with a pre-lubricated nut and tighten to torque. - Refit the right crankcase as indicated in the relevant paragraph. Workshop Manual Ed.09-0 F.

72 GENERAL ENGINE PROCEDURES CHAIN SPROCKET REMOVAL/INSTALLATION 4 Removal: - Remove the screw (). - Remove the bushing () and the tapered washer (). - Remove the sprocket (4), using a puller if necessary, being careful not to ruin the shaft threading. H656 Installation: - Clean and lubricate the teeth on the main shaft and on the sprocket with "KLUEBER 46 MR 40" grease. - Mate the sprocket (4) with the shaft and make sure to keep the side with the "EXT" marking facing outwards. - Insert the tapered washer () so that the larger diameter rests on the sprocket and that the taper side of the bushing () faces the washer. - Apply a thin layer of Loctite 4 on the retaining screw (). - Tighten the screw () on the shaft to torque, being careful to insert the taper side of the bushing in the hole of the tapered washer. H545 STARTER MOTOR REMOVAL/INSTALLATION Removal: - Remove the screws (). - Extract the starter motor (), paying attention to the sealing ring. H546 4 Installation: - Check the sealing ring () for damage and replace it if necessary. - Clean and lubricate the ring (), then place it on the starter motor. - Lubricate the centring tang (4) and the teeth (5). - Fit the starter motor () on the crankcase and fix it with the screws (), tightening them to torque. Workshop Manual Ed H547 F.

73 GENERAL ENGINE PROCEDURES REMOVING THE NEUTRAL POSITION SENSOR - Remove the screw (). - Remove the connection cable. - Unscrew the sensor () and replace it. - Screw on a new sensor with Loctite 4. H548 REMOVAL/INSTALLATION OF THE COMPLETE CLUTCH Removal: - Remove the gearbox lever, the clutch cover and secure the engine at the top dead centre, as described in the relevant paragraphs. - Loosen the screws () proceeding with diametrically opposite operations, then remove them with the washers () and the springs (). - Remove the pressure plate (4). 4 H Remove the lined plates (5) and the steel plates (6). - Remove the Belleville washer (7) and coupling washer (8). Z 8 Z 7 H55 - Insert the special tool (A) on the hub (9) to block rotation. - Lift the safety tab of the washer (). - Remove the nut (0) with the washer (). - Remove the hub (9) and the tool (A). A H55 H55 Workshop Manual Ed.09-0 F.

74 GENERAL ENGINE PROCEDURES 6 - Remove the washer () and the "OR" gasket (). - Disassemble the clutch housing (4), paying attention to the needle roller bearings (5) and to the washer (6). 5 4 H a 4 Installation: - Lubricate the needle roller bearings (5) with engine oil. - Insert both needle roller bearings (5) with the washer (6) into the clutch housing (4) making sure that the bearing (5a) is positioned towards the engine. - Fit the clutch housing (4) all the way down, paying attention to the oil pump gears. - Fit the OR gasket () onto the gearbox shaft. - Mount the broached washer () onto the shaft and push into its seat. H Clean the tapered teeth on the primary shaft and on the clutch hub (9) and lubricate them. S 0 H556 The clutch shaft oil nozzle shall not be dirtied with threadlocker. - Insert the special tool (A) on the hub (9) to block rotation. - Fit the corrugated washer () and nut (0) with the bevelled edge "S" facing outwards. - Tighten nut to torque (0), bend the safety tab on the washer () (use Loctite 4). - Remove the special tool (A). A 4 9 H65 Workshop Manual Ed.09-0 F.4

75 GENERAL ENGINE PROCEDURES Fit the thrust washer (8) and the Belleville washer (7) so that the greater diameter faces outwards. - Lubricate the lined plates (6) with engine oil. - Insert first a lined plate (5) then a steel disc (6) and alternate layers until ending with a lined plate. - The plate pack contains seven lined plates and six made of steel. Z Z 8 7 H558 - Fit the pressure plate (4). - Insert the flanged bushings () on the springs () and fit the springs on the pressure plate (4). - Tighten the screws () to torque in a diametrically opposite order. Refit the other parts that were previously removed as described in the relevant paragraph. 4 H550 Workshop Manual Ed.09-0 F.5

76 GENERAL ENGINE PROCEDURES Clutch pressure plate disassembly - Disassemble the pressure plate () as described in the paragraph "Clutch disassembly". - Remove the circlip (). - Remove the actuator pin (), the rounded washer (4) and the Belleville washer (5). 4 5 H559 - Position the pressure plate with the upper side facing downwards. - Heat the pressure plate to approx. 80 C. - Remove the disengagement bearing (6) using a suitable puller. - Clean the housing of the support. - Lubricate the clutch disengagement bearing with engine oil. - Heat the pressure plate to approx. 80 C. 6 H560 - Fit the clutch disengagement bearing (6) using a suitable tool. The writing on the bearing must face towards the engine (visible during installation). - Refit components (), (), (4) and (5) proceeding in reverse order of disassembly. - Refit the pressure plate () as described in the paragraph "Clutch disassembly". 6 H56 Workshop Manual Ed.09-0 F.6

77 GENERAL ENGINE PROCEDURES A PUMPS Oil pump removal/installation Remove the clutch as described in the relevant paragraph. A) Supply pump B) Intake oil pump B H65 Removal: - Remove the retaining ring (). - Disassemble the gear (). - Remove the pin (4). - Remove the washer (5). - Loosen the screws (6) and remove the oil pump cover (7). - Remove the pin (8), piston (9) and rotor (0). Oil pump check Use a feeler gauge to check the clearance between the rotor (0) and casing; maximum allowed clearance is 0.5 mm (0.0 in.). Replace the pump if the clearance is greater. Installation: - Check pin integrity () and (4), and replace if ruined. - Refit pin () onto pivot (8) and insert into the casing. - Clean the parts and lubricate the engine (0) and the piston (9) with motor oil and fit into the pin (8), making sure that the reference dot on the engine 0) and the piston (9) fit and that is facing the outside. Make sure that the pin is positioned properly () on the piston (9). - Fit the cover () tightening the screws (6) to torque with Loctite 4. - Insert the washer (5) into the pivot (8) and mount the pin (4) onto the pivot (8). - Fit the gear () and retainer ring () H56 Workshop Manual Ed.09-0 F.7

78 GENERAL ENGINE PROCEDURES H564 REPLACEMENT OF THE OIL PRESSURE VALVE AND UNIDIRECTIONAL VALVE - Position a container under the oil filter cover in order to collect the oil in the filter seat and oil filter. - Loosen the two screws () and remove the oil pump cover (). - Remove the oil filter (). - Clean the filter box of residual oil. - Loosen the pressure control valve (4) and the unidirectional valve (5). - Replace the valves and screw down all the way with Loctite 4. - Refit the oil filter (). - Check the condition of the OR gasket (6), replace if ruined, lubricate with motor oil. - Fit the cover () tightening the screws () to torque. 6 H H566 Workshop Manual Ed.09-0 F.8

79 GENERAL ENGINE PROCEDURES COOLANT FLUID PUMP REMOVAL/INSTALLATION - Remove the pump cover and left cover as described in the relevant paragraph. Removal: - Remove the transmission sprocket () of the pump shaft. - Remove the pin () paying attention to the washer (). - Extract the impeller (4) with the pin (5) and shaft (6). - Extract the seal rings (7) and (8) from the left cover. Installation: - Check for any signs of wear on the shaft (6) Check the seal rings; replace if necessary. If replacing the sealing rings or shaft, be sure to replace both in tandem. - Insert the sealing ring (7) into the seat of the left cover (use a suitable tool). - Fill the gaps between the sealing rings with lubricant grease (use Molycote ). - Insert the sealing ring (8), using a suitable tool, until the outer lip touches the edge of the left cover. - Check that the impeller (4) is not damaged, mount onto the shaft (6) and secure with the pin (5). - Mount the shaft (6) and impeller inside the left cover. - Fit the washer (). - Install the pin () into the shaft (6) of the pump. - Mount the transmission sprocket () onto the shaft (6) by connecting it to the pin () H567 Workshop Manual Ed.09-0 F.9

80 GENERAL ENGINE PROCEDURES REMOVAL/INSTALLATION OR REPLACEMENT OF THE TIMING CHAIN - Remove the head cover and the camshafts as described in the relevant paragraphs. - Fix the timing chain with metal wire so that it does not slip into the engine. - Remove the left cover as described in the relevant paragraph. 5 - Unscrew the nut () and remove the spring washer (). - Press the chain tensioner towards the rear of the engine (). - Remove the dual gearbox (4) from the shaft and remove the timing chain (5). - Check the chain tensioner slide () for wear, replace if worn by undoing screw (6). 4 6 H568 - Insert the timing chain (5) into the recess and position it around the crankshaft, push towards the chain tensioner slider () rear of the engine. - Mount the dual gearbox (4) onto the crankshaft. - Fit the chain (5) onto the dual gearbox (4). - Fit the split washer (). - Clean the threads of crankshaft and hex nut (). - Tighten the nut () to torque with Loctite 4. - Refit all the previously removed components as described in the relevant paragraph and perform phasing operations. Workshop Manual Ed.09-0 F.0

81 CYLINDER HEAD REMOVAL/DISASSEMBLY Section F Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-0 F.

82 CYLINDER HEAD REMOVAL/DISASSEMBLY Sommario Removal of the ignition coils...f. Cylinder head cover removal/installation...f. Chain tensioner removal/installation...f.4 Locking the crankshaft...f.4 Crankshaft locking screw removal...f.5 Camshaft removal/replacement...f.5 Checking the decompression lever...f.6 Removing the decompression lever...f.6 Installing the decompression lever...f.6 Camshaft assembly...f.7 Timing chain slider replacement...f.7 Cylinder head removal/installation - replacement of cylinder head gasket...f.8 Valve removal...f.0 Workshop Manual Ed.09-0 F.

83 CYLINDER HEAD REMOVAL/DISASSEMBLY Removal of the ignition coils - Using an appropriate tool remove the coil () of the main spark plug, and the coil () of the secondary spark plug. Do not mount coils in inverse positions. The coil with the with gasket covering must be placed towards the outside, that having the black gasket covering towards the inside. H569 Cylinder head cover removal/installation Removal: - Remove the screws (). - Remove the head cover () with the gasket (). Installation: - Clean the gasket () and the sealing surfaces on the cover () and head (). - Lubricate the gasket and the sealing surfaces. - Fit the gasket () and the cover () tightening the screws () to torque. H574 H575 Workshop Manual Ed.09-0 F.

84 CYLINDER HEAD REMOVAL/DISASSEMBLY Chain tensioner removal/installation Removal: - Remove the screw () with the sealing ring (). - Remove the chain tensioner () from the hole. Installation: - Insert the chain tensioner () into the hole. - Replace the sealing ring () and tighten the screw () to torque. H49 H490 Locking the crankshaft Rotate the motor in the normal direction of rotation, as indicated in the previous paragraph, until the markings (dashes) on the gears of the camshafts are in position coplanar with the sealing surface. Remove the screw () with the sealing ring. Check that the notch on the crankshaft is visible through the hole. H487 Fully screw down the retaining screw () manually; the screw must perfectly engage in the notch of the crankshaft. Workshop Manual Ed.09-0 H488 H65 F.4

85 CYLINDER HEAD REMOVAL/DISASSEMBLY Crankshaft locking screw removal - Remove the locking screw () and re-tighten the screw () to torque, replacing the gasket. H499 H654 Camshaft removal/replacement - Remove the head cover and lock the engine at the top dead centre, as described in the relevant paragraphs. 4 Removal: - Remove the screws () with the washers.(). - Remove the top part of the support (). - Remove the chain (4) from the gears and fix to a point safe to avoid it from falling into the engine. - Remove the camshafts (5) with the chain gears. 5 5 H49 Workshop Manual Ed.09-0 F.5

86 CYLINDER HEAD REMOVAL/DISASSEMBLY Checking the decompression lever - With the spring fully extended, the minimum projection of the weight is equal to A: 0.7 mm (0.0 in). - When activated, the projection of the centrifugal weight on the base circumference of the cam must not be less than the measurement (A). - Replace the decompression lever if the distance is lower. A H576 Removing the decompression lever - Use a punch to extract the pin () from the weight (). - Remove the spring (). H577 4 Installing the decompression lever - Insert the new spring () into the camshaft (). - Install the weight (), install the pin (4). H578 Workshop Manual Ed.09-0 F.6

87 CYLINDER HEAD REMOVAL/DISASSEMBLY a 4 b Camshaft assembly - Lubricate all contact surfaces with engine oil. - Fit the camshaft exhaust (a), then the cam shaft intake (b) with the timing chain and positioning them in phase. - Mount the top part of the support (). - Tighten the screws () with the washers.(4). - Reassemble all parts previously removed, in the reverse order compared to disassembly. H655 Timing chain slider replacement - Remove the head cover, the chain tensioner, the intake camshaft and the clutch as described in the relative paragraphs. - Unscrew the screw (). - Remove the mobile chain tensioner slider () towards the top. H579 - Remove the fixed slider () of the timing chain towards the top. - Check the chain sliders for wear and replace them if worn. - Insert the slider (). - Clean the threading. - Tighten the screw () to torque with Loctite 4. - Install the slider () making sure that it is correctly positioned on the timing chain and that the top section is aligned with the sealing surface. - Reassemble all parts previously removed, in the reverse order compared to disassembly, as in the relative paragraphs. H580 Workshop Manual Ed.09-0 F.7

88 CYLINDER HEAD REMOVAL/DISASSEMBLY Cylinder head removal/installation - replacement of cylinder head gasket - Remove the camshafts, timing chain sliders as described in the relevant paragraphs. Removal: - Undo screws () and () H58 - Undo screws () and (4) 4 H58 - Unscrew the screw (5). - Unscrew the nuts (6). 6 5 H58 - Remove the cylinder head (7). 7 Workshop Manual Ed.09-0 H584 F.8

89 CYLINDER HEAD REMOVAL/DISASSEMBLY - Remove the gasket (8). 0 Installation: - Clean the sealing surfaces and eliminate all traces of oil and grease. 9 8 H585 - Replace the gasket (8) and position it on the cylinder. - Pull the timing chain (9) through the well. - Mount the cylinder head (7) while paying attention not to damage the timing chain (9) and the chain tensioner slider (0). - Tighten the screws (6) in a cross pattern with a first pre-tightening torque, then tighten with a final specified torque. 6 H586 - Tighten the screws (), (), (), (4) and (5) without securing them. - Tighten the screws (), (), (), (4), and (5) at the torque specified, according to sequence A to F as shown in the figure. A - Reassemble all parts previously removed, in the reverse order compared to disassembly, as in the relative paragraphs. F H587 D 5 C 4 B 4 E H588 H589 Workshop Manual Ed.09-0 F.9

90 CYLINDER HEAD REMOVAL/DISASSEMBLY Valve removal - Mark the valve buckets () so that they can be refit in the same positions, use a suitable tool to remove them. - Remove the pads () and position on their respective valve buckets. H590 - Place the cylinder head on the support plate () so that the valves do not come into contact with the work bench. H Mount the appropriate tool to remove the valves, pre-load the spring to remove the collets (4). - Widen and remove the collets using a screwdriver (4). - Remove the valve removal tool by releasing the valve springs. - Extract the top retainer (5), the valve spring (6), the valve stem gasket (7) and the bottom retainer (8) from the cylinder head and position near their respective valve buckets. - Disassemble the valves (9) and place near their respective components (springs, valve buckets, etc...). Refit after all necessary checks and/or repairs have been made. - Insert the valve. - Fit the cylinder head to the jig (No. ). - Insert the bottom retainer (8) into the cylinder head. Make sure that the inner lip of the oil seal (7) is not damaged during installation due to the profile of the shaft. H59 - Install the valve stem seal (7) using a suitable tool. - Insert the valve spring (6) and the top retainer (5) from the cylinder head. - Screw the cylinder head onto the support plate. - Remount the appropriate tool to install the valves and compress the springs. - Lubricate and install the valve collets (4). - Remove the tool used to install the valves, install the pads and the valve buckets on the respective valves. - Refit all the previously removed components as described in the relevant paragraphs. Workshop Manual Ed.09-0 F.0

91 CRANKCASE DISASSEMBLY Section F Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed.09-0 F.

92 CRANKCASE DISASSEMBLY Sommario Cylinder disassembly/installation...f. Piston removal/ installation...f.4 Measurement of a piston and cylinder...f.5 CRANKCASE DISASSEMBLY...F.6 Crankshaft disassembly...f.8 Crankshaft and countershaft installation...f.0 Crankshaft axial clearance check...f.0 Removal/refitting the countershaft and checking axial clearance... F. Countershaft clearance check...f. Crankshaft and countershaft gear removal...f. Removal of the countershaft gear...f. Gear installation...f. Crankshaft gear removal...f. Gear installation...f. Replacement of the countershaft bearings...f. GEARBOX SHAFTS REMOVAL/INSTALLATION...F.4 Removal of the gear engage forks...f.4 Gearbox shafts removal...f.4 Gearbox shafts installation...f.5 Fork installation...f.5 Engagement system check...f.5 Disassembly/assembly of the gearbox input shaft (shaft removed)... F.6 Disassembly/assembly of the gearbox output shaft (shaft removed)... F.7 Replacement of the gearbox control shaft (engine disassembled)... F.8 Engagement system check...f.8 Replacement of the selector drum (engine disassembled)... F.9 IEngagement system check...f.9 Replacement of the gearbox shaft bearings (shafts removed)...f.0 Mesh oil filter...f.0 Workshop Manual Ed.09-0 F.

93 CRANKCASE DISASSEMBLY Cylinder disassembly/installation Removal: - Remove the head cover as described in the relevant paragraph. - Remove the complete head as described in the relevant paragraph. - Remove the screws (). - Press the chain tensioner forward and extract the cylinder with care, making sure that the piston does not strike the engine casing. H Installation: - Insert a new gasket () into the stud bolts (). - Lubricate the piston rings. - Install the timing chain () through the slot on the cylinder (4). - Fit the cylinder (4) onto the stud bolts () while paying attention to the chain tensioner slider (5). - Place the piston (6) into the cylinder (4) pressing the rings and paying attention not to scratch the piston barrel. - Tighten the screws (7) to torque. H596 7 H597 Workshop Manual Ed.09-0 F.

94 CRANKCASE DISASSEMBLY Piston removal/ installation - Remove the cylinder as described in the relevant paragraph. Removal: - Cover the engine crankcase with paper. - Mark the exhaust side of the piston crown with a marker. - Remove the piston pin retainer rings () from both sides of the piston. - Extract the piston pin () using a suitable tool. - Remove the piston (). H598 H599 H600 Installation: - Visually inspect the piston rings and grooves of the piston. - Pay attention that the gaps between the sealing rings do not coincide with the piston pin axis. - Turn both the piston ring gaps () approx. 0 with respect to each other. - Offset the gaps of the other piston rings (), () respectively 0 with respect to the upper gap of the scraper ring. - Lubricate the piston pin with motor oil. - Install the piston on the connecting rod. - Use a suitable tool to insert the piston pin (4) into the piston. - Mount the retainer rings (5) from both sides of the piston. - Remove the paper covering the crankcase. - Refit all the previously removed components as described in the relevant paragraphs. 4 5 H60 H60 Workshop Manual Ed.09-0 F.4

95 CRANKCASE DISASSEMBLY Measurement of a piston and cylinder Inspecting the cylinder: - Check that the cylinder liner and sealing surfaces are not damaged. - Using a bore gauge for internal areas, measure the cylinder diameter in three points (), () and (). H60 Cylinder bore diameter Measurement when new mm in. Wear limit mm.99 in. - If the cylinder is damaged or falls out on tolerance, replace the cylinder and piston assembly. Checking piston diameter: - Measure the piston diameter (dimension A) transversely relative to the axis of the pin at a distance of 6mm (0.6 in.) above the lower edge of the piston. 6 mm 0,6 in. Piston diameter Measurement when new mm in. - Replace the piston if its diameter falls out of tolerance. Wear limit mm.95 in. A H604 Checking piston ring clearance: - Use a feeler to measure the clearance, in height, between piston ring and groove. Technical specifications Measurement when new Wear limit ^ groove mm in. max. 0.5 mm max in. H605 ^ groove ^ groove mm in mm in. max. 0.5 mm max in. max. 0.5 mm max in. - Replace the piston if the clearance in height falls out of tolerance. Workshop Manual Ed.09-0 F.5

96 CRANKCASE DISASSEMBLY CRANKCASE DISASSEMBLY Crankcase disassembly: - Remove the starter motor. - Remove the flywheel. - Remove the starter motor idle gear. - Remove the chain sprocket. - Remove the coolant pump cover. - Remove the complete clutch. - Remove the drive gear and the oil pump gears. - Remove the transmission gear for the coolant pump - Remove the cylinder and piston. Refer to the relevant paragraphs/chapters for the removal operations. Disassembly: - Remove the screws (). - Disassemble the oil filter cover () and the filter. H Disassemble the switch () of the neutral position. - Undo screws (4) and (5) 5 4 When refitting correctly position the relevant housing in the screws (4) and (5) as they are of two different lengths: Screws 4= 45 mm (.77 in.). Screws 5= 75 mm (.95 in.). 4 - Position the engine with left crankcase side (clutch side) facing upwards. 4 H607 - Tighten the knurled screws (6). 6 The bearings may be damaged if the crankcase is not disassembled/ assembled vertically. Do not rock the engine crankcase during disassembly and assembly. - Lift the left engine cover, beat alternately with light blows (plastic mallet) on the main shaft and countershaft transmission, so that they remain on the right crankcase. Workshop Manual Ed.09-0 H608 F.6

97 CRANKCASE DISASSEMBLY 4 Assembly: - Check that the washers () are installed correctly (also see the relevant paragraph on checking the axial clearance). - Clean the sealing faces and fit a new gasket (). - Check that the crankshaft () and countershaft (4) are timed correctly (see relative paragraph). H Check that the oil seal valve (5) is installed properly. - Check that the pins (6) of the gearbox forks, the drum (7), the ratchet (8), the lever (9) and the spring (0) are installed properly H60 The bearings may be damaged if the crankcase is not disassembled and assembled vertically. Do not rock the engine crankcase during disassembly and assembly. - Mount the left-side crankcase onto the left side casing. - Tighten the screws ( and ) to torque: Screws = 45 mm (.77 in.) length. Screws = 75 mm (.95 in.) length. - Clean the threading and install the neutral switch (). - Screw to torque with Loctite 4. H Check that the O-ring of the oil filter cover is not damaged, replace if necessary. - Insert the oil filter and install the cover (4) with the screws (5). - Refit all the previously removed components as described in the relevant paragraphs. 5 H6 Workshop Manual Ed.09-0 F.7

98 CRANKCASE DISASSEMBLY Crankshaft disassembly - Disassemble the crankcase as described in the relevant paragraph. Removal: - Match the marking () of the countershaft and marking () of the crankshaft with the crankcase marking (). H First remove the crankshaft (4), followed by the countershaft (5), paying attention to the spacer rings of the crankshaft. - Check piston ring wear by measuring inside diameter. wear limit ø 46.8 mm (.8 in.). Replace the rings if this value is exceeded. H64 Workshop Manual Ed.09-0 F.8

99 CRANKCASE DISASSEMBLY - Check the wear of the crankshaft in correspondence of the "Z" contact area of the bushings: wear limit ø mm (.8 in.). Replace the crankshaft and bearings if this value is exceeded. Bearings disassembly: - Use a suitable tool to remove the bearings (6) and (7) from the left and right side casings, heat the two semi-casings if needed. Bearings installation: If bearings are installed incorrectly, lubrication may be insufficient with consequential seizure. Do not invert the bearings: the bearings with the inner groove should be mounted on the right half, the smooth bearings are mounted on the left crankcase half. - Place the bearings (6a) and (7a) in the lower part taking care to align the hole in the bushing with the one present in the crankcase halves. - Use an appropriate tool to install, heat the two crankcase halves if needed. - Lubricate the bearings with temperature resistant oil. 6 6a Z 7 Z 7a H65 Workshop Manual Ed.09-0 F.9

100 CRANKCASE DISASSEMBLY Crankshaft and countershaft installation - Place the right crankcase half with the flywheel side facing down. - Oil the crankcase bearing seats. - Position the crankshaft washer on the right casing. - Insert the countershaft () and the crankshaft () in the crankcase and phase them; match the marking () of the countershaft and marking (4) of the crankshaft with the crankcase marking (5). - Make sure that the washers (6) are positioned correctly and lubricate with motor oil. 6 H H67 Crankshaft axial clearance check - On the right crankcase half of the engine with an appropriate tool measure the distance from the crank arm to the outer surface of the crankcase (B). - On the left crankcase half of the engine with an appropriate tool measure the distance from the outer surface of the casing to the contact surface of the crankshaft washer - Calculate the axial clearance of the engine according to the following formula, paying attention to the thickness of the crankcase gasket. B Crankcase gasket thickness: 0.4 mm (0.0 in.). H68 - A: distance from the external casing surface to the contact surface of the crankshaft washer. - B: Distance from the crank arm to the outer surface of the casing. - G: Casing gasket thickness: - X: Crankshaft axial clearance - A + G - B= X - Axial clearance of the crankshaft must be equal to mm ( in.). A - If this condition is not satisfied, use a spacer washer of appropriate thickness to obtain the correct clearance. - Refit the right crankcase half as described under the relevant paragraph. H69 Workshop Manual Ed.09-0 F.0

101 CRANKCASE DISASSEMBLY Removal/refitting the countershaft and checking axial clearance - Disassemble the crankcase as described in the relevant paragraph. Removal: - Match the marking () of the countershaft and marking () of the crankshaft with the crankcase marking (). H First remove the crankshaft (4), followed by the countershaft (5), paying attention to the spacer rings of the crankshaft. H64 Installation: - Place the right crankcase half with the flywheel side facing down. - Oil the crankcase bearing seats. - Position the crankshaft washer on the right casing. - Insert the countershaft (5) and the crankshaft (4) in the crankcase, placing them aligned with the marking () on the countershaft and the mark () on the crankshaft must coincide with the mark () on the crankcase. - Insert the oiled thrust washer for crankshaft into the crankcase. H H64 Workshop Manual Ed.09-0 F.

102 CRANKCASE DISASSEMBLY B Countershaft clearance check - On the right crankcase half of the engine with an appropriate tool measure the distance from countershaft bearing seat to the outer surface of the crankcase (B). - On the left crankcase half of the engine with an appropriate tool measure the distance from the outer surface of the casing to the internal ring of the ball bearing. - Calculate the axial clearance of the countershaft according to the following formula, paying attention to the thickness of the crankcase gasket. Crankcase gasket thickness: 0.4 mm (0.0 in.). H6 - A: distance from the outside surface of the crankcase to the internal ring of the ball bearing. - B: distance from the bearing seat to the outside surface of the crankcase. - G: Crankcase gasket thickness - X: Countershaft axial clearance A + G - B= X - Axial clearance of the countershaft must be equal to mm ( in.). A - If this condition is not satisfied, use a spacer washer of appropriate thickness to obtain the correct clearance. - Refit the right crankcase half as described under the relevant paragraph. H6 Crankshaft and countershaft gear removal - Remove the crankshaft and countershaft as described in the relative paragraphs. The gears must be replaced in tandem! H6 Removal of the countershaft gear - Place the countershaft in a vice with protection clamp. - Use a puller to extract the gear. Gear installation - Heat the gear to approx. 00 C. - Insert the gear into the countershaft all the way down by using a suitable tool. Workshop Manual Ed.09-0 F.

103 CRANKCASE DISASSEMBLY Crankshaft gear removal - Place the crankshaft in a vice with protection clamps. - Use a puller to extract the gear. H64 Gear installation - Heat the gear to approx. 40 C. - Fit a pin () into the gear () and mount onto the crankshaft until it stops by using a suitable tool, centring the pin () with the hole in the crankshaft. When installed, check that the pin () does not protrude from the gear. H65 Replacement of the countershaft bearings - Remove the countershaft as described in the relevant paragraph. Removal: - Remove the oil seal by extracting it from the outside section of the crankcase. - Heat the left crankcase half to 00 C. - Use a puller to remove the bearing towards the internal part of the crankcase. - Disassembly the right bearing in the same way. H66 Workshop Manual Ed.09-0 F.

104 CRANKCASE DISASSEMBLY Installation: - Heat the left crankcase half to approx. 00 C. - Use an appropriate tool to install the bearing () into the crankcase half with the closed side towards the outside. - When the crankcase has cooled, insert a new oil seal using an appropriate tool. - Repeat on the right side of the crankcase. H67 H68 GEARBOX SHAFTS REMOVAL/INSTALLATION - Disassemble the crankcase as described in the relevant paragraph. Removal of the gear engage forks - Extract the pins () from the forks (). - Tip the forks () outwards and extract them. H69 4 Gearbox shafts removal - Remove the input shaft assembly () and the output shaft (4) by tapping the portion of output shaft that projects from the crankcase with a plastic mallet. Workshop Manual Ed.09-0 H60 F.4

105 CRANKCASE DISASSEMBLY 4 Gearbox shafts installation - Oil the gearbox shaft main bearing seats. - Install the input shaft () and output shaft (4) of the gearbox. - Use a plastic mallet to tap the shafts until they are fully mated with their seats. H60 Fork installation - During installation pay attention to the proper fork and shaft coupling. - Install the engagement fork (5) onto the input shaft (). - Install the engagement forks (6) and (7) onto the output shafts. - Insert the engagement forks (5), (6) and (7) into the corresponding sliding gears of the gearbox shaft. - Rotate the forks inwards and insert the ratchet guides into the selector drum (8). - Insert the pins () into their seats H6 Engagement system check - Test proper gearbox operation by checking if the ratchet engages and disengages all the gears correctly from the star positioned on the selector drum (You should hear a "click" at engagement). 8 H6 Workshop Manual Ed.09-0 F.5

106 CRANKCASE DISASSEMBLY Disassembly/assembly of the gearbox input shaft (shaft removed) Disassembly: - Secure the gearbox input shaft () in a vice with protective clamps. - Remove the cogwheels () and (). Be careful not to damage the needle roller bearings during disassembly. - Extract the needle roller bearings (4) and ring (5). - Extract the cogwheel (6). - Remove the retaining ring (7). - Extract the washer (8) and gear (9). H6 Re-assembly: During operation, the gear pairs slide towards each other. If just one coupling gear is replaced, the load bearing capacity on gears may become significantly worse. Replace the paired gears, but one at a time! - All components must be checked before installation and replaced if necessary. - Secure the gearbox input shaft () in a vice with protective clamps. - Install the cogwheel (9) and the washer (8). - Fit a new retaining ring (7) in its seat. - Install the cogwheel (6). - Install the ring (5) and the needle roller bearing (4). - Install the cogwheels () and (). Workshop Manual Ed.09-0 F.6

107 CRANKCASE DISASSEMBLY Disassembly/assembly of the gearbox output shaft (shaft removed) H64 Disassembly: - Secure the gearbox output shaft () in a vice with protective clamps. - Remove the ring (). - Extract the gear () and (4) with the needle roller bearing (5) and washer (6). - Use an appropriate tool to push back the retainer ring (7), to remove the ring (8) locked in place by ring (9). Be careful not to damage the needle roller bearings during disassembly. - Extract gear (0) with the needle roller bearings () and ring (). - Remove the retaining ring (7). - Extract the gear (). - Disassemble the retaining ring (4) and the washer (5). - Extract the cogwheel (6). - Extract the needle roller bearing (7). Re-assembly: During operation, the gear pairs slide towards each other. If just one coupling gear is replaced, the load bearing capacity on gears may become significantly worse. Replace the paired gears, but one at a time! - All components must be checked before installation and replaced if necessary. - Secure the gearbox output shaft () in a vice with protective clamps. - Install the lubricated needle roller bearing (7). - Install the gear (6) so that the front teeth of the sliding gear () mate properly. - Install the ring (5). - Fit the new retaining ring (4). - Install the sliding gear (). - Fit a new retaining ring (7) in its seat. - Install the washer (), the needle roller bearing () and gear (0). - Install the ring (9). - Fit the new retaining ring (8). - Position the retainer ring (7) using an appropriate tool into the groove. - Install the cogwheel (4) and the washer (6). - Install the oiled needle roller bearing (5) and the gear () so that the front teeth of the sliding gear (4) mate properly. - Fit the washer (). Workshop Manual Ed.09-0 F.7

108 CRANKCASE DISASSEMBLY Replacement of the gearbox control shaft (engine disassembled) Removal: - Move the lever () outwards and extract the gearbox shaft () complete with lever (). - Extract the ratchet () and spring H65 Installation: - Insert into the crankcase the ratchet () with the spring () in correspondence with the star of the selector drum. H Latch the spring () to the lever (4). - Insert the spring (5) with the bushing (6) and the thrust washer (7) onto the gearbox shaft (8). - Insert into the crankcase the gearbox shaft (8) placing it into the ratchet (). - Make sure that the spring (5) is properly inserted into the retainer (9). 4 7 H Engagement system check - Test proper gearbox operation by checking if the ratchet engages and disengages all the gears correctly from the star positioned on the selector drum (You should hear a "click" at engagement). Workshop Manual Ed.09-0 H68 F.8

109 CRANKCASE DISASSEMBLY Replacement of the selector drum (engine disassembled) - Lift the pins () slightly until extracting them from the crankcase. - Move the pins and forks to free the drum (). - Extract the selector drum (). H69 - Check that the guides () of the selector drum and the insulating washer (4) are not worn. 4 H640 Installation: - Move the ratchet () so that the drum () can be easily fit. - Check that the ratchet () is properly positioned on the drum star (). - Turn the selector drum () to the neutral position (arrow). (The ratchet () is in the position shown in figure (arrow)). - Rotate the pins () towards the drum () with the relative forks inserting the ratchets (4) into the relative drum slots. - Use a plastic mallet to tap the pins () into their seats. H64 Engagement system check - Test proper gearbox operation by checking if the ratchet engages and disengages all the gears correctly from the star positioned on the selector drum (You should hear a "click" at engagement). 4 H64 H64 Workshop Manual Ed.09-0 F.9

110 CRANKCASE DISASSEMBLY Replacement of the gearbox shaft bearings (shafts removed) Removal: - Heat the crankcase to about C. - Extract the bearing () of the input shaft and the bearing () of the output shaft with a puller. - Repeat for the bearings on the right crankcase half. Installation: - Heat the engine crankcase to about C. - Install the bearings () and () on the crankcase with appropriate tools, making sure that the closed side of the bearings faces outwards. H644 A Mesh oil filter During engine overhaul we recommend cleaning the mesh oil filter (A) using compressed air. - Remove the screws () and the plate (). - Extract the mesh oil filter (A) and clean with compressed air being careful to avoid damaging it. - Replace the filter (A) paying attention to the correct direction of mounting, mount the plate () and screws () tightening to torque. H766 A H767 Workshop Manual Ed.09-0 F.0

111 ENGINE TORQUE FIGURES Section F4 Tighten all nuts and screws to the specified torque using a torque wrench. An insufficiently tightened screw or nut could get damaged or come completely loose, damaging the motorcycle and/or injuring the rider. A screw or nut tightened beyond the permitted max. torque value might get damaged or break and therefore come completely loose. The specified values refer to clean threads. Workshop Manual Ed F4.

112 ENGINE TORQUE FIGURES KEY A B C : Lubricate with engine oil. : Grease. : Tighten manually. CONVERSION TABLE Nm = 0. Kgm Nm = ft/lb Workshop Manual Ed F4.

113 ENGINE TORQUE FIGURES A 0 Nm A 8 Nm H77 Workshop Manual Ed F4.

114 ENGINE TORQUE FIGURES Nm + Loctite 4 Nm Nm + Loctite 4 9 ± mm Nm + Loctite 4 Nm A A A A A A 7 Nm H77 Workshop Manual Ed F4.4

115 ENGINE TORQUE FIGURES 0 Nm 0 Nm H774 Workshop Manual Ed F4.5

116 ENGINE TORQUE FIGURES 0 Nm 0 Nm 6 Nm ± mm 0 Nm 60 Nm 5 Nm 0 Nm 0 Nm H775 Workshop Manual Ed F4.6

117 ENGINE TORQUE FIGURES 0 Nm 0 Nm H776 Workshop Manual Ed F4.7

118 ENGINE TORQUE FIGURES A A Nm Nm Nm Nm H777 Workshop Manual Ed F4.8

119 ENGINE TORQUE FIGURES 4 Nm 4 Nm 0 Nm AIR BOX Nm H778 Workshop Manual Ed F4.9

120 ENGINE TORQUE FIGURES A A H779 Workshop Manual Ed F4.0

121 ENGINE TORQUE FIGURES 60 Nm + Oil 40 Nm 60 Nm + Oil 0 Nm 0 Nm + Loctite 4 80 Nm + Loctite H780 Workshop Manual Ed F4.

122 ENGINE TORQUE FIGURES 0 Nm PRESSURE PUMP A 6 Nm + Loctite 4 40 Nm A SCAVENGE PUMP 6 Nm + Loctite 4 H78 Workshop Manual Ed F4.

123 ENGINE TORQUE FIGURES 0 Nm A A H78 Workshop Manual Ed F4.

124 ENGINE TORQUE FIGURES A 0 Nm H78 Workshop Manual Ed F4.4

125 ENGINE TORQUE FIGURES 8 Nm B 6 Nm 0 Nm H784 Workshop Manual Ed F4.5

126 ENGINE TORQUE FIGURES 5 Nm + Loctite Nm + Loctite 4 80 Nm 0 Nm + Loctite 4 H785 Workshop Manual Ed F4.6

127 ENGINE TORQUE FIGURES 6 Nm H786 Workshop Manual Ed F4.7

128 ENGINE TORQUE FIGURES Nm H787 Workshop Manual Ed F4.8

129 ENGINE TORQUE FIGURES 40 Nm + Loctite 4 0 Nm H788 Workshop Manual Ed F4.9

130 ENGINE TORQUE FIGURES 40 Nm V III IV II I II V III I IV H789 Workshop Manual Ed F4.0

131 ENGINE PARTS WEAR LIMITS Section F5 Workshop Manual Ed.09-0 F5.

132 ENGINE PARTS WEAR LIMITS Table of Contents Engine block... F5. Cylinder head and cover...f5. Crankshaft and bearings...f5. Connecting rods and bearings...f5. Piston with rings and bearings...f5. Countershaft...F5.4 Camshaft...F5.4 Valve with springs...f5.4 Workshop Manual Ed.09-0 F5.

133 ENGINE PARTS WEAR LIMITS WEAR VALUE TABLE FOR ENGINE Description Condition UL Engine block Cylinder bore diameter New, from top edge 60 mm (.6 in.) Wear limit from top edge 60 mm (.6 in.) mm in mm.99 in. Internal diameter of crankshaft main bearings. Diameter of crankshaft main bearings on crankshaft Projection of the cylinder drag link in the crankcase. Cylinder head with cover Projection measured from the sealing surface. Crankshaft with bearings Crankshaft main bearing clearance Crankshaft axial clearance Connecting rod and bearings Connecting rod axial clearance Radial clearance of large connecting rod eye Diameter of small connecting rod eye Piston with rings and pins Piston diameter Piston installation clearance: Piston ring assembly direction Pin diameter Wear limit Wear limit Stud bolt (exhaust manifold) New Wear limit New Wear limit Wear limit New Wear limit New: measure taken transversally at the piston pin axis, at 6 mm (0.699 in.) from the bottom edge of the piston. Wear limit: measure taken transversally at the piston pin axis, at 6 mm (0.699 in.) from the bottom edge of the piston. New Wear limit New Wear limit max mm.84 in. max mm.8094 in. 94 ± mm ± in mm.04 ± in mm in. 0.0 mm in mm in mm in. max 0.8 mm max 0.05 in. max 0.08 mm max 0.00 in mm in. max.04 mm max in ± 0.05 mm.964 ± in. min mm min.95 in mm in. max mm max in. "TOP" mark pointing up min.996 mm in. min.98 mm min in. Workshop Manual Ed.09-0 F5.

134 ENGINE PARTS WEAR LIMITS WEAR VALUE TABLE FOR ENGINE Description Condition UL Radial clearance of the pin in the connecting rod Radial clearance of the piston pin inside the piston Gap between piston segments ^ groove Gap between piston segments ^ groove Gap between piston segments ^ groove Countershaft Axial clearance of the countershaft Camshaft Centrifugal force decompressor Valve with springs New Wear limit New New Wear limit New Wear limit New Wear limit Centrifugal weight projection Intake valve clearance With cold engine max. 5 C Exhaust valve clearance With cold engine max. 5 C mm in. max mm max 0.00 in mm in mm in. max.00 mm max in mm in. max.00 mm max in mm in. max.00 mm max in mm in. min 0.7 mm min in mm in mm in. Workshop Manual Ed.09-0 F5.4

135 TIGHTENING TORQUE FIGURES Section X Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent. Workshop Manual Ed X.

136 TIGHTENING TORQUE FIGURES Description of tasks Assembly cycle Nm Comment Safety torque Fastening of tank assembly screw on LH side 8,0 Fastening of mesh oil filter on chassis 0,0 Fastening of oil pipe clamps,0 Fastening of plug on union for oil drainage from chassis 4,0 Insert bushing for adjustment of swinging arm clearance on chassis seat GREASE Fastening of oil delivery/return/breather pipes on engine 8,0 S Fastening of rigid pipes on engine cylinder head seat,0 Fastening of engine to chassis on LH side 5,0 Fastening of oil refuelling cap on chassis 0,0 Fastening of ECU to support 8,0 Fastening of ECU support to chassis 8,0 Fastening of ignition/starter lock 9,0 Fastening of handlebar clamps 9,0 S Fastening of steering upper plate nut 80,0 S Fastening of handlebar clamp screws 9,0 S Fastening of fork plate side screws 9,0 S Fastening of brake pipe screws to pumps/callipers/abs ECU 4,0 S Remove the two screws of the bottom yoke on LH side and refit with plate,0 Tightening of bushing for adjustment of swinging arm clearance 6,0 Insert the swinging arm pin on the LH side part GREASE Fastening of swinging arm pin to chassis 0,0 S Fastening of engine lower screw on chassis 8,0 S Fastening of engine LH screw to chassis 8,0 S Fastening of engine RH screw to chassis with spacer 8,0 S Fastening of engine front clamp nuts 4,0 S Fastening of engine clamp plate - close 56,0 S Retrieve the lower clamp upper screw - reclose 56,0 S Retrieve the lower clamp lower screw - reclose 56,0 S Fastening of clamp on throttle body coupling 0,6 Fit fuel pipe on union and then on throttle body GREASE Fastening of earth cable to engine cylinder RH side 8,0 S Fastening of nut for starter motor cable 6,0 Fastening of neutral sensor cable to engine RH side 0,8 Fastening of turn indicator screws,0 Fastening of light support to upper plate 5,0 Fastening of front fairing support bracket screws to light support,0 Fastening of filter box air temperature sensor,0 Fastening of cover to filter box base,0 Fastening of central front locking to filter box base,0 Fastening of filter drawer to filter box base,5 Fastening of filter drawer to filter box,0 Workshop Manual Ed X.

137 TIGHTENING TORQUE FIGURES Description of tasks Assembly cycle Nm Comment Insert piston pin in swinging arm seat GREASE Safety torque Insert piston pins in seats of rear suspension kinematic mechanisms GREASE Fastening of top of shock absorber 56,0 S Fastening of bottom of shock absorber 56,0 GREASE S Fastening of rear suspension kinematic mechanisms 80,0 GREASE S Fastening of airbox to RH seat of chassis,0 Fastening of expansion tank to chassis (LH side),0 Fastening of airbox to chassis (LH side) 8,0 Fastening of pinion guard 4,0 Fastening of rear chassis 8,0 S Fastening of fuel tank to rear chassis 8,0 Fastening of fuel tank to chassis (RH side) 8,0 Fastening of gear shift pedal to chassis,0 Fastening of number plate holder to rear chassis,0 Screws for fastening saddle release onto chassis 8,0 Screws for fastening saddle release onto chassis,0 Fastening of rear mudguard lower clamp to chassis,0 Fastening of ECU to support plate 6,0 Damping pads for fastening of ECU support plate to rear mudguard GREASE Fastening of ECU support plate to rear mudguard,5 Fastening of sprocket 9,0 S Screw for fastening footrest fixing plate onto support 8,0 Fastening of rear brake master cylinder 8,0 Fastening of rear stop switch cover 0,7 Fastening of stop switch support,0 Bushing in rear brake lever seat GREASE Fastening of rear brake lever 8,0 S Screw for fastening footrest fixing plate onto support 8,0 Spacer for fixing side stand GREASE Fastening of side stand 8,0 S Fastening of side stand switch 5,0 Fastening of silencer to chassis 9,0 Fastening of silencer and manifold clamps 9,0 Fastening of front manifold to cylinder head 9,0 Fastening of Lambda sensor to manifold 45,0 Fastening of heat-protecting cover onto exhaust manifold 8,0 Fastening of RH and LH footrest supports to chassis 56,0 S ABS - Fasten rear brake pipe to master cylinder using screw and two washers 0,0 S ABS - Fasten rear brake pipe to master cylinder using screw and two washers 4,0 S Fasten the delivery and return pipes to engine seat,0 Fastening of top of radiator to chassis 8,0 Workshop Manual Ed X.

138 TIGHTENING TORQUE FIGURES Description of tasks Assembly cycle Nm Comment Safety torque Fastening of BLOW-BY pipe from filter box to engine ignition cover,0 Fastening of BLOW-BY pipe to filter box,0 Fastening of horn 5,0 Fastening of voltage regulator plate to engine 5,0 Fastening of front mudguard / fork guards 5,0 Grease front wheel axle GREASE Fastening of front wheel axle 80,0 S Fastening of screws on fork feet 8,0 Fastening of front brake calliper 8,0 S Connect and fasten front brake pipe to brake calliper seat 4,0 S Terra-fastening of wire guide plate to LH fork guard,5 Strada-fastening of wire guide plate to mudguard,5 Fastening of front wheel speed sensor 8,0 Fastening of voltage regulator 8,0 Grease the rear wheel axle GREASE Nut for rear wheel assembly pin 0,0 Tighten rear wheel axle to torque 00,0 S Screw for fastening brake hose ring to swinging arm seat 7,0 Fastening of rear wheel speed sensor 8,0 Fastening of chain casing 8,0 Terra-fastening of pushrod to front mudguard tail,5 Fastening of front fairing / front mudguard lower clamp to plate 8,0 Front fastening of front fairing lower clamp to light support,0 Rear fastening of front fairing lower clamp to light support,0 Fastening of front headlight to support,0 Fastening of voltage regulator guard 5,0 Fastening of anti-theft cover,0 Fastening of rear brake oil tank,0 Fastening of chain slider to swinging arm 5,0 Fastening of clutch control assy clamp 5,0 Fastening of LH switch to handlebar,0 Fastening of front master cylinder to handlebar 5,0 Fastening of RH switch to handlebar,0 Fastening of throttle control to handlebar,0 Fastening of front brake disc to rim,0 S Fastening of rear brake disc to rim,0 S Fastening of tone wheel to brake disc 5,0 Fastening of chain roller 8,0 Fastening of fuel pump ring nut to tank 6,0 S Fastening of fuel cap ring nut,0 Fastening of reflectors to number plate holder 0,8 Workshop Manual Ed X.4

139 TIGHTENING TORQUE FIGURES Description of tasks Assembly cycle Nm Comment Safety torque Fastening of turning indicators,0 Fastening of licence plate light to number plate holder seat,0 Fastening of tail light to number plate holder seat,0 Fastening of radiator guards,8 Fastening of sides to chassis,8 Fastening of side connecting cover,8 Fastening of scoops,8 Fastening of tank cover,8 Fastening of heat-protecting covers onto silencers 5,0 Fastening of front fairing,8 Fastening of luggage rack 9,0 S Workshop Manual Ed X.5

140

141 CHASSIS AND WHEELS Section Y Workshop Manual Ed Y.

142 CHASSIS AND WHEELS Sommario Chassis... Y. Lubrication points (lubricant)... Y. Front wheel... Y.6 Front wheel... Y.7 Removing the front wheel... Y.8 Reassembling the front wheel... Y.9 Rear wheel... Y.0 Rear wheel... Y. Removing the rear wheel (procedure valid for all models)... Y. Wheel axle warpage... Y. Axle runout over 00 mm... Y. Wheel rim warpage... Y. Rear chain sprocket, secondary drive sprocket and chain... Y.4 Checking sprocket wear... Y.4 Workshop Manual Ed Y.

143 CHASSIS AND WHEELS Chassis The chassis is a tubular steel trellis type with stainless steel removable rear small chassis. In case of violent shocks or accidents, if you think that the chassis might be bent or damaged, proceed with an immediate inspection and, if necessary, replace it. Lubrication points (lubricant) H7 Steering bearings (grease) Workshop Manual Ed Y.

144 CHASSIS AND WHEELS A A A H746 C C B C B B B B C Workshop Manual Ed H7 Y.4

145 CHASSIS AND WHEELS Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING SCREWS B REAR CHASSIS MOUNTING SCREWS C FOOTREST-PINS-SPRINGS Workshop Manual Ed Y.5

146 CHASSIS AND WHEELS Front wheel 7 STRADA H74 ) Tyre ) Rim ) Ball beraing 4) Sealing ring 5) Internal spacer 6) Spacer 7) Wheel axle 8) Brake disc 9) Tone wheel 0) Washer ) Tone wheel and disc retaining screw ) Washer ) Axle fixing nut 4) Valve For technical characteristics regarding the front wheel, see section A General Information of this manual. Workshop Manual Ed Y.6

147 CHASSIS AND WHEELS Front wheel TERRA H75 Legend ) Tyre ) Inner tube ) Front wheel assy 4) Spoke 5) Nipple 6) Wheel axle 7) Sealing ring 8) Ball bearing 9) Hub 0) Bushing ) Brake disc ) Tone wheel and disc retaining screw (ABS version) ) Tone wheel (ABS version) 4) Spacer 5) Washer 6) Nut 7) Washer 8) Gasket For technical characteristics regarding the front wheel, see section A General Information of this manual. Workshop Manual Ed Y.7

148 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. H76 Loosen the bolts () holding the wheel axle () to the front fork mounts. Hold the wheel axle head in place and simultaneously unscrew the nut () on the opposite side, then remove the wheel axle. H77 Do not operate the front brake lever when the wheel has been removed; this causes the calliper pistons to move outwards. After removal, lay down the wheel with brake disc on top. Workshop Manual Ed H747 H79 Y.8

149 CHASSIS AND WHEELS Reassembling the front wheel Fit the L.H. spacer () on the wheel hub. Fit the wheel between the fork legs so as to set the brake disc into the calliper. Fit the wheel axle () from the R.H. side, after greasing it and push it fully home against the L.H. fork leg; during this operation, the wheel should be turned. H7 Tighten the nut () on the left-hand side of the fork WITHOUT locking it. Now, pump for a while, pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned. Lock: the screws (4) on the right-hand fork leg (8 Nm, 0.8 kgm, 5.9 ft/lb), the nut () on the left-hand side (80 Nm, 8 kgm, ft/lb) and the screws () on the left-hand fork leg (8 Nm, 0.8 kgm, 5.9 ft/lb). After reassembly, pull the brake control lever until the pads are against the brake disc. H7 4 H H7 Workshop Manual Ed Y.9

150 CHASSIS AND WHEELS Rear wheel 4 STRADA H74 ) Tyre ) Rim ) Internal spacer 4) Ball bearing 5) Retaining circlip 6) Sealing ring 7) Spacer 8) Tone wheel 9) Spacer 0) Anti-vibration buffer rubber ring ) Sprocket carrier ) Spacer ) Chain sprocket 4) Brake disc 5) Wheel axle 6) Valve 7) Screw 8) Screw 9) Washer 0) Nut ) Spacer Workshop Manual Ed Y.0

151 CHASSIS AND WHEELS Rear wheel 5 4 TERRA ) Tyre ) Air chamber ) Rim 4) Spacer 5) Ball bearing 6) Retaining circlip 7) Sealing ring 8) Spacer 9) Spacer 0) Tone wheel ) Anti-vibration buffer rubber ring ) Sprocket carrier ) Spacer 4) Chain sprocket 5) Brake disc 6) Spoke 7) Nipple 8) Wheel axle 9) Sealing ring 0) Spacer ) Screw ) Screw ) Screw 4) Washer 5) Nut 6) Gasket 7) Hub H75 Workshop Manual Ed Y.

152 CHASSIS AND WHEELS H749 Removing the rear wheel (procedure valid for all models) Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut () of the wheel axle () and extract it. It is not necessary to loosen the chain tensioners (); in this way, the chain tension will remain unchanged after reassembly. Remove the chain (4) and remove the full wheel paying attention to the spacers on the sides of the hub. For reassembly follow the removal procedure in the reverse order by inserting the brake disc in the calliper. Refit the chain tensioner sliders (5) correctly so that the head of the axle () and the washer (6) slot into the corresponding slider housings. The flat part (A) of the chain tensioner sliders must face the chain tensioner screw. Check the cush drive dampers for wear (7); if only one of the appears to be damaged, all of them must be replaced. Do not operate the rear brake pedal when the wheel has been removed; this causes the calliper pistons to move outwards. After removal, lay down the wheel with brake disc on top. After reassembly, depress the brake pedal until the pads are against the brake disc. H750 Tightening of rear wheel axle nut (): 00 Nm - 0 kgm ft/lb. 5 A H78 H740 7 A H79 H74 Workshop Manual Ed Y.

153 CHASSIS AND WHEELS PIN REAR Wheel axle warpage Use a feeler gauge to check the pint out-of-round; if the value of the warpage exceeds the max allowed limit, replace it. Axle runout over 00 mm Wheel axle Standard Max. limit Wheel axle less than 0. mm 0. mm (0.079 in.) less than 0.09 in. H090 PIN FRONT H090 Wheel rim warpage The table below reports the allowed limits for wheel rim warpage. An excessive side runout and out-of-round are generally caused by worn out bearings. In these cases, replace the bearings and the sealing rings. If this does not solve the problem, change the wheel rim or the wheel. Standard Max. limit Side runout Out-of-round less than 0.5 mm (0.0 in.) less than 0.8 mm (0.0 in.) mm (0.079 in.) H090 Workshop Manual Ed Y.

154 CHASSIS AND WHEELS Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket. Normal wear Exceeding wear H0904 If the sprocket is exceedingly worn, replace it after loosening the six nuts () that retain it to the cush drive damper. Chain and sprockets must always be replaced as a set. H74 Checking sprocket wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced. Wheel misalignment causes abnormal wear, making the motorcycle unsafe to ride. Workshop Manual Ed Y.4